FILTRONETICS INC. Quality Technology by Quality People

Transcription

1 FILTRONETICS INC. Quality Technology by Quality People

2 INTRODUCTION Filtronetics, Inc offers a broad line of frequency control products for diverse applications. We have been in business for over 40 years, with our main manufacturing and design facility located in Kansas City, Missouri. Our mission is to be a valued supplier for all of our customers, from University Researchers to Defense Contractors to Fortune 500 companies. We proudly provide parts for the space program as well as other critical applications in telecommunications Quality Technology by Quality People

3 FILTRONETICS, INC Custom Manufacturer of Military, Space Qualified and Commercial Electronic Filters

4 FILTRONETICS, INC ISO Static Control Program FOD Control Program Leader in No Pure Tin Filter Production Supplier of Space Qualified Filters ITAR Registered Separate RoHS Compliant Assembly Line

5 GENERAL FILTER TYPES LC or Lumped delement Filters Crystal Filters Ceramic Filters SAW Filters EMI/RFI Filters Cavity & Stripline Filters Oscillators TCXO, TCVCXO,VCXO, Clock, VCO

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17 LC OR LUMPED ELEMENT FILTERS Specifications All Types of Band Pass, Notch, Low Pass, High Pass & Diplexers Frequency range DC 15GHz 1.5 Center Frequency, Stop bands to 8.5GHz Phase & Amplitude Matched Linear Phase Designs Military and Commercial Parts Available Applications Front End Filtering Wide Band Filtering Applications Satellite Receivers Up and Downlink Communications Pros & Cons Inexpensive Easy to Manufacture Small Quantities Quickly

18 Dual BandPass Dual LowPass Phase and Amplitude Matched Package Dimensions 1.15 X 0.98 X 0.15

19 Dual BandPass PhaseandAmplitude and Matched

20 Dual LowPass Phase and Amplitude Matched Mthd

21 CRYSTAL FILTERS Specifications 1MHz to 500 MHz Bandwidth 0.005% to 1.5% for Discrete Filters Bandwidth 0.01% to 0.3% for Monolithic Filters Common Frequencies 1 MHz, 10.7 MHz, 21.4 MHz, 45 MHz, 70 MHz, 140 MHz & 150 MHz Custom Frequencies Phase & Amplitude Matched Linear Phase Designs Available for Military and Commercial Applications Available lbl in No Pure Tin (Tin Whisker Mitigation) and RoHS Applications Radio Receivers Radar Base Stations Satellite Receivers Flight Control Pros & Cons Manufactured at Filtronetics in a Clean Room Facility High Cost Very Narrow Bandwidth & High Selectivity Typical Insertion Loss 1 10 db Long Lead Time

22 20 Crystal Band Pass Filter y Package Dimensions 7.00 X 1.80 X 0.50

23 8 Pole Crystal Filter y Package Dimensions 1.15 X 0.60 X 0.435

24 Simple 4 Pole Monotonic

25 MONOLITHIC FILTERS Applications Specifications 10 MHz to 150 MHz Bandwidth 0.005% to.03% for Monolithic Filters Common Frequencies 1 MHz, 10.7 MHz, 21.4 MHz, 45 MHz, 70 MHz, 140 MHz & 150 MHz Custom Frequencies Available for Military and Commercial Applications Parts for ITAR controlled applications can be supplied with State Department Approval. Radio Receivers Commercial Products Base Stations Satellite Receivers Flight Control Pros & Cons Manufactured off shore Low Cost Narrow Bandwidth Natural Impedance 500 Ohms, 3 4k Ohms (Matching may be required) Typical Insertion Loss 1.5 7db Lead Time 5 7 Weeks

26 45MHz Monolithic Band Pass Package Dimensions 7mm X 5mm X 1.4mm

27 45MHz Monolithic Band Pass

28 CERAMIC FILTERS Manufactured off Shore Specifications Band pass, Notch, Diplexers & Triplexers Available 300 MHz to 6 GHz Plus New Product Line up to 15 GHz for High Powered Applications Bandwidth 0.5% 40% of Center Frequency 2 10 Poles Applications GPS Base Stations Wireless I.E.D. Jammers Test Equipment Origin Made in Asia Normally Commercial Only Hi Rel, No Pure Tin Parts can be Supplied for Military Application with Customer approval for production in Asia Pros & Cons Inexpensive Quick Turn around for Samples Production Quantities Low Cost l f d ti i Ai Can do High Volume and Low Quantity (MOQ 10 units) No Tooling Cost Parts for ITAR controlled applications can be supplied with State Department Approval.

29 Ceramic Filters 5 Pole BandPass 6 Pole BandPass

30 5.99GHz Ceramic Filter Matching Bad Match

31 5.99GHz Ceramic Filter Matching Good Match

32 SAW FILTERS (Surface Acoustic Wave) Manufactured Off Shore Commercial & Military Specifications Applications IF (Intermediate Frequencies 20 MHz to 300 MHz RF (Radio Frequencies) 130 MHz to 2.5 GHz GPS Base Stations Wireless IED s Jammers Guidance Systems Origin Made in Asia Normally Commercial Only Parts can be Supplied for Military Application with Customer approval for production in Asia Pros & Cons Inexpensive Quick Turn around for Samples Very Price Competitive with Major Manufacturers Can do High Volume and Small Quantity (~100 units) Parts for ITAR controlled applications Can do High Volume and Small can be supplied with State Department Approval. Low Tooling Cost (~$10K)

33 140MHz Band Pass SAW Filter Package Dimensions x x 0.210

34 140MHz Band Pass SAW Filter

35 EMI/RFI FILTERS Assembly Applications Specifications DC to 50 MHz Ma to 50 amps & Above One to 10 Lines Used to Remove Noise from Power Lines in and out of Systems Black Box Filters Pros & Cons Typically High Cost Commercial and Military Can Be Large and Heavy Can Handle High Power

36 CAVITY & STRIP LINE FILTERS Manufactured in the U.S and off Shore Specifications Applications Origin 500 MHz to 15 GHz Bandwidth Range is 1% and Above Micro Strip, Suspended Substrate t & Cavity Made in US or Asia Low Cost Parts can be supplied for Military Application with Customer approval for production in Asia Parts for ITAR controlled applications can be supplied from Asia with State Department Approval. Narrow Band High Frequency Signal to Noise Improvement Pros & Cons Typically High Cost Commercial and Military Can Be Large and Heavy Can Handle High Power Long Design Cycle

37 3.1 GHz Strip Line Low Pass Filter

38 3.1 GHz Low pass Plot

39 OSCILLATORS Private Label Commercial Only Applications Specifications Crystal Oscillators VCXO TCXO VCTCXO 3 to 5 Volts 10 Hz to 8 GHz Signal Generation Timing Devices Survey Equipment Meters Garage Door Openers Pros & Cons Can be very Specialized Commercial Only

40 20MHz VCTCXO Package Dimensions 3mm x 5mm

41 20 MHz VCTCXO Package Dimensions 3mm x 5mm

42 FILTRONETICS,, INC Mil STD 202 Mil STD 220 Mil F 18327E MIL Hdbk 883 PRF 3098H Mil T 10727C Mil STD 454 J STD 001 soldering No Pure Tin SN96 solder (RoHS)

43 Quartz Crystal The Heart of a Crystal Filter

44 QUARTZ CRYSTALS This presentation is to discuss the basic fundamentals of Quartz Crystal types and the different processes that a crystal blank goes through to make a finished crystal. These crystals are primarily used in Bandpass and Notch Filters.

45 TYPES OF BLANKS There are 3 basic types of blanks that are used in our products. Inverted Mesa Flat blank Flat blank w/ bevel

46 FLAT VS MESA Comparison 21.4 MHz Flat blank 150 MHz Inverted Mesa Thickness in mils = 3.06 Thickness in mils =.437 Electrode diameter =.045 Typ Plateback = 450 KHz Typ ordering tol =.7 F sq min 1u typical finish.200 O.D min Etches at a rate typ of around.075 KHz / sec Electrode diameter =.0085 Typ Plateback = 2 MHz Typ ordering tol = +/.01F sq.141 x.141, small as.098 x.072 Swept Quartz Highly polished surface Etches at a rate typ of around 2.3 KHz / sec

47 BLANK STYLES Flat Blanks in spring mount Inverted Mesa in spring mount

48 FLAT vs MESA Flat blanks are round and are anywhere from down to in diameter. Frequencies range from 1 MHz to approximately 40 MHz Lower frequency blanks are beveled for better performance. Inverted Mesas come in a few different styles and dimensions sq &.098 x.072 Outer ring thickness is approx 3.45 mils thick Frequencies range from 30 MHz to approximately 360 MHz Mesas have an outer ring which is more rigid for support during mounting..

49 FINISHES Blanks come in many different finishes depending on the frequency and type of crystal. All Inverted Mesas have a highly polished surface. Flat and beveled blanks typically have a 1u, 3u, or a polished surface. Flat blanks with polished surfaces are used for 3 rd overtone crystals, which are the 3 rd harmonic of the fundamental frequency.

50 LAPPING/POLISHING Once a blank finish is determined, the blanks go through a process called lapping, which is placing the blank between two surfaces and grinding them down to a predetermined thickness. If a polished surface is required, a much finer material is used to give the blank a mirror like surface.

51 ETCHING Blanks are etched by two different methods Hydrofluoric Acid is used as a preliminary etchant to remove the contaminants from flat blanks. A Proprietary Hydrofluoric Acid solution which is used for all Inverted Mesas, Polished Blanks and final Flat Blank etching. Blanks are etched to the Nominal Freq + Plateback

52 CLEANING All blanks go through a six stage cleaning process prior to being plated. Filtronetics uses 18.2 Mega ohm D.I. water for all of it s solutions. This is the same quality water that is used by the semiconductor industry. Filtronetics also uses Denatured Ethanol Alcohol to dry it s parts. All blanks are put into a spin dryer which is most efficient method of drying the parts.

53 BASEPLATING Crystal blanks are plated with one of three different metals or combination of metals. Aluminum (typically used on all Inverted Mesas and polished surfaces) Silver (typically used on flat blanks with a rough surface) Chrome/Silver (typically used on flat blanks with a smooth surface)

54 BASEPLATER PICS Front view Inside view

55 BASEPLATER MASK PICS Loaded Mask Unloaded Mask

56 AFTER BASEPLATING After all blanks are baseplated, they are mounted on the appropriate base and then checked for all electrical parameters to be sure they are within specification. This includes checking for Inductance Resistance / Q Frequency Spurs (if applicable) If blanks do not meet the specification, they are stripped down and re processed.

57 PASTING After all blanks are mounted, they are pasted using a two part silver epoxy and then cured at +125 c for 30 minutes minimum. After curing blanks are stored in a dry nitrogen After curing, blanks are stored in a dry nitrogen environment until they are ready for the next process.

58 CHEMICAL ADJUSTMENT OF THE BLANK FREQUENCY All crystal blanks must have their frequency chemically adjusted between +25 ppm to +250 ppm of the Nominal Frequency. There are two methods used to do this depending on the type metal you are adjusting. Aluminum is adjusted using a de plating method. Deplating removes some aluminum and increases the frequency of the blank. Silver is adjusted using an electroplating method which allows you to plate the frequency down or bring the frequency back up.

59 AGING After all crystals are chemically adjusted, they go through two very important aging steps Two days in a proprietary aging process,then Three days in a convection type oven at +125 c For Hi reliability parts or space applications, Filtronetics Inc. has developed additional proprietary stabilization techniques.

60 FREQUENCY PLATING After all aging is completed, the crystals are plated in an automated machine that plates each crystal individually (under vacuum) down to within 2 ppm of any frequency between MHz. After plating is finished the crystals are placed into After plating is finished, the crystals are placed into the +125 c oven for 1 2 hours depending on the crystal.

61 FREQUENCY PLATER PICS Inside View

62 FINAL ELECTRICAL CHECK After final aging is completed, and the crystals are back to room temp, they are ready for final electrical checks which include: Frequency Inductance Resistance/Q Spurs (if applicable) If all tests are passed, the crystals are ready to be sealed

63 SEALING All crystals go through a series of heated cycles being pulled under vacuum and purged with nitrogen prior to being sealed. Filtronetics use a Resistance Weld System There are many different types of cans and can heights available.

64 CRYSTAL DEPT WELDER Front view of Welder Wld Weld Heads

65 THERMAL SHOCK After all crystals are sealed, they get thermal shocked at 55 c to +95 c ten times at 30 minutes/cycle Space Applications or High Reliability are thermal shocked from 65 c to +125 c ten times at 30 minutes/cycle All crystals supplied by Filtronetics undergo thermal shock to assure superior reliability.

66 TEMPERATURE TESTING All crystals that go into filters with temperature requirements are tested with an automated system which test the extreme limits of the filter. Filtronetics i monitors for any change in resistance or angle drift that is too great. Hi Reliability/ Space Applications are tested at more intervals throughout the temp limits to be sure there are no anomalies at any particular frequency.

67 CRYSTAL TEMPERATURE TESTER

68 FUNDAMENTAL VS 3 RD OVERTONE Fundamental Spur sample 3 rd Overtone Spur sample

69 FINAL DATA AND GROUPING After all testing have been completed and passed, the crystals are serialized. Final Data will be taken which h includes: Frequency Inductance Resistance/ Q DLD2 = Drive level dependency Data will be printed for each frequency and then they are Grouped for the filter they are put into.

70 Monolithics Filtronetics i Inc. supplies a wide array of Custom SMD Monolithic Crystals filters like the one pictured to the right, as well as other types that can be found listed on our Web site at 7 X 5 X 1.5 mm

71 Environmental Testing