Applications - Filtronetics, Inc.

FILTRONETICS NETICS
INC.
www filtro net
www.filtro.net
Quality Technology by Quality People
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
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
critical applications in telecommunications
Quality Technology by Quality People
FILTRONETICS INC
FILTRONETICS, INC
Custom Manufacturer of Military, Space Qualified and Commercial
Space Qualified and Commercial Electronic Filters
FILTRONETICS, INC
FILTRONETICS, INC
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ISO 9001 – 2008
Static Control Program
Static Control Program
FOD Control Program
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Leader in No Pure Tin Filter Production
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Supplier of Space Qualified Filters
ITAR Registered
Separate RoHS Compliant Assembly Line
Separate RoHS Compliant Assembly Line
GENERAL FILTER TYPES
GENERAL FILTER TYPES
 LC or Lumped Element Filters
LC L
d El
t Filt
 Crystal Filters
 Ceramic Filters
Ceramic Filters
 SAW Filters
 EMI/RFI Filters
EMI/RFI Filters
 Cavity & Stripline Filters
 Oscillators – TCXO, TCVCXO,VCXO, Clock, VCO
LC OR LUMPED ELEMENT FILTERS
LC OR LUMPED ELEMENT FILTERS
Applications
Specifications
 All Types of Band Pass, Notch, Low Pass, High Pass & Diplexers
 Frequency
Frequency range DC range DC – 1.5 GHz
1 5 GHz
 Center Frequency, Stop bands to 8.5GHz
 Phase & Amplitude Matched
 Linear Phase Designs
 Military and Commercial Parts Available
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Front End Filtering
Wide Band Filtering Applications
Satellite Receivers
Up and Downlink Communications
Pros & Cons
 Inexpensive
 Easy to Manufacture Small Quantities Quickly
Dual BandPass Dual LowPass
Ph
Phase and Amplitude Matched
d A lit d M t h d
Package Dimensions 1.15” X 0.98” X 0.15”
Dual BandPass
Phase and Amplitude Matched
Phase and Amplitude Matched
Dual LowPass
Ph
Phase and Amplitude Matched
d A lit d M t h d
CRYSTAL FILTERS
CRYSTAL FILTERS
Specifications
 1MHz to 500 MHz
 Bandwidth 0.005% to 1.5% for Discrete Filters
Discrete Filters
 Bandwidth 0.01% to 0.3% for Monolithic Filters
 Common Frequencies 1 MHz, 10 7 MH 21 4 MH 45 MH 70
10.7 MHz, 21.4 MHz, 45 MHz, 70 MHz, 140 MHz & 150 MHz
 Custom Frequencies
 Phase & Amplitude Matched
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 Linear Phase Designs
 Available for Military and Commercial Applications
 Available in No Pure Tin (Tin l bl
(
Whisker Mitigation) and RoHS
Applications
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Radio Receivers
Radar
Base Stations
Satellite Receivers
Flight Control
Pros & Cons
 Manufactured at Filtronetics in a Clean Room Facility
Clean Room Facility
 High Cost
 Very Narrow Bandwidth & High Selectivity
 Typical Insertion Loss 1‐10 db
 Long Lead Time
20 Crystal Band Pass Filter
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Package Dimensions 7.00” X 1.80” X 0.50”
8 Pole Crystal Filter
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Package Dimensions 1.15” X 0.60” X 0.435”
Simple 4 Pole Monotonic
Simple 4 Pole Monotonic
MONOLITHIC FILTERS
MONOLITHIC FILTERS
Applications
Specifications
 10
10 MHz to 150 MHz
MHz to 150 MHz
 Bandwidth 0.005% to .03% for Monolithic Filters
 Common Frequencies 1 MHz, 10 7 MH 21 4 MH 45 MH 70
10.7 MHz, 21.4 MHz, 45 MHz, 70 MHz, 140 MHz & 150 MHz
 Custom Frequencies
 Available for Military and y
Commercial Applications
 Parts for ITAR controlled applications can be supplied with State Department Approval.
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Radio Receivers
Commercial Products
Base Stations
Satellite Receivers
Flight Control
Pros & Cons
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Manufactured off‐shore
Low Cost
Narrow Bandwidth Natural Impedance 500 Ohms, 3‐
4k Ohms (Matching may be q
)
required)
 Typical Insertion Loss 1.5 – 7db  Lead Time 5‐7 Weeks
45MHz Monolithic Band Pass
Package Dimensions 7mm X 5mm X 1.4mm
45MHz Monolithic Band Pass
45MHz Monolithic Band Pass
CERAMIC FILTERS
Manufactured off‐Shore
Specifications
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 Band pass, Notch, Diplexers & Triplexers Available
 300 MHz to 6 GHz Plus New Product Line up to 15 GHz for High Powered Applications
Powered Applications
 Bandwidth 0.5% ‐ 40% of Center Frequency
 2 – 10 Poles
Applications
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GPS
Base Stations
Wireless
I.E.D. Jammers
Test Equipment
Pros & Cons
Origin
 Made in d
Asia
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Normally Commercial Only
Hi Rel, No Pure Tin Parts can be Supplied for Military Application with Customer approval for production in Asia
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Parts for ITAR controlled applications can be supplied with State Department Approval.
 Inexpensive
 Quick Turn‐around for Samples Production Quantities
 Low Cost
 Can do High Volume and Low Can do High Volume and Low
Quantity (MOQ 10 units)
 No Tooling Cost
Ceramic Filters
Ceramic Filters
5 Pole BandPass
5 Pole BandPass
6 Pole BandPass
6 Pole BandPass
5.99GHz Ceramic Filter Matching
Bad Match
5.99GHz Ceramic Filter Matching
Good Match
SAW FILTERS
(Surface Acoustic Wave)
Manufactured Off‐Shore – Commercial & Military
Specifications
 IF (Intermediate Frequencies 20 MHz to 300 MHz
 RF (Radio Frequencies) 130 MHz to 2.5 GHz
Origin
 Made in Asia
 Normally Commercial Only
 Parts can be Supplied for Military Application with Customer approval for production in Asia
 Parts for ITAR controlled applications can be supplied with State Department Approval.
Applications
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GPS
Base Stations
Wireless
IED’s ‐ Jammers
Guidance Systems
Pros & Cons
 Inexpensive
 Quick Turn‐around for Samples
 Very Price Competitive with Major Manufacturers
 Can do High Volume and Small Can do High Volume and Small
Quantity (~100 units)
 Low Tooling Cost (~$10K)
140MHz Band Pass SAW Filter
Package Dimensions 0.870” x 0.498” x 0.210”
140MHz Band Pass SAW Filter
140MHz Band Pass SAW Filter
EMI/RFI FILTERS
/
Assembly
Applications
Specifications
 DC to 50 MHz
 Ma to 50 amps & Above
Ma to 50 amps & Above
 One to 10 Lines
 Used
Used to Remove Noise from to Remove Noise from
Power Lines in and out of Systems
 Black Box Filters
Pros & Cons
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Typically High Cost
Typically
High Cost
Commercial and Military
Can Be Large and Heavy
Can Handle High Power
CAVITY & STRIP‐LINE FILTERS
Manufactured in the U.S and off‐Shore
Specifications
 500
500 MHz to 15 GHz
MHz to 15 GHz
 Bandwidth Range is 1% and Above
 Micro‐Strip, Suspended S b t t & C it
Substrate & Cavity
Origin
 Made in US or Asia
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 Low Cost Parts can be supplied for Military Application with Customer approval for production in Asia
 Parts for ITAR controlled applications Parts for ITAR controlled applications
can be supplied from Asia with State Department Approval.
Applications
 Narrow Band High Frequency
Narrow Band High Frequency
 Signal to Noise Improvement
Pros & Cons
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Typically High Cost
Typically
High Cost
Commercial and Military
Can Be Large and Heavy
Can Handle High Power
Long Design Cycle
3.1 GHz Strip Line Low Pass Filter
3.1 GHz Strip Line Low Pass Filter
3.1 GHz Low pass Plot
3.1 GHz Low pass Plot
OSCILLATORS
Private Label – Commercial Only
Applications
Specifications
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Crystal Oscillators
VCXO
TCXO
VCTCXO
3 to 5 Volts
10 Hz to 8 GHz
10 Hz to 8 GHz
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Signal Generation
Timing Devices
Timing Devices
Survey Equipment
Meters
Garage Door Openers
Pros & Cons
 Can be very Specialized
 Commercial Only
20MHz VCTCXO
Package Dimensions 3mm x 5mm
20 MHz VCTCXO
Package Dimensions 3mm x 5mm
FILTRONETICS, INC
,
 Mil
Mil‐STD‐202
STD 202
 Mil‐STD‐220
Mil F 18327E
 Mil‐F‐18327E
 MIL‐Hdbk‐883
 PRF‐3098H
 Mil‐T‐10727C
 Mil‐STD‐454
 J‐STD‐001 soldering
 No Pure Tin
 SN96 solder (RoHS)
Quartz Crystal
Quartz
Crystal
The Heart of a Crystal Filter
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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 f
finished crystal.
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These crystals are primarily used in Bandpass and Notch Filters.
TYPES OF BLANKS
 There are 3 basic types of blanks that are used in our products.
 Inverted Mesa
 Flat blank
 Flat blank w/ bevel
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”
 Electrode diameter = .0085”
 Typ Plateback = 450 KHz
 Typ Plateback = 2 MHz
 Typ ordering tol = .7 F sq Typ ordering tol = 7 F sq min
 Typ ordering tol = +/‐ .01F sq
01F sq
 .141”x.141”, small as .098”x.072”
 Swept Quartz
 1u typical finish
 .200 O.D min  Etches at a rate typ of around .075 Etches at a rate typ of around 075 KHz / sec
 Highly polished surface
 Etches at a rate typ of around 2.3 KHz / sec
BLANK STYLES
Flat Blanks in spring mount Inverted Mesa in spring mount
FLAT vs MESA
 Flat blanks are round and are anywhere from 0.550” down to 0.200” in diameter
diameter.
 Frequencies range from 1 MH t i t l MHz to approximately 40 MHz
 Lower frequency blanks f
bl k
are beveled for better performance.
 Inverted Mesas come in a few different styles and dimensions.
 0.141
0 141” sq & sq & .098
098” x x .072
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
mounting..
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 3rd overtone crystals, which are the 3rd harmonic of the fundamental frequency.
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.
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ETCHING
 Blanks are etched by two different methods
Blanks are etched b t o 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
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 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.
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 All blanks are put into a spin dryer which is most efficient method of drying the parts.
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))
BASEPLATER PICS
Front view
Inside view BASEPLATER MASK PICS
Loaded Mask
Unloaded Mask
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.
parameters to be sure they are within specification
 This includes checking for –
 Inductance
 Resistance / Q
 Frequency
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 Spurs (if applicable)
 If blanks do not meet the specification, they are stripped down and re‐processed.
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.
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.
CHEMICAL ADJUSTMENT OF THE
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.
Frequency
 There are two methods used to do this depending on the type metal you are adjusting.
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 Aluminum is adjusted using a de‐plating method. De‐
plating removes some aluminum and increases the f
frequency of the blank.
f th bl k
 Silver is adjusted using an electroplating method which y
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q
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allows you to plate the frequency down or bring the frequency back up.
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
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For Hi‐reliability parts or space applications, F
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Filtronetics Inc. has developed additional proprietary stabilization techniques. q
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 2‐500 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.
FREQUENCY PLATER PICS
Inside View
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)
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( pp
)
 If all tests are passed, the crystals are ready to be sealed
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.
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CRYSTAL DEPT WELDER

F
Front view of Welder
i f W ld
W ld H d
Weld Heads
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
shocked from 65°c to +125°c ten times at 30 c to +125 c ten times at 30 minutes/cycle
 All crystals supplied by Filtronetics undergo thermal shock to assure superior reliability.
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 monitors for any change in resistance or angle Fil
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f h
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l 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.
“anomalies at any particular frequency.”
CRYSTAL TEMPERATURE TESTER
FUNDAMENTAL VS 3RD OVERTONE
Fundamental Spur sample
3rd Overtone Spur sample
FINAL DATA AND GROUPING
 After all testing have been completed and passed, the crystals are serialized.
 Final Data will be taken which includes:
Fi l D t ill b t k hi h i l d
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.
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Monolithics
Filtronetics Inc. Fil
i I supplies a wide array of Custom SMD Monolithic Crystals y
filters like the one pictured to the right, as well as other types that can be found listed on b f
d li t d our Web site at WWW.FILTRO.NET
7 X 5 X 1.5 mm
Environmental Testing
Environmental Testing