One-Piece Resonant Element With Cross-Coupling for Compact RF Filters
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Solution Overview
Problem
Existing sheet metal filters for radio frequency applications in 5G communication systems face challenges with high production costs, complex manufacturing processes, low consistency, and low debugging efficiency due to their single cavity structure and separate resonator components.
Innovation Solution
A one-piece resonant element with a main body featuring elongate middle and resonant end parts, and a cross-coupling arm for inductive or capacitive cross-coupling, integrated into a resonant unit with other resonant elements, allowing for simplified manufacturing and enhanced coupling within a filter frame.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Ease of manufacture
If a single cavity structure with separate resonator components is adopted, then the filter can be manufactured with conventional processes, but the production cost increases, manufacturing complexity increases, and consistency decreases
Solution Approach 1:
The patent combines the resonator and cross-coupling structure into a single integrated resonant element made of one-piece sheet metal. This merging eliminates the need for separate components and assembly steps, directly reducing manufacturing complexity while maintaining ease of manufacture through conventional sheet metal processing techniques
Solution Approach 2:
The one-piece resonant element serves multiple functions simultaneously: it provides resonance functionality through its main body while the integrated cross-coupling arm provides coupling between resonators. This multi-functionality reduces the overall number of components needed in the filter structure
2Adaptability or versatility
If separate resonator components are used, then the filter can be assembled from modular parts, but the production efficiency decreases and debugging efficiency becomes low
Solution Approach 1:
By integrating the cross-coupling arm directly into the resonator body as a one-piece structure, the patent eliminates assembly steps required for separate modular components. This merging maintains design flexibility while significantly improving production efficiency through reduced assembly operations and faster manufacturing cycles
3Ease of manufacture
If separate resonator components are connected by a separate step, then the filter can be manufactured with conventional assembly processes, but the consistency and reliability decrease
Solution Approach 1:
The patent merges the resonator and cross-coupling structures into a single monolithic resonant element fabricated from one-piece sheet metal. This integration eliminates all connection interfaces between separate components, thereby maximizing reliability and consistency while still using conventional sheet metal forming and assembly processes
4Adaptability or versatility
If a traditional filter structure with multiple components is used, then the filter can accommodate various design requirements, but the size, weight, and cost increase
Solution Approach 1:
The patent integrates multiple functional elements (resonator body, cross-coupling arms, and supporting structures) into a single one-piece sheet metal component. This merging dramatically reduces the total number of parts, eliminating the weight of multiple separate components and their fasteners while maintaining the necessary design flexibility for different filter configurations
Solution Approach 2:
The one-piece resonant element is designed to perform multiple functions: providing resonance, enabling cross-coupling between adjacent resonators, and serving as a structural support. This multi-functionality reduces the overall component count and total weight while maintaining adaptability for various filter design requirements
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This solution enables a miniaturized filter with reduced weight, low insertion loss, low cost, high debugging and production efficiency, improved consistency, and flexibility, while integrating resonators with the filter frame for enhanced performance.
Implementation Method 1
a cross-coupling arm extending integrally from the middle part and configured for creating inductive or capacitive cross-coupling with a resonator
Implementation Method 2
a cross-coupling arm extending integrally from the middle part and configured for creating inductive or capacitive cross-coupling with a resonator
Implementation Method 3
one-piece resonant element for a filter, comprising a main body which comprises an elongate middle part and resonant end parts provided on both ends of the middle part
Data Source
AI summary
A one-piece resonant element (100, 100′) for a filter (10, 10′), comprising a main body (100-12, 100′-12) which comprises an elongate middle part (100-1, 100′-1) and resonant end parts (100-2, 100′-2) provided on both ends of the middle part (100-1, 100′-1), wherein the one-piece resonant element further comprises a cross-coupling arm (100-3, 100′-3, 100′-3i) extending integrally from the middle part (100-1, 100′-1) and configured for creating inductive or capacitive cross-coupling with a resonator that is located on a signal transmission path of the filter. A resonant unit (200, 200′) comprising above-said resonant element and a filter (10, 10′) comprising the above said resonant element or resonant unit.