Swiss-roll Resonator Structure for Low Frequency Compact Design
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Solution Overview
Problem
The challenge lies in creating a thin layered monolithic structure with high dielectric permittivity and low loss for electromagnetic resonating structures, particularly for high power applications requiring resonance frequencies below 1 MHz, while maintaining a diameter less than 20-50 cm, which is complicated by the conflicting properties of metal and ceramic materials and the brittle nature of ceramic materials.
Innovation Solution
A Swiss-roll structure is formed by alternating ceramic and metallic layers, where the ceramic layers have a dielectric constant of at least 10 and a dielectric loss tangent less than 0.01, and the structure is heat-treated in a vacuum or inert atmosphere to minimize air gaps and achieve a monolithic form, enhancing capacitance and inductance for lower resonance frequencies.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Power
If the diameter of the resonating structure is reduced to maintain compact size, then the resonance frequency increases, but for high power applications requiring resonance frequencies below 1 MHz, the diameter must be kept small (less than 20-50 cm)
Solution Approach 1:
The patent uses composite materials consisting of ceramic layers with high dielectric permittivity (at least 10) and low dielectric loss tangent (less than 0.01) combined with metallic layers to form a Swiss-roll structure. This composite material approach enables achieving low resonance frequencies below 1 MHz while maintaining a compact diameter of less than 20-50 cm, resolving the contradiction between power requirements and size constraints.
2Power
If high dielectric permittivity material is used to enhance self-capacitance and reduce resonance frequency, then the resonance frequency decreases, but the conflicting properties of metal and ceramic materials make it challenging to process them into a thin layered monolithic structure
Solution Approach 1:
The patent segments the resonating structure into alternating thin layers of ceramic and metallic materials, with each layer being relatively thin and manageable. This segmentation allows the conflicting metal and ceramic materials to be processed separately and then combined into a monolithic Swiss-roll structure, overcoming the manufacturing challenges posed by their conflicting properties.
Solution Approach 2:
The patent employs a nested structure where multiple thin layers of ceramic and metallic materials are wound together in a Swiss-roll configuration. This nesting approach allows the thin layered structure to achieve the required self-capacitance enhancement while maintaining processability, as each layer can be manufactured and then assembled into the final monolithic structure.
3Power
If ceramic material is used to achieve high dielectric permittivity, then the dielectric constant increases, but the brittle nature of ceramic material challenges the processing into required resonator structures
Solution Approach 1:
The patent creates a composite material structure combining ceramic layers with high dielectric constant (at least 10) and low dielectric loss tangent (less than 0.01) with metallic layers. This composite approach maintains the high dielectric constant needed for low resonance frequencies while the metallic layers provide structural support that compensates for the brittleness of the ceramic material.
Solution Approach 2:
The patent divides the ceramic material into thin layers that are easier to process and less prone to brittleness-related failures. By segmenting the ceramic into thin sheets that are then wound into a Swiss-roll structure, the overall structural integrity is maintained while still achieving the required high dielectric constant 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
This configuration allows for compact resonators with extended magnetic field focusing strength, achieving lower resonance frequencies with reduced size, increased capacitance, and inductance, suitable for high power applications while maintaining structural integrity.
Implementation Method 1
heat treating the resultant Swiss-roll structure in vacuum, inert atmosphere, or reducing atmosphere to form a monolithic Swiss-roll structure, such that the air gap between turns of the Swiss-roll structure is less than about 1 μm
Implementation Method 2
embedding the resonating structure in high dielectric permittivity material to enhance the self-capacitance and thereby reduce the frequency of resonance
Data Source
AI summary
A resonator in the Swiss-roll structure, method of making the resonator structure and the system employing the resonator are disclosed. The resonator includes a plurality of layers, including a ceramic layer and a metallic layer. The ceramic and metallic layers are configured in a Swiss-roll form such that the neighboring ceramic layers are separated by the metallic layer. Further, the ceramic layer includes materials that have a dielectric constant of at least about 10 and dielectric loss tangent less than about 0.01 in the frequency range of about 1 KHz to about 100 MHz. The method of forming the resonator includes the steps of disposing a metallic layer, depositing a dielectric ceramic layer, and forming a Swiss-roll structure of the metallic and ceramic layers. Alternate method includes swaging the dielectric material filled metal tubes and forming into Swiss-rolls. Further steps include heat treating the resultant Swiss-roll structure in vacuum, inert atmosphere, or reducing atmosphere to form a monolithic Swiss-roll structure, such that the air gap between turns of the Swiss-roll structure is less than about 1 μm.