WO2012122922A1 - 制造谐振管的方法、谐振管和滤波器 - Google Patents
制造谐振管的方法、谐振管和滤波器 Download PDFInfo
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- WO2012122922A1 WO2012122922A1 PCT/CN2012/072175 CN2012072175W WO2012122922A1 WO 2012122922 A1 WO2012122922 A1 WO 2012122922A1 CN 2012072175 W CN2012072175 W CN 2012072175W WO 2012122922 A1 WO2012122922 A1 WO 2012122922A1
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01P—WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE
- H01P11/00—Apparatus or processes specially adapted for manufacturing waveguides or resonators, lines, or other devices of the waveguide type
- H01P11/008—Manufacturing resonators
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/05—Metallic powder characterised by the size or surface area of the particles
- B22F1/052—Metallic powder characterised by the size or surface area of the particles characterised by a mixture of particles of different sizes or by the particle size distribution
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F1/00—Metallic powder; Treatment of metallic powder, e.g. to facilitate working or to improve properties
- B22F1/10—Metallic powder containing lubricating or binding agents; Metallic powder containing organic material
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/10—Sintering only
- B22F3/1003—Use of special medium during sintering, e.g. sintering aid
- B22F3/1007—Atmosphere
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F3/26—Impregnating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0207—Using a mixture of prealloyed powders or a master alloy
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0207—Using a mixture of prealloyed powders or a master alloy
- C22C33/0228—Using a mixture of prealloyed powders or a master alloy comprising other non-metallic compounds or more than 5% of graphite
-
- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C33/00—Making ferrous alloys
- C22C33/02—Making ferrous alloys by powder metallurgy
- C22C33/0257—Making ferrous alloys by powder metallurgy characterised by the range of the alloying elements
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/10—Electroplating with more than one layer of the same or of different metals
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/34—Pretreatment of metallic surfaces to be electroplated
- C25D5/36—Pretreatment of metallic surfaces to be electroplated of iron or steel
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D5/00—Electroplating characterised by the process; Pretreatment or after-treatment of workpieces
- C25D5/60—Electroplating characterised by the structure or texture of the layers
-
- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D7/00—Electroplating characterised by the article coated
- C25D7/04—Tubes; Rings; Hollow bodies
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01P—WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE
- H01P11/00—Apparatus or processes specially adapted for manufacturing waveguides or resonators, lines, or other devices of the waveguide type
- H01P11/007—Manufacturing frequency-selective devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01P—WAVEGUIDES; RESONATORS, LINES, OR OTHER DEVICES OF THE WAVEGUIDE TYPE
- H01P7/00—Resonators of the waveguide type
- H01P7/06—Cavity resonators
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F3/00—Manufacture of workpieces or articles from metallic powder characterised by the manner of compacting or sintering; Apparatus specially adapted therefor ; Presses and furnaces
- B22F3/24—After-treatment of workpieces or articles
- B22F2003/241—Chemical after-treatment on the surface
- B22F2003/242—Coating
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B22—CASTING; POWDER METALLURGY
- B22F—WORKING METALLIC POWDER; MANUFACTURE OF ARTICLES FROM METALLIC POWDER; MAKING METALLIC POWDER; APPARATUS OR DEVICES SPECIALLY ADAPTED FOR METALLIC POWDER
- B22F9/00—Making metallic powder or suspensions thereof
- B22F9/02—Making metallic powder or suspensions thereof using physical processes
- B22F9/04—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling
- B22F2009/043—Making metallic powder or suspensions thereof using physical processes starting from solid material, e.g. by crushing, grinding or milling by ball milling
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C5/00—Alloys based on noble metals
- C22C5/06—Alloys based on silver
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22C—ALLOYS
- C22C9/00—Alloys based on copper
Definitions
- the present invention relates to the field of communications, and more particularly to a method of manufacturing a resonant tube, a resonant tube, and a filter in the field of communications.
- a duplexer of a base transceiver station is constructed by a radio frequency cavity filter, which is generally located on a rear structural member of a transceiver board for single-channel high-power signal transmission. Due to the thermal expansion characteristics of the material, the filter characteristics of the filter also change with temperature. In particular, the effect of temperature on the filtering characteristics of narrow-band cavity filters is particularly pronounced. Usually, the temperature changes cause the frequency band to drift in the frequency band, commonly known as “warm drift", which causes the RF system to function down.
- the dimensions of the components of the resonance tube in the cavity filter such as the width of the tuning screw, the diameter, the width of the cavity, the diameter, the diameter of the resonance tube, and the height.
- the single-cavity resonance frequency of the resonance tube filter will be changed, such as the cavity height and the height of the tuning rod.
- the frequency variation trend of the filter is just opposite, which can be achieved by using this characteristic.
- the cavity filter performs temperature compensation.
- the frequency variation of the filter may be less than 0.1 MHz, and zero temperature can be basically achieved. Drifting, thereby ensuring that the electrical performance of the cavity filter is almost unchanged at different temperatures.
- the cavity filter can be temperature compensated by changing the size of each component in the cavity filter, however, the dimensional change of each component of the cavity affects the Q value (quality factor) of the cavity.
- Q value quality factor
- the Q value of the cavity increases, and the product volume increases significantly.
- the Q value of the cavity decreases, which causes the insertion loss index of the filter to change significantly. difference.
- embodiments of the present invention provide a method of fabricating a resonant tube, a resonant tube, and a filter.
- a relatively low coefficient of linear expansion can be obtained according to the application frequency band of the filter, thereby achieving the quality factor without affecting the cavity quality. Temperature compensation of the filter.
- an embodiment of the present invention provides a method of manufacturing a resonance tube, the method comprising: mixing a powder material to form a uniform powder particle, wherein the powder material comprises iron powder in a weight ratio of 50% to 90%. , at least one of copper powder and steel powder having a weight ratio of 1% to 30%, and an auxiliary material having a weight ratio of 1% to 20%; the powder particles are subjected to press forming treatment to form a resonance tube blank; in a protective atmosphere The resonance tube blank is sintered to form a resonance tube semi-finished product; the resonance tube semi-finished product is subjected to a plating treatment to form the resonance tube.
- an embodiment of the present invention provides a resonance tube, which is fabricated according to a method for manufacturing a resonance tube according to an embodiment of the present invention, the method comprising: mixing a powder material to form a powder particle of a uniform hook Wherein the powder material comprises iron powder in a weight ratio of 50% to 90%, at least one of copper powder and steel powder in a weight ratio of 1% to 30%, respectively, and an auxiliary material in a weight ratio of 1% to 20%; The powder particles are subjected to press forming treatment to form a resonance tube blank; the resonance tube blank is sintered in a protective atmosphere to form a resonance tube semi-finished product; and the resonance tube semi-finished product is subjected to electroplating treatment to form the resonance tube.
- an embodiment of the present invention provides a filter including at least one resonant tube according to an embodiment of the present invention, and at least one tuning device disposed on the resonant tube, the resonant tube being implemented according to the present invention
- the method for manufacturing a resonance tube comprises: mixing a powder material to form a uniform powder particle, wherein the powder material comprises iron powder in a weight ratio of 50% to 90%, and the weight ratio is 1 respectively.
- an embodiment of the present invention provides a resonance tube, wherein the resonance is made of a powder material and is based on a powder metallurgy technique, wherein the powder material comprises iron powder in a weight ratio of 50% to 90%, and the weight ratio is 1 respectively.
- an embodiment of the present invention provides a filter including at least one resonance tube according to an embodiment of the present invention, and at least one tuning device disposed on the resonance tube, — —
- the powder material comprises at least one of iron powder in a weight ratio of 50% _90%, copper powder and steel powder in a weight ratio of 1% _30% respectively And an auxiliary material with a weight ratio of 1% to 20%.
- the method, the resonance tube and the filter of the embodiments of the present invention can obtain a relatively low linear expansion coefficient according to the application frequency band of the filter by selecting a plurality of powder materials and manufacturing the resonance tube based on the powder metallurgy technology. Therefore, the temperature compensation of the filter can be realized without affecting the quality factor of the cavity, thereby ensuring the electrical performance of the filter at different temperatures.
- the drawings to be used in the embodiments of the present invention will be briefly described below. Obviously, the drawings described below are only some of the present invention. For the embodiments, those skilled in the art can obtain other drawings according to the drawings without any creative work.
- FIG. 1 is a flow chart of a method of fabricating a resonant tube in accordance with an embodiment of the present invention.
- FIG. 2 is a schematic structural view of a resonance tube according to an embodiment of the present invention.
- FIG. 3 is a flow chart of a method of fabricating a resonant tube in accordance with another embodiment of the present invention.
- FIG. 4 is a comparison diagram of filter temperature drift curves in accordance with an embodiment of the present invention.
- the technical solutions in the embodiments of the present invention are clearly and completely described in the following with reference to the accompanying drawings in the embodiments of the present invention. It is obvious that the described embodiments are a part of the embodiments of the present invention, but not all embodiments. . All other embodiments obtained by a person of ordinary skill in the art based on the embodiments of the present invention without making creative labor are within the scope of the present invention.
- FIG. 1 shows a flow chart of a method 100 of fabricating a resonant tube in accordance with an embodiment of the present invention. As shown in Figure 1, the method 100 includes:
- the powder material is mixed to form a uniform powder particle, wherein the powder material comprises iron powder in a weight ratio of 50% _90%, copper powder and steel powder in a weight ratio of 1% _30% respectively. At least one, and an auxiliary material having a weight ratio of 1% to 20%;
- the resonance tube semi-finished product is subjected to a plating process to form the resonance tube.
- the method of the embodiment of the invention can ensure the temperature compensation of the filter by selecting a plurality of powder materials and manufacturing based on the powder metallurgy technology without affecting the quality of the cavity, thereby ensuring The electrical properties of the filter at different temperatures.
- the powder material for manufacturing the resonance tube may mainly include iron powder and copper powder, or mainly include iron powder and steel powder or mainly including iron powder, copper powder and steel powder, and the powder material may further include an auxiliary material.
- the powder material optionally constituting the resonance tube may further include at least one of re-pulverized powder, nickel powder, molybdenum powder and titanium powder, for example, the powder material may mainly include iron powder, copper powder and pulverized powder, or include iron powder and copper powder. And nickel powder or iron powder, steel powder and molybdenum powder, or iron powder, steel powder and titanium powder.
- the powder material may further include a plurality of powdered powder, nickel powder, molybdenum powder and titanium powder, for example, the powder material may include iron powder, copper powder, lotus powder and titanium powder.
- the iron powder may have a weight ratio of 50% to 90%, for example, the iron powder in the powder material may have a weight ratio of 50%, 60%, 70%, 80% or 90%, copper powder And/or the steel powder may have a weight ratio of 1% to 30%, for example, the copper powder and/or steel powder in the powder material may have a weight ratio of 5%, 10%, 15%, 20%, 25% or 30%.
- each of the copper powder, the steel powder, the copper powder, and the steel powder may also have a minimum weight of 0, 1%, 2%, 3%, 4%, or 5%.
- the ratio may also have a weight ratio of a maximum of 20%, 25%, 30%, 35%, 40% or 45%.
- each of the copper powder and the steel powder may have a weight ratio of 2% to 40%, or a weight ratio of 5% to 45%.
- the at least one powder may have a weight ratio similar to that of copper powder or steel powder, for example, manufacturing
- the powder material of the resonance tube includes iron powder, steel powder, molybdenum powder and titanium powder, wherein the molybdenum powder and the titanium powder may have a weight ratio of 3% to 35%.
- each of the at least one powder may have a weight ratio of a minimum of less than 2%, and a weight ratio of a maximum of less than 40%, for example, each of the at least one powder may have 1% _35% weight ratio.
- the powder material for manufacturing the resonance tube may further include a metal auxiliary material and/or a non-metal auxiliary material in addition to the metal
- the metal auxiliary material may include, for example, copper powder, steel powder, powdered powder, nickel powder, At least one of molybdenum powder and titanium powder
- the non-metal adjuvant may include, for example, at least one of carbon powder, ceramic powder, and glass powder.
- the powder material may include iron powder and ceramic powder, or iron powder, copper powder, glass powder, and the like.
- the non-metallic adjuvant has a weight ratio of from 1% to 20%, for example, the non-metallic adjuvant may have a weight ratio of 5%, 10% or 15%.
- the various non-metallic materials have a total weight ratio of 1% to 20%.
- the powder material further includes ceramic powder and glass powder
- the ceramic powder and the glass powder may have a weight ratio of 0.5% and 2%, respectively, or the ceramic powder and the glass powder may have a weight ratio of 10% and 4%, respectively.
- the powder material from which the resonance tube is fabricated may also include other metal materials, and may also have other weight ratios.
- the above examples are for illustrative purposes only, and embodiments of the invention are not limited thereto.
- the components of the powder material and the weight ratio thereof may be selected according to the frequency band used by the resonance tube or the filter, the temperature variation range, the temperature drift size, and the like.
- the metal powder with a small coefficient of linear expansion can be selected.
- the metal powder with a slightly larger linear expansion coefficient and cheaper price such as copper or aluminum, can be selected.
- the method according to the embodiment of the present invention can not only make a resonance tube from a plurality of powder materials, thereby obtaining a lower coefficient of linear expansion, realizing temperature compensation of the filter, and also selecting a powder material, thereby being applied according to practical applications.
- the situation adjusts the coefficient of linear expansion of different resonance tubes.
- the method according to the embodiment of the present invention can change the cavity size of the resonance tube, thereby enabling different frequency bands and without affecting the quality factor of the cavity.
- the cavity size filter is temperature compensated.
- the method of manufacturing a resonance tube according to an embodiment of the present invention has the advantages of low cost, high production efficiency, good consistency, and the like.
- the cost of the high-frequency resonance tube manufactured according to the embodiment of the present invention is less than 0.50 yuan, and the cost of the resonance tube manufactured by the metal machining is about 0.80 yuan, and the price of each single resonance tube is different.
- a cavity filter includes 24 resonant tubes for receiving, thereby saving 7.2 yuan per filter product. If the annual output of the filter is 1.2 million units, then the method of manufacturing the resonance tube according to the embodiment of the present invention can save a cost of 8.64 million yuan a year, and has a high economic benefit.
- the method according to an embodiment of the present invention can greatly improve production efficiency.
- a powder molding machine can mass produce more than 20,000 resonance tubes per day, while a processing machine can process only about 500 resonance tubes a day, whereby the resonance tube can be produced according to the method of the embodiment of the present invention.
- the efficiency is increased by 20 to 40 times, which can greatly save production time and save time cost for RF products that are urgent and need to be mass-produced.
- the powder metallurgy technique according to the embodiment of the present invention employs a precision mold and a powder pressing technique, and the uniformity of the product size is 4 ⁇ high, for example, the height tolerance can be controlled within ⁇ 0.05 ,, thereby according to an embodiment of the present invention.
- the method also has the advantage of high product consistency. Further, in the process of manufacturing the resonance tube according to the embodiment of the present invention, no waste is generated, the material utilization rate is high, and material cost can be saved.
- the selected powder particles may have a particle size of 200 mesh or more.
- the particle size of the powder particles may have a weight ratio of: the powder particles having a particle size of less than 50 microns have a weight ratio of 0-10%; and the particle size is less than 100 microns and greater than or equal to 50 microns.
- the powder particles have a weight ratio of 70-100%; the powder particles having a particle size of less than 150 micrometers and greater than or equal to 100 micrometers have a weight ratio of 0-20%; and the powder particles having a particle size larger than 150 micrometers have The weight ratio is 0-10%.
- the powder particles have a median particle size of about 80 microns.
- the selected powder particles can also have a smaller particle size.
- the mixed powder material may be subjected to a drying treatment to form uniform powder particles.
- the 5% by weight of the organic binder is added to the powder granules after the pulverization of the granules.
- the sieving treatment forms viscous powder particles to select the desired particle size.
- the pressed shape may also be The semi-finished product of the resonance tube is shaped to improve the appearance of the product.
- the shaped resonance tube semi-finished product may be subjected to a sealing treatment, wherein the sealing treatment may include: placing the shaped resonance tube semi-finished product into a molten stearic acid word, white The at least one of the oil and the silicone oil is impregnated to avoid defects in plating appearance due to adsorption of the plating solution during the plating of the semi-finished product; and drying of the resonance tube semi-finished product after the immersion.
- the sealing treatment may include: placing the shaped resonance tube semi-finished product into a molten stearic acid word, white
- the at least one of the oil and the silicone oil is impregnated to avoid defects in plating appearance due to adsorption of the plating solution during the plating of the semi-finished product; and drying of the resonance tube semi-finished product after the immersion.
- the electroplating treatment of the resonance tube semi-finished product may be: performing electroplating copper treatment on the dried resonance tube semi-finished product, and the electroplated copper layer has a thickness of not less than 3 micrometers, for example, the thickness of the copper layer is 5 microns, then silver plating is performed on the plated copper layer.
- the plated silver layer has a thickness of from 3 microns to 5 microns.
- FIG. 3 is a flow chart of a method 200 of fabricating a resonant tube in accordance with another embodiment of the present invention.
- a method 200 in accordance with an embodiment of the present invention will now be described in detail with reference to FIG.
- the powder material is subjected to a mixing treatment, wherein the powder material comprises at least one of iron powder in a weight ratio of 50% to 90%, copper powder and steel powder in a weight ratio of 1% to 30%, respectively, and a weight ratio. 1% _20% excipients.
- powder materials of different weight ratios can be weighed and mixed, and the powder materials are placed in a ball mill and mixed for 24 to 48 hours, and the materials are mixed after being mixed.
- the powder material is mixed and stirred by a ball mill, on the one hand, the powder particles are more uniformly mixed, and the other side ball mill can grind the powder particles to a certain degree of fineness.
- the mixed powder material is subjected to a drying treatment to form uniform powder particles. Since the wet mixing makes it easier to mix the powder materials, the above mixing treatment is usually carried out by wet mixing, whereby the mixed powder material needs to be dried to remove moisture, thereby forming uniformly mixed powder particles. For example, the discharged slurry is dried in an oven at 120 °C - 150 °C for 12 hours.
- an organic binder having a mass ratio of 0.5% to 3% is added to the powder particles after drying, and granulated and sieved to form viscous powder particles to form a desired particle size, wherein
- the organic binder includes at least one of stearic acid, stearic acid, and polyvinyl alcohol.
- a stearic acid having a mass ratio of 1.5% is added to the powder particles after drying, and granulation and sieving are carried out.
- the viscous powder particles are subjected to a press forming treatment to form a resonance tube blank.
- the viscous powder particles are added to a powder molding machine, and the molding pressure is adjusted to 5 - 10 tons, and the powder particles are pressed into a resonance tube of a desired size.
- the thickness of the resonance tube may be 1. 0 mm - 2.0 mm, or 1. 3 mm - 1.8 mm. Alternatively, the thickness of the resonance tube may be 1.5 mm.
- the sintering temperature may be 700 ° C _ 115 (TC , sintering time can be 4h_10h.
- the resonance tube semi-finished product can have the required strength and hardness.
- the resonance tube semi-finished product is shaped to improve the appearance of the resonance tube.
- the shaped resonance tube blank is infiltrated in at least one of molten stearic acid, white oil and silicone oil to avoid appearance defects during plating.
- the half into —, ⁇ The product is infiltrated in silicone oil for 4h_24h, optionally, for 12h.
- the semi-finished product of the resonance tube after the immersion is dried.
- the semi-finished product is placed in a 100 ° C - 150 ° C oven and dried at a low temperature for sealing.
- the dried semi-finished tube of the resonance tube is subjected to electroplating copper treatment, and then silver plating treatment is performed on the electroplated copper layer.
- the thickness of the plating layer can be determined according to the frequency band and skin effect to be applied. For example, for a resonance tube applied to the 90 Hz band, the required plating thickness is 5 ⁇ m; for application to 180 ⁇ Hz or above 260 ⁇ Hz For the resonant tube of the frequency band, the required plating thickness can be 3 microns. If the thickness of the plating layer is too large, the cost is increased. If the thickness of the plating layer is too small, the conductivity of the resonance tube is not good, which in turn affects the insertion loss of the filter.
- the thickness of the plating layer can be selected as needed.
- the thickness of the plated copper layer is not less than 3 ⁇ m or not less than 5 ⁇ m, for example, the thickness of the copper layer is 6 ⁇ m, and optionally, the thickness of the plated silver layer is 3 ⁇ m to 5 ⁇ m.
- other metals with good conductivity can also be selected for electroplating, so that the filter has good conductivity and low insertion loss.
- the method of the embodiment of the invention can realize the temperature compensation of the filter by selecting a plurality of powder materials and manufacturing based on the powder metallurgy technology without affecting the quality of the cavity, thereby ensuring the electrical performance of the filter at different temperatures.
- the method of the embodiment of the present invention can also adjust the linear expansion coefficient of different resonance tubes according to actual application conditions by selecting the powder materials, thereby enabling temperature of filters of different frequency bands and cavity sizes. make up.
- the method of manufacturing a resonance tube according to an embodiment of the present invention has the advantages of low cost, high production efficiency, good consistency, and the like.
- the manufacturing process of the resonance tube is as follows: : _ _ _ _
- the powder particles are added to the organic binder in a mass ratio of 0.5% to 3%, for example, by adding an organic binder having a mass ratio of 1%, and granulating and sieving to form powder particles having a certain viscosity.
- the viscous powder particles are added to a powder molding machine for press molding, and the molding pressure is adjusted to 5 to 10 tons.
- the formed blank is sintered in a tunnel kiln having a hydrogen atmosphere at a temperature of 700 ° C _1 150 ° C for 6 h, for example, the tunnel kiln has a high temperature of 1120 ° C.
- the sintered product is shaped. _
- the sealed product is subjected to electroplating copper treatment, wherein the plated copper layer has a thickness of 3 ⁇ m or more, for example, the plated copper layer has a thickness of 8 ⁇ m, and then subjected to electroplating silver treatment, wherein the plated silver layer has a thickness of 3 ⁇ m 5 ⁇ m.
- the manufactured resonance tube was placed in a test environment of -40 ° C to +85 ° C, and the coefficient of linear expansion of the resonance tube was calculated to be +8 ppm / ° C.
- the electroplating resonance tube product is installed in the cavity filter for debugging, it is found that when the filter is in a test environment of -40 ° C to +85 ° C, the temperature drift of the filter is less than 20 kHz. It can be considered that the filter has no temperature drift.
- the resonant tube is fabricated as follows:
- the reduced iron powder, the 355% copper powder and the 15% nickel powder with the mass ratio of 50% respectively are selected for mixing, and the mixture is stirred and stirred for 24_48 hours in the ball mill, and the powder material is uniformly mixed and discharged.
- the powder particles are added to the organic binder stearic acid in a mass ratio of 1% to 2%, and granulated and sieved to form powder particles having a certain viscosity.
- the sintered product is shaped to improve the appearance of the product.
- the shaped product is immersed in silicone oil, and then baked at a low temperature of 80 ° C _ 100 ° C for sealing treatment.
- the sealed product is subjected to electroplating copper treatment, wherein the electroplated copper layer has a thickness of 3 ⁇ m to 6 ⁇ m, and then subjected to electroplating silver treatment, wherein the plated silver layer has a thickness of 3 ⁇ 4 ⁇ .
- the manufactured resonance tube was placed in a test environment of -40 ° C to +85 ° C, and the coefficient of linear expansion of the resonance tube was calculated to be +15.5 ppm / ° C.
- the resonance tube product after the electric ⁇ is installed in the cavity filter, and after debugging, it is found that the filter has a temperature drift of less than 30 kHz in a test environment of -40 ° C _ + 85 ° C, which can also be considered as The filter has no temperature drift.
- the embodiment of the present invention further provides a resonance tube which is manufactured according to the method for manufacturing a resonance tube according to an embodiment of the present invention, wherein the method comprises: mixing a powder material to form uniform powder particles, wherein the The powder material comprises iron powder in a weight ratio of 50% to 90%, and at least one of copper powder and steel powder in a weight ratio of 1% to 30%, respectively; the powder particles are subjected to press forming treatment to form a resonance tube blank; The resonance tube blank is sintered in a protective atmosphere to form a resonance tube semi-finished product; the resonance tube semi-finished product is subjected to a plating treatment to form the resonance tube.
- the method comprises: mixing a powder material to form uniform powder particles, wherein the The powder material comprises iron powder in a weight ratio of 50% to 90%, and at least one of copper powder and steel powder in a weight ratio of 1% to 30%, respectively; the powder particles are subjected to press forming treatment to form a resonance tube blank; The resonance tube blank is sintered in a protective atmosphere to form a
- the resonance tube has a linear expansion coefficient of +4 ppm/ Within the range of °C ⁇ +16 ppm/ °C.
- the resonance tube can have a coefficient of linear expansion of +6 ppm/ °C, +8 ppm/ °C, +1 0 ppm/ °C, +12 ppm/ °C, or +14 ppm/ °C. 5 ⁇
- the thickness of the resonance tube may be 1. 5 mm.
- the thickness of the resonance tube may be 1. 5 mm.
- Embodiments of the present invention also provide a filter including at least one resonance tube according to an embodiment of the present invention, and at least one tuning device disposed on the resonance tube, the tuning device for adjusting resonance of the resonance tube Frequency, the resonance tube is made according to the method for manufacturing a resonance tube according to an embodiment of the present invention, the method comprising: mixing a powder material to form a uniform powder particle, wherein the powder material comprises a weight ratio of 50% _90% Iron powder, and at least one of copper powder and steel powder in a weight ratio of 1% to 30%, respectively; press-forming the powder particles to form a resonance tube blank; sintering the resonance tube blank in a protective atmosphere Processing, forming a resonance tube semi-finished product; plating the semi-finished product of the resonance tube to form the resonance ⁇ .
- FIG. 4 shows the S-parameter curve of the cavity filter applied to WiMAX 2.
- 5GHz with a bandwidth of 17MHz at +25 ° and +85 °, as can be seen from the figure
- the two curves are substantially coincident, that is, the passband of the filter does not drift at different temperatures, and thus the filter can be considered to be a zero temperature drift product.
- the resonance tube and the filter of the embodiment of the invention can realize the filter and the line temperature compensation based on the powder metallurgy by using a plurality of powder materials, and can ensure the actual application of the filter at different temperatures.
- the linear expansion coefficient of the resonance tube is adjusted, thereby enabling temperature compensation of filters of different frequency bands and cavity sizes, thereby enabling the product to be applied not only to cold regions but also to hot climates in Africa.
- the area and the normal RF index insertion loss of the filter are guaranteed, and the normal operation of the base transceiver station is also guaranteed.
- the resonance tube and the filter according to the embodiment of the present invention have the advantages of low cost, high production efficiency, good consistency, and the like.
- the embodiment of the present invention further provides a resonance tube, wherein the resonance f is made of a powder material and is based on a powder metallurgy technique, wherein the powder material comprises iron powder in a weight ratio of 50% _90%, and the weight ratio is 1% _30 respectively. At least one of % copper powder and steel powder, and a proportion by weight of 1% to 20%.
- the powder material may further comprise at least one of a powder, a nickel powder, a molybdenum powder, and a titanium powder.
- the powder material may further include at least one of carbon powder, ceramic powder, and glass powder.
- the resonance tube has a coefficient of linear expansion in the range of +4 ppm / ° C ⁇ +16 ppm / °C.
- the coefficient of linear expansion of the resonance tube can be +6 ppm/ °C, +8 ppm/ °C, +1 0 ppm/ °C, +12 ppm/ °C or +14 ppm/ °C.
- the thickness of the resonance tube may be 1. 0 mm "2.0 mm, or 1. 3 mm - 1.8 mm. Alternatively, the thickness of the resonance tube may be 1.5 mm.
- the surface of the resonance tube is plated with a copper layer, wherein the thickness of the copper layer is not less than 3 micrometers.
- the copper layer of the resonance tube is also plated with a silver layer, wherein the thickness of the silver layer is 3 micrometers to 5 micrometers.
- the embodiment of the invention further provides a filter comprising at least one resonance tube according to an embodiment of the invention, and at least one tuning device disposed on the resonance tube, the resonance tube powder material is based on powder metallurgy technology
- the powder material comprises at least one of iron powder in a weight ratio of 50% to 90%, copper powder and steel powder in a weight ratio of 1% to 30%, respectively, and an auxiliary material in a weight ratio of 1% to 20%.
- the resonance tube and the filter of the embodiment of the present invention can realize the temperature compensation of the filter without affecting the quality factor of the cavity by selecting a plurality of powder materials and based on the powder number, thereby ensuring that the filter is in the The electrical properties at different temperatures, and by selecting the powder material, can adjust the linear expansion coefficient of different resonance tubes, thereby enabling temperature compensation of filters of different frequency bands and cavity sizes.
- the resonance tube and the filter according to the embodiment of the present invention have the advantages of low cost, high production efficiency, good consistency, and the like.
- the methods or steps described in connection with the embodiments disclosed herein may be implemented in hardware, a software program executed by a processor, or a combination of both.
- the software program can be placed in random access memory (RAM), memory, read only memory (OM), electrically programmable ROM, electrically erasable programmable ROM, registers, hard disk, removable disk, CD-ROM, or in the art. Any other form of storage medium. ... ' , , , , . . . but the invention is not limited thereto.
- RAM random access memory
- OM read only memory
- electrically programmable ROM electrically erasable programmable ROM
- registers hard disk, removable disk, CD-ROM
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Description
制造谐振管的方法、 谐振管和滤波器
技术领域 本发明涉及通信领域, 特别涉及通信领域中制造谐振管的方法、 谐振管 和滤波器。 背景技术 基站收发信机的双工器由射频腔体滤波器构成, 该射频腔体滤波器一般 位于收发信机单板的背面结构件上, 用于单路大功率的信号传输。 由于受材 料热膨胀特性的影响, 滤波器的滤波特性也随温度变化而改变。 特别地, 温 度对窄带腔体滤波器的滤波特性影响尤为明显。 通常, 温度的变化使得射频 指标产生频带漂移, 俗称为 "温漂", 由此会造成射频系统功能下降。 并且随 着移动通信向高频段的发展, 这种温漂现象愈发严重, 例如对于全球微波互 联接入 ( Wor ldwide Interoperabi l i ty for Microwave Acces s , 筒称为 "WiMAX" ) 2. 6GHz或 3. 5GHz制式的腔体滤波器而言, 温度变化对该腔体滤波 器产生的频带漂移现象已经非常严重。 采用传统的铝合金压铸件以及机加工 制造的金属谐振管, 已经难以满足通信技术的高速发展对射频指标的要求, 这已成为困扰高频段的腔体滤波器发展的主要原因。
通过对腔体滤波器的频率随温度变化的关系进行研究, 可以发现, 腔体 滤波器中谐振管的各组件尺寸, 例如调谐螺釘宽度、 直径, 腔体的宽度、 直 径, 谐振管 直径、 高度等, 都会引起谐振管^滤波器的单腔谐振频†的变 如腔体高度和调谐杆高度在温度升高时, 引起的滤波器的频率变化趋势刚好 相反, 由此可以利用该特性实现对腔体滤波器进行温度补偿。
实验研究表明, 对于未经过温度补偿的腔体滤波器, 该滤波器在 +25 °C时 的中心频率为 2. 4GHz , 而当温度变化至 -40 °C时, 该滤波器的中心频率偏移到 2. 4035GHz , 频率偏移量为 3. 5MHz。 因而对于未进行温度补偿的腔体滤波器而 言, 当温度发生变化时, 滤波器的通带发生了偏移, 由此在使用频率的左右 边缘频率点时, 插入损耗非常大, 带外抑制变差, 从而直接造成了滤波器电 性能的恶化和收发信机系统性能的下降。
而对于通过上述方法进行温度补偿后的腔体滤波器而言, 当温度从 -40 °C 变化至 +25 °C时, 该滤波器的频率变化量可以小于 0. 1MHz ,基本可以实现零温 漂, 从而能够保证腔体滤波器的电性能在不同温度下几乎没有变化。
虽然通过改变腔体滤波器中的各组件尺寸, 可以实现对腔体滤波器进行 温度补偿, 然而, 腔体各组件的尺寸改变会影响该腔体的 Q值(品质因素)。
当腔体尺寸增加时, 腔体的 Q值增加, 并且产品体积也会显著增加; 而当腔 体尺寸减小时, 腔体的 Q值减小, 由此会使得滤波器的插损指标显著变差。
因而, 需要一种既不影响腔体品质因素又能够实现温度补偿的滤波器。
发明内容 为此, 本发明实施例提供了一种制造谐振管的方法、 谐振管和滤波器。 本发明实施例通过选用多种粉末材料, 并基于粉末冶金技术制造谐振管, 可 以根据滤波器的应用频段获得相对较低的线膨胀系数, 由此能够在不影响腔 体品质因素的同时, 实现对滤波器进行温度补偿。
一方面, 本发明实施例提供了一种制造谐振管的方法, 该方法包括: 对 粉末材料进行混合处理, 形成均勾的粉末颗粒, 其中该粉末材料包括重量比 例为 50%_90%的铁粉、 重量比例分别为 1%_30%的铜粉和钢粉中的至少一种、 以及重量比例为 1%_20%的辅料; 对该粉末颗粒进行压制成型处理, 形成谐振 管毛坯; 在保护气氛中对该谐振管毛坯进行烧结处理, 形成谐振管半成品; 对该谐振管半成品进行电镀处理, 形成该谐振管。
另一方面, 本发明实施例提供了一种谐振管, 该谐振管根据本发明实施 例的制造谐振管的方法而制成, 该方法包括: 对粉末材料进行混合处理, 形 成均勾的粉末颗粒, 其中该粉末材料包括重量比例为 50%_90%的铁粉、 重量比 例分别为 1%_30%的铜粉和钢粉中的至少一种、以及重量比例为 1%_20%的辅料; 对该粉末颗粒进行压制成型处理, 形成谐振管毛坯; 在保护气氛中对该谐振 管毛坯进行烧结处理, 形成谐振管半成品; 对该谐振管半成品进行电镀处理, 形成该谐振管。
再一方面, 本发明实施例提供了一种滤波器, 该滤波器包括至少一个根 据本发明实施例的谐振管, 以及至少一个设置在该谐振管上的调谐装置, 该 谐振管根据本发明实施例的制造谐振管的方法而制成, 该方法包括: 对粉末 材料进行混合处理, 形成均勾的粉末颗粒, 其中该粉末材料包括重量比例为 50%_90%的铁粉、 重量比例分别为 1%_30%的铜粉和钢粉中的至少一种、 以及重 量比例为 1%_20%的辅料; 对该粉末颗粒进行压制成型处理, 形成谐振管毛坯; 在保护气氛中对该谐振管毛坯进行烧结处理, 形成谐振管半成品; 对该谐振 管半成品进行电镀处理, 形成该谐振管。
再一方面, 本发明实施例提供了一种谐振管, 其中该谐振 由粉末材料 并基于粉末冶金技术制成, 其中该粉末材料包括重量比例为 50%_90%的铁粉、 重量比例分别为 1%_30%的铜粉和钢粉中的至少一种、 以及重量比例为 1%_20% 的辅料。
再一方面, 本发明实施例提供了一种滤波器, 该滤波器包括至少一个根 据本发明实施例的谐振管, 以及至少一个设置在该谐振管上的调谐装置, 该
— —
― ― 谐振管^粉末材料并基于粉末冶金技术 成, 其中该粉末材料包括重量比例 为 5 0%_90%的铁粉、 重量比例分别为 1%_30%的铜粉和钢粉中的至少一种、 以 及重量比例为 1%_20%的辅料。
基于上述的技术方案, 本发明实施例的方法、 谐振管和滤波器, 通过选 用多种粉末材料, 并基于粉末冶金技术制造谐振管, 可以根据滤波器的应用 频段获得相对较低的线膨胀系数, 由此能够在不影响腔体品质因素的同时, 实现对滤波器进行温度补偿, 从而能够保证滤波器在不同温度下的电性能。 附图说明 为了更清楚地说明本发明实施例的技术方案, 下面将对本发明实施例中 所需要使用的附图作筒单地介绍, 显而易见地, 下面所描述的附图仅仅是本 发明的一些实施例, 对于本领域普通技术人员来讲, 在不付出创造性劳动的 前提下, 还可以根据这些附图获得其他的附图。
图 1是根据本发明实施例的制造谐振管的方法的流程图。
图 2是根据本发明实施例的谐振管的结构示意图。
图 3是根据本发明另一实施例的制造谐振管的方法的流程图。
图 4是根据本发明实施例的滤波器温漂曲线对比图。 具体实施方式 下面将结合本发明实施例中的附图, 对本发明实施例中的技术方案进行 清楚、 完整地描述, 显然, 所描述的实施例是本发明的一部分实施例, 而不 是全部实施例。 基于本发明中的实施例, 本领域普通技术人员在没有做出创 造性劳动的前提下所获得的所有其他实施例, 都应属于本发明保护的范围。
图 1示出了根据本发明实施例的制造谐振管的方法 1 00的流程图。如图 1 所示, 该方法 1 00包括:
S 1 1 0 , 对粉末材料进行混合处理, 形成均勾的粉末颗粒, 其中该粉末材 料包括重量比例为 50%_90%的铁粉、 重量比例分别为 1%_30%的铜粉和钢粉中 的至少一种、 以及重量比例为 1%_20%的辅料;
S 1 20 , 对该粉末颗粒进行压制成型处理, 形成谐振管毛坯;
S 1 30 , 在保护气氛中对该谐振管毛坯进行烧结处理, 形成谐振管半成品;
S 140 , 对该谐振管半成品进行电镀处理, 形成该谐振管。
本发明实施例的方法通过选用多种粉末材料, 并基于粉末冶金技术制造 在不影响腔体品质因素的同时, 实现对滤波器进行温度补偿, 从而能够保证
滤波器在不同温度下的电性能。
在本发明实施例中, 制造谐振管的粉末材料可以主要包括铁粉和铜粉, 或主要包括铁粉和钢粉 或主要包括铁粉、 铜粉和钢粉, 另外该粉末材料还 可以包括辅料。 可选地 制造谐振管的粉末材料还可以包括辞粉、 镍粉、 钼 粉和钛粉中的至少一种 例如粉末材料可以主要包括铁粉、 铜粉和辞粉, 或 包括铁粉、 铜粉和镍粉 或包括铁粉、 钢粉和钼粉, 或包括铁粉、 钢粉和钛 粉。 当然该粉末材料也可以还包括辞粉、 镍粉、 钼粉和钛粉中的多个, 例如 该粉末材料可以包括铁粉、 铜粉、 辞粉和钛粉。
在制造谐振管的粉末材料中, 铁粉可具有 50%_90%的重量比例, 例如粉末 材料中的铁粉可以具有 50%、 60%、 70%、 80%或 90%的重量比例, 铜粉和 /或钢 粉可具有 1%_30%的重量比例, 例如粉末材料中的铜粉和 /或钢粉可以具有 5%、 10%、 15%、 20%、 25%或 30%的重量比例。 在本发明另一实施例中, 铜粉、 钢粉、 铜粉和钢粉中的每一种粉末也可具有最小值为 0、 1%、 2%、 3%、 4%或 5%的重 量比例, 也可以具有最大值为 20%、 25%、 30%、 35%、 40%或 45%的重量比例。 例如铜粉和钢粉中的每一种粉末可具有 2%_40%的重量比例, 或 5%_45%的重量 比例。
当制造谐振管的粉末材料还包括辞粉、 镍粉、 钼粉和钛粉中的至少一种 粉末时, 该至少一种粉末一共可以具有与铜粉或钢粉相似的重量比例, 例如, 制造谐振管的粉末材料包括铁粉、 钢粉、 钼粉和钛粉, 其中钼粉和钛粉一共 可具有 3%_35%的重量比例。 当然, 该至少一种粉末中的每一种粉末可以具有 最小值小于 2%的重量比例, 以及最大值小于 40%的重量比例, 例如该至少一 种粉末中的每一种粉末可以具有 1%_35%的重量比例。
在本发明实施例中, 制造谐振管的粉末材料除了主要包括金属之外, 还 可以包括金属辅料和 /或非金属辅料, 该金属辅料例如可以包括铜粉、 钢粉、 辞粉、 镍粉、 钼粉和钛粉中的至少一种, 该非金属辅料例如可以包括碳粉、 陶瓷粉和玻璃粉中的至少一种。 例如, 该粉末材料可以包括铁粉和陶瓷粉, 或铁粉、 铜粉和玻璃粉等。 该非金属辅料具有 1%_20%的重量比例, 例如该非 金属辅料可以具有 5%、 10%或 15%的重量比例。 当该非金属辅料包括多种非金 属材料时, 各种非金属材料一共具有 1%_20%的重量比例。 例如, 当粉末材料 还包括陶瓷粉和玻璃粉时, 陶瓷粉和玻璃粉可以分别具有 0. 5%和 2%的重量比 例, 或陶瓷粉和玻璃粉可以分别具有 10%和 4%的重量比例。
当然, 本领域技术人员应理解, 制造谐振管的粉末材料还可以包括其他 金属材料, 并且也可以具有其他重量比例, 上述例子仅是示例目的, 本发明 实施例并不限于此。
在本发明实施例中, 可以根据谐振管或滤波器使用的频段、 温度变化范 围、 温漂大小等, 对粉末材料的组分以及其重量比例进行选择。 例如, 如果 需要的滤波器用于高频段, 或该滤波器使用环境的温差变化较大, 或相关设 备对滤波器的温漂要求较高, 那么可以选择线膨胀系数较小的金属粉末, 例
如钛、 钢, 并且可以增加该金属粉末的重量比例。 如果需要的滤波器使用环 境的温差变化较小, 或相关设备对滤波器的温漂要求不高, 那么可以选择线 膨胀系数稍大且价格便宜的金属粉末, 例如铜、 铝等。
因此, 根据本发明实施例的方法不仅可以用多种粉末材料制成谐振管, 从而获得较低的线膨胀系数, 实现滤波器的温度补偿, 还可以通过对粉末材 料进行选择, 从而根据实际应用情况对不同的谐振管的线膨胀系数进行调整, 此外, 根据本发明实施例的方法可以不改变谐振管的腔体尺寸, 由此能够在 不影响腔体品质因素的同时, 实现对不同频段和腔体尺寸的滤波器进行温度 补偿。
另外, 根据本发明实施例的制造谐振管的方法还具有成本低、 生产效率 高、 一致性好等优点。
具体而言,根据本发明实施例制造的高频段谐振管的成本在 0. 50元以下, 而通过金属机加工制造的谐振管的成本在 0. 80元左右, 单各谐振管的价格相 差 0. 30元, 而 1台腔体滤波器包括接收用的谐振管 24个,由此每台滤波器产 品可节约成本 7. 2元。 如果以滤波器的年产量为 120万台计算, 那么 ^据本 发明实施例的制造谐振管的方法一年就可节约成本 864 万元, 具有^艮高的经 济效益。
另一方面, 根据本发明实施例的方法可以大幅提高生产效率。 例如, 一 台粉末成型设备一天可批量生产 2 万个以上的谐振管, 而一台加工机床一天 却只能加工大概 500 个谐振管, 由此根据本发明实施例的方法可以将谐振管 的生产效率提高 20 ~ 40倍,这对于非常紧急且需大批量生产的射频产品而言, 可大大节约生产时间, 节省时间成本。
并且, 根据本发明实施例的粉末冶金技术采用精密模具和粉末压制技术, 产品尺寸的一致性 4艮高, 例如高度公差通常可以控制在 ± 0. 05匪以内, 由此 根据本发明实施例的方法还具有产品一致性高的优点。 此外, 根据本发明实 施例的制造谐振管的过程中不产生废料, 材料利用率高, 能够节省材料成本。
在本发明实施例中, 选取的粉末颗粒的颗粒度可以在 200 目以上。 可选 地, 粉末颗粒的粒径尺寸具有的重量比例可以为: 粒径尺寸小于 50微米的该 粉末颗粒具有的重量比例为 0—10%; 粒径尺寸小于 100微米且大于或等于 50 微米的该粉末颗粒具有的重量比例为 70—100%;粒径尺寸小于 150微米且大于 或等于 100微米的该粉末颗粒具有的重量比例为 0—20%;粒径尺寸大于 150微 米的该粉末颗粒具有的重量比例为 0—10%。 可选地, 粉末颗粒的中位粒径为 80微米左右。 当然, 选取的粉末颗粒还可以具有更小的颗粒度。
在本发明实施例中, 还可以将混合后的粉末材料进行烘干处理, 形成均 匀的粉末颗粒。 可选地, 在本发明实施例中, 在对粉末颗粒进行压制成型处 理之前, 还可以在烘干后的粉末颗粒中加入质量比为 0. 5%_3%的有机粘合剂, 进行造粒过筛处理, 形成粘性的粉末颗粒, 以选择需要的颗粒度。 可选地, 在本发明实施例中, 在将粉末颗粒进行压制成型处理之后, 还可以将压制形
成的谐振管半成品进行整形处理, 以提高产品外表的光洁度。 可选地, 在本 发明实施例中, 还可以将整形后的谐振管半成品进行封孔处理, 其中该封孔 处理可以包括: 将整形后的谐振管半成品放入熔融的硬脂酸辞、 白油和硅油 中的至少一种中进行浸润, 以避免由于该半成品中的孔隙在电镀时吸附电镀 溶液, 而造成电镀外观上的缺陷; 以及对浸泡后的该谐振管半成品进行烘干 处理。 可选地, 在本发明实施例中, 对该谐振管半成品进行电镀处理可以是: 对烘干后的谐振管半成品进行电镀铜处理, 电镀的铜层厚度不小于 3微米, 例如铜层厚度为 5 微米, 然后在电镀的铜层上进行电镀银处理, 可选地, 该 电镀的银层厚度为 3微米至 5微米。 对谐振管半成品进行电镀处理之后, 可 以形成如图 2所示的谐振管。
图 3是根据本发明另一实施例的制造谐振管的方法 200的流程图。 下面 将结合图 3 , 对根据本发明实施例的方法 200进行详细描述。
在 S210中, 对粉末材料进行混合处理, 其中该粉末材料包括重量比例为 50%_90%的铁粉、 重量比例分别为 1%_30%的铜粉和钢粉中的至少一种、 以及重 量比例为 1%_20%的辅料。 为此, 可以称取不同重量比例的粉末材料进行配料, 并将粉末材料置入球磨机中混合搅拌 24_48h, 待混合均勾后出料。 通过球磨 机对粉末材料进行混合搅拌, 一方面可以使得粉末颗粒混合更均勾, 另一方 面球磨机可以将粉末颗粒磨成一定的细度。
在 S220中,将混合后的该粉末材料进行烘干处理,形成均勾的粉末颗粒。 由于湿法混合更容易使得粉末材料混合均勾, 因此上述混合处理通常采用湿 法混合, 由此需要将混合后的该粉末材料进行烘干以去除水分, 从而形成混 合均匀的粉末颗粒。例如,将出料的浆料放在 120 °C_150 °C的烘箱中烘干 12h。
在 S230中, 在烘干后的该粉末颗粒中加入质量比为 0. 5%_3%的有机粘合 剂, 进行造粒过筛处理, 形成粘性的粉末颗粒, 以形成需要的颗粒度, 其中 该有机粘合剂包括硬脂酸、 硬脂酸辞和聚乙烯醇中的至少一种。 例如, 在烘 干后的粉末颗粒中加入质量比为 1. 5%的硬脂酸辞, 进行造粒过筛处理。
在 S240中, 对该粘性的粉末颗粒进行压制成型处理, 形成谐振管毛坯。 例如,将该粘性粉末颗粒加入到粉末成型机中,并将成型压力调整为 5—10吨, 将粉末颗粒压制成 需尺寸的谐振管。 该谐振管的厚度可以是 1. 0 毫米—2. 0 毫米, 或 1. 3毫米—1. 8毫米, 可选地, 该谐振管的厚度可以是 1. 5毫米。
在 S250中, 在保护气氛中对该谐振管毛坯进行烧结处理, 形成谐振管半 成品, 其中该保护^氛包括真空气氛, 或氢气和 性气体中的至少一种, 烧 结温度可以是 700 °C_115 (TC , 烧结时间可以是 4h_10h。 通过烧结处理后, 该 谐振管半成品可具有所需的强度和硬度。
在 S260中, 将该谐振管半成品进行整形处理, 以提高谐振管外表的光洁 度。
在 S270中, 将整形后的该谐振管半成品放入熔融的硬脂酸辞、 白油和硅 油中的至少一种中进行浸润, 以避免电镀时产生外观缺陷。 例如, 将该半成
—,― 品放入硅油中浸润 4h_24h , 可选地, 浸润 12h。
在 S280中, 对浸泡后的该谐振管半成品进行烘干处理。 例如, 将该半成 品放入 100 °C_150 °C烘箱中低温烘干, 进行封孔处理。
在 S290中, 对烘干后的该谐振管半成品进行电镀铜处理, 再在电镀的铜 层上进行电镀银处理。 其中电镀层的厚度可以根据需要应用的频段和趋肤效 应来确定, 例如, 对于应用于 90幌 Hz频段的谐振管, 需要的镀层厚度为 5微 米; 对于应用于 180幌 Hz或 260幌 Hz以上频段的谐振管, 需要的镀层厚度可 以是 3微米。 如果镀层厚度太大则增加了成本, 而如果镀层厚度太小, 则谐 振管的导电性不好, 进而影响滤波器的插入损耗偏大, 因此, 可以根据需要 选择镀层的厚度。 在本发明实施例中, 电镀的铜层厚度不小于 3微米或不小 于 5微米, 例如铜层厚度为 6微米, 可选地, 该电镀的银层厚度为 3微米至 5 微米。 当然, 也可以选择导电性良好的其他金属进行电镀, 使得滤波器导电 性好, 并且插入损耗较小。
本发明实施例的方法通过选用多种粉末材料, 并基于粉末冶金技术制造 在不影响腔体品质因素的同时, 实现对滤波器进行温度补偿, 从而能够保证 滤波器在不同温度下的电性能。 另外, 本发明实施例的方法还可以通过对粉 末材料进行选择, 从而根据实际应用情况对不同的谐振管的线膨胀系数进行 调整, 由此能够实现对不同频段和腔体尺寸的滤波器进行温度补偿。 此外, 根据本发明实施例的制造谐振管的方法还具有成本低、 生产效率高、 一致性 好等优点。
下文中将以两个具体实施例为例, 对根据本发明实施例的制造谐振管的 方法进行描述。
对于应用于个人通信月良务 ( Per sona l Communi ca t ion Serv i ce , 筒称为 "PCS" )频段( 1920—198幌 Hz ) 的腔体滤波器而言, 其谐振管的制造过程如 下: _ _ _
( 1 )选取质量比分别为 50%_90%的铁粉、 1%_30%的钢粉和 1%_20%的石墨 粉进行配料, 可选地, 选取质量比分别为 70%的还原铁粉、 28 %的钢粉以及 2 %的石墨粉进行配料, 在球磨机中混合搅拌 24_48h, 例如混合搅拌 48h, 待 粉末材料混合均勾后出料。 _
( 2 )将出料的浆料放在 120 °C_150 °C的烘箱中烘干 12h左右, 形成均匀 的粉末颗粒。
( 3 )将粉末颗粒按照 0. 5%_3%的质量比加入有机粘合剂, 例如, 加入质 量比为 1%的有机粘合剂, 进行造粒过筛, 形成具有一定粘性的粉末颗粒。
( 4 )将该粘性的粉末颗粒加入到粉末成型机中压制成型, 成型压力调整 为 5—10吨。
( 5 )将成型的毛坯放在具有氢气气氛的 700 °C _1 150 °C高温的隧道窑中烧 结 6h , 例如该隧道窑具有 1120 °C的高温。
( 6 )将烧结后的产品进行整形。 _
( 7 )将整形后的产品放在硅油中浸泡, 然后在 100°C_15(rC下进行烘烤, 可选地, 在 120°C的温度下进行烘烤, 从而进行封孔处理。
( 8 )将封孔后的产品进行电镀铜处理,其中电镀的铜层厚度为 3μηι以上, 例如电镀的铜层厚度为 8μηι, 然后再进行电镀银处理, 其中电镀的银层厚度为 3μηι 5μηι。
在上述方法中, 将制造的该谐振管放在 -40°C_+85°C的测试环境中, 计算 出该谐振管的线膨胀系数为 +8ppm/ °C。 并且将该电镀后 ^谐振管产品安装在 腔体滤波器中进行调试后发现, 当该滤波器处于 -40°C~+85°C的测试环境中 时, 该滤波器的温漂小于 20kHz, 由此可以认为该滤波器没有温漂。
对于应用于 WiMAX 2.5GHz且带宽为 17MHz的滤波器而言, 其谐振管采用 如下方法进行制造:
( 1 )选取质量比分别为 50%的还原铁粉、 35 %的铜粉和 15 %的镍粉进行 配料, 在球磨机中混合搅拌 24_48h, 待粉末材料混合均匀后出料。
( 2)将出料的浆料放在 120°C_150°C的烘箱中烘干, 形成均匀的粉末颗 粒。
( 3 )将粉末颗粒按照 1%_2 %的质量比加入有机粘合剂硬脂酸, 进行造粒 过筛, 形成具有一定粘性的粉末颗粒。
(4)将该粘性粉末颗粒加入到粉末成型机中压制成型, 成型压力调整为 6 8 p屯。
( 5 )将成型的毛坯在氢气气氛下并且在 750°C_120(rC的温度下进行烧 结, 烧结时间为 8h, 例如将该毛坯放在 820°C的温度下进行烧结。
( 6)将烧结后的产品进行整形, 以提高产品外观^光洁度。
( 7 )将整形后的产品在硅油中浸泡, 然后在 80°C_100°C的低温下进行烘 烤, 以进行封孔处理。
( 8 ) 将封孔后的产品进行电镀铜处理, 其中电镀的铜层的厚度为 3μηι~6μηι, 然后再进行电镀银处理, 其中电镀的银层厚度 3μηΓ4μηι。
在上述方法中, 将制造的该谐振管放在 -40°C_+85°C的测试环境中, 计算 出该谐振管的线膨胀系数为 +15.5ppm/°C。 并且将电^后的谐振管产品安装在 腔体滤波器中, 进行调试后发现, 该滤波器在 -40°C_+85°C的测试环境中, 温 漂小于 30kHz, 由此也可以认为该滤波器没有温漂。
本发明实施例还提供了一种谐振管, 该谐振管根据本发明实施例的制造 谐振管的方法而制成, 其中该方法包括: 对粉末材料进行混合处理, 形成均 匀的粉末颗粒, 其中该粉末材料包括重量比例为 50%_90%的铁粉, 以及重量比 例分别为 1%_30%的铜粉和钢粉中的至少一种; 对该粉末颗粒进行压制成型处 理, 形成谐振管毛坯; 在保护气氛中对该谐振管毛坯进行烧结处理, 形成谐 振管半成品; 对该谐振管半成品进行电镀处理, 形成该谐振管。
在本发明实施例的谐振管中, 该谐振管具有的线膨胀系数可以在 +4 ppm/
°C~+16 ppm/ °C的范围内。例如,谐振管的线膨胀系数可以是 +6 ppm/ °C、+8 ppm/ °C、 +1 0 ppm/ °C、 +12 ppm/ °C或 +14 ppm/ °C。 另外, 该谐振管的厚度可以是 1. 0毫米—2. 0毫米, 或 1. 3毫米—1. 8毫米, 可选地, 该谐振管的厚度可以是 1. 5毫米。
本发明实施例还提供了一种滤波器, 该滤波器包括至少一个根据本发明 实施例的谐振管, 以及至少一个设置在该谐振管上的调谐装置, 该调谐装置 用于调整谐振管的谐振频率, 该谐振管根据本发明实施例的制造谐振管的方 法而制成, 该方法包括: 对粉末材料进行混合处理, 形成均勾的粉末颗粒, 其中该粉末材料包括重量比例为 50%_90%的铁粉,以及重量比例分别为 1%_30% 的铜粉和钢粉中的至少一种; 对该粉末颗粒进行压制成型处理, 形成谐振管 毛坯; 在保护气氛中对该谐振管毛坯进行烧结处理, 形成谐振管半成品; 对 该谐振管半成品进行电镀处理、,、形成该谐振^。 、、、、、 。。、 、 、、 、 、 如图 4所示,示出了应用于 WiMAX 2. 5GHz且带宽为 17MHz的腔体滤波器在 +25 ° 和+85 ° 时的 S参数曲线, 从图中可以看出两条曲线基本重合, 即该滤波器 的通带在不同的温度下未产生漂移, 由此可以认为该滤波器为零温漂产品。
本发明实施例的谐振管和滤波器通过选用多种粉末材料, 并基于粉末冶 由此实现对滤波器,行温度补偿,、 而能够保证滤波器在不同温度下的电性 实际应用情况对不同的谐振管的线膨胀系数进行调整, 由此能够实现对不同 频段和腔体尺寸的滤波器进行温度补偿, 由此可以使得该产品不但可以应用 于寒冷的地区, 也可以应用于气候炎热的非洲地区, 并保证了滤波器的正常 射频指标插入损耗, 也保证了基站收发信机的正常工作。 此外, 根据本发明 实施例的谐振管和滤波器还具有成本低、 生产效率高、 一致性好等优点。
本发明实施例还提供了一种谐振管, 其中该谐振 f由粉末材料并基于粉 末冶金技术制成, 其中该粉末材料包括重量比例为 50%_90%的铁粉、 重量比例 分别为 1%_30%的铜粉和钢粉中的至少一种、 以及重量比例为 1%_20%的辅料。
在本发明实施例中, 该粉末材料还可以包括辞粉、 镍粉、 钼粉和钛粉中 的至少一种。 可选地, 该粉末材料还可以包括碳粉、 陶瓷粉和玻璃粉中的至 少一种。
在本发明实施例中, 该谐振管具有的线膨胀系数在 +4 ppm/ °C ~+16 ppm/ °C的范围内。 例如, 谐振管的线膨胀系数可以是 +6 ppm/ °C、 +8 ppm/ °C、 +1 0 ppm/ °C、 +12 ppm/ °C或 +14 ppm/ °C。 另外, 该谐振管的厚度可以是 1. 0 毫米 "2. 0毫米, 或 1. 3毫米—1. 8毫米,可选地, 该谐振管的厚度可以是 1. 5毫米。
在本发明实施例中, 该谐振管的表面电镀有铜层, 其中铜层的厚度_不小 于 3微米。 该谐振管的铜层上还电镀有银层, 其中银层的厚度为 3微米 _5微 米。
本发明实施例还提供了一种滤波器, 该滤波器包括至少一个根据本发明 实施例的谐振管, 以及至少一个设置在谐振管上的调谐装置, 该谐振管 粉 末材料并基于粉末冶金技术制成, 其中该粉末材料包括重量比例为 50%_90% 的铁粉、 重量比例分别为 1%_30%的铜粉和钢粉中的至少一种、 以及重量比例 为 1%_20%的辅料。
本发明实施例的谐振管和滤波器, 通过选用多种粉末材料, 并基于粉末 数, 由此能够在不影响腔体品质因素的同时, 实现对滤波器进行温度补偿, 从而能够保证滤波器在不同温度下的电性能, 并且通过对粉末材料进行选择, 可以调整不同谐振管的线膨胀系数, 由此能够实现对不同频段和腔体尺寸的 滤波器进行温度补偿。 另外, 根据本发明实施例的谐振管和滤波器还具有成 本低、 生产效率高、 一致性好等优点。
本领域普通技术人员可以意识到, 结合本文中所公开的实施例中描述的 各方法步骤和单元, 能够以电子硬件、 计算机软件或者二者的结合来实现, 为了清楚地说明硬件和软件的可互换性, 在上述说明中已经按照功能一般性 地描述了各实施例的步骤及组成。 这些功能究竟以硬件还是软件方式来执行, 取决于技术方案的特定应用和设计约束条件。 本领域普通技术人员可以对每 个特定的应用来使用不同方法来实现所描述的功能, 但是这种实现不应认为 超出本发明的范围。
结合本文中所公开的实施例描述的方法或步骤, 可以用硬件、 处理器执 行的软件程序,或者二者的结合来实施。软件程序可以置于随机存储器( RAM ), 内存、 只读存储器 0M )、 电可编程 R0M、 电可擦除可编程 R0M、 寄存器、 硬 盘、 可移动磁盘、 CD-R0M、 或技术领域内所公知的任意其它形式的存储介质 中。 … … ' 、 , 、 、 、 . ; 但本发明并不限于此。 在不脱离本发明的精神和实质的前提下, 本领域普通 技术人员可以对本发明的实施例进行各种等效的修改或替换, 而这些修改或 替换都应在本发明的涵盖范围内。
Claims
1、 一种制造谐振管的方法, 其特征在于, 包括:
对粉末材料进行混合处理, 形成均勾的粉末颗粒, 其中所述粉末材料包括 重量比例为 50%_90%的铁粉、 重量比例分别为 1%_30%的铜粉和钢粉中的至少一 种、 以及重量比例为 1%_20%的辅料;
对所述粉末颗粒进行压制成型处理, 形成谐振管毛坯;
在保护气氛中对所述谐振管毛坯进行烧结处理, 形成谐振管半成品; 对所述谐振管半成品进行电镀处理, 形成所述谐振管。
2、 根据权利要求 1所述的方法, 其特征在于, 所述粉末材料还包括辞粉、 镍粉、 钼粉和钛粉中的至少一种。
3、 根据权利要求 1所述的方法, 其特征在于, 所述粉末材料还包括碳粉、 陶瓷粉和玻璃粉中的至少一种。
4、 根据权利要求 1至 3中任一项所述的方法, 其特征在于, 所述粉末颗粒 的粒径尺寸具有的重量比例为:
粒径尺寸小于 50微米的所述粉末颗粒具有的重量比例为 0—1 0%;
粒径尺寸小于 1 00微米且大于或等于 5 0微米的所述粉末颗粒具有的重量比 例为 70—1 00%;
粒径尺寸小于 150微米且大于或等于 1 00微米的所述粉末颗粒具有的重量 比例为 0—20%;
粒径尺寸大于 150微米的所述粉末颗粒具有的重量比例为 0—1 0%。
5、 根据权利要求 1所述的方法, 其特征在于, 所述方法还包括:
将混合后的所述粉末材料进行烘干处理, 形成均匀的粉末颗粒。
6、 根据权利要求 5所述的方法, 其特征在于, 所述方法还包括:
在对所述粉末颗粒进行压制成型处理之前, 在烘干后的所述粉末颗粒中加 入质量比为 0. 5%_3%的有机粘合剂, 进行造粒过筛处理, 形成粘性的粉末颗粒。
7、根据权利要求 6所述的方法, 其特征在于, 所述有机粘合剂包括硬脂酸、 硬脂酸辞和聚乙烯醇中的至少一种。
8、根据权利要求 1所述的方法, 其特征在于, 所述保护气氛包括真空气氛, 或氢气和惰性气体中的至少一种。
9、 根据权利要求 1所述的方法, 其特征在于, 所述方法还包括:
在对所述谐振管半成品进行电镀之前, 将所述谐振管半成品进行整形处理。
1 0、 根据权利要求 9所述的方法, 其特征在于, 所述方法还包括: 在对所述谐振管半成品进行电镀之前, 将整形后的所述谐振管半成品进行 封孔处理。
11、 根据权利要求 10所述的方法, 其特征在于, 所述将整形后的所述谐振 管半成品进行封孔处理, 包括:
将整形后的所述谐振管半成品放入熔融的硬脂酸辞、 白油和硅油中的至少 一种中进行浸润; 对浸泡后的所述谐振管半成品进行烘干处理。
12、 根据权利要求 1 1所述的方法, 其特征在于, 所述对所述谐振管半成品 进行电镀处理, 包括:
对烘干后的所述谐振管半成品进行电镀铜处理, 再在电镀的铜层上进行电 镀银处理。
1 3、 根据权利要求 1 所述的方法, 其特征在于, 在所述电镀铜处理中, 电 镀的铜层厚度不小于 3微米。
14、 根据权利要求 1 所述的方法, 其特征在于, 在所述电镀银处理中, 电 镀的银层厚度为 3微米 _5微米。
15、 一种谐振管 其特征在于, 所述谐振管包括:
重量比例为 5 0%_90%的铁;
重量比例分别为 1%_30%的铜和钢中的至少一种; 以及
重量比例为 1 %_20%的辅料,
其中所述谐振管根据权利要求 1至 14中任一项所述的方法进行制造。
16、 根据权利^;求 15所述的谐振管, 其特征在于, 所述谐振管具有的线膨 胀系数在 +4 ppm/ °C~+16 ppm/ °C的范围内。
17、根据权利要求 1 5所述的谐振管,其特征在于,所述谐振管的厚度为 1. 5 毫米。
18、 一种滤波器, 其特征在于, 所述滤波器包括:
至少一个根据权利要求 15至 17中任一项所述的谐振管; 以及
至少一个设置在所述谐振管上的调谐装置。
19、 一种谐振管, 其特征在于, 所述谐振管 粉末材料并基于粉末冶金技 术^成, 其中所述粉末材料包括重量比例为 50%_90%的 粉、 重量比例分别为 1%_30%的铜粉和钢粉中的至少一种、 以及重量比例为 1 %_20%的辅料。
20、 根据权利要求 19所述的谐振管, 其特征在于, 所述粉末材料还包括辞 粉、 镍粉、 钼粉和钛粉中的至少一种。
21、根据权利要求 19所述的方法, 其特征在于, 所述粉末材料还包括碳粉、 陶瓷粉和玻璃粉中的至少一种。
22、 根据权利要求 19所述的谐振管, 其特征在于, 所述谐振管的表面电镀 有铜层, 所述铜层的厚度不小于 3微米。
23、 根据权利要求 19所述的谐振管, ^特征在于, 所述谐振管的所述铜层 上还电镀有银层, 所述银层的厚度为 3微米 _5微米。
24、 根据权利^ ^ 19所述的谐振管, 其特征在于, 所述谐振管具有的线膨 胀系数在 +4 ppm/ °C~+16 ppm/ °C的范围内。
25、根据权利要求 1 9所述的谐振管,其特征在于,所述谐振管的厚度为 1. 5 毫米。
26、 一种滤波器, 其特征在于, 所述滤波器包括:
至少一个根据权利要求 19至 25中任一项所述的谐振管; 以及
至少一个设置在所述谐振管上的调谐装置。
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CN103928731A (zh) * | 2014-04-30 | 2014-07-16 | 华为技术有限公司 | Tem模介质滤波器和制造方法 |
CN107086348A (zh) * | 2017-04-19 | 2017-08-22 | 东莞洲亮通讯科技有限公司 | 谐振柱放料装置 |
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