Abstract:
A high power RF connector receptacle having a solder able pin, an outer connector receptacle shell and a high breakdown voltage dielectric such as Silicon Carbide. The connector receptacle can be completed as a stepped process where the Silicon Carbide substrate can be mounted to the package, the pin can be dropped into place and soldered, and then the outer shell can be soldered onto the SiC substrate. Alternatively, the SiC, pin and outer shell can be assembled as a subassembly and then soldered to the package. The combination of SiC and solder gives a hermetic seal to the package. In addition, the SiC has an extraordinarily high dielectric breakdown voltage for high power connections,

Description:
CROSS REFERENCE TO RELATED APPLICATION 
       [0001]    This application claims priority from U.S. Provisional Patent Application Ser. No. 62/263,147 filed on Dec. 4, 2015 which is incorporated herein by reference in its entirety 
     
    
     TECHNICAL FIELD 
       [0002]    This disclosure relates generally to radio frequency (RF) electrical connector receptacles and more particularly to RF electrical connector receptacles adapted for handling relatively high power RIF signals. 
       BACKGROUND 
       [0003]    As is known in the art, radio frequency (RF) electrical connectors adapted for mounting onto a package having therein radio frequency component come in a variety of configurations. These connector receptacles generally require a ground plane conductor mounted to a wall of the package and a signal conductor, or pin having an end passing into the interior of the package. One such connector receptacle is a coaxial connecter having an outer electrically conductive outer conduit or shell which serves as the ground plane conductor, an inner electrically conductive center conductor; sometimes, as noted above, referred to as a conductive pin, used to provide the signal conductor, and a dielectric disposed between the center conductor and the outer conductor. Typical dielectrics are glass, ceramic or Teflon material. Connector receptacles using a glass dielectric are used provide a hermetic seal between the connector receptacle and package but require the glass dielectric/pin assembly to be soldered into the package and then the outer connector receptacle, or shell, is mounted separately to the package. Ceramic dielectric microstip connector receptacles are also soldered into the package to provides a hermetic bond with the package but tends to radiate radio frequency energy creating unwanted feedback issues in packages having high gain components such as high gain amplifiers. 
       SUMMARY 
       [0004]    In accordance with the present disclosure, a radio frequency energy connector receptacle is provided. The connector receptacle includes a dielectric substrate having a hole passing there-through between an upper surface of the substrate and a lower surface of the substrate. An electrically conductive layer is disposed on sidewalls of the hole, a portion of the electrically conductive layer being disposed on portions of the upper surface and lower surface of the substrate contiguous to the sidewalls of the hole. An upper electrically conductive layer is disposed on the upper surface of the substrate, such upper electrically conductive layer having an aperture then-through exposing an underlying portion of the upper surface of the substrate. A lower electrically conductive layer is disposed on the lower surface of the substrate, such lower electrically conductive layer having an aperture there-through exposing an underlying portion of the lower surface of the substrate. The aperture in the upper electrically conductive layer is vertically aligned with the aperture in the lower electrically conductive layer. The hole is disposed coaxially within the aperture in the upper electrically conductive layer and the lower electrically conductive layer. A plurality of electrically conductive vias pass through the substrate between the upper electrically conductive layer and the lower electrically conductive layer, the electrically conductive vias being disposed about the aperture in the upper electrically conductive layer and the aperture in the lower electrically conductive layer. The electrically conductive vias electrically interconnect the upper electrically conductive layer and the lower electrically conductive layer. The electrically conductive vias have a spacing less than a quarter wavelength, of the operating radio frequency energy of the connector receptacle. An electrically conductive pin has a lower portion passing through the hole and is connected and bonded to the electrically conductive layer disposed on the sidewalls of the hole. A hollow electrically conductive shell is provided. A dielectric layer is disposed within the shell. The dielectric layer has an opening there-through, the electrically conductive shell being disposed around a mid-portion of the electrically conductive pin. The electrically conductive pin is disposed to provide a signal conductor for the connector receptacle and the shell providing a ground plane conductor for the connector receptacle. 
         [0005]    In one embodiment, the pin is a solderable pin. 
         [0006]    In one embodiment, the substrate is Silicon Carbide (SiC). 
         [0007]    In one embodiment, the connector receptacle can be completed as a stepped process where the Silicon Carbide substrate can be mounted to the shell, the pin then dropped into place and soldered, and then the outer hosing can be soldered onto the SiC substrate. 
         [0008]    In one embodiment, the SiC substrate, pin and outer shell can be assembled as a subassembly and then soldered to the package, 
         [0009]    The combination of SiC and solder  0 .ves a hermetic seal to the package. In addition, the SiC has an extraordinarily high dielectric breakdown voltage for high power connections. 
         [0010]    With such an arrangement, a high power RF connector receptacle is provided having a solder able pin, an outer connector receptacle shell and a Silicon Carbide dielectric. The connector receptacle can be completed as a stepped process where the Silicon Carbide substrate can be mounted to the package, the pin can be dropped into place and soldered, and then the outer shell can be soldered onto the SiC substrate. Alternatively, the SiC, pin and outer shell can be assembled as a subassembly and then soldered to the package. The combination of SiC and solder  0 .ves a hermetic seal to the package. In addition, the Si. 0  has an extraordinarily high dielectric breakdown voltage for high power connections, 
         [0011]    The details of one or more embodiments of the disclosure are set forth in the accompanying drawings and the description below. Other features, objects, and advantages of the disclosure will be apparent from the description and drawings, and from the claims. 
     
    
     
       DESCRIPTION OF DRAWINGS 
         [0012]      FIG. 1A  is an exploded perspective view of an RF connector receptacle according the disclosure; 
           [0013]      FIG. 1B  is a perspective view of the RE connector receptacle of  FIG. 1A  after assembly according the disclosure; 
           [0014]      FIG. 1C  is a perspective view of a base used in the RF connector receptacle of  FIG. 1A  according the disclosure; 
           [0015]      FIG. 2A  is a plan view of the base used in the RF connector receptacle of  FIG. 1A  according the disclosure; 
           [0016]      FIG. 2B  is a cross sectional view of base used in the RF connector receptacle of  FIG. 1A  according the disclosure, such cross section being taken along line  2 B- 2 B in  FIG. 2A ; 
           [0017]      FIG. 3  is an exploded cross sectional view of the an RF connector receptacle of  FIG. 1A  according the disclosure; 
           [0018]      FIG. 4  is a cross sectional view of the an RE connector receptacle of  FIG. 1A  bonded to a hermetically sealed package having therein a microwave transmission line structure connected to the RE connector receptacle of  FIG. 1A  according the disclosure; 
           [0019]      FIGS. 5A-5D  is a series of perspective views of the RE connector receptacle of  FIG. 1A  connected to a stripline structure to provide a coaxial to stripline transition structure at stages in the fabrication thereof according to the disclosure; and 
           [0020]      FIGS. 6A-6D  is a series of cross sectional views of the RF connector receptacle of  FIG. 1A  connected to a stripline structure to provide the coaxial to stripline transition structure of  FIGS. 5A-5D  according to the disclosure. 
       
    
    
       [0021]    Like reference symbols in the various drawings indicate like elements. 
       DETAILED DESCRIPTION 
       [0022]    Referring now to  FIGS. 1A and 1B , an RF connector receptacle  10  is shown to include: a base  12 , shown in  FIG. 1C , an outer shell  14 , and a conductive pin  16 . The base  12 , shown more clearly in  FIGS. 1C, 2A and 2B  includes a dielectric substrate  22  having a relatively high breakdown voltage, for example in the range of 100 to 500 megavolts per meter and a thickness in the range of 3.9 to 4.1 mils here for example silicon carbide, having a hole  24  passing there-through between an upper surface  23  of the substrate  22  and a lower surface  25  of the substrate  22 . An electrically conductive layer  26  ( FIG. 2B ) is disposed on sidewalls  27  of the hole  24 , a portion of the electrically conductive layer  26  being disposed on adjacent portions of the upper surface  23  and lower surface  25  of the substrate  22  contiguous to the sidewalls  27  of the hole  24 . The base  12  may be formed using conventional photolithographic-chemical or other types of etching techniques. 
         [0023]    An upper electrically conductive layer  30 , here for example gold having a thickness in the range of 0.10 to 0.15 mils is disposed on the upper surface  23  of the substrate  22 , such upper electrically conductive layer  30  having an aperture  32  there-through exposing an underlying portion of the upper surface  23  of the substrate  22 . 
         [0024]    A lower electrically conductive layer  34 , here for example gold having a thickness in the range of 0.10 to 0.15 mils is disposed on the lower surface  25  of the substrate  22 , such. lower electrically conductive layer  34  having an aperture  36  there-through exposing an underlying portion of the lower surface  25  of the substrate  22 . The aperture  32  in the upper electrically conductive layer  30  is vertically aligned with, and of the same size as, the aperture  36  in the lower electrically conductive layer  34 . The hole  24  is disposed coaxially within the aperture  32  in the upper electrically conductive layer  22  and the aperture  36  in the lower electrically conductive layer  34 . 
         [0025]    A plurality of electrically conductive vias  40   a ,  40   b  ( FIG. 2 ) pass vertically through the substrate  22  between the upper electrically conductive layer  30  and the lower electrically conductive layer  34 , the electrically conductive vias  40   a  being disposed about the aperture  32  in the upper electrically conductive layer  30  and the aperture  36  in the lower electrically conductive layer  34 , the electrically conductive vias  40   a ,  40   b  electrically interconnecting the upper electrically conductive layer  30  and the lower electrically conductive layer  34 , the electrically conductive vias  40   a  having a spacing less than an eighth wavelength of the operating radio frequency energy of the connector receptacle. It is noted that the electrical conductive vias  40   b  are disposed between the upper electrically conductive layer  30  and the lower electrically conductive layer  34  through the outer peripheral region of the substrate  12 . 
         [0026]    Referring also to  FIG. 3 , the electrically conductive pin  16  having a mid-portion passes through the hole  24  and is bonded to the electrically conductive layer  26  disposed on the sidewalls of the hole  24 . Also shown in FIG,  3 , the shell  14  is a hollow electrically conductive shell  14  here for example, copper, provided, a receptacle for a coaxial connector such as an GPO, SMA, MPM, connector. Thus, in the case of an SMA connector the inner walls of the shell would be threaded and the outer walls of the SMA connector would be threaded onto the shell  13 . For an GPO connector, the GPO connector would be press fit into the inner walls of the shell  14 . The electrically conductive shell  14  is disposed around the upper portion of the electrically conductive pin  16 , the electrically conductive pin  16  being disposed to provide a signal conductor for the connector receptacle  10  and the electrically conductive shell  14  providing a ground plane conductor for the connector receptacle  10 . The bottom portion of the shell  14  is mounted to the upper electrically conductive layer  30  which is electrically connected to the upper region s of the electrically conductive vias  40   a . 
         [0027]    Referring now to  FIG. 4 , a package  48  is shown. A microwave structure  50 , here a microstrip transmission line structure having a strip conductor  52  separated from a ground plane conductor  54  by a dielectric substrate  56 . Electrical components  58  are connected to the microstrip transmission line structure  50  in any conventional manner. Prior to hermetically sealing the top lid  62  of the package  48 , the microwave structure  50  is placed within the package  48  and the ground plane conductor  54  is bonded to an electrically conductive bottom wall  60  of the package  48 . The distal end  64  of the pin  16  is bonded to an end of the strip conductor  52 . Next, the lower portion of the electrically conductive layer  24  and lower portion of the conductive vias  40   a ,  40   b , of base  12  are bonded, electrically connected and hermetically sealed, to the a side of the bottom wall  60  and an upper portion of the package  48 , as shown. 
         [0028]    Referring now to  FIGS. 5A-5D and 6A-6D , another embodiment of the &amp;Closure is shown. Here the connector receptacle  10  is used to connect to a microwave stripline transmission line structure  70  ( FIGS. 5A and 6A ). Thus, a coaxial to stripline transition. structure is provided. The structure  70  includes a pair of dielectric layers  72 ,  74  having a slap conductor  76  between the layers  72 ,  74 . The structure  70  includes an upper electrically conductive gourd plane layer  73  on the upper surface of the dielectric layer  72  and a lower electrically ground plane conductive layer  75  on the bottom surface of dielectric layer  74 . The upper electrically conductive layer  73  has an aperture  78  therein, electrically conductive via  80  is disposed in the center of the aperture  78  and passes through the dielectric layer  72  to electrically connect with an end  82  of the strip conductor  76 . The strip conductor  76  is shielded by ground plane conductor layers  77 ; it being noted that the shielding conductor layers  77  are sufficiently spaced from the strip conductor  76  so as not to provide a coplanar waveguide transmission line. More particularly, the layers  77  should be at least  1 . 5  times the spacing between the strip conductor  76  and the upper or lower ground plane conductors  73 ,  75 , preferably 2.5 times to 3 times the spacing between the strip conductor  76  and the upper or lower ground plane conductors  73 ,  75 . A plurality of electrically conductive vias  84   a ,  84   h  are provided to electrically connect the upper electrically conductive layer  73  on the upper surface of the dielectric layer  72  to the lower electrically conductive layer  75  on the bottom surface of dielectric layer  74  and the layer  77 . 
         [0029]    Next, the base  12  is bonded to the upper surface of the microwave stripline transmission line structure  70  as shown in  FIGS. 5B and 6B . It is noted that the bottom. conductive layer  34  of base  12  ( FIG. 3 ) is connected to the upper conductive layer  73  of microwave stripline transmission line structure  70 . 
         [0030]    Next, the pin  16  has its bottom end soldered to the top of the electrically conductive layer  26  and the top of conductive via  80  as shown in  FIGS. 6C and 6C . 
         [0031]    Next, the outer shell  14  is soldered to the upper surface of the base  12 , as shown in  FIGS. 5D and 6D . 
         [0032]    One fabrication method that may be used to form the connector receptacle  10  is as follows: Utilizing an electrically insulating substrate  22 , such as 4 mil thick SiC, photoresist is spun onto the top side of the substrate  22 . Using standard photolithography techniques, a mask is pattern in the shape of the desired metalized aperture  23 . Metal layer  26  is then deposited over the mask and onto the exposed portions of the upper surface  30  of the substrate  22  using either evaporation or sputtering techniques. Next, the mask is removed along with the portions of the metal thereon forming the aperture  23  in the metal layer  26 . Next, through vias  40   a ,  40   b  are formed after their location is defined using a similar photolithographic process on the bottom surface  25  of the substrate  22 . Plasma etch technology is, for example, used to form via through holes through the substrate  22 . With via holes formed, a seed layer of metal is sputter on the backside of the substrate  22  and into via holes  40   a ,  40   h  prior to plating the bottom side with metal layer  34 . A photoresist is spun onto the bottom surface  25  in the portion of the surface  25  wherein the aperture  32  is to be formed in the same manner as used to form aperture  23 . Thus, metal layer  34  is then deposited over the mask and onto the exposed portions of the lower surface  25  of the substrate  22  using either evaporation or sputtering techniques. Next, the mask is removed along with the portions of the metal thereon forming the aperture  32  in the metal layer  26 . The unwanted metal is then etched away. The photoresist is stripped leaving the desire aperture  32  and plated via conductors  40   a ,  40   b . The next step is to solder a mechanical connector receptacle shell  14  to the topside metal  26  pad. The metal pin  16  is then inserted through one of the plated through hole  24  and soldered in place forming an electrical. connector receptacle  10 . 
         [0033]    A number of embodiments of the disclosure have been described. Nevertheless, it will be understood that various modifications may be made without departing from the spirit and scope of the disclosure. Accordingly, other embodiments are within the scope of the following claims.