Microwave circuits on alumina

f95toli

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Nov 21, 2002
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I wonder if anyone can suggest a good company where we can order some simple microwave circuits?
We essentially need a coplanar waveguide fabricated in gold on a alumina (Al2O3) substrate, i.e. a fairly simple thing.

The problem is that we only need a few "boards" so what I am looking for is something like PCB Express (i.e a company which accepts small orders) but for microwave circuits.



 

bobsmith1492

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Feb 21, 2004
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I have no idea, but just out of curiosity, what is it for? Waveguides are used synonymously with wires but for high frequencies, is that correct? Is there any way you could slap something together yourself like aluminum foil and cardboard or does it have to be perfectly smooth? How big is the waveguide? I'm thinking like 1" size... I'm sure that's wrong.
 

f95toli

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Nov 21, 2002
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Yes, waveguides are used for high frequencies. Although the relevant frequencies are are not very high in this case, something like 4-8 GHz.

First or all, alumina is not the same thing as aluminium in this context. Alumina is Al2O3, i.e. aluminium oxide; when grown as a single crystal this material is generally known as sapphire (which is milky white by the way, the sapphires used in jewellery get their colour from impurities).
Alumina is sometimes used instead of ordinary laminate to make PCBs for high frequency applications ("ordinary laminate" here means duroid or other low-loss materials). We want to use it because in additional to being a low-loss material it is also a good thermal conductor which is important in our application.

A coplanar waveguide consits of a thin strip of metal (a few hundred nanometers thick), a gap on each side, and then wide ground planes. I.e if if you look at the profile it will look something like.

-------------------------___-----___--------------------------------

if you choose the dimensions correctly you get a 50 ohm waveguide suitable for transmission of high frequencies. In our application the waveguide is perhaps 10 mm long and the distance between the ground planes around 50-500 micrometer (the waveguide starts out being pretty wide but gets gradually narrower).

"Waveguides" is a general name for just about everything that can support a TEM,TE or TM wave. Some waveguides are very large and "3 dimensional", essentially pipework, where the diameter of the pipe is of the same order of magnitude as the wavelengt of the wave (i.e. it can be centimeters for e.g. radar).

As you might have guessed this is work-related....

My problem is that although this is standard technology I haven't been able to find a company which accepts small orders, we are doing research and only need a few samples; we don't want to order 1000 boards. We could make them ourself (it is pretty straigthforward, plain photolithography) but we haven't got access to a cleanroom at the
moment.
 

Born2bwire

Diamond Member
Oct 28, 2005
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So you're looking at a tolerance of what, 2 mils? Do you have the substrate on hand?
 

f95toli

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Nov 21, 2002
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Better than that. At the 50 micron wide end the the precision should be a few microns, so the tolerenace is something like 0.1-0.5 mils (I don't know, I would need to calculate how much it affects the impedance). But again, this is easy using standard lithography.

No, I don't have the substrate. But alumina is easy to find, a 3" wafer is something like $30 so it is cheap; i.e. the cost of the material is not an issue; finding someone who can do the processing and cutting/drilling the substrate to the right shape is the tricky bit.




 

Born2bwire

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Oct 28, 2005
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I might know of a company I used when I was at Intel to run off a few microwave antenna boards. I'll see if I can't find that contact though it has been a while.
 

Born2bwire

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Oct 28, 2005
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Here we are, Mid-Atlantic Circuits, Inc.

Text

They go down to .002 mils, well within your tolerance. I used them previously for their low cost and the fact that I could do a single board. Try them out. They're a small operation. I remember I was given their contact from a guy who was from the University of Kentucky who used them for his microwave antenna fabrication. I called them up and they knew the guy by name. They also will probably have the substrate on hand, I know they were well stocked with most Rogers Duroid when I ordered with them. So I imagine if alumina is common then they would probably have it on hand.
 

f95toli

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Nov 21, 2002
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Thanks:)
Alumina is not among the materials they list on their website but I'll contact them and ask if they can help us.
 

patentman

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Apr 8, 2005
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Originally posted by: bobsmith1492
I have no idea, but just out of curiosity, what is it for? Waveguides are used synonymously with wires but for high frequencies, is that correct? Is there any way you could slap something together yourself like aluminum foil and cardboard or does it have to be perfectly smooth? How big is the waveguide? I'm thinking like 1" size... I'm sure that's wrong.

Waveguides can be used for relatively low frequencies too (100 MHz), but they are freaking huge. When I was at the Naval Research Lab working in the signature technology office, we had a couple "low" frequency waveguides that were about 6'X30'