Low-temperature co-fired ceramic (LTCC) are widely acknowledged for wide-band and microwave circuits. Within the project consortium KERAMIS, implementation of higher functionality in LTCC substrates is being investigated. Among the applications considered are a 4 × 4 switch matrix [1], voltage-controlled oscillators [2], and amplifiers for multimedia satellite communications working in Ka-band. In order to add more functionality (e.g., filters, couplers) in LTCC, current patterning limits of line width and line separation need to be extended. Four different technologies were considered for higher resolution: a) fine-line printing technology with special screens, b) photo-imageable pastes, c) etching of thick-film conductors (co- and post-fired), and d) thin films on LTCC. Evaluation of patterning technologies is based on a test coupon that was designed and manufactured by the consortium members. The artwork contains lines, line transitions, ring resonators (microstrip and stripline), edge-coupled filters, DC blocking structures, and various lines for DC resistance testing. The smallest gap definition is 50 μm. Two substrate materials, Du Pont tapes 951 and 943, are included in the study. In addition to the main frequency band of interest in the project (17–22 GHz), these structures have been characterized up to 50 GHz. Electrical results are correlated to physical measurements of the structures (line width, spaces, and tolerances) and are evaluated with respect to performance, manufacturability, and yield. Results show excellent performance for screen-printed structures and demonstrated the importance of mask tuning to achieve optimum resolution (under etching etc.).
KERAMIS is the acronym of a German research and development project funded by the German Space Agency (DLR) and the Federal Ministry of Economics and Technology (BMWI). The consortium is developing an RF circuit technology for Ka band multimedia satellite applications. A set of modules has been designed, manufactured, and tested by the partners of the consortium. The goal of this effort is to qualify the KERAMIS technology for space applications and to participate in an on-orbit-verification (OOV) program of the DLR. The launch of the technology verification satellite (TET) is scheduled for late 2010. This paper will give an overview of innovative circuit and module designs as well as the assembly, integration, and test results of the project. The authors will present a modular circuit concept for state-of-the-art transmitters and receivers in space at around 20 GHz. Selected modules are a 4 × 4 switch matrix, two synthesizers, and other RF modules. All circuits are based on multilayer ceramic (LTCC) including passive components, transitions, housings, and DC supply.
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