Resonator Buffer Structure for Welded Metal-Dielectric Joints
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Solution Overview
Problem
The significant difference in linear expansion coefficients between metal and dielectric materials in resonant rods leads to deformation issues during welding, resulting in the rupture of the metal and dielectric components in resonators.
Innovation Solution
A resonator design incorporating a buffer with a linear expansion coefficient between that of the metal and dielectric materials, sequentially connected to both, mitigates deformation stress and reduces the risk of cracking by acting as a cushion during welding.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Strength
If welding is used to connect the metal resonant rod and dielectric member, then the connection strength is improved, but the difference in linear expansion coefficient causes deformation and rupture
Solution Approach 1:
The patent introduces a buffer member as an intermediary component between the metal resonant rod and dielectric member. This buffer has a linear expansion coefficient that is intermediate between the metal and dielectric, serving as a mediator that gradually transitions the thermal expansion characteristics and reduces the shock of differential expansion during welding, thereby preventing rupture while maintaining connection strength.
Solution Approach 2:
The patent changes the physical parameter (linear expansion coefficient) of the buffer member to be intermediate between the metal resonant rod and dielectric member. By selecting a material with specific thermal expansion properties, the system creates a gradual transition zone that accommodates the differential expansion during welding, resolving the contradiction between connection strength and rupture risk.
2Reliability
If a buffer with intermediate linear expansion coefficient is introduced, then the risk of rupture is reduced, but the device complexity increases
Solution Approach 1:
The patent segments the original direct connection between metal resonant rod and dielectric member into two separate connection interfaces: one between the metal rod and buffer, and another between the buffer and dielectric member. This segmentation allows each interface to handle smaller differential expansion, reducing rupture risk while keeping the overall structure relatively simple through the use of a single intermediate component.
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
The buffer effectively reduces the risk of cracking at the metal-dielectric interface, maintaining structural integrity and improving the resonator's performance and tuning capabilities while lowering costs.
Implementation Method 1
the large difference in the linear expansion coefficient between the metal resonant rod and the dielectric leads to a significant difference in the deformation generated during welding
Implementation Method 2
the large difference in the linear expansion coefficient between the metal resonant rod and the dielectric leads to a significant difference in the deformation generated during welding, resulting in the rupture of the metal resonant rod and the dielectric
Data Source
AI summary
The embodiment discloses a resonator and a filter, the resonator comprises a housing, a cover plate, a metal resonant rod, a buffer, and a dielectric member. A resonant cavity with one side opening is formed inside the housing. The cover plate covers the outside of the opening. The metal resonant rod, buffer, and dielectric member are fixed in the resonant cavity, and sequentially welded. The linear expansion coefficient of the buffer is between the linear expansion coefficients of the metal resonant rod and the dielectric member, so that the deformation generated by the buffer during welding is between the deformations generated by the metal resonant rod and the dielectric member, providing a buffering effect when the metal resonant rod and the dielectric member deform, avoiding cracking at the connection between the metal resonant rod and the dielectric member due to significant differences in deformation during welding.