In this article, a novel design method for rectangular waveguide filters intended for fabrication using direct metal additive manufacturing (AM) is proposed. The synthesized filters will feature a smooth profile that allows us to fabricate them orienting the filter propagation axis in the vertical building direction, achieving an optimum configuration for direct metal AM fabrication. The novel design method is valid for any all-pole transfer function, which is initially implemented with a commensurate-line distributed unit element prototype. The impulse response of that initial prototype is then properly interpolated to obtain the target response for a smooth-profiled filter with similar length and profile excursion. Finally, the target impulse response just generated is implemented in the rectangular waveguide technology employing a novel inverse scattering synthesis technique that relies on the coupled-mode theory to model the electromagnetic behavior of the waveguide filter. The novel inverse scattering synthesis technique is general and also valid for the case of filters with very high rejection levels, which is of great relevance in rectangular waveguide technology. A Ku-band low-pass filter with stringent satellite specifications is designed using the proposed method, fabricated by means of a direct metal AM technique, and measured with a vector network analyzer. A very good agreement is achieved between the simulated and measured results, fulfilling the required specifications and demonstrating the feasibility and performance of the novel design method.
This paper presents a design methodology that significantly increases the peak power handling capability (PPHC) of microstrip filters. The PPHC is limited in microstrip technology by the corona effect: a physical phenomenon caused by the ionization of the air in the presence of strong electric fields around the planar circuit. Microstrip filter with low electric field strength in the air increases the corona threshold level, resulting in high PPHC. Conventional stepped impedance (SI) filters, which consist of cascaded step-shaped elements, exhibit sharp discontinuities. These geometric edges amplify the electric field strength in the air, consequently reducing the corona threshold. Our research group has recently reported a new synthesis technique that introduces a smooth-profile (SP) conductor strip. This SP strip eliminates any sharp discontinuities and significantly reduces the strength of the electric field. This paper focuses on the examination of the high power performance of 7th-order SP and SI low-pass filters. The cut-off frequency (f c ) for both types of filters is set at 447.45 MHz, while the frequency for maximum stop-band rejection (f o ) is 1 GHz. The findings indicate that the SP filter shows a notable enhancement in peak power handling capability (PPHC), with gains of 2.48 dB and 4.80 dB observed at critical pressure and ambient pressure, respectively.
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