Abstract:
A method for attaching an additional object to a resonator body. The method includes the steps of (1) placing the additional object in a recess of a pushing part of an extrusion machine; (2) pressing the pushing part against a bloom of a resonator body; and (3) pulling the pushing part back from the resulting resonator body. The attaching of the additional object occurs in conjunction with the extrusion process.

Description:
This application is a divisional of application Ser. No. 09/902,852, filed Jul. 10, 2001. 
    
    
     FIELD OF INVENTION 
     The invention relates to a method for attaching a part to a body of a resonator, which body is made by the process of extruding. The resonator may be a portion of a resonator filter. 
     BACKGROUND 
     Air-insulated coaxial resonators are popular e.g. in radio-frequency filters at base stations of mobile communication networks because of their relatively good electrical characteristics and good manufacturability. A coaxial resonator is most often a quarter-wave resonator where one end of the resonator is short-circuited, ie. the inner conductor and outer conductor of the resonator are in galvanic contact, and the other end is open. When manufacturing a filter comprising a plurality of resonators, it has to be taken into account that the desired frequency response of the filter may require inner conductors of different lengths. In addition, it may be necessary to compensate for the change in the resonance frequency caused by thermal expansion in the resonator structure. 
     There are several known methods for manufacturing coaxial resonators functioning as filter elements. FIGS. 1 and 1 a  depict a known structure viewed from the side (FIG. 1) and from the bottom (FIG. 1 a ). Shown in the figures are a resonator&#39;s outer conductor  111 , inner conductor  120 , and the bottom  112 . The outer conductor and the bottom have shown in longitudinal section in FIG.  1 . They constitute a single body  110  having a quadrangular cross section and a cylinder-shaped cavity. The body  110  is manufactured by the process of milling or extruding, for example. The inner conductor is in the said cavity, attached to the bottom  112  of the resonator so that the bottom provides the short circuit between the inner and outer conductor. In this example, the attachment of the inner conductor is realized using a screw  130  extending through the bottom to the inner conductor. The inner conductor may be of the same or different material than the body  110 . In the latter case, the temperature compensation in the resonator may be realized through the choice of materials. 
     A disadvantage of the method appearing in FIGS. 1 and 1 a  is that the attachment of the inner conductor takes several manufacturing stages and the attachment strength does not meet the strictest requirements. Moreover, the interfaces between the different metals in the structure may cause harmful intermodulation products when using the device. 
     FIG. 2 shows a longitudinal section of another known structure. The figure shows the resonator&#39;s outer conductor  211  and bottom  212 . The resonator&#39;s inner conductor has now two parts: A lower part  213  nearer the bottom of the resonator and an upper part  220  forming a continuation of the lower part. In this example, the lower part  213  of the inner conductor, bottom  212  and the outer conductor  211  constitute a single body  210 . At the bottom end of the upper part of the inner conductor there is a cylindrical hollow  221  the diameter of which equals that of the lower part of the inner conductor. Thus the upper part  220  may be pushed onto the lower part  213  as a cap. The purpose of the upper part of the inner conductor is to provide for the temperature compensation in the resonator. A disadvantage of the manufacturing method appearing in FIG. 2 is that the attachment of the inner conductor requires a separate manufacturing stage. Moreover, in this case, too, the risk of harmful intermodulation is apparent at the boundary surface of pressing joint. 
     SUMMARY 
     An object of the invention is to reduce the above-mentioned disadvantages associated with the prior art. The method according to the invention is characterized by that which is specified in the independent claim 1. Some preferred embodiments of the invention are specified in the other claims. 
     The basic idea of the invention is as follows: A resonator body is manufactured by means of extrusion. In the pushing part of the extrusion machine a recess is made which is shaped like a portion of the surface of the additional object to be attached to the body. The additional object, such as a portion of an inner conductor, is inserted prior to the extrusion in the recess so that said portion of the surface of the additional object is positioned tightly against the surface of the recess and the rest of the surface of the additional object remains free. In the extrusion stage, the pushing part with the additional object is pressed against the bloom of body whereby the material of the bloom is pressed tight against the free surface of the additional object. When the pushing part is retracted the additional object remains attached to the body thus formed. The extrusion machine may have several pushing parts, whereupon several additional objects will be attached at the same time in a manufacturing process of a filter. 
     An advantage of the invention is that in conjunction with the manufacturing of the body part of the structure being manufactured, parts may be added to the body without separate manufacturing steps. This means savings in the manufacturing costs. Another advantage of the invention is that the joint according to the invention between the additional part and body part is stronger and more uniform than similar prior-art joints. This means higher reliability of the structure and less intermodulation at the boundary surface of the joint. A further advantage of the invention is that in the case of several additional objects the inner conductors of the different resonators may be manufactured in different lengths, if necessary, by using recesses of different lengths in the pushing parts of the extrusion machine. The additional objects to be attached to the inner conductors may then be identical, which is advantageous from the standpoint of manufacture. 
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS 
     The invention is described in more detail in the following. Reference is made to the accompanying drawings in which 
     FIGS. 1 and 1 a  show examples of a method for attaching a part to a resonator, according to the prior art, 
     FIG. 2 shows another example of a method for attaching a part to a resonator, according to the prior art, 
     FIGS. 3 a-   1 ,  3   a-   2 ,  3   b,    3   c,    3   d-   1  and  3   d-   2  show examples of methods according to the invention and resulting resonator. 
     FIGS. 4 a-   4   e  show more examples of resonators manufactured according to the invention, and 
     FIG. 5 shows an example of a filter manufactured by the method according to the invention. 
    
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS 
     FIGS. 1,  1   a  and  2  were already discussed in conjunction with the description of the prior art. 
     FIGS. 3 a,    3   a-   1  and  3   a-   2  depict initial situations of the manufacturing method according to the invention. Shown in the FIG. 3 a  is a bloom  31   a  of a resonator body, an additional object  320  to be attached to the body structure, an extrusion base EB (FIG. 3 a-   1 ) serving as a mold, and a pushing part ES FIGS. 3 a-   1  and  3   a-   2  of an extrusion machine. The additional object  320  (FIG. 3 a ) is drawn vertical. In this example, it comprises on one and the same axis a cylindrical upper part s 1  and a lower part having a first neck section n 1 , a second cylinder section s 1 , a second neck section n 2 , a third cylinder section s 3  and a cone section co. The second and third cylinder sections are rounded at the corners. The diameter of the upper part is greater than the diameter of the lower part at any point. The shape of the bloom  31   a  is a rectangular prism. The extrusion base EB is drawn in FIG. 3 a-   1  in longitudinal section and the upper part cut out. It has in the center a recess EBH that corresponds to the outer dimensions of the object to be manufactured. The pushing part ES of the extrusion machine is depicted both in longitudinal section and viewed from below. The dimensions of the cross section of the pushing part correspond to the inner dimensions of the cross section of the body of the object to be manufactured. The pushing part has a recess ESH according to the invention. The cylindrical recess ESH starts from the lower surface of the pushing part and its diameter is substantially the same as the diameter of the upper part of the additional object. 
     In FIG. 3 b  the bloom  31   b  is placed on the extrusion base EB. An additional object  320  is placed in the recess of the pushing part ES of the extrusion machine. The diameters of the upper part of the additional object and the recess of the pushing part correspond to each other so that the additional object, when its upper part is suitably lubricated, fits tightly into the recess. In this example the length of the recess of the pushing part is such that the conic lowest section of the additional object  320  remains below the lower surface of the pushing part. An empty space is left around the lower part of the additional object. 
     FIG. 3 c  depicts the extrusion stage. The pushing part ES is pressed at a force F downward against the bloom. The pressure forces the material  31   c  of the bloom to spread into free spaces, which include the relatively narrow space between the walls of the extrusion base EB and pushing part ES and the space around the lower part of the additional object in the recess of the pushing part. In the situation of FIG. 3 c  the latter space has been a bit over half filled. As the downward movement of the pushing part ES ceases, the body material  31   c  has totally filled the space around the lower part of the additional object and risen between the walls into the designated height. After that, the pushing part ES is pulled back up. The additional object  320  remains attached to the body part thus formed. The joint between the body part and the additional object achieved in the manner described is strong because the metallic extrusion material tightly fills up the space around the lower part of the additional object. The shape of the lower part of the additional object according to this example adds to the strength of the bond: Said two neck sections n 1  and n 2  having cylinder surfaces constricted at the middle provide excellent attachment points. 
     FIGS. 3 d-   1  and  3   d-   2  show a longitudinal section (FIG. 3 d - 1 ) and a top view (FIG. 3 d-   2 ) if a resonator structure removed from the extrusion base. The cross section of the outer conductor  311  of the resonator structure is quadrangular in accordance with the shape of the extrusion base and pushing part of the extrusion machine. A homogeneous body part  310  comprises the outer conductor  311 , bottom  312  and conductive material  313  around the lower part of the additional object  320 . The inner conductor of the resonator comprises said conductive material  313  and additional object  320  excluding the cone section. The cone section remains within the bottom  312 . FIG. 3 d  shows a single resonator (without a cover) produced by the manufacturing stage at issue. 
     FIGS. 4 a-   4   e,  show in longitudinal sections further examples of resonators manufactured according to the invention. In FIG. 4 a  the additional object  42   a  is a cylindrical object the lower part of which spreads into a flange-like base. In the extrusion stage, the additional object fills the recess in the pushing part of the extrusion machine in its entirety. The base part of the additional object remains outside the recess so that it lies inside the bottom of the resonator body  41   a  after the extrusion has been completed. The inner conductor of the resonator comprises the additional object  42   a  excluding the part that remains inside the resonator bottom. 
     In FIG. 4 b  the additional object is an object shaped like a cylinder mantle, in the lower part of which the cylinder walls spread into a flange-like base. In the extrusion stage, the additional object  42   b  fills the recess in the pushing part of the extrusion machine in its entirety but the recess itself is now shaped like a cylinder mantle. The base part of the additional object remains outside the recess so that it lies inside the bottom of the resonator body  41   b  after the extrusion has been completed. The inner conductor of the resonator comprises the additional object  42   b  excluding the part that remains inside the resonator bottom. 
     In FIG. 4 c  the additional object  42   c  is a thin-walled object shaped like a cylinder mantle. In the extrusion stage, the additional object is in the pushing part&#39;s recess shaped like an open cylinder so that the additional object does not reach the edge of the recess. Extrusion thus produces in the body part  41   c  a cylindrical inner conductor around the upper end of which the additional object is attached. 
     In FIG. 4 d  the additional object  42   d  is a relatively thin-walled object comprising a cylinder mantle and one end. In the extrusion stage, the additional object is positioned in the pushing part&#39;s recess, which is shaped like an open cylinder, so that its closed end is in the bottom of the recess and the open end does not reach the edge of the recess. The recess in the pushing part, additional object and the bloom of the resonator body are dimensioned such that in the extrusion, the material of the bloom extends inside the additional object but fills it only partly. Thus is produced a resonator inner conductor comprising a cylindrical part in the body  41   d  and additional object  42   d  around its upper end. In accordance with the above, the body extends only partly inside the additional object, so the upper end of the inner conductor is hollow. 
     In FIG. 4 e  the additional object  42   e  is a cylindrical object having at one end a cylindrical recess the diameter of which is nearly the same as that of the additional object. In the extrusion stage, the additional object is positioned in the recess of the pushing part of the extrusion machine, which recess is shaped like an open cylinder, so that its solid end is in the bottom of the recess of the pushing part and the open end does not reach the edge of the recess. In the extrusion, the material of the bloom fills entirely the recess of the open end of the additional object. Thus is produced a resonator inner conductor the lower part of which comprises a cylindrical part in the body  41   e  and the upper part of which comprises the additional object  42   e . In accordance with the above, the additional object is compressed around the upper end of the lower part of the inner conductor. 
     Using the method described it is possible to manufacture at one time a whole filter body with several attached objects by means of an extrusion machine with several pushing parts. The recesses in the pushing parts may have different depths. Using a recess in which the additional object can be inserted in its totality, the additional object in the finished product will be positioned higher from the bottom of the structure than in FIG. 3 d . Thus in the filter the resonators may have inner conductors of different lengths, if necessary, even when the additional objects are identical. FIG. 5 shows an example of such a structure. In the figure is seen a filter body  512 , a first resonator RES 1  having additional object  521  and a second resonator RES 2  having additional object  522 . The inner conductor of the resonator RES 1  is shorter than the inner conductor of another resonator RES 2 . 
     In all versions of the resonator or filter manufactured according to the invention, the additional objects attached to the body are primarily used for temperature compensation in the resonator. The body part is advantageously aluminum and the additional objects may be copper or steel, for example. 
     Above it was described the method according to the invention and some structures according to it. The invention is not limited solely to those. The shapes of the objects belonging to the structure may understandably vary a great deal. The inventional idea may be applied in various ways within the scope defined by the independent claim.