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Micromachining integration platform for sub-terahertz and terahertz systems

Published online by Cambridge University Press:  10 April 2018

Vladimir Ermolov*
Affiliation:
VTT Technical Research Centre of Finland, Tietotie 3, Espoo, Finland
Antti Lamminen
Affiliation:
VTT Technical Research Centre of Finland, Tietotie 3, Espoo, Finland
Jaakko Saarilahti
Affiliation:
VTT Technical Research Centre of Finland, Tietotie 3, Espoo, Finland
Ben Wälchli
Affiliation:
VTT Technical Research Centre of Finland, Tietotie 3, Espoo, Finland
Mikko Kantanen
Affiliation:
VTT Technical Research Centre of Finland, Tietotie 3, Espoo, Finland
Pekka Pursula
Affiliation:
VTT Technical Research Centre of Finland, Tietotie 3, Espoo, Finland
*
Author for correspondence: Vladimir Ermolov, vladimir.ermolov@vtt.fi
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Abstract

We demonstrate a sub-terahertz (THz) and THz integration platform based on micromachined waveguides on silicon. The demonstrated components in the frequency range 225–325 GHz include waveguides, filters, waveguide vias, and low-loss transitions between the waveguide and the monolithic integrated circuits. The developed process relies on microelectromechanical systems manufacturing methods and silicon wafer substrates, promising a scalable and cost-efficient system integration method for future sub-THz and THz communication and sensing applications. Low-temperature Au/In thermo-compression and Au–Au laser bonding processes are parts of the integration platform enabling integration of millimeter-wave monolithic integrated circuits.

Information

Type
Research Papers
Copyright
Copyright © Cambridge University Press and the European Microwave Association 2018 
Figure 0

Fig. 1. Vision of 3D stackable wafer-level integration for THz system. Waveguides on silicon wafers connect active MMICs to each other for a compact system.

Figure 1

Fig. 2. (a) Simplified process flow using Au/Au thermo-compression bonding, (b) process flow for low-temperature Au/In bonding.

Figure 2

Fig. 3. SEM images of a band-pass filter.

Figure 3

Fig. 4. Microscope images of cap (a) and bottom (b) Si halves after laser bonding. One image has been mirrored horizontally to illustrate pattern correspondence.

Figure 4

Fig. 5. Measurement setups for the fabricated silicon dies: (a) and (b) sample holder for dies with side entry; (c) and (d) sample holder for dies with top and bottom entry.

Figure 5

Fig. 6. Silicon micromachined WR-3 waveguide: (a) simulation model, (b) photograph of the bonded die, (c) simulated (dashed line) and measured (solid line) S-parameters.

Figure 6

Fig. 7. WR-3 waveguide with bends: (a) simulation model, (b) micrograph of a manufactured structure, (c) simulated (dashed line) and measured (solid line) S-parameters.

Figure 7

Fig. 8. Silicon micromachined WR-6 waveguide: (a) simulation model, (b) micrograph of a manufactured structure, (c) simulated (dashed line) and measured (solid line) S-parameters.

Figure 8

Fig. 9. Measured transmission coefficients of silicon micromachined WR-3 waveguides manufactured using Au/Au and Au/In thermo-compression bonding and laser bonding.

Figure 9

Fig. 10. WR-3 low-pass filter fabricated with Au/Au thermo-compression bonding: (a) simulation model, (b) micrograph of a manufactured structure, (c) simulated (dashed line) and measured (solid line) S-parameters.

Figure 10

Fig. 11. WR-3 band-pass filter fabricated with Au/Au thermo-compression bonding: (a) simulation model, (b) micrograph of a manufactured structure, (c) simulated (dashed line) and measured (solid line) S-parameters.

Figure 11

Fig. 12. WR-3 band-pass filter fabricated with Au/In thermo-compression bonding: simulated (dashed line) and measured (solid line) S-parameters.

Figure 12

Fig. 13. WR-3 through-wafer via: (a) simulation model, (b) photograph of two manufactured structures, (c) simulated (dashed line) and measured (solid line) S-parameters.

Figure 13

Fig. 14. WR-3-to-microstrip probe transition: (a) simulation model, (b) micrograph of a manufactured structure, (c) simulated (dashed line) and measured (solid line) S-parameters.

Figure 14

Fig. 15. SEM image showing the 2 µm gap in the metallization at the waveguide corner due to over etching. (b) Effect of small longitudinal gaps of width g in the WR-3 corners on the transmission coefficient.