Broadband circulator and method of manufacturing the same
View Patent ↗A broadband microstrip ferrite circulator or isolator includes a carrier. The broadband microstrip ferrite circulator or isolator further includes a dielectric substrate having an opening therein. The broadband microstrip ferrite circulator or isolator further includes a ferrite disc positioned within the opening of the dielectric substrate. The broadband microstrip ferrite circulator or isolator further includes a conductor having three contacts extending therefrom, the conductor being positioned on the ferrite disc. The broadband microstrip ferrite circulator or isolator further includes a magnet. The broadband microstrip ferrite circulator or isolator further includes a spacer positioned between the conductor and the magnet.
1. A broadband microstrip ferrite circulator or isolator, comprising:
a carrier;
a dielectric substrate having an opening therein and being non-metallized;
a first low loss microwave adhesive for attaching the dielectric substrate to the carrier, the first low loss microwave adhesive having a melting temperature of above 230 degrees Celsius in order to withstand curing and solder reflow temperatures;
a ferrite disc positioned within the opening of the dielectric substrate;
a conductor having three contacts extending therefrom, the conductor being positioned on the ferrite disc;
a second low loss microwave adhesive for attaching the conductor to the dielectric substrate and to the ferrite disc;
a magnet; and
a spacer positioned between the conductor and the magnet.
2. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the carrier is a plated steel carrier.
3. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the carrier is a ferrous carrier.
4. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the dielectric substrate is made of a ceramic material.
5. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the ferrite disc is a no metallization ferrite disc.
6. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the ferrite disc is a high saturation magnetization ferrite disc.
7. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the conductor extends to an edge of the dielectric substrate to eliminate the need for a pattern on the dielectric substrate.
8. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the conductor is a standalone conductor that is adhered to the ferrite disc with leads crossing a ferrite/dielectric gap.
9. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the spacer is attached to the conductor using a third low loss microwave adhesive.
10. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the magnet is attached to the spacer using a nonconductive adhesive.
11. The broadband microstrip ferrite circulator or isolator of claim 1 wherein the spacer has an integrated ground plane.
12. The broadband microstrip ferrite circulator or isolator of claim 1 wherein each of the three contacts of the conductor extends beyond an outer dimension of the carrier.
13. A method of manufacturing a circulator, comprising:
forming a pre-circulator structure by stacking, in order, a carrier, a first adhesive, a non-metallized dielectric substrate having an opening therein, a ferrite disc in the opening of the non-metallized dielectric substrate, a second adhesive, a conductor having a center portion with three legs extending therefrom, a third adhesive, a spacer, a fourth adhesive, and a magnet; and
applying pressure to the pre-circulator structure and heating the pre-circulator structure with the pressure applied to a temperature between about 200 degrees Celsius and about 325 degrees Celsius in order to cure the first adhesive, the second adhesive, the third adhesive, and the fourth adhesive.