Rotatable Disk Microwave Coupler for Tunable Directivity
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Solution Overview
Problem
Existing microwave directional couplers face challenges in manufacturing due to high complexity and failure rates, particularly in achieving desired directivity and match, which affects yield and cost, and they often require larger sizes and weights.
Innovation Solution
A microwave coupler assembly featuring a rotatable disk-shaped circuit board with a conductive coupling loop and adjustable resistors, allowing for tunable coupling and directivity through a test fixture, enabling smaller size, lower cost, and improved manufacturability.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Reliability
If traditional directional coupler designs (slabline, stripline, coupled line, multi-hole waveguide) are used, then coupling and directivity functions are achieved, but manufacturing complexity increases and yield decreases due to failures in achieving desired directivity and match
Solution Approach 1:
The coupler is divided into modular components: a housing, a rotatable disk with circuit board, separate coupling loop, and adjustable resistors. This segmentation allows each component to be manufactured and adjusted independently, simplifying the overall manufacturing process and improving yield by isolating potential failure points.
Solution Approach 2:
The invention introduces a rotatable disk mechanism that allows the coupling loop to be dynamically adjusted to different angular positions. This dynamic adjustment capability enables precise tuning of coupling and directivity parameters after manufacturing, ensuring desired performance without complex manufacturing tolerances.
2Reliability
If traditional coupler designs are used to achieve adequate coupling and directivity, then performance requirements are met, but the size and weight of the assembly increase
Solution Approach 1:
The invention replaces traditional mechanical waveguide structures with an electrical circuit board implementation. The coupling loop and resistors on the circuit board provide the same coupling and directivity functions using electrical components rather than large mechanical structures, significantly reducing weight while maintaining performance.
3Reliability
If traditional coupler designs are used to achieve desired directivity and match, then performance specifications are met, but production cost increases due to low yield
Solution Approach 1:
The invention allows directivity and coupling parameters to be changed by adjusting the angular position of the rotatable disk and the values of the resistors. This parameter adjustability enables post-manufacturing tuning to meet specifications without requiring tight manufacturing tolerances, improving both manufacturability and yield.
Solution Approach 2:
The adjustable resistors and rotatable mechanism allow the coupler to self-adjust to meet performance specifications. The design inherently provides the capability to achieve desired directivity and match through simple adjustments rather than complex manufacturing processes.
4Ease of manufacture
If fixed-geometry coupler designs are used, then manufacturing is simplified, but adaptability to different frequency bands and coupling values is limited
Solution Approach 1:
The rotatable disk mechanism provides dynamic adaptability by allowing the coupling loop to be rotated to different angular positions. This single mechanical adjustment enables the same physical coupler to be tuned for different frequency bands and coupling values, providing versatility without requiring multiple fixed-geometry designs.
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 provides a compact, cost-effective, and easily manufacturable directional coupler with adjustable directivity and coupling, enhancing performance and reducing production bottlenecks by allowing precise tuning and measurement of RF power flow.
Implementation Method 1
a conductive coupling loop mounted to the first surface of the circuit board in the first region and oriented away from the surface
Data Source
AI summary
A coupling loop with each leg connected by two resistors, R1 and R2 going to ground on a disk shaped printed circuit board provides a directional coupler with directivity tuned by rotating this disk assembly and coupling controlled by the distance to the main RF transmission line. Once the desired level of directivity is obtained, this board is locked with screws from the top.