Flexible printed circuit boards (flex PCBs) are used in a wide range of electronic devices today due to their light weight, bendability, extensive wiring possibilities, and low-cost manufacturing techniques. The general trend in the flex PCB industry is further miniaturization alongside increasing functionality per device and reduced costs. To meet these demands, a new generation of low cost manufacturing technologies is being developed to enable structures with smaller lateral dimensions and higher packing densities. Wet etching is today the most cost-efficient method for producing a large number of through-foil structures in flex PCBs. However, conventional wet etch techniques do not allow for through-foil structures with aspect ratios over 1 – a fact that either necessitates thin and mechanically weak foils or puts severe limitations on the packing density. The fabrication techniques presented in this thesis allow for through-foil structures with higher aspect ratios and packing densities using wet etching. To achieve high aspect ratios with wet etching, the flex PCB foils are pre-treated with irradiation by swift heavy ions. Each ion that passes through the foil leaves a track of damaged material which can be subsequently etched to form highly vertical pores. By using conventional flex PCB process techniques on the porous foils, high aspect ratio metallized through-foil structures are demonstrated. The resulting structures consist of multiple sub-micrometer sized wires. These structures are superior to their conventional counterparts when it comes to their higher aspect ratios, higher possible packing densities and low metallic cross-section. Furthermore, metallized through-foil structures with larger areas and more complicated geometries are possible without losing the mechanical stability of the foil. This in turn enables applications that are not possible using conventional techniques and structures. In this thesis, two such applications are demonstrated: flex PCB vertical thermopile sensors and substrate integrated waveguides for use in millimeter wave applications. / wisenet

Design techniques and procedures to improve performances of radio-frequency and millimeter-wave front-end integrated circuits were developed. Power amplifiers for high data-rate wireless communication applications were designed using CMOS technology employing a novel device resizing and concurrent power-combining technique to implement a multi-mode operation. Comprehensive analysis on the efficiency degradation effect of multi-input-single-output combining transformers with idle input terminals was performed. The proposed discrete resizing and power-combining technique effectively enhanced the efficiency of a linear CMOS power amplifier at back-off power levels. In addition, a novel power-combining transformer that is suitable to generate multi-watt-level output power was proposed and implemented. Employing the proposed power-combining transformer, a high-power linear CMOS power amplifier was designed. Furthermore, receiver building blocks such as a low-noise amplifier, a down-conversion mixer, and a passive balun were implemented using SiGe technology for W-band applications.

The objective of the research is to develop high-speed ADCs and mixed-signal demodulator for multi-gigabit communication systems using millimeter-wave frequency bands in standard CMOS technology. With rapid advancements in semiconductor technologies, mobile communication devices have become more versatile, portable, and inexpensive over the last few decades. However, plagued by the short lifetime of batteries, low power consumption has become an extremely important specification in developing mobile communication devices. The ever-expanding demand of consumers to access and share information ubiquitously at faster speeds requires higher throughputs, increased signal-processing functionalities at lower power and lower costs. In today’s technology, high-speed signal processing and data converters are incorporated in almost all modern multi-gigabit communication systems. They are key enabling technologies for scalable digital design and implementation of baseband signal processors. Ultimately, the merits of a high performance mixed-signal receiver, such as data rate, sensitivity, signal dynamic range, bit-error rate, and power consumption, are directly related to the quality of the embedded ADCs. Therefore, this dissertation focuses on the analysis and design of high-speed ADCs and a novel broadband mixed-signal demodulator with a fully-integrated DSP composed of low-cost CMOS circuitry. The proposed system features a novel dual-mode solution to demodulate multi-gigabit BPSK and ASK signals. This approach reduces the resolution requirement of high-speed ADCs, while dramatically reducing its power consumption for multi-gigabit wireless communication systems.

Recent advances in molecular biology and nanotechnology have enabled scientists to study biological systems at molecular and atomic scales. This level of sophistication demands for new technologies to emerge for providing the necessary sensing tools and equipment. Recent studies have shown that terahertz technology can provide revolutionary sensing techniques for organic and non-organic materials with unprecedented accuracy and sensitivity. This is due to the fact that most of the macromolecules have vibrational and/or rotational resonance signatures in terahertz range. To further increase the sensitivity, terahertz radiation is generated and interacted with the bio-sample on a miniaturized test site or the so-called biochip. From the view point of generation and manipulation of terahertz radiation, the biochip is designed based on the same rules as in high frequency electronic chips or integrated circuits (IC). By increasing the frequency toward terahertz range, the conventional IC design methodologies and analysis tools fail to perform accurately. Therefore, development of new design methodologies and analysis tools is of paramount importance for future terahertz integrated circuits (TIC) in general and terahertz biochips in particular. In this thesis, several advancements are made in design methodology, analysis tool and architecture of terahertz and millimeter-wave integrated circuits when used as a biochip. A global and geometry independent approach for design and analysis of the travelling-wave terahertz photomixer sources, as the core component in a TIC, is discussed in details. Three solvers based on photonic, semiconductor and electromagnetic theories are developed and combined as a unified analysis tool. Using the developed terahertz photomixer source, a resonance-based biochip structure is proposed, and its operation principle, based on resonance perturbation method, is explained. A planar metallic resonator acting as a sample holder and transducer is designed, and its performance in terms of sensitivity and selectivity is studied through simulations. The concept of surface impedance for electromagnetic modeling of DNA self-assembled monolayer on a metal surface is proposed, and its effectiveness is discussed based on the available data in the literature. To overcome the loss challenge, Whispering Gallery Mode (WGM) dielectric resonators with high Q factor are studied as an alternative for metallic resonator. The metallic loss becomes very high at terahertz frequencies, and as a result of that planar metallic resonators do not exhibit high Q factor. Reduced Q factor results in a low sensitivity for any sensor using such resonators. Theoretical models for axially and radially layered dielectric resonators acting on WGM are presented, and the analytical results are compared with the measured data. Excitation of WGM through dielectric waveguide is proposed, and the critical coupling condition is explained through analytical formulation. The possibility of selecting one resonance among many for sensing application is also studied both theoretically and experimentally. A high sensitivity sensor based on WGM resonance in mm-wave and terahertz is proposed, and its sensitivity is studied in details. The performance of the proposed sensor is tested for sensing drug tablets and also liquid droplets through various measurements in mm-wave range. The comprehensive sensitivity analysis shows the ability of the proposed sensor to detect small changes in the order of 10−4 in the sample dielectric constant. The results of various experiments carried out on drug tablets are reported to demonstrate the potential multifunctional capabilities of the sensor in moisture sensing, counterfeit drug detection, and contamination screening. The measurement and simulation results obtained in mm-wave hold promise for WGM to be used for sensing biological solutions in terahertz range with very high sensitivity.

Recent advances in molecular biology and nanotechnology have enabled scientists to study biological systems at molecular and atomic scales. This level of sophistication demands for new technologies to emerge for providing the necessary sensing tools and equipment. Recent studies have shown that terahertz technology can provide revolutionary sensing techniques for organic and non-organic materials with unprecedented accuracy and sensitivity. This is due to the fact that most of the macromolecules have vibrational and/or rotational resonance signatures in terahertz range. To further increase the sensitivity, terahertz radiation is generated and interacted with the bio-sample on a miniaturized test site or the so-called biochip. From the view point of generation and manipulation of terahertz radiation, the biochip is designed based on the same rules as in high frequency electronic chips or integrated circuits (IC). By increasing the frequency toward terahertz range, the conventional IC design methodologies and analysis tools fail to perform accurately. Therefore, development of new design methodologies and analysis tools is of paramount importance for future terahertz integrated circuits (TIC) in general and terahertz biochips in particular. In this thesis, several advancements are made in design methodology, analysis tool and architecture of terahertz and millimeter-wave integrated circuits when used as a biochip. A global and geometry independent approach for design and analysis of the travelling-wave terahertz photomixer sources, as the core component in a TIC, is discussed in details. Three solvers based on photonic, semiconductor and electromagnetic theories are developed and combined as a unified analysis tool. Using the developed terahertz photomixer source, a resonance-based biochip structure is proposed, and its operation principle, based on resonance perturbation method, is explained. A planar metallic resonator acting as a sample holder and transducer is designed, and its performance in terms of sensitivity and selectivity is studied through simulations. The concept of surface impedance for electromagnetic modeling of DNA self-assembled monolayer on a metal surface is proposed, and its effectiveness is discussed based on the available data in the literature. To overcome the loss challenge, Whispering Gallery Mode (WGM) dielectric resonators with high Q factor are studied as an alternative for metallic resonator. The metallic loss becomes very high at terahertz frequencies, and as a result of that planar metallic resonators do not exhibit high Q factor. Reduced Q factor results in a low sensitivity for any sensor using such resonators. Theoretical models for axially and radially layered dielectric resonators acting on WGM are presented, and the analytical results are compared with the measured data. Excitation of WGM through dielectric waveguide is proposed, and the critical coupling condition is explained through analytical formulation. The possibility of selecting one resonance among many for sensing application is also studied both theoretically and experimentally. A high sensitivity sensor based on WGM resonance in mm-wave and terahertz is proposed, and its sensitivity is studied in details. The performance of the proposed sensor is tested for sensing drug tablets and also liquid droplets through various measurements in mm-wave range. The comprehensive sensitivity analysis shows the ability of the proposed sensor to detect small changes in the order of 10−4 in the sample dielectric constant. The results of various experiments carried out on drug tablets are reported to demonstrate the potential multifunctional capabilities of the sensor in moisture sensing, counterfeit drug detection, and contamination screening. The measurement and simulation results obtained in mm-wave hold promise for WGM to be used for sensing biological solutions in terahertz range with very high sensitivity.

Several fabrication techniques for surface micromachined 3-D structures have been developed for RF components. The fabrication techniques all have in common the use of epoxy patterning and subsequent metallization. Techniques and structures such as embedded conductors, epoxy-core conductors, a reverse-side exposure technique, a multi-exposure scheme, and inclined patterning are presented. The epoxy-core conductor technique makes it easy to fabricate high-aspect-ratio (10-20:1), tall (~1mm) RF subelements as well as potentially very complex structures by taking advantage of advanced epoxy processes. To demonstrate feasibility and usefulness of the developed fabrication techniques for RF applications, two test vehicles are employed. One is a solenoid type RF inductor, and the other is a millimeter wave radiating structure such as a W-band quarter-wavelength monopole antenna. The embedded inductor approach provides mechanical robustness and package compatibility as well as good electrical performance. An inductor with a peak Q-factor of 21 and an inductance of 2.6nH at 4.5GHz has been fabricated on a silicon substrate. In addition, successful integration with a CMOS power amplifier has been demonstrated. A high-aspect-ratio inductor fabricated using epoxy core conductors shows a maximum Q-factor of 84 and an inductance of 1.17nH at 2.6GHz on a glass substrate with a height of 900um and a single turn. Successful W-band monopole antenna fabrication is demonstrated. A monopole with a height of 800um shows its radiating resonance at 85GHz with a return loss of 16dB. In addition to the epoxy-based devices, an advanced tunable ferroelectric device architecture is introduced. This architecture enables a low-loss conductor device; a reduced intermodulation distortion (IMD) device; and a compact tunable LC module. A single-finger capacitor having a low-loss conductor with an electrode gap of 1.2um and an electrode thickness of 2.2um has been fabricated using a reverse-side exposure technique, showing a tunability of 33% at 10V. It shows an improved Q-factor of 21.5. Reduced IMD capacitors consist of wide RF gaps and narrowly spaced high resistivity electrodes with a gap of 2um and a width of 2um within the wide gap. A 14um gap and a 20um gap capacitor show improved IMD performance compared to a 4um gap capacitor by 6dB and 15dB, respectively, while the tunability is approximately 21% at 30V for all three devices due to the narrowly spaced multi-pair high resistivity DC electrodes within the gap. Finally, a compact tunable LC module is implemented by forming the narrow gap capacitor in an inductor shape. The resonance frequency of this device is variable as a function of DC bias and a frequency tunability of 1.1%/V is achieved. The RF components developed in this thesis illustrate the usefulness of the application of micromachining technology to this application area, especially as frequencies of operation of RF systems continue to increase (and therefore wavelengths continue to shrink).

The molecular compositions of the atmospheres of the giant planets (Jupiter, Saturn, Uranus and Neptune) are fundamental to understanding the processes which formed these planets and the solar system as a whole. Microwave observations of these planets probe regions in their atmospheres from approximately 0.1 to several bars, a process otherwise unachievable by visible and infrared means. Many gases and various cloud layers influence the millimeter wave spectra of the outer planets; however phosphine and ammonia are the main microwave absorbers at Saturn at pressures less than two bars. Understanding the pressure induced absorption of both constituents at observational frequencies is therefore vital to the analysis of any observational data. Laboratory measurements have been conducted to measure the microwave absorptivity and refractivity of phosphine and ammonia at Ka-band (32-40 GHz) and W-band (94 GHz), under conditions characteristic of the atmosphere of Saturn. The results were used to verify the accuracy of the phosphine formalism created by Hoffman et. al (2001) for use at millimeter wavelengths. Based on the laboratory measurements conducted, new formalisms were also created to express the opacity of ammonia at the measured frequencies. An important method for the study of planetary atmospheres is the radio occultation experiment ??method that uses radio links between Earth, and the spacecraft which passes behind the planet. The Cassini mission to Saturn, which will be conducting such experiments at Ka-band as well as S (2.3 GHz) and X (8.4 GHz) bands, has prompted the development of a radio occultation simulator used to calculate excess Doppler shifts and attenuation profiles for Saturn, utilizing the newest formalisms for phosphine and ammonia. The results indicate that there will be unambiguous detection and profiling of phosphine and ammonia, and predictions are made for the pressures at which loss of signal is anticipated.

As Si-manufacturing compatible SiGe HBTs are making rapid in-roads into RF through mm-wave circuit applications, with performance levels steadily marching upward, the use of these devices under extreme environment conditions are being studied extensively. In this work, test structures of SiGe HBTs were designed and put into extremely low temperatures, and a new negative differential resistance effect and a novel collector current kink effect are investigated in the cryogenically-operated SiGe HBTs. Theory based on an enhanced positive feedback mechanism associated with heterojunction barrier effect at deep cryogenic temperatures is proposed. The accumulated charge induced by the barrier effect acts at low temperatures to enhance the total collector current, indirectly producing both phenomena. This theory is confirmed using calibrated 2-D DESSIS simulations over temperature. These unique cryogenic effects also have significant impact on the ac performance of SiGe HBTs operating at high-injection. Technology evolution plays an important role in determining the magnitude of the observed phenomena, and the scaling implications are addressed. Circuit implication is discussed.

This thesis presents development of microwave lumped elements for a specific surface-micromachining based technology, a self-contained mechanical characterization of fixed-fixed type beams and realization of a shunt, capacitive-contact RF MEMS switch for millimeter-wave applications. Interdigital capacitor, planar spiral inductor and microstrip patch lumped elements developed in this thesis are tailored for a surface-micromachining technology incorporating a single metallization layer, which allows an easy and low-cost fabrication process while permitting mass production. Utilizing these elements, a bandpass filter is fabricated monolithically with success, which exhibits a measured in-band return loss better than -20 dB and insertion loss of 1.2 dB, a pass-band located in S-band and a stop-band extending up to 20 GHz. Analytical derivations for deflection profile and spring constant of fixed-fixed beams are derived for constant distributed loads while taking axial effects into account. Having built experience with the mechanical domain, next, Finite Difference solution schemes are established for pre-pull-in and post-pull-in electrostatic actuation problems. Using the developed numerical tools / pull-in, release and zipping phenomena are investigated. In particular, semi-empirical expressions are developed for the pull-in voltage with associated errors not exceeding 3.7 % of FEA (Finite Element Analysis) results for typical configurations. The shunt, capacitive-contact RF MEMS switch is designed in electromagnetic and mechanical domains for Ka-band operation. Switches fabricated in the first process run could not meet the design specifications. After identifying sources of relevant discrepancies, a design modification is attempted and re-fabricated devices are operated successfully. In particular, measured OFF-state return and insertion losses better than -16.4 dB and 0.27 dB are attained in 1-40 GHz. By applying a 20-25V actuation, ON-state resonances are tuned precisely to 35 GHz with an optimum isolation level of 39 dB.

The objective of this research is to present a low power modem technology for a high speed millimeter wave wireless system. The first part of the research focuses on a robust ASIC design methodology. There are several aspects of the ASIC flow that require special attention such as logical synthesis, timing driven physical placement, Clock Tree Synthesis, Static Timing Analysis, estimation and reduction of power consumption and LVS and DRC closure. The latter part is dedicated to high speed baseband circuits such as Coherent and Non coherent demodulator which are critical components of a multi-gigabit wireless communication system. The demodulator operates at input data rates of multiple gigabits per second, which presents the challenge of designing the building blocks to operate at speeds of multiple GHz. The high speed complex multiplier is a major component of the non coherent demodulator. As part of the coherent demodulator the complex multiplier derotates the input sequence by multiplying with cosine and sine functions, Costas error calculator computes the phase error in the derotated input signal. The NCO (Numerically controlled Oscillator) is a look up table based system used to generate the cosine and sine functions, used by the derotator.The CIC filter is used to decimate the costas error signal as the loop bandwidth is significantly smaller compared to the sampling frequency. All these modules put together form the coherent demodulator which is an integral part of the wireless communication system. An implementation of Serdes is also presented which acts as an interface between the baseband modules and the RF front end.