For the first time, the DC and RF power handling capability of NiCrAlSi thin film resistors on Liquid Crystal Polymer (LCP) is presented. It is shown that there is a maximum power that the resistors can handle without causing degradation of the resistors, and this value is significantly less than the power required for burn out of the resistors. EDAX shows that the resistors fail due to electromigration of Ni and Cr, and migration of C from the LCP.
IntroductionLiquid Crystal Polymer (LCP) substrates are currently being used for packaging of microwave and millimeter wave circuits In many applications, large RF and DC power is required. For example, MEMS switches as reported in [4] require typical bias voltages of 50 V, and if the MEMS switch has extra stress, the bias voltage may be as high as 100 V. Ideally, no current is drawn when the capacitive switch is open or closed, but if a switch fails, a large DC current may flow through the bias resistors. Antenna arrays are typically used for radar, and high RF power is usually desired to increase sensitivity. If the antenna array incorporates MMIC power amplifiers, the DC power consumption of the amplifier can be very high. For example, a wide bandgap transistor based amplifier can draw between 4 and 24 W. Thus, the thin film embedded resistors on LCP should be characterized to determine their RF and DC power characteristics. To the best of our knowledge, thin film embedded resistors have not been characterized.In this paper, thin film resistors embedded in a coplanar waveguide (CPW) structure [5] are characterized. First, the measured DC and RF resistance as a function of resistor length is presented, followed by the variation in resistance as a function of DC and RF power. Finally, the maximum DC and RF power that may be placed across the resistors and the variation in DC resistance as a function of temperature are discussed.