This invention relates to switch arrangements which may be used for making andor breaking electrical connections, and more particularly to such switches using microelectromechanical (MEMS) devices in conjunction with high density interconnects (HDI).
a is a simplified cross-sectional representation of a prior-art arrangement using a microelectromechanical (MEMS) switch in conjunction with high density interconnect (HDI) structures. MEMS structures are mechanical structures made, in general, by processes which are akin to those used to fabricate solid-state integrated circuits, including photolithography and resist, etching, multiple layers of material. In
A MEMS switch structure designated generally as 220 lies under HDI interconnect transmission-line structures 10 and 210 in
In order to avoid transmission-line discontinuities which might perturb proper transmission, it is desirable to have strip conductor 234 of
In order to provide a space or “room” for the desired movement of movable conductive element 224 of the MEMS structure 220, a layer 240 of dielectric is placed between the transmission line structure 210 and the MEMS structure 220, with a gap or opening 242 at the location of movable element 224. Finally, the connections are completed by a plurality of through vias and metallizations. More particularly, a through via 250 extends at transverse plane T2 from ground plane 16 to a metallization 251, and a further through via 252 extends at a transverse plane T4 from metallization 251 to ground plane 226. Thus, the combination of through vias 250 and 252, in conjunction with metallization 251, provides contact between the right-most end of ground plane 16 and the left-most end of ground plane 226. In addition, a through via 256 extends at transverse plane T18 from ground plane 216 to a metallization 257, and a further through via 254 extends at a transverse plane T16 from metallization 257 to ground plane 226. Thus, the combination of through vias 254 and 256, in conjunction with metallization 257, provides contact between the left-most end of ground plane 216 and the right-most end of ground plane 226. Some strip conductor connections are made by means of a through via 260 extending at a plane T6 through dielectric plate 12 to a metallization 261, and a further through via 262 extending through dielectric plate 240 at plane T8 from metallization 261 to the left-most end of strip conductor 234. The strip conductor connections are completed by means of a through via 266 extending at a plane T14 through dielectric plate 212 to a metallization 267 lying between dielectric plates 212 and 240, and a further through via 254 extending at a plane T12 through dielectric plate 240 to the right-most end of strip conductor 234. Thus, through vias 264 and 266, in conjunction with metallization 267, provides electrical continuity from strip conductor 214 to the right end of strip conductor 234. In general, it may be said that the fields associated with a propagating electromagnetic wave are constrained to lie between the strip conductor/ground plane sets 14,16; 234, 226; 214, 216.
b illustrates the electric field resulting at transverse plane T1 of
In general, the invention relates to a transmission line structure including first and second mutually separated strip conductors lying on an upper side of an upper dielectric sheet, and a ground conductor juxtaposed with the lower side of the upper dielectric sheet. A further strip conductor lies on a lower side of a lower dielectric sheet, with its ends registered with the ends of the first and second strip conductors. In one embodiment, a gap in the further strip conductor is controllably bridged by a MEMS switch element, which may lie below the second dielectric sheet or in a cavity defined in the second dielectric sheet.
A transmission-line structure according to an aspect of the invention comprises a first dielectric sheet defining first and second broad sides. The first broad side of the first dielectric sheet bears first and second separate electrically conductive planar strips. Each of the separate electrically conductive planar strips defines at least a first end. The first end of the first planar strip and the first end of the second planar strip are spaced apart by a distance. A second dielectric sheet defines first and second broad sides. The first broad side of the second dielectric sheet defines a single continuous electrical conductor which defines first and second nonconductive regions. The first and second nonconductive regions are spaced apart by about the distance. The first broad side of the second dielectric sheet is juxtaposed with the second broad side of the first dielectric sheet, with at least portions of the first and second nonconductive regions of the continuous electrical conductor registered with the first ends of the first and second planar strips, respectively. The transmission-line structure also includes a nonconductive planar surface bearing a third electrically conductive planar strip defining first and second ends. The first and second ends of the third planar strip are separated by about the distance. The nonconductive planar surface is associated with the second side of the second dielectric sheet, with the first and second ends of the third planar strip registered with the first ends of the first and second planar strips, respectively. A first electrically conductive through via arrangement connects the first end of the first planar strip to the first end of the third strip through the first nonconductive region. A second electrically conductive through via arrangement connects the first end of the second planar strip to the second end of the third strip through the second nonconductive region, to thereby form the first, second and third planar strips into a continuous strip conductor in which at least a portion of each of the first, second and third planar strips overlies a side of the continuous electrical conductor to thereby form a strip transmission line including at least portions of the first, second and third planar strips.
A preferred embodiment of the transmission-line structure further includes a gap in the third planar strip, and mechanically operated switch means making controllable electrical and mechanical contact with a portion of the third planar strip on each side of the gap. In one version of this preferred embodiment, the mechanically operated switch means lies on a side of the gap which is remote from the first dielectric sheet, and moves toward and away from the second dielectric sheet in order to make and break connection. In another version of this preferred embodiment, the mechanically operated switch means lies within a cavity defined in the second dielectric sheet.
Another embodiment of the transmissionline structure includes a gap in the third planar strip, and a planar signal processing module with at least first and second signal ports. The first and second signal ports are mechanically and electrically connected to portions of the third planar strip on each side of the gap. In a preferred version of this embodiment, the signal processing module performs amplification, and the first and second signal ports are signal input and output ports, respectively.
a is a simplified cross-sectional view of a prior-art transmission-line switch including a MEMS switch in an HDI structure,
a is a simplified cross-sectional view of a transmission line structure according to an aspect of the invention,
a is a simplified representation of a transmission-line structure similar to that of
a is a simplified representation of a transmission-line structure similar to
a is a simplified cross-sectional illustration of a transmission-line arrangement according to an aspect of the invention, including upper and lower dielectric layers 312 and 392, respectively. The lower surface of dielectric layer 312 is designated 312ls The upper surface of dielectric layer 312 is designated 312us, and bears a pattern MT2 of metallization which is illustrated in plan view in
c illustrates the conductor pattern of metallization layer MT1, which lies between dielectric layers 312 and 316 of
d illustrates in plan view the conductive or metallization pattern of bottom layer MTO of
a and 4b are similar to
Microelectromechanical actuators for accomplishing such motion are known in the art. The length of break 412 is a distance S, which is less than the length of movable element 410. In the “making contact” position of conductive element 410 illustrated in
a is a simplified cross-sectional view of a switch 500 generally similar to switch 400 of
Those skilled in the art of transmission lines know that the removal of dielectric material from a location adjacent the strip conductor tends to reduce the capacitance per unit length of the transmission line including the strip conductor, thereby tending to make the transmission line “inductive” or higher impedance in the affected region. In order to compensate for the effects of removing dielectric from dielectric sheet or plate 392 in the region around movable MEMS switch element 410, the strip conductor is made wider than it would otherwise be.
A salient advantage of at least some arrangements according to the invention lies in reduced electromagnetic reflections attributable to ground discontinuities or ground current reflections, which is particularly important in microwave applications.
Other embodiments of the invention will be apparent to those skilled in the art. For example, the “MMIC amplifier 620” could be, or include, a phase shifter, a low-noise amplifier, a power amplifier, filter components, or a further MEMS switch. The structure could include plural items corresponding to “MMIC amplifier 620,” or more than one MEMS switch, or both. Adhesives may be used to join the various surfaces of the dielectric sheets and MEMS or other substrates.
Thus, a transmission-line structure according to an aspect of the invention comprises a first dielectric sheet (312) defining first (312us) and second broad (312ls) sides. The first broad side (312us) of the first dielectric sheet (312) bears first (314l) and second (314r) separate electrically conductive planar strips. Each of the separate electrically conductive planar strips defines at least a first end (350, 360, respectively). The first end (350) of the first planar strip (314l) and the first end (360) of the second planar strip (314r) are spaced apart by a distance (S1). A second dielectric sheet (392) defines first (392us) and second (392ls) broad sides. The first broad side (392us) of the second dielectric sheet (392) defines a single continuous electrical conductor (ground 316) which defines first (370) and second (380) nonconductive regions. The first and second nonconductive regions are spaced apart by about the distance (S1). The first broad side (392us) of the second dielectric sheet (392) is juxtaposed with the second broad side (312ls) of the first dielectric sheet (312), with at least portions of the first (370) and second (380) nonconductive regions of the continuous electrical conductor (316) registered with the first ends (350, 360) of the first (314l) and second (314r) planar strips, respectively. The transmission-line structure also includes a nonconductive planar surface (392ls; 460us) bearing a third electrically conductive planar strip (326) defining first (326l) and second (326r) ends. The first (326l) and second (326r) ends of the third planar strip (326) are separated by about the distance (S1). The nonconductive planar surface (392ls; 460us) is associated with the second side (392ls) of the second dielectric sheet (392), with the first (326l) and second (326r) ends of the third planar strip (326) registered with the first ends (350, 360) of the first (314l), and second (314r) planar strips, respectively. A first electrically conductive through via (352, 372) arrangement connects the first end (350) of the first planar strip (314l) to the first end (326l) of the third strip (326L) through the first nonconductive region (370). A second electrically conductive through via arrangement (362, 374) connects the first end (360) of the second planar strip (314r) to the second end (326r) of the third strip (326R) through the second nonconductive region (380), to thereby form the first (314l), second (314r) and third (326) planar strips into a continuous strip conductor in which at least a portion of each of the first (314l), second (314r) and third (326) planar strips overlies a side of the continuous electrical conductor (316) to thereby form a strip transmission line including at least portions of the first, second and third planar strips.
A preferred embodiment of the transmission-line structure further includes a gap (412) in the third planar strip (326), and mechanically operated switch means (410) making controllable electrical and mechanical contact with a portion (326l) (326r) of the third planar strip (326) on each side of the gap (412). In one version of this preferred embodiment, the mechanically operated switch means lies on a side of the gap (412) which is remote from the first dielectric sheet (312), and moves toward and away from the second dielectric sheet (392) in order to make and break connection. In another version of this preferred embodiment, the mechanically operated switch means lies within a cavity (510) defined in the second dielectric sheet (392).
Another embodiment of the transmission-line structure includes a gap (626g) in the third planar strip (626), and a planar signal processing module (620) with at least first (626l) and second (626r) signal ports. The first (626l) and second (626r) signal ports are mechanically and electrically connected to portions of the third planar strip (626l, 626r) on each side of the gap (626g). In a preferred version of this embodiment, the signal processing module (620) performs amplification, and the first and second signal ports are signal input and output ports, respectively.
This invention was made with government support under Contract/Grant MDA972-00-C-0043 (DARPA). The United States Government has a non-exclusive, non-transferable, paid-up license in this invention.
Number | Name | Date | Kind |
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6020853 | Richards et al. | Feb 2000 | A |
6104934 | Patton et al. | Aug 2000 | A |
6525623 | Sridharan et al. | Feb 2003 | B2 |
6714169 | Chau et al. | Mar 2004 | B1 |