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Complex Module For High Frequency Applications
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ONK is a Materials and Process Engineer, Product Development Specialist, Advanced Materials Consultant with world-class expertise in successful development of patented state of the art ceramic, composite, metal, powder, and electronic module products and processes.
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This case study focuses on one specific development, part of an all ceramic materials system fulfilling electrical, physical, mechanical, and thermal requirements of a complex module for high frequency applications.
Due to high capacitive loads and the requirement to lower propagation delays in digital applications and to provide an impedance - controlled dielectric for microwave applications, a new dielectric was invented. The essence of the invention was to develop a composite adding hollow microspheres (constant 1.1) to thick film glass ceramic dielectric lowering its constant 8.5 to 4.0 adding hermetic porosity.
A dielectric thickness of 30 microns was desired, and the maximum particle size of the microspheres was 40 microns. Development focused on reducing the maximum and average particle size distribution of the microspheres.
The particle size of standard product was first characterized. Materials were furnished by Emerson and Cuming and particles tested on a Laser Diffraction instrument by Beckman -- Coulter, Horiba and Malvern.
The initial particle size distribution:
Maximum particle size is 40 microns, larger than maximum of 25 microns.
Processes investigated were:
- Dry Screening and Wet Screening
- Centrifuge
- Elutriation
- Field Flow Fractionation
Screening processes were tested; difficulties stemmed around obtaining screen mesh of a very small dimension and the ability to pass the particles through without clogging the screen, as well as exposing the spheres to the mesh efficiently for sorting.
Difficulties were addressed by investigating ultrasonics, impacts to the screen, screen rolling, and wet screening. An inclined plane wet screener appeared to be the best alternative for screening.
Mechanical processes such as centrifuge were tested. The spheres are hollow so friable or fragile. Fracture of too many of the microspheres resulted.
Reverse elutriation was also characterized. Spheres were introduced to a cylinder of water and water flowed from bottom to top. With normal powders of densities much greater than 1.0 g/cc small particles are forced to the top and the heavier particles sink to the bottom. Since the spheres are hollow, and have density less than 1.0 g/cc (water), larger particles float to the top and the smaller ones remain in the vicinity of the bottom of the cylinder. Flow mechanisms and rates, positions of sphere entry, and rate of microsphere introduction to the cylinder were studied. Initial results were very encouraging, as the concept worked on trial runs. The final result of this work, however, was that consistent results were very difficult to maintain through an extended period or production run.
Finally a process used to characterize particle size, Field Flow Fractionation, was tested. This process is one which flows water through a channel that is very thin, however wide. Eddy currents were set up in the water, and much like shoreline pools of river rapids, reverse eddy currents flow. These reverse eddy currents carried the larger of the particles while the smaller particles dropped out of the channel. This process proved successful over long runs and provided spheres of diameter less than 22 microns.
Read other articles by this KKAI Associate:
The Evolution of a Ceramic Materials System for Chip Packaging
Electrical and Materials Characterization of Microsphere Powder
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