The disclosed embodiments relate to circulators used in radio systems.
Microwave radios play an increasingly important role in backhaul connectivity because of their high flexibility and low cost. In a radio system, a circulator is often used in the front end of a transmitter/receiver (TX/RX) to increase the isolation between transmitted and received signals. A circulator is a non-reciprocal three- or four-port microwave device, in which a microwave or radio frequency signal entering any port is transmitted, in the ideal case, only to the next port in a rotation direction. This is called “non-reciprocal behavior” because the transmission between a first port and a second port is not the same as the transmission between the second port and the first port. A port in this context is a point where an external waveguide or transmission line (such as a microstrip or a coaxial cable), connects to the circulator. For a three-port circulator, a signal applied to port S1 only comes out of port S2; a signal applied to port S2 only comes out of port S3; and a signal applied to port S3 only comes out of port S1. To reduce cost and size, microstrip circulators are popular for low cost radios, while waveguide circulators are expensive, bulky and hard to integrate with printed circuit boards (PCB), which are widely used in electronic products.
Ferrite circulators are radio frequency circulators that include magnetized ferrite materials. They fall into two main classes: 4-port waveguide circulators based on Faraday rotation of waves propagating in a magnetized material, and 3-port “Y-junction” circulators based on cancellation of waves propagating over two different paths near the magnetized ferrite material. Waveguide circulators may be of either type, while more compact devices based on strip lines are of the 3-port type. Two or more Y-junctions can be combined in a single component to give four or more ports, but these differ in behavior from a true 4-port circulator. A permanent magnet produces magnetic flux through the magnetic ferrite material in the circulator.
Unfortunately, ferrite material is not suitable to be used as a microwave substrate due to its high resistivity and large anisotropy. Hence, in most circulators, use of ferrite material is limited to a small portion of the circulator and not as the substrate.
To address the aforementioned problems, some implementations provide a circulator that includes a substrate having a blind hole. The substrate has one or more dielectric layers and one or more conductive layers, including a top conductive layer on a top surface of the substrate. The circulator includes a plurality of conductive microstrips formed on the top conductive layer on the top surface of the substrate and a ferrite disk positioned within the blind hole. A top surface of the ferrite disk is flush with a top surface of the plurality of conductive microstrips. The circulator further includes a flat metal film coupling a top surface of the ferrite disk to the conductive microstrips disposed on the top surface of the substrate.
In some embodiments, the substrate includes a first ground plane formed from a respective conductive layer of substrate. The respective conductive layer is disposed within an interior of the substrate. The substrate further includes a second ground plane formed from a bottom conductive layer of the substrate. The bottom conductive layer is disposed on a bottom surface of the substrate. The circulator further comprises a magnet coupled with the second ground plane disposed on the bottom surface of the substrate.
In some embodiments, the circulator includes a second magnet coupled with a surface of the flat metal film that is distal to the top surface of the ferrite disk.
In some embodiments, the circulator includes a metal pin that is coupled with a surface of the flat metal film that is distal to the top surface of the ferrite disk.
In some embodiments, the flat metal film comprises a metallization layer on the top surface of the ferrite disk.
In some embodiments, the flat metal film is a flat metal plate.
In some embodiments, each of the plurality of conductive microstrips is electrically coupled by the flat metal film to pass a signal between respective conductive microstrips of the plurality of microstrips according to a rotation direction of the circulator.
In some embodiments, the circulator is a three-port microstrip circulator.
In some embodiments, the blind hole goes through a top dielectric layer of the substrate without going into any other dielectric layers of the substrate.
For a better understanding, reference should be made to the following detailed description taken in conjunction with the accompanying drawings, in which:
Like reference numerals refer to corresponding parts throughout the drawings.
Reference will now be made in detail to various implementations, examples of which are illustrated in the accompanying drawings. In the following detailed description, numerous specific details are set forth in order to provide a thorough understanding of the present disclosure and the described implementations herein. However, implementations described herein may be practiced without these specific details. In other instances, well-known methods, procedures, components, and mechanical apparatus have not been described in detail so as not to unnecessarily obscure aspects of the implementations.
As used herein, the term radio frequency (RF) includes microwave frequencies. In some embodiments, RF frequencies are frequencies in the range extending from around 3 kHz to 300 GHz. In some embodiments, RF frequencies include very low frequency (VLF) signals, low frequency (LF) signals, medium frequency (MF) signals, high frequency (HF) signals, very high frequency (VHF) signals, ultra-high frequency (UHF) signals, super high frequency (SHF) signals, and extremely high frequency (EHF) signals. Microwave frequencies are generally in a band between 3 GHz to 300 GHz, but definitions may vary.
As used herein, the term “metal plate” means a distinct metal piece, such as a piece of sheet metal or foil. A metal plate is distinct from and not chemically bonded to an underlying surface, except indirectly (e.g., in the case of solder). The term “metallization layer” means a layer of metal deposited directly on an underlying surface using a metallization technique (e.g., a technique for coating metal on the surface of objects). A metallization layer is chemically bonded to the underlying surface. The term “metal film” is used to encompass both metal plates and metallization layers (e.g., aluminum foil is a metal film, but so is a metal coating on a surface).
As used herein, the term “microstrip” refers to a patterned metal layer that serves as one of the conductors in a microstrip transmission line. A microstrip has a dielectric on one side, but unlike a stripline, is not sandwiched in dielectric.
As noted above, integrating ferrite material with RF/Microwave circuit substrates is a challenge. To address this problem,
Thus, in a geometry in which ferrite disk 102 is floating on substrate 104, patterned metal plate 110 has to be formed into a 3-D shape (e.g., by bending a patterned sheet of metal). This introduces many disadvantages, such as high cost, difficult assembly, and large impedance mismatching stemming from the tolerances needed to place a manufactured 3-D shape over ferrite disk 102.
Circulator 200 includes a substrate 204, which in this example is a three-layer PCB. The three-layer PCB includes dielectric layers 208A-208C and metal layers 209A-D. Metal layers 209A-D include ground planes 211A-C that are connected (e.g., electrically coupled) by vias 212A-212B. In some embodiments, ground plane 211A (e.g., the ground plane of microstrips 214) is formed on metal layer 209B, which is disposed within an interior of substrate 204. Ground plane 211C is formed on metal layer 209D, which is on a bottom surface of substrate 204. Circulator 200 further includes a magnet 206 adjacent to ground plane 211C disposed on the bottom surface of substrate 204 (e.g., a neodymium or other rare-earth magnet).
Substrate 204 has a blind hole 216 (e.g., substrate 204 has a slot removed from its top surface). As used herein, the term “blind hole” refers to a hole that is reamed, drilled, milled, or otherwise manufactured to a specified depth without breaking through to the other side of the work piece (e.g., substrate 204). The etymology is that, since the hole does not go all the way through the work piece, it is not possible to see through the blind hole. In some embodiments, blind hole 216 in substrate 204 is a through hole through the top layer of the three-layer PCB (where the top layer includes a top dielectric layer 208A). In some embodiments, blind hole 216 is formed by fabricating a through hole in the top layer of the three-layer PCB before assembling the PCB.
Circulator 200 includes a plurality of conductive microstrips 214 disposed on a top surface of substrate 204 (e.g., microstrip 214A-214B, as well as a third microstrip not shown because of the perspective). In some embodiments, conductive microstrips 214 are formed by patterning top metal layer 209A of substrate 204. In some embodiments, a conductive microstrip is a conductive portion of a metal transmission line printed on the circuit board. An outer terminus of a conductive strip 214 is a port of circulator 200.
Circulator 200 includes ferrite disk 202 positioned within blind hole 216. Ferrite disk 202 is embedded below the top surface of substrate 204 (as shown in
Circulator 200 also includes a flat (e.g., unbent) metal film 210 coupling a top surface of ferrite disk 202 to conductive microstrips 214. Metal layer 210 is disposed on the top surface of microstrip 214. In some embodiments, because ferrite disk 202 is inset into substrate 204, metal film 210 can be placed flush over ferrite disk 202 while maintaining electrical contact (e.g., conductive contact) with both ferrite disk 202 and conductive microstrips 214 (e.g., each of conductive microstrips 214). For example, flat metal film 210 is in direct contact with both the top surface of the ferrite disk 202 and each of the plurality of conductive microstrips 214. In some embodiments, as shown in
In some embodiments, although not shown, circulator 200 further includes a metal pin or a second magnet positioned above (e.g., on top of) patterned metal plate 210, as described with reference to
By embedding ferrite disk 202 in substrate 204 so that the top of ferrite disk 202 is flush with the top of substrate 204, circulator 200 eliminates the problems associated with the 3-D shaping of patterned metal plate 110 shown in
Because no real circulator is ideal, circulators are characterized by insertion loss, return loss, and isolation. Insertion loss refers to the attenuation between two ports that are arranged, with respect to one another, in the rotation direction of circulator 300 (e.g., the direction for which circulator 300 is supposed to pass a signal). For example, the attenuation from S1 to S2 is referred to as the S-parameter S[2,1] insertion loss. Isolation refers to the attenuation between two ports that are arranged, with respect to each other, opposite the rotation direction of circulator 300 (e.g., the direction for which circulator 300 is supposed to attenuate signals). For example, the attenuation from S2 to S1 is referred to as the S-parameter S[1,2] isolation. Return loss refers to the power returned to a respective port relative to the incident power (e.g., as measured in decibels). For example, the power incident upon port S1 and returned to S1 is referred to as the S-parameter S[1,1] return loss.
Because circulator 300 is a partially-integrated microstrip circulator, circulator 300 includes a metal plate 310 soldered to microstrips 314 (e.g., soldered to each microstrip 314) that is positioned over a ferrite disk 302.
In accordance with some embodiments, circulator 300 can be fabricated as follows (1) a top metal layer of a substrate is patterned according to a desired circuit pattern; (2) a blind hole is fabricated into substrate; (3) metal plate 310 is fabricated from a thin metal sheet (e.g., a 30-38 gauge copper sheet metal, although the thickness may differ for different applications); (5) ferrite disk 302 is placed in the blind hole of the substrate, and (5) metal plate 310 is aligned to at least partially cover ferrite disk 302 and subsequently soldered to the microstrips 314.
The partially-integrated microstrip circulator 300 shown in
In some circumstances, a fully-integrated microstrip circulator can be fabricated with reduced assembly time and improved (e.g., reduced) discontinuity of the signal paths (e.g., RF signal paths). Accordingly, the fabrication process of microstrip circulator 318 is follows: (1) a top metallization layer of substrate is patterned according to a desired circuit pattern; (2) a blind hole in the top layer of the substrate is fabricated; (3) the ferrite disk is fixed in place in the blind hole; (4) a thin layer of metal 320, such as silver or copper, is deposited on the top surface of the ferrite disk; and (5) a desired circuit pattern is etched into the layer of metal (alternatively, a mask can be used to pattern the desired circuit pattern when it is deposited). Lastly, (6) the circuit pattern on the top of ferrite disk is connected with the circuit on substrate (e.g., metallization technique or plating). Using this approach, the soldering step is unnecessary, thus making the assembly much easier and reducing discontinuities due to the soldering.
The fully-integrated microstrip circulator 318 shown in
In addition, microstrip circulator assembly 500 includes several packaging components, including a cover 520 (e.g., an aluminum cover), a base 522 (e.g., an aluminum base), and screws 524. Cover 520 includes unthreaded through holes 526. Base 522 includes threaded holes 528. Screws 524 pass through holes 526 in cover 520, pass through holes 518 in substrate 504, and are screwed into holes 528 in base 522. However,
In some embodiments, microstrip circulator assembly 500 further includes a metal pin or a second magnet positioned above (e.g., on top of) metal plate 510, as described with reference to
The foregoing description, for purpose of explanation, has been described with reference to specific implementations. However, the illustrative discussions above are not intended to be exhaustive or to limit the implementations to the precise forms disclosed. Many modifications and variations are possible in view of the above teachings. The implementations were chosen and described in order to best explain the principles of the disclosure and its practical applications, to thereby enable others skilled in the art to best utilize the various implementations with various modifications as are suited to the particular use contemplated.
It will be understood that, although the terms “first,” “second,” etc. are sometimes used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another. For example, a first element could be termed a second element, and, similarly, a second element could be termed a first element, without changing the meaning of the description, so long as all occurrences of the “first element” are renamed consistently and all occurrences of the second element are renamed consistently. The first element and the second element are both elements, but they are not the same element.
The terminology used herein is for the purpose of describing particular implementations only and is not intended to be limiting of the claims. As used in the description of the implementations and the appended claims, the singular forms “a”, “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will also be understood that the term “and/or” as used herein refers to and encompasses any and all possible combinations of one or more of the associated listed items. It will be further understood that the terms “comprises” and/or “comprising,” when used in this specification, specify the presence of stated features, integers, operations, elements, and/or components, but do not preclude the presence or addition of one or more other features, integers, operations, elements, components, and/or groups thereof.
As used herein, the term “if” may be construed to mean “when” or “upon” or “in response to determining” or “in accordance with a determination” or “in response to detecting,” that a stated condition precedent is true, depending on the context. Similarly, the phrase “if it is determined (that a stated condition precedent is true)” or “if (a stated condition precedent is true)” or “when (a stated condition precedent is true)” may be construed to mean “upon determining” or “in response to determining” or “in accordance with a determination” or “upon detecting” or “in response to detecting” that the stated condition precedent is true, depending on the context.
Throughout the preceding description, various implementations are described within the outdoor units and antenna assemblies. This is purely for convenience of explanation and is not intended to limit the claims that follow. Various implementations described can be implemented in waveguide applications of any sort.
Filing Document | Filing Date | Country | Kind |
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PCT/US2017/061524 | 11/14/2017 | WO | 00 |
Number | Date | Country | |
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62424192 | Nov 2016 | US |