Printed circuit board with first and second surfaces configured for waveguide coupling a diplexer mounted on the first surface to a transmitter and a receiver mounted on the second surface

A surface mount constructed millimeter wave transceiver device and methods of making a surface mount constructed millimeter wave transceiver device are disclosed. The transceiver device includes a printed circuit board having a first waveguide port and a second waveguide port. A diplexer is surface mounted to a first side of the printed circuit board, the diplexer comprising a low frequency waveguide port and a high frequency waveguide port each coupled to an antenna port. A transmitter and a receiver are surface mounted to a second side of the printed circuit board, located opposite the first side of the printed circuit board, wherein the transmitter and the receiver comprise a transmitter waveguide port and a receiver waveguide port, respectively, that are configured to be aligned to the first waveguide port and the second waveguide port of the printed circuit board, respectively.

FIELD

This technology relates to a surface mount constructed millimeter wave transceiver device and methods thereof.

BACKGROUND

The use of millimeter wave (mmWave) frequencies for high speed data transport continues to grow. The mmWave spectrum is defined from approximately 30 GHz to 300 GHz, with this frequency range designated as extremely high frequency (EHF). A communication system designed for the EHF range can take advantage of the fact that the physical amount of spectrum available at a particular operating frequency exhibits naturally wide bandwidth. Typical examples of operating channel bandwidths are between 1 and 2 GHz in the 60 to 90 GHz operating frequencies. Future telecommunication systems are targeting new semiconductor technologies that will operate above 100 GHz, with the potential for even wider channel bandwidths.

One of the key technologies that has been rapidly evolving is how a mmWave semiconductors are packaged for implementation in high speed communications systems. Initially, only the bare die from a semiconductor fabrication wafer was available. A bare die requires careful placement and some form of wire bonding for interconnection between the die and other circuitry needed to create a complete transmitter and receiver. Newer mmWave packaging methods, such as wafer level ball grid array (WLBGA), and wafer level chip scale packaging (WLCSP), allowed the creation of efficient, low loss packages that enabled much simplified manufacturing techniques. These types of packages were implemented as surface-mount devices (SMD) and became part of the vast multitude of components in the surface-mount technology (SMT) domain. What this meant was much lower manufacturing costs, higher manufacturing yields, and predictable mmWave performance.

As the frequency of mmWave operation continues to move upwards in the electromagnetic spectrum, electrical conductors, such as wire bonds or even SMT package electrical pins that interface to electrical PCB traces, constrains the ultimate performance and efficiency due to electrical losses. These electrical losses are characterized in the areas of electrical resistance, inductance, and capacitance. The industry has recognized this limitation and has introduced mmWave semiconductor packages that transduce the electrical energy into electromagnetic waves, carried via a waveguide port, within the package itself. By constructing the package such that the waveguide port is at the same planar surface as the other input and output (I/O) pins on the package, it is now possible to place the package as an SMD directly on to a printed circuit board (PCB) with the possibility of transferring the mmWave energy without any electrical conductors. One example of this kind of new direct waveguide package is the land grid array cavity (LGA_CAV) type used in newer mmWave up converter devices (for use as a transmitter) and down converter devices (for use as a receiver).

High speed, low latency mmWave wireless transport systems make use of the ability to transmit and receive simultaneously, known as frequency division duplex (FDD), which result in high throughput data rates with low latency delay in data delivery. The use of a frequency filter diplexer allows the ability for FDD operation by isolating the transmitter energy from desensitizing the local receiver while coupling both the transmitter and the receiver to a common antenna. Typically, mmWave diplexers are designed as waveguide devices to exhibit low energy loss and high transmitter to receiver isolation. The traditional method used to couple the transmitter and receiver to the diplexer was through the use of standard waveguide flange type mechanical interfaces. These allowed low loss and good electrical connectivity, but at the cost and larger size of using separate waveguide flanges for the transmitter and receiver connections.

FIG.1shows a prior art system and method for coupling mmWave or microwave electromagnetic energy from transmitter and receiver modules,210and208, respectively, to a diplexer212. The final assembly, mounted in enclosure102, forms a full duplex transceiver terminal used as part of a full duplex link for mmWave or microwave wireless digital transport. The use of separate mechanical transmitter and receiver modules with waveguide flanges must be assembled to the final mechanical assembly and then interconnected to the single printed circuit board (PCB)206and diplexer212. The transmitter module, receiver module, and PCB are all manufactured separately. The transmitter and receiver modules also require extra manufacturing steps for mechanically mounting to the enclosure, mechanical coupling to the diplexer waveguide flanges, and electrically interconnecting to the PCB. The separate waveguide module construction for the transmitter and receiver, and the added steps in the final assembly increase the overall manufacturing costs due to the costs of the separate assemblies. The separate assembly procedures for the transmitter module, receiver module, diplexer, and PCB also significantly increase the total manufacturing assembly time.

SUMMARY OF THE INVENTION

One aspect of the present technology relates to a surface mount constructed millimeter wave transceiver device. The transceiver device includes a printed circuit board having a first waveguide port and a second waveguide port. A diplexer is surface mounted to a first side of the printed circuit board, the diplexer comprising a low frequency waveguide port and a high frequency waveguide port each coupled to an antenna port. A transmitter and a receiver are surface mounted to a second side of the printed circuit board, located opposite the first side of the printed circuit board, wherein the transmitter and the receiver comprise a transmitter waveguide port and a receiver waveguide port, respectively, that are configured to be aligned to the first waveguide port and the second waveguide port of the printed circuit board, respectively.

Another aspect of the present technology relates to a method of making a millimeter wave transceiver device. The method includes providing a printed circuit board having a first waveguide port and a second waveguide port. A diplexer is surface mounted to a first side of the printed circuit board, the diplexer comprising a low frequency waveguide port and a high frequency waveguide port, each of the low frequency waveguide port and the high frequency waveguide port coupled to an antenna port. A transmitter and a receiver are surface mounted to a second side of the printed circuit board, located opposite the first side of the printed circuit board, wherein the transmitter and the receiver comprise a transmitter waveguide port and a receiver waveguide port, respectively, aligned to the first waveguide port and the second waveguide port of the printed circuit board, respectively, when the transmitter and the receiver are surface mounted.

This technology provides a number of advantages including providing surface mount constructed millimeter wave transceiver devices and methods of making the same that rely entirely on surface mounting of the waveguide components. This provides a transceiver device that is easy to manufacture, allows for efficient transfer of electromagnetic energy, and efficient coupling between the packages and a diplexer without the need for separate waveguide flanges. Further, the diplexer can be surface mounted in either a high transmit or low transmit configuration without the need for changing the part or the fabrication technique.

DETAILED DESCRIPTION OF THE INVENTION

An exemplary surface mount constructed millimeter wave transceiver device10is illustrated inFIGS.2A and2B. The transceiver device10includes a printed circuit board (PCB)12that supports waveguide transmitter package14, waveguide receiver package16, and a diplexer18, the elements of which are surface mounted on the PCB12. Surface mounting techniques are known in the art. The PCB12may also support a number of additional elements for operation of the transceiver device10including, by way of example only, a modem, one or more processors, one or more memory devices, and one or more communication interfaces, although the PCB12may also include other types and/or numbers of elements in other configurations for operation of the transceiver device10.

Referring againFIGS.2A and2B, in this example, the diplexer18is surface mounted to a first side20of the PCB12. The diplexer18includes a common antenna port34. The waveguide transmitter package14and the waveguide receiver package16are surface mounted to a second side22of the PCB12, located opposite the first side20of the PCB12, although the PCB12may include other types and/or numbers of elements in other configurations, including transmitter and receiver local oscillators, by way of example only. The surface mount constructed millimeter wave transceiver device10of this technology advantageously provides an entirely surface mounted PCB assembly that is easy to manufacture. More specifically, the surface mount constructed millimeter wave transceiver device10allows for implementing waveguide mmWave packages directly onto a PCB that allows efficient transfer of electromagnetic energy. This technology allows the mmWave electromagnetic energy to efficiently couple between the packages and a diplexer without the need for separate waveguide flanges. The waveguide transmitter package14can be either a low frequency transmitter IC (FIG.2A) or a high frequency transmitter IC (FIG.2B). The waveguide receiver package16can be either a high frequency receiver IC (FIG.2A) or a low frequency receiver IC (FIG.2B). Further, the diplexer18can be surface mounted in either a high transmit (diplexer in “transmit high” position as shownFIG.2B) or low transmit (diplexer in “transmit low” position as shown inFIG.2A) configuration without the need for changing the part or the fabrication technique, as described in further detail below. As shown inFIGS.2A and2B, the diplexer18includes a low frequency waveguide port26and a high frequency waveguide port28

In this example, transceiver device10is a fully integrated transceiver device, although in other examples, such a transceiver device100may be formed as a plug-in module as shown inFIGS.3A and3Bwith the same elements as described with respect to transceiver device10.FIGS.2A and2Bshow examples of the fully integrated transceiver device10configured for transmit (TX) Low and transmit (TX) High (as described below), respectively, with similar relationships of the waveguide transmitter package14and the waveguide receiver package16to the PCB12and the diplexer18compared with the transceiver device100, which is formed as a plug-in module, shown inFIGS.3A and3B. The layout of PCB12and fabrication are identical for the TX Low and TX high integrated transceiver for both transceiver device10and transceiver device100. The same reduced manufacturing complexity applies to the integrated transceiver design since the PCB fabrication is the same for both configurations.

As shown inFIGS.2A,2B,3A, and3B, the PCB12includes internal waveguide ports24that extend through the PCB12and allow for connection between waveguide transmitter package14and waveguide receiver package16and the diplexer18as described below. As shown inFIGS.3A and3B, the transceiver100, which is a plug-in module, also includes a connector.

FIGS.4A and4Billustrate top and bottom views, respectively, of an exemplary diplexer that may be utilized for the diplexer18in either transceiver device10(FIGS.2A and2B) or transceiver device100(FIGS.3A and3B). In one example, the diplexer18is Universal Microwave Technology part number SK80168DX diplexer, although other diplexers may be employed. In this example, the diplexer18is designed for the low “L”) and high “H”) mmWave frequency bands, although other frequency bands may be utilized. In this example, the 71 GHz to 76 GHz band is identified as the “Low” (“L”) frequency, and the 81 GHz to 86 GHz band as the “High” (“H”) frequency (as shown inFIG.4A). The diplexer18includes a low frequency waveguide port26(FIG.4B) and a high frequency waveguide port28(FIG.4B) that are coupled through low and high frequency internal filters (not shown), respectively, to a common antenna port34(FIG.4A) on the other side of the diplexer18. In one example, the diplexer18allows reception of high frequency electromagnetic energy and simultaneous transmission of low frequency electromagnetic energy coupled to a common antenna enabling frequency division duplexing (FDD) operation. In this example, a transceiver configured in this way is known in the industry as the “TX Low” side of a full duplex link. In another example, the diplexer18allows reception of low frequency electromagnetic energy and simultaneous transmission of high frequency electromagnetic energy which produces the “TX High” side of a full duplex link.

FIGS.5A-5Dillustrate an exemplary millimeter waveguide transmitter package14(FIGS.5A-5C) that may be employed in either transceiver device10(FIGS.2A and2B) or transceiver device100(FIGS.3A and3B). The waveguide transmitter package14in this example is part number ADMV7310 from Analog Devices, Inc., which uses the land grid array cavity (LGA_CAV) package with an integrated waveguide port36(FIGS.5A and5D), although other transmitter IC packages that may be surface mounted may be employed. The waveguide port36(shown in more detail inFIG.5D) is planar to the other input/output and power pins37(FIG.5A) around the periphery of the package, allowing the package to be surface mounted, including the waveguide port36, directly to the PCB12as shown inFIGS.2A,2B,3A and3Band described in further detail below.

FIGS.6A-6Dillustrates an exemplary millimeter waveguide receiver package16that may be employed in either transceiver device10(FIGS.2A and2B) or transceiver device100(FIGS.3A and3B). The waveguide receiver package16(FIGS.6A-6C) in this example is part number ADMV7410 from Analog Devices, Inc., which uses the land grid array cavity (LGA_CAV) package with an integrated waveguide port38(FIGS.6A and6D), although other receiver IC packages that may be surface mounted may be employed. The waveguide port38(shown in more detail inFIG.6D) is planar to the other input/output and power pins39(FIG.6A) around the periphery of the package, allowing the package to be surface mounted, including the waveguide port, directly to the PCB12as shown inFIGS.2A,2B,3A and3Band described in further detail below.

Referring now more specifically toFIG.3A, transceiver device100is a mmWave all surface mount transceiver designed as a plug-in module and assembled for a TX Low configuration. The transceiver device100includes the exemplary waveguide transmitter package14and the waveguide receiver package16as shown inFIGS.5A-5C and6A-6C, respectively, and the diplexer18as shown inFIGS.4A and4B. In this example, the waveguide transmitter package14is a low frequency transmitter IC that operates in a range from about 71 GHz to about 76 GHz, as shown for example inFIG.4A. Waveguide transmitter package14is surface mounted to the second side22of the PCB12and is accurately positioned such that the waveguide port36(as shown inFIGS.5A and5D) is aligned with one of the waveguide ports24formed in the PCB12at the right side as shown inFIG.3A. The diplexer18is affixed to the first side20of the PCB12with alignment of its high and low waveguide ports26and28to the respective waveguide ports24in the PCB12as shown inFIG.3A. Waveguide receiver package16is a high frequency receiver IC that operates in a range from about81GHz to about86GHz, as shown for example inFIG.4A. Waveguide receiver package16is surface mounted to the second side22of the PCB12assembly positioned such that the waveguide port38(as shown inFIGS.6A and6D) is aligned with one of the waveguide ports24in the PCB12at the left side as shown inFIG.3A. In this configuration, the diplexer18is positioned with its low frequency waveguide port26at the right side of the PCB12and its high frequency waveguide port28at the left side of the PCB12as shown inFIG.3A. The diplexer18includes a common antenna port34.

FIG.3Billustrates the all surface mount transceiver device100designed as a plug-in module and assembled for a TX High configuration. The transceiver device100includes the exemplary waveguide transmitter package14and the waveguide receiver package16as shown inFIGS.5A-5C and6A-6C, respectively, and the diplexer18as shown inFIGS.4A and4B[[4]]. In this example, the waveguide transmitter package14is a high frequency transmitter IC (as shown for example inFIG.2B) that operates in a range from about81GHz to about86GHz. The waveguide transmitter package14is surface mounted to the second side22of the PCB12assembly accurately positioned such that the waveguide port36(as shown inFIGS.5A and5D) is aligned with one of the waveguide ports24formed in the PCB12at the right side as shown inFIG.3B. The diplexer18is affixed to the first side20of the PCB12with alignment of its low and high waveguide ports26and28to the respective waveguide ports24in the PCB12. The waveguide receiver package16in this example is a low frequency receiver IC as shown for example inFIG.2B) that operates in a range of about71GHz to about76GHz. The waveguide receiver package16is surface mounted to the second side22of the PCB12assembly positioned such that the waveguide port38(as shown inFIGS.6A and6D) is aligned with one of the waveguide ports24in the PCB12at the left side as shown inFIG.3B. In this configuration, the diplexer18is positioned with its high frequency waveguide port28at the right side of the PCB12and its low frequency waveguide port26at the left side of the PCB12as shown inFIG.3B. The diplexer18includes a common antenna port34.

The layout on PCB12shown inFIGS.3A and3Bincludes internal waveguide ports24positioned relative to the low and high frequency diplexer ports26and28, and to the IC package layout footprints for the periphery I/O pins. The receiver local oscillator IC42and the transmitter local oscillator IC40, as shown inFIGS.2A,2B,3A, and3B, are programmable in terms of their respective operating frequencies, which determine the operating frequencies (either High or Low) of the waveguide transmitter package14and the waveguide receiver package16. However, the waveguide transmitter package14and the waveguide receiver package16are specifically built, with unique part numbers, for all of the combinations of TX High and TX Low, meaning there is a unique waveguide receiver package14for low frequency (i.e., 71 GHz to 76 GHz) and a unique waveguide receiver package14for high frequency (i.e., 81 GHz to 86 GHz). Also, there is a unique waveguide transmitter package16for low frequency and a unique waveguide transmitter package16for high frequency. The layout accommodates the diplexer18to be mounted in either the TX Low/RX High position, or effectively rotated 180 degrees creating the opposite TX High/RX Low position. Therefore, the only assembly changes required to change the transceiver device100from a TX Low (FIG.3A) configuration to a TX High (FIG.3B) configuration are the mounting of the correct SMT waveguide transmitter package14and the waveguide receiver package16, and the orientation of the diplexer18. As such, the PCB12itself is identical in layout and fabrication allowing the same PCB fabrication to be used in either configuration. By having the same PCB12layout available for either the TX High (FIG.3B) or TX Low (FIG.3A) assembled configurations, the manufacturing complexity and cost is reduced. There may be other waveguide transmitter package14and waveguide receiver package16used that can cover the full range of about 71 GHz to about 86 GHz that may also be applied to the common PCB12layout. Such devices can be used for either a transmit high or transmit low by providing the correct local oscillator frequency for either case using the programmable receiver local oscillator IC40and the transmitter local oscillator IC42.

Referring now toFIGS.7A,7B,8A-8E,9A-9E,10A-10F,11A-11C,12,13A, and13B, in additional examples, the surface mount mmWave transceiver devices10or100may include additional components for implementing a pair of surface mount (SMT) waveguide adaptors44(FIGS.8A-8E) on the first side20of the PCB to allow surface mounting of the diplexer18. The purpose of the SMT waveguide adaptors44is to extend the electrical waveguide interfaces from the waveguide transmitter package14and the waveguide receiver package16, which are system-in-package (SiP) devices, that are surface mounted to the second side22of the host PCB12.

Referring now more specifically toFIGS.7A and7B, in this example, the second side22of the PCB12includes mounting areas46for RF shields48(as shown inFIGS.9A-9E) for both the SiP waveguide transmitter package14having waveguide port36and the SiP waveguide receiver package16having waveguide port38(as shown inFIG.7B) when located on the second side22(FIG.7B) of the host PCB12, as shown inFIG.7B, for example. Referring again toFIG.7B, the mounting areas46for the RF shields48include alignment pin holes50to receive alignment pins52(also shown inFIG.10D) located on the SMT waveguide adaptors44(as shown inFIGS.8A and8B, and10D), as well as through holes54for connecting the RF shields48to the SMT waveguide adaptors44as described in further detail below. Referring now toFIG.7A, the first side20of the PCB12includes mounting areas56for the SMT waveguide adaptors44(FIGS.8A-8E). The mounting areas56for the SMT waveguide adaptors44include alignment pin holes58to receive the alignment pins52located on the SMT waveguide adaptors44(as shown inFIGS.8A and8B), as well as the through holes54for connecting the RF shields48to the SMT waveguide adaptors44as described in further detail below.

The host PCB12further includes waveguide ports24, as described above, for both the SiP waveguide transmitter package14and the waveguide receiver package16and the diplexer18(FIG.4A and4B). In this example, the waveguide ports24extend through the host PCB12and are internally plated to form a waveguide electrical connection between the SiP waveguide transmitter package14and the waveguide receiver package16through the PCB12and out to the first side20of the host PCB12for connection of the SMT waveguide adaptors44. The first side20of the host PCB12electrically extends the internal plated wall of the waveguide ports24to the first side20, which is plated in the mounting areas56for the SMT waveguide adaptors44.

Referring now toFIGS.8A-8E, schematics for an exemplary SMT waveguide adaptor44are illustrated.FIG.8Eis a cross-sectional view ofFIG.8Calong the direction marked8E inFIG.8C. In one example, the SMT waveguide adaptors44are constructed of aluminum with a silver plating, although other electrically conductive materials may be employed. The SMT waveguide adaptors44are surface mounted to the surface of the first side20of the PCB12in the SMT waveguide mounting areas56as shown inFIG.7A, during the SMT reflow process, as described below. The SMT waveguide adaptors44include waveguide openings62, as shown inFIGS.8A-8C,10A,10D, and11A. The SMT waveguide adaptors44are mounted on the first side20of the host PCB12such that the waveguide openings62in the SMT waveguide adaptors44are aligned with the waveguide ports24in the host PCB12, as shown inFIG.11A. Referring again toFIGS.8A-8E, the SMT waveguide adaptors44have alignment pins52(FIGS.8A,8B, and10D) that align with alignment holes58in the host PCB12(as shown inFIG.7A) that allow precision registration within ±0.003″ (±0.08 mm) when mounted to the host PCB12as shown inFIGS.11A-11C, by way of example only. The SMT waveguide adaptors44also include threaded holes64(FIGS.8A-8C,10A, and10D) that align with the through holes54in the host PCB12(as shown inFIG.7A) to allow connection to the corresponding RF shields48as described below. The SMT waveguide adaptors44also include a set of threaded holes66(FIGS.8B,8C,10A, and10D) for mounting the diplexer18, as shown inFIG.12.

Referring now toFIGS.9A-9E, schematics for an exemplary RF shield48are illustrated.FIG.9Eis a cross-sectional view ofFIG.9Dalong the direction marked9E inFIG.9D. In one example, the RF shields48are constructed of aluminum with a silver plating, although other materials may be employed. The RF shields48are mounted to the surface of the second side22of the PCB12has shown inFIGS.10B and10C) in the RF shield mounting areas46kFIG.7B) using threaded screws70fFIG.10E), as described below. The RF shields48also include holes68that align with the through holes54in the host PCB12has shown inFIG.7B) to allow connection to the corresponding SMT waveguide adaptors44as shown inFIG.10E, for example, and as described below.

FIGS.10A-10Fillustrates the alignment of the RF shields48and the SMT waveguide adaptors44when mounted to the second side22and the first side20, respectively, of the host PCB12(as shown inFIGS.10A-10C). Threaded screws70as shown inFIG.11C) may be used to couple the RF shields48and SMT waveguide adaptors44through the holes68(as shown inFIG.10F), although other coupling mechanisms may be employed.FIGS.11A-11Cillustrate the RF shields48(FIGS.11B and11C) and the SMT waveguide adaptors44(FIGS.11A and11C) when mounted on the second side22of the host PCB12as shown inFIG.11B. The RF shields48may be located at both transmit and receive locations on the PCB12.

FIG.12shows the diplexer18coupled to the SMT waveguide adaptors44located on the first side20of the host PCB12. In this example, the diplexer18has the high frequency waveguide port28for a high frequency interface, the low frequency waveguide port26for a low frequency interface (as shown inFIG.4B), and the common antenna port34. The high frequency waveguide port28(FIG.4B) aligns with a mating waveguide pattern on one SMT waveguide adaptor44, and the low frequency waveguide port26(FIG.4B) aligns with a mating waveguide pattern on the other SMT waveguide adaptor44. In one example, each of the SMT waveguide adaptors44is composed of aluminum with a silver-plated surface to facilitate low electrical loss. These materials also allow for the SMT waveguide adaptors44to be soldered in the SMT reflow production process, as described below.

The SMT waveguide adaptors44are soldered onto the first side20of the PCB12, as shown inFIG.12, during the SMT reflow process. Referring now toFIG.13A, SMT waveguide adapter solder paste patterns are stenciled onto the first side20of the PCB12(printed circuit board bottom side area) to allow the solder to reflow into the locations required for adhering the SMT waveguide adaptors44to ensure electrical and mechanical integrity. The waveguide ports24for the SMT waveguide adaptors44(FIG.12) require that the solder surrounds the waveguide ports24but does not flow into the waveguide ports24. This is controlled by the solder paste pattern artwork as part of the PCB design. The outer perimeter solder paste pattern ensures rigid mechanical integrity by allowing the solder to flow around the perimeter footprint of the SMT waveguide adaptors44(FIG.12). The solder paste mask patterns are stenciled onto the first side20of the PCB12as part of the standard SMT process.

Referring now toFIG.13B, the waveguide transmitter package14and the waveguide receiver package16, which are SiP SMT packages, as shown inFIG.7B, are also mounted to the host PCB12using the SMT reflow process on the second side22of the PCB12(printed circuit board top side area) to form a millimeter wave receiver SiP solder paste pattern and a millimeter wave transmitter SiP solder paste pattern. The waveguide port24areas for the waveguide transmitter package14and the waveguide receiver package16has shown for example inFIG.7B) require that the solder surrounds the waveguide port24openings but does not flow into the openings. This is controlled by the solder paste pattern artwork as part of the PCB design. The solder paste mask patterns for the waveguide transmitter package14and the waveguide receiver package16(FIG.7B) are stenciled to the second side22of the PCB12as part of the standard SMT process.

After the SMT reflow production process, the PCB12assembly for the surface mount mmWave transceiver device10(FIGS.2and2B) or100(FIGS.3A and3B) contains all SMT components including the SMT waveguide adaptors44mounted to the first side20of the PCB12(as shown inFIG.12). The SMT waveguide adaptors44(FIG.12) provide electrical waveguide connectivity and secure mechanical mounting surfaces for the diplexer18, as shown inFIG.12. The final assembly steps include mounting the diplexer18to the SMT waveguide adaptors44with screws (not shown) that thread into the SMT waveguide adaptors44, which in one example have threaded holes66(FIGS.8B,8C,10A, and10D) that align to the diplexer mounting holes (FIG.10A). The next assembly steps include mounting the RF shields48(FIG.11B) over the transmitter and receiver SiP device locations on the second side22of the PCB12, using screws that pass through the RF shields48and the PCB12, and thread into the SMT waveguide adaptors44, which have threaded holes64that align to the RF shield mounting holes68(as shown inFIGS.10B and10C).

A method of making the millimeter wave transceiver device10(FIGS.2A and2B), which is a fully integrated transceiver device, or the transceiver device100(FIGS.3A and3B), which is a plug-in module, is also disclosed and is described with respect toFIGS.2A,2B,3A,3B,4A,4B,5A-5D, and6A-6D. The method includes providing the printed circuit board (PCB)12having waveguide ports24located therein. The diplexer18, such as the diplexer illustrated inFIGS.4A and4Bhaving low frequency waveguide port26and high frequency waveguide port28(FIG.4B), is surface mounted to the first side20of the PCB. The low frequency waveguide port26and the high frequency waveguide port28of the diplexer18are each aligned to a respective one of the waveguide ports24of the PCB. In one example, the diplexer18is Universal Microwave Technology part number SK80168DX diplexer as illustrated inFIGS.4A and4B, although other diplexers may be employed. Each of the low frequency waveguide port26and the high frequency waveguide port28of the diplexer18are coupled to the antenna port34.

In one example, the diplexer18is surface mounted to the PCB12in a first orientation such that is configured to be utilized with a low frequency waveguide transmitter package14and a high frequency waveguide receiver package16. In another example, the diplexer18is surface mounted to the PCB12in a second orientation (rotated 180 degrees from the first orientation) such that it is configured to be utilized with a high frequency waveguide transmitter package14and a low frequency waveguide receiver package16.

Next, the waveguide transmitter package14and the waveguide receiver package16are surface mounted to the second side22of the PCB12, located opposite the first side20of the PCB12. The transmitter waveguide port36and the receiver waveguide port38are each aligned to one the waveguide ports24of the PCB12when the waveguide transmitter package14and the waveguide receiver package16are surface mounted. In one example, the waveguide transmitter package14is part number ADMV7310from Analog Devices, Inc., as shown inFIGS.5A-5D, while the waveguide receiver package16in is part number ADMV7410 from Analog Devices, Inc., as shown inFIGS.6A-6D, although other transmitters and receivers configured to be surface mounted to the PCB12may be used. The waveguide transmitter package14and the waveguide receiver package16are selected based on the orientation of the diplexer18on the PCB.

Although the surface mounting of the diplexer18, waveguide transmitter package14, and the waveguide receiver package16are described, it is to be understood that various other elements may be surface mounted to the PCB for operation of either the transceiver device10(FIGS.2A and2B) or the transceiver device100(FIGS.3A and3B) of this technology. Further, the order of method steps outlined above is not meant to be limiting and the surface mounting can take place with other orders of operation.

Accordingly, this technology provides a number of advantages including providing a surface mount constructed millimeter wave transceiver device and methods of making the same that rely entirely on surface mounting of the waveguide components. This provides a transceiver device that is easy to manufacture, allows for efficient transfer of electromagnetic energy, and efficient coupling between the packages and a diplexer without the need for separate waveguide flanges. Further, the diplexer can be surface mounted in either a high transmit or low transmit configuration without the need for changing the part or the fabrication technique.