Syntactic Foam - A New Dielectric

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1 Syntactic Foam - A New Dielectric for Beam Forming Networks in Space Applications Peter Uhlig, Jens Leiß, Dietmar Köther IMST GmbH VDE ITG DISKUSSIONSSITZUNG ZUM THEMA MATERIALCHARAKTERISIERUNG RUHR-UNIVERSITÄT BOCHUM, 31. März 2011

2 Content Scope of VERSA Background and Motivation New Multilayer Concept Material Characterization Technology Demonstrator 2 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

3 VERSA: Scope of the Project Power distribution networks for satellites realized as multilayer in syntactic foam. Development and verification of multilayer and packaging technique Component library Demonstrator: 1:64 power distribution network 3 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

4 Project Consortium IMST GmbH EM-Simulation, Design Microwave Measurement EADS Astrium Specification / Application Elekonta Marek Production Technology for Multilayer Fraunhofer ENAS (Micro Materials Center Chemnitz) Thermomechanical Simulation and Characterization Fraunhofer Institute for Environmental, Safety and Energy Technology UMSICHT Material Preparation 4 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

5 Power Distribution Network Requirements Distribution of RF-Signals to Antenna Elements Amplitude and Phase Identical at all Antenna Outputs Spatial Distribution of Signals Low Loss Low Weight Antenna Array Power Distribution Network TX D/A RX A/D 5 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

6 Concepts for Power Distribution Networks Wave Guides 6 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

7 Concepts for Power Distribution Networks Wave Guides Reduce Weight Shielded Microstrip on µw PCB Size: mm x 72.4 mm x 5.5 mm TerraSAR X TanDEM X 7 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

8 TerraSAR-X : Earth 9.65 GHz 1:32 Power Divider / Combiner Binary tree of Wilkinson dividers Low losses Equal amplitude and phase for all paths High isolation between ports Stable thermal properties Planar circuit (PCB) 8 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

9 Concepts for Power Distribution Networks Wave Guides Reduce Weight Shielded Microstrip on µw PCB Reduce Weight Multilayer in µw PCB 1,2 m 9 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

10 TerraSAR-L : EFN Layout + Setup GPO connectors (+X direction) M4 screw J1 J2 J 3 J4 J5 J6 J7 J8 J9 J10 J11 J12 J13 J14 J15 J16 J17 J18 J19 J20 J21 M5 M5 M4 M3 M2 M1 M7 197 mm M8 M9 M10 M11 J22 J23 J24 M12 M13 SMA connectors (+Z direction) z x y M mm 2 x Prepreg (Epoxy): 0.1mm CFRP Epoxy filled Cu-Via CFRP: 1mm Bonding Film RO 3001: 38um RO 6002: mm 2 x Prepreg (Epoxy): 0.1mm RO 6002: mm Bonding Film RO 3001: 38um RO 6002: mm 2 x Prepreg (Epoxy): 0.1mm RO 6002: mm Bonding Film RO 3001: 38um RO 6002: mm RO 6002: mm 2 x Prepreg (Epoxy): 0.1mm CFRP CFRP: 1mm 10 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

11 TerraSAR-L : Connectors and Transitions GPO connector cavity GND GND GND Via OUT matching stripline GND GND SMA connector cavity GND Via IN Signal Via Multilayer Transition matching stripline 11 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

12 TerraSAR-L (LEO, Earth Observation) - Power 1.26 GHz - 3 x (1 : 7) Divider Networks: 1.2 m x 20 cm - Multi-Layer PTFE Board - Bandwidth 70 MHz - Return Loss > 25 db - Insertion Loss < -11 db - Transmission Loss < -2 db - Ampl. Flatness < 0.09 db - Gain Balance < 0.16 db - Phase Balance < 4 - Port Isolation > 32 db - Cross Talk < -80 db 12 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

13 Concepts for Power Distribution Networks Wave Guides Reduce Weight Shielded Microstrip on µw PCB Reduce Weight Multilayer in µw PCB Reduce Weight? Multilayer with Air as Dielectric? 13 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

14 PTFE Challenges Teflon Knee Poor mechanical properties Critical PCB Process Weight ITAR / Availability 14 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

15 VERSA: Syntactic Foam & Carbon Fibre Reinforced Plastic Used for lightweight structural parts also in space applications The main components have space heritage Syntactic foam as close approximation to air as dielectric Exploit potential of structural part for RF-circuitry rather than adding a circuit board 15 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

16 VERSA Syntactic Foam as Dielectric: Low Density and Permittivity Reinforcement (CFRP) Ground Planes Centre Conductor Syntactic Foam Via Fences Shield Laterally 16 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

17 Syntactic Foam Syntactic foam is a composite, made up of hollow spherical glass fillers, which are bound into a plastic matrix. Low loss dielectrics around 1.38 and higher make syntactic foam ideal for microwave uses. Key Features: Low density High compressive strength Good machineability Temperature-resistant typ. up to 177 C Linear CTE typ. 4.1*10-6 /K 17 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

18 Material Characterization Electrical Parameters Waveguide measurement setup Waveguide section with syntactic foam specimen 18 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

19 Material Characterization Permittivity of thin sheet from NWA Coaxial-Waveguide- Transition Programmable Manipulator Reflector Waveguide Syntactic Foam (DUT) 19 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

20 Component Library Box of Bricks Wilkinson power divider Branchline coupler Coaxial to stripline transition Vertical transitions between layers with via or slot coupling Transmission lines with various impedances (53 Ω, 61 Ω, 106 Ω, 181 Ω) Compensated transmission line bends 20 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

21 Material Characterization Thermo-Mechanical Data Coefficient of Thermal Expansion 21 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

22 Finite Element Model FE model 22 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

23 Processing the Multilayer Syntactic Foam Ground Plane Conductor Pattern (on Kapton) Stacking Laminating Via Formation Conductor Laminating of CFRP Contour Milling 23 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

24 Demonstrator Power Distribution Network 1:16 24 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

25 Conclusion State of the Art: Multilayer-PDN in Polymer or LTCC VERSA: Multilayer-PDN in Sandwich of Syntactic Foam and CFRP Advantages of Syntactic Foam: Low weight, low permittivity, low losses, good mechanical properties Structural part and electrical function combined Challenges: Qualification of a new manufacturing technology in a very conservative environment Target: Proof of concept and suitability for space applications 25 VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

26 Questions? Acknowledgment The work presented in this paper is derived from the project VERSA Power Distribution Networks for Satellite Communication. The authors wish to acknowledge the funding of this work by the German Space Agency (DLR Bonn) on behalf of the German Federal Ministry of Science and Education (BMBF) under research contract No. 50 YB VDE ITG Diskussionssitzung Materialcharakterisierung, Bochum 31. März 2011 P. Uhlig Mrz-11 IMST GmbH - All rights reserved

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