PCB-Mounted Resonator Heads for Consistent RF Filter Coupling

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Solution Overview

Problem

Existing RF filter technologies face challenges in achieving consistent coupling between resonator heads due to variations in height and bending, leading to inconsistent performance.

Innovation Solution

The use of a printed circuit board (PCB) to facilitate the assembly of inexpensive, flat resonator heads that are precisely positioned and easily assembled, enhancing capacitive coupling between resonators.

Engineering Contradictions & Design Principles

VSEngineering Contradiction Analysis

1Ease of manufacture

If traditional resonator heads are used without PCB support, then manufacturing cost is reduced, but assembly precision and coupling consistency deteriorate due to height variations and bending

Engineering Contradiction:

Improvemanufacturing costVSAvoidassembly precision

Core Design Contradiction:

Ease of manufactureVSManufacturing precision

Solution Approach 1:

A printed circuit board (PCB) is introduced as an intermediary component between the resonator heads and the housing. The PCB provides a rigid support structure with precisely positioned mounting holes that hold multiple resonator heads in a fixed geometric arrangement, eliminating height variations and bending issues while maintaining cost-effectiveness through standardized PCB manufacturing processes

Inventive Principle:

Principle #24Intermediary (Mediator)

2Device complexity

If resonator heads are positioned without PCB support, then device complexity is reduced, but coupling consistency deteriorates due to height and bending variations

Engineering Contradiction:

Improvestructural complexityVSAvoidcoupling consistency

Core Design Contradiction:

Device complexityVSReliability

Solution Approach 1:

The PCB serves as a mediating structure that establishes precise spatial relationships between resonator heads. By mounting multiple resonator heads on the PCB with controlled positioning, the system achieves consistent capacitive coupling and reliable electromagnetic performance while the PCB itself remains a relatively simple, planar component

Inventive Principle:

Principle #24Intermediary (Mediator)

3Ease of manufacture

If traditional assembly methods are used without PCB, then ease of assembly is reduced, but manufacturing simplicity is maintained

Engineering Contradiction:

Improvemanufacturing simplicityVSAvoidease of assembly

Core Design Contradiction:

Ease of manufactureVSEase of operation

Solution Approach 1:

The resonator heads are pre-positioned and fixed to the PCB during PCB manufacturing or pre-assembly processes. This preliminary action ensures that when the complete assembly is installed in the housing, the resonator heads are already in their correct positions and orientations, significantly easing the final assembly process while maintaining manufacturing simplicity through standardized PCB techniques

Inventive Principle:

Principle #10Preliminary action

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 approach reduces manufacturing variations and improves assembly tolerances, resulting in consistent RF filter performance with reduced insertion loss and improved group delay distortion.

Implementation Method 1

enhancing capacitive coupling between resonators

Methodology Applied

Scientific EffectCapacitive coupling: Capacitance

Data Source

PatentUS12244047B2Radio frequency filters having a circuit board with multiple resonator heads, and resonator heads having multiple arms

Publication Date: 2025.03.04 COMMSCOPE ITAL SRL

AI summary

Filter devices are provided herein. In some embodiments, a filter device includes first and second resonator stalks in respective first and second openings in a PCB that has first and second metal resonator heads that are on the first and second resonator stalks, respectively. Moreover, in some embodiments, a filter device includes a metal resonator head that has a loop portion on a resonator stalk and a plurality of arms that extend outward from the loop portion.