RF Combiner Splitter Using Ferromagnetic Body on PCB
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Solution Overview
Problem
Existing radio frequency combiner/splitter circuits, particularly in high-frequency applications, face challenges with impractical quarter-wavelength transmission lines and high costs due to the use of Teflon coated windings in toroidal transformers, making them difficult and expensive to manufacture.
Innovation Solution
A radio frequency combiner/splitter design utilizing a printed circuit board with a ferromagnetic body and conductive traces to create summing and transformer toroidal inductors, eliminating the need for cumbersome wire windings and reducing manufacturing complexity and cost.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If quarter-wavelength transmission lines are used in Wilkinson type power combiners for HF applications, then port-to-port isolation is achieved, but the physical length becomes impractical for high frequency applications
Solution Approach 1:
Ferrite toroidal transformers are introduced as intermediary components to replace the quarter-wavelength transmission lines. These transformers provide the necessary 180-degree phase shift and port isolation through magnetic coupling, eliminating the need for physically long transmission lines while maintaining the isolation performance in HF applications
Solution Approach 2:
The invention changes the operating parameters by using ferrite materials with specific magnetic properties that enable phase shifting and isolation at high frequencies without requiring proportional increases in physical length. The transformers are designed with specific turn ratios and core materials to achieve the required electrical length equivalent to quarter-wavelength lines but with much shorter physical dimensions
2Reliability
If Teflon coated windings are used in toroidal transformers, then high breakdown voltage properties are achieved, but manufacturing becomes time consuming and expensive
Solution Approach 1:
The invention replaces expensive, labor-intensive Teflon coated hand-wound wire with inexpensive, machine-windable enamel coated wire. The enamel coating provides sufficient insulation for the application while allowing automated winding processes, dramatically reducing both manufacturing time and cost while maintaining adequate electrical performance
Solution Approach 2:
The manual mechanical process of hand-winding Teflon coated wire is replaced with automated machine winding of enamel coated wire. This substitution enables consistent, repeatable manufacturing with lower labor costs and higher productivity, while the enamel coating provides the necessary electrical insulation properties
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 solution enables efficient RF signal combining/splitting over a 2 to 30 MHz frequency range with reduced manufacturing complexity and cost, improved mechanical robustness, and consistent performance without the need for expensive Teflon coated windings.
Implementation Method 1
conductive traces cooperating with the ferromagnetic body to define circuitry for combining/splitting RF signals
Implementation Method 2
ferromagnetic body comprising a first portion spaced from the first major surface of the PCB, a second portion spaced from the second major surface of the PCB
Data Source
AI summary
A radio frequency (RF) signal combiner/splitter may include a printed circuit board (PCB) having first and second opposing major surfaces, and openings therethrough. The RF signal combiner/splitter may further include a ferromagnetic body. The ferromagnetic body may include a first portion spaced from the first major surface of the PCB, a second portion spaced from the second major surface of the PCB, and interconnecting portions coupling the first and second portions and extending through respective openings in the PCB. The PCB may include conductive traces cooperating with the ferromagnetic body to define circuitry for combining/splitting RF signals. For example, the PCB may further comprise additional conductive traces cooperating with the ferromagnetic body to define impedance matching circuitry coupled to the circuitry for combining/splitting RF signals.