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Proceedings Paper

Manufacture of a conformal multilayer rf antenna substrate using excimer mask imaging technology and a 6-axis robot
Author(s): Michel Charrier; Daniel Everett; Jim Fieret; Tobias Karrer; Sven Rau; Jean-Luc Valard
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Paper Abstract

A novel method is presented to produce a high precision pattern of copper tracks on both sides of a 4-layer conformal radar antenna made of PEI polymer and shaped as a truncated pseudo-parabolic cylinder. The antenna is an active emitter-receiver so that an accuracy of a fraction of the wavelength of the microwave radiation is required. After 2D layer design in Allegro, the resulting Gerber file-format circuits are wrapped around the antenna shape, resulting in a cutter-path file which provides the input for a postprocessor that outputs G-code for robot- and laser control. A rules file contains embedded information such as laser parameters and mask aperture related to the Allegro symbols. The robot consists of 6 axes that manipulate the antenna, and 2 axes for the mask plate. The antenna can be manipulated to an accuracy of +/- 20 micrometers over its full dimensions of 200x300x50 mm. The four layers are constructed by successive copper coating, resist coating, laser ablation, copper etching, resist removal, insulation polyimide film lamination and laser dielectric drilling for microvia holes and through-holes drilling. Applications are in space and aeronautical communication and radar detection systems, with possible extensions to automotive and mobile hand-sets, and land stations.

Paper Details

Date Published: 29 June 2001
PDF: 10 pages
Proc. SPIE 4274, Laser Applications in Microelectronic and Optoelectronic Manufacturing VI, (29 June 2001); doi: 10.1117/12.432532
Show Author Affiliations
Michel Charrier, Thomson-CSF (France)
Daniel Everett, Exitech Ltd. (United Kingdom)
Jim Fieret, Exitech Ltd. (United Kingdom)
Tobias Karrer, CAE Consulting GmbH (Germany)
Sven Rau, CAE Consulting GmbH (Germany)
Jean-Luc Valard, Thomson-CSF (France)

Published in SPIE Proceedings Vol. 4274:
Laser Applications in Microelectronic and Optoelectronic Manufacturing VI
Malcolm C. Gower; Henry Helvajian; Koji Sugioka; Jan J. Dubowski, Editor(s)

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