Single-Piece Cavity Filter Element for Lower Mass and Easier Manufacturing
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Solution Overview
Problem
Existing cavity filters are large in size and costly, and there is a need for cavity filter elements that can be manufactured more efficiently and with lower mass.
Innovation Solution
The design of cavity filter elements with dual supports and a coupling element, formed from a single piece of metal, allows for a self-supported structure that can be manufactured using automated processes, reducing mass and cost while maintaining performance.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Weight of moving object
If traditional cavity filter designs are used, then filtering performance is achieved, but mass and cost increase
Solution Approach 1:
The cavity filter is divided into multiple modular cavity filter elements, each containing a resonator structure with first and second supports. This segmentation allows for standardized manufacturing of individual elements that can be assembled into complete filter assemblies, reducing overall manufacturing complexity while maintaining performance.
Solution Approach 2:
The patent employs deformable portions in the cavity filter elements that can be adjusted to tune the resonant frequency and filtering characteristics. This parameter adjustment capability allows a single basic design to serve multiple frequency requirements, reducing the need for multiple specialized components and lowering overall mass and cost.
2Productivity
If cavity filter elements are made from single piece of metal, then manufacturing efficiency improves, but structural complexity increases
Solution Approach 1:
Multiple functional components (supports, resonator elements, coupling structures) are merged into a single monolithic metal piece for each cavity filter element. This integration eliminates the need for separate manufacturing and assembly steps for individual components, significantly improving manufacturing efficiency while the internal geometry provides the necessary structural complexity for filtering functionality.
Solution Approach 2:
The single-piece metal construction creates a self-supported structure where the cavity filter element is mechanically self-contained and requires no additional support structures or fastening hardware. The deformable portions provide self-tuning capability, further reducing the need for external adjustment mechanisms.
3Adaptability or versatility
If deformable portions are added for tuning, then adaptability improves, but manufacturing complexity increases
Solution Approach 1:
Static cavity filter structures are transformed into dynamically adjustable structures by incorporating deformable portions that can be mechanically or thermally actuated. These deformable elements allow real-time tuning of resonant frequencies and coupling characteristics, providing adaptability across different operating conditions while maintaining a relatively simple overall structure.
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 proposed design enables smaller, lighter, and more cost-effective cavity filters with improved manufacturing efficiency, suitable for applications such as massive multiple-input multiple-output (mMIMO) configurations.
Implementation Method 1
The cavity filter elements operate as resonators
Implementation Method 2
a galvanic current path extends via the first support to the second support via the coupling element
Data Source
Figure 1A~2D
Figure 3A~4
Figure 5~7
AI summary
An apparatus comprising: at least one cavity filter element wherein the cavity filter element comprises a first support, a second support distinct from the first support, and a coupling element supported by the first support and the second support. In some examples, there is a series of cavity filter elements. In some examples, the cavity filter element(s) are part of a cavity filter.