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Toward a flexible and adaptive wireless hub by embedding power amplifier thinned silicon chip and antenna in a polymer foil

Published online by Cambridge University Press:  08 May 2019

Golzar Alavi*
Affiliation:
Institute for Nano-and Microelectronic System (INES), University of Stuttgart, Pfaffenwaldring 47, 70569, StuttgartGermany
Sefa Özbek
Affiliation:
Institute of Electrical and Optical Communications Engineering (INT), University of StuttgartStuttgart, 70569, Germanyand
Mahsa Rasteh
Affiliation:
Institute of Radio Frequency Technology (IHF), University of Stuttgart, 70569, StuttgartGermany
Markus Grözing
Affiliation:
Institute of Electrical and Optical Communications Engineering (INT), University of StuttgartStuttgart, 70569, Germanyand
Manfred Berroth
Affiliation:
Institute of Electrical and Optical Communications Engineering (INT), University of StuttgartStuttgart, 70569, Germanyand
Jan Hesselbarth
Affiliation:
Institute of Radio Frequency Technology (IHF), University of Stuttgart, 70569, StuttgartGermany
Joachim N. Burghartz
Affiliation:
Institute for Nano-and Microelectronic System (INES), University of Stuttgart, Pfaffenwaldring 47, 70569, StuttgartGermany
*
Author for correspondence: Golzar Alavi E-mail: alavi@ines.uni-stuttgart.de
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Abstract

A flexible and adaptive energy-efficient high-speed wireless hub is developed in polymer foil as a Hybrid System-in-Foil (HySiF) using Chip-Film Patch (CFP) technology. In this matter, the SiGe BiCMOS silicon chips (2.39 × 1.65 mm2) are thinned down to 45 μm and are embedded face-up inside a two-polymer CFP carrier. The active pads of the embedded silicon chips inside foil are extended to the surface of the foil to interconnect to the antenna on the foil. The integrated hybrid system has a signal transmission at 5–6 GHz frequency band. The overall thickness of the system is below 100 μm and its bendability is down to 4 mm radius of curvature. The designed and fabricated PA silicon chips operate at 50 mA with a 1.5 V supply voltage. Therefore, in addition to the high lateral thermal resistance of the thinned chip, self-heating loop inside polymer due to the low thermal conductivity of the embedding polymer raises the system temperature. Consequently, the thermal behavior and RF performance of the PA chip under different conditions are investigated. Moreover, the antenna with the required carrier frequency is simulated, fabricated, and measured on top of the polymer foil as a stand-alone system in the flexible CFP.

Information

Type
Mini-Special Issue on Flexible Electronics for Wireless Communication
Creative Commons
Creative Common License - CCCreative Common License - BY
This is an Open Access article, distributed under the terms of the Creative Commons Attribution licence (http://creativecommons.org/licenses/by/4.0/), which permits unrestricted re-use, distribution, and reproduction in any medium, provided the original work is properly cited.
Copyright
Copyright © Cambridge University Press and the European Microwave Association 2019
Figure 0

Fig. 1. Schematic illustration of a HySiF [16].

Figure 1

Fig. 2. Schematic cross-section of the two-polymer CFP technology for high-frequency application [16].

Figure 2

Fig. 3. Process flow illustration of the high-frequency CFP: (1) wafer pre-surface treatment, (2) spin coating the base polymer, curing, and cavity opening, (3) face-up PA chip embedding using a permanent glue, (4) top polymer coating, (5) via opening using lithography, (6) metallization, patterning, and antenna fabrication, and finally (7) releasing system-in-foil from the substrate [16].

Figure 3

Fig. 4. Layout of the 3-Path DPA. The red blocks represent the DPA as a heater whereas four green blocks are bipolar-based temperature-sensing diode [16].

Figure 4

Fig. 5. Measured surface temperature increase using four different diode locations. ΔT = T2 − T1, T2 and T1 are the measured temperatures while PA is switched ON and OFF, respectively [16].

Figure 5

Fig. 6. Process flow illustration of substructuring ultra-thin silicon chip inside foil, (1) embedding ultra-thin test chip inside CFP, (2) metal hard mask deposition and patterning, (3) polymer plasma RIE, (4) Si3N4, SiO2, and Si deep RIE by using Bosch process [15], (5) removal of hard mask and next steps of CFP process such as via opening, metallization, and metal structuring.

Figure 6

Fig. 7. SEM cross-section of substructuring the thin chip in Chip-Film Patch foil using a metal hard mask to introduce physical thermal barrier.

Figure 7

Fig. 8. Process flow to embed the PA chip with a backside heat spreader inside the CFP, (a) coating polyimide and curing, (b) fabricating and structuring heat spreader using AlSiCu, and covering it with a polymer layer, (c) defining a cavity,(d) placing the PA thinned chip in the cavity, (e) polymer coating, chip covering, planarization, and via opening, (f) metallization and metal structuring, and finally(g) release from carrier, and back side plasma etching.

Figure 8

Fig. 9. Demonstration of the embedded PA chip with the backside heat spreader in the CFP polymer foil. The integrated system-in-foil is released from the temporary silicon carrier and is bent over a cylinder with approximately 4 mm radius of curvature [16].

Figure 9

Fig. 10. Thin, flexible amplifier integrated circuit operating at 5.5 GHz, embedded in a flexible foil and connected to a broadband bowtie antenna [16].

Figure 10

Fig. 11. (a) Simplified schematic view of the DPA [14], (b) the measured surface topography of PA chip by using an optical profiler, and (c) the microscopic image of the PA chip.

Figure 11

Fig. 12. Simulated and measured magnitude of S21 of the embedded PA chip in the CFP polymer foil.

Figure 12

Fig. 13. Graphical illustration of the bowtie antenna measurement on the polymer foil using VNA, (a) measurement as a straight bowtie, (b) measurement during bent status.

Figure 13

Fig. 14. The reflection coefficient of the antenna in the bent and straight profile.