Claims
- 1. A method of assembling a monolithic phased array of the type having a n.times.m array of radiating elements and at least a first layer electrically connected to a second layer, said method comprising the steps of:
- a. fabricating a plurality of T/R modules from at least one wafer, each of said plurality of T/R modules having integrated thereon a plurality of gold posts for interconnecting said first layer to said second layer;
- b. placing a predetermined amount of solder reform on each tip of said plurality of gold posts during said fabrication of said plurality of T/R modules;
- c. testing said plurality of T/R module wafers according to a set of predetermined criteria and identifying each T/R module that is functional;
- d. selecting from said at least one wafer sub-arrays of said functional T/R modules;
- e. fabricating a metallic tray having a set of precision alignment marks and a plurality of slits forming a n.times.m array corresponding to said n.times.m array of radiating elements;
- f. populating said metallic tray with said sub-arrays of said functional T/R modules such that said sub-arrays of T/R modules are mounted on said metallic tray in alignment with said precision alignment marks on said metallic tray, said populated metallic tray constituting said first layer;
- g. placing a distribution network substrate which constitutes said second layer on said first layer;
- h. heating the thus assembled phased array to the melting point of said solder reform disposed on said gold posts; and
- i. cooling the thus heated assembled phased array causing said second layer to be electrically connected to said first layer thereby forming said monolithic phased array.
Parent Case Info
This is a divisional of application Ser. No. 07/732,269 filed Jul. 18, 1991, now U.S. Pat. No. 5,262,794.
US Referenced Citations (8)
Foreign Referenced Citations (4)
Number |
Date |
Country |
0432647 |
Jun 1991 |
EPX |
62-144355 |
Jun 1987 |
JPX |
62-242337 |
Oct 1987 |
JPX |
63-147318 |
Jul 1988 |
JPX |
Non-Patent Literature Citations (2)
Entry |
Austin et al., Design Concepts For Active Phased Modules, IEE Proc. F., vol. 127, No. 4, Aug., 1980, pp. 290-300. |
J. F. McIlvenna, Monloithic Phased Arrays For EHF Communications Terminals, Microwave Journal, Mar., 1988, pp. 113-125. |
Divisions (1)
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Number |
Date |
Country |
Parent |
732269 |
Jul 1991 |
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