Method and apparatus to increase radar range
11536800 · 2022-12-27
Assignee
Inventors
Cpc classification
H01Q1/2283
ELECTRICITY
H01Q1/3233
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2924/15151
ELECTRICITY
H01Q23/00
ELECTRICITY
H01L2224/48225
ELECTRICITY
H01L25/50
ELECTRICITY
H01L2223/6683
ELECTRICITY
H01L24/82
ELECTRICITY
H01L2924/00014
ELECTRICITY
H01L2224/24155
ELECTRICITY
H01L2924/15153
ELECTRICITY
H01L2224/24137
ELECTRICITY
H01L2224/16225
ELECTRICITY
H01L2224/24147
ELECTRICITY
H01L24/94
ELECTRICITY
H01L2223/6677
ELECTRICITY
H01L2224/94
ELECTRICITY
International classification
H01L23/538
ELECTRICITY
H01L25/065
ELECTRICITY
H01L23/482
ELECTRICITY
H01L25/16
ELECTRICITY
Abstract
An integrated radar circuit comprising: a first substrate, of a first semiconductor material, said first substrate comprising an integrated transmit and receive radar circuit; a second substrate, of a second semiconductor material, said second substrate comprising at least on through-substrate cavity having cavity walls; at least one discrete transistor chip, of a third semiconductor material, said at least one discrete transistor chip having chip walls and being held in said at least one through-substrate cavity by a metal filling extending from at least one cavity wall to at least one chip wall; a conductor on said second substrate, electrically connecting a portion of said integrated transmit and receive radar circuit to a discrete transistor on said at least one discrete transistor chip.
Claims
1. An integrated, radar circuit comprising: a first substrate, of a first material, said first substrate comprising an integrated transmit and receive radar circuit; a second substrate, of a second material, said second substrate comprising at least one through-substrate cavity having cavity walls; at least one discrete transistor chip, of a third material, said at least one discrete transistor chip having chip walls and being held in said at least one through-substrate cavity by direct contact with a metal filling extending from at least one cavity wall to at least one chip wall; a conductor on said second substrate, electrically connecting a portion of said integrated transmit and receive radar circuit to a discrete transistor on said at least one discrete transistor chip; wherein the first material is a first semiconductor material and the third material is a third semiconductor material.
2. The circuit of claim 1, wherein the first and second substrate form a single substrate and the first and second materials are a same semiconductor material.
3. The circuit of claim 2, wherein the first material is Silicon and the third material is a III-V semiconductor.
4. The circuit of claim 3, wherein the third material is GaN.
5. The circuit of claim 1, wherein the first and second substrates are attached to a third substrate.
6. The circuit of claim 1, comprising an antenna electrically coupled to said discrete transistor.
7. The circuit of claim 6, wherein said antenna is formed on said second substrate.
8. The circuit of claim 1, wherein passive circuit elements electrically coupled to said discrete transistor are formed on said second substrate, wherein said passive circuit elements form at least an impedance matching circuit.
9. The circuit of claim 1, wherein said at least one discrete transistor chip comprises a plurality of discrete transistor chips having each discrete transistor chip walls; each at least one discrete transistor chip being held in said at least one through-substrate cavity by direct contact with said metal filling; said metal filling extending from at least one cavity wall to at least one wall of said discrete transistor chip; or extending from at least one wall of said discrete transistor chip to at least one wall of a neighboring discrete transistor chip; the discrete transistor chips, comprising each discrete transistors and being connected electrically to form a power amplifier.
10. The circuit of claim 9, wherein each discrete transistor of a discrete transistor chip comprises a plurality of discrete transistors connected in parallel to a single current input terminal, a single current output terminal, and a single control terminal.
11. The circuit of claim 1, wherein said integrated transmit and receive radar circuit comprises RF I/O terminals of said integrated transmit and receive radar circuit.
12. A method of manufacturing an integrated radar circuit, the method comprising: providing a first substrate, of a first material, on which is formed an integrated transmit and receive radar circuit; providing a second substrate, of a second material, comprising at least one through-substrate cavity having cavity walls; providing at least one discrete transistor chip, of a third material, on which is formed at least one discrete transistor, said at least one discrete transistor chip having chip walls; attaching said at least one discrete transistor chip in said through-substrate cavity with a metal filling extending from at least one cavity wall to at least one chip wall; forming on said second substrate a conductor electrically connecting a portion of said integrated transmit and receive radar circuit to said discrete transistor; wherein the first material is a first semiconductor material and the third material is a second semiconductor material.
13. The method of claim 12, wherein said attaching said at least one discrete transistor chip in said through-substrate cavity with a metal filling comprises: temporarily attaching a top surface of said second substrate to a carrier wafer; temporarily attaching a top surface of said at least one discrete transistor chip to said carrier wafer in said through-substrate cavity; filling at least a portion of said through-substrate cavity with said metal filling; and removing said carrier wafer.
14. The method of claim 12, wherein the first and second substrates form a single substrate and the first and second materials are a same semiconductor.
15. The method of claim 14, wherein the first material is Silicon and the third material is a III-V semiconductor.
16. The method of claim 12, comprising forming an antenna on said second substrate, and electrically coupling said antenna to said discrete transistor.
17. The method of claim 12, comprising forming, on said second substrate, passive circuit elements electrically coupled to said discrete transistor, said passive circuit elements, forming an impedance matching circuit.
18. The method of claim 12, wherein said providing at least one discrete transistor chip comprises providing a plurality of discrete transistor chips each attached by the metal filling in the through wafer substrate of the second substrate; and connecting discrete transistors on said discrete transistor chips to form a power amplifier.
19. The method of claim 13, wherein each discrete transistor of a discrete transistor chip comprises a plurality of discrete transistors connected in parallel to a single current input terminal, a single current output terminal, and a single control terminal.
20. The method of claim 18, wherein said attaching said at least one discrete transistor chip in said through-substrate cavity with a metal filling comprises: temporarily attaching a top surface of said second substrate to a carrier wafer; temporarily attaching a top surface of each discrete transistor chip to said carrier wafer in said through-substrate cavity; filling at least a portion of said though-substrate cavity with said metal filling, such that each discrete transistor chip be held in said through-substrate cavity by said metal filling extending from at least one cavity wall to at least one wall of said discrete transistor chip; or extending from at least one wall of said discrete transistor chip wall to at least one wall of a neighboring discrete transistor chip; and removing said carrier wafer.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
(1) Various embodiments in accordance with the present disclosure will be described with reference to the drawings, in which:
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(8) The figures are drawn to clearly illustrate the relevant aspects of the embodiments and are not necessarily drawn to scale.
DETAILED DESCRIPTION
(9) Specifically, embodiments of this presentation provide for creating an integrated radar circuit by integrating RF GaN transistor chips into a low-cost interposer wafer (or CMOS wafers) using a metal-embedded chip assembly process such as detailed in co-pending U.S. application Ser. No. 16/158,212, which is hereby incorporated by reference (hereafter the MECAMIC (Metal Embedded Chip Assembly for Microwave Integrated Circuits) process). According to embodiments of this presentation, each “chiplet” or “chip” can be a semiconductor chip comprising only one transistor cell (a transistor cell can comprise a single transistor or a plurality of transistors connected in parallel) having a single current input terminal (e.g. source terminal), a single current output terminal (e.g. drain terminal), and a single control terminal (e.g. gate terminal). According to embodiments of this presentation, each terminal can comprise a conductive terminal pad, such as a metallic pad formed on a top surface of the chip. According to embodiments of this presentation, the terminal pads of the chips can be devoid of impedance adaptation circuitry and/or devoid of protection circuitry (as opposed to the well-known contact pads of integrated circuits, which can comprise such impedance adaptation and/or protection circuitry).
(10) A method according to this presentation allows manufacturing an integrated Transmit and Receive radar circuit having an output power improved over the output power of a traditional technology CMOS Transmit and Receive module radar chip by 100×, and a Noise Figure reduced with respect to the Noise Figure of the same radar chip by 10 dB. Embodiments of a method according to this presentation comprise using the MECAMIC process to add some power amplifiers and low noise amplifiers that use traditional GaN transistor technology to a low cost, for example CMOS, integrated transmit and receive radar circuit (
(11) A circuit according to embodiments of this presentation comprises an integrated mm-wave radar circuit having a range that is increased by using RF GaN transistor chips integrated into a low-cost interposer using the above-described MECAMIC process.
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(13) According to embodiments of this presentation, and as illustrated in
(14) According to an embodiment of this presentation, the discrete transistor chips 18 can be connected together by conductors 19, such as bonded wire or strip conductors, to form a power amplifier 26. A four-transistor, non-inverting power amplifier 26 is illustrated in
(15) According to embodiments of this presentation, the interposer wafer 16 can have as many through-substrate cavities 20 as there are discrete transistor chips 18 to be embedded. According to embodiments of this presentation, the interposer wafer 16 can have fewer through-substrate cavities 20 than there are discrete transistor chips 18 to be embedded in the interposer wafer 16, in which case at least two discrete transistor chips 18 can be embedded together in a single through-substrate cavity, as for example described above.
(16) As illustrated in
(17) According to embodiments of this presentation, the first and second semiconductors are Silicon and the third semiconductor is a III-V semiconductor, for example GaN. According to, embodiments of this presentation, the first and second substrates 12, 16 are attached to a third substrate 28. Substrate 28 can be an integrated substrate or a printed wiring hoard. According to embodiments of this presentation, circuit 10 comprises at least one antenna 30 electrically coupled to power amplifiers 26.
(18) According to embodiments of this presentation, integrated transmit and receive radar circuit 14 comprises RF I/O terminals 32 for said integrated transmit and receive radar circuit 14.
(19) As outlined above, discrete transistor chips 18 can comprise GaN power and/or low noise transistor chips, and integrating such GaN chips with high-performance low-cost Si integrated circuits for mm-wave radar such as circuit 14 (in other words a co-integration of Si CMOS and III-V RF transistors) allows maintaining low cost production (the area of discrete transistor chips 18 can be very small, for example of the order of 100 um×100 um); and allows improving performance (range and noise figure) of mm-wave radars, compared to what could be obtained with known mm-wave radars of a same order of price.
(20) Embodiments of this presentation comprise a Transmit and Receive circuit for high-performance mm-wave radar with increased range. A circuit such as illustrated in
(21) Combining high-frequency chipsets (such as GaN MMIC) with CMOS drivers enables improved circuit performance. At mm-wave (e.g., 77 GHz), GaN HEMI technology has record output power and power added efficiency when compared against other technologies (e.g., CMOS, InP, GaAs). However, the cost of the high-frequency high-performance GaN MMICs (Monolithic Microwave Integrated Circuits) are prohibitively expensive for commercial applications. This presentation addresses this barrier by integrating III-V (e.g. GaN) chips with a CMOS chip or chipset, where the CMOS chip is used as a driver for the III-V chips and the III-V (e.g. GaN) chips form RF Front End. Because the GaN chips can have a small (˜100×100 um) area, their production yield is high and their cost is low. In contrast, traditional GaN MMIC are large (1 to 5 mm at these frequencies and output power level of e.g. 0.5-1W at 77 GHz which corresponds to 100× larger area than the chips). They also have a longer manufacturing cycle time and have lower yield (larger die size).
(22) According to embodiments of the presentation, such as illustrated in
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Where P.sub.Tx is the transmitted power, G is the (one-way) antenna gain, λ is the wavelength, σ is the target radar cross section, T is the observation time, α.sub.aim is the attenuation due to atmospheric losses (one-way), R is the target range, k.sub.B is Boltzmann's constant, T.sub.o is the reference temperature (290K), and F is the receiver noise factor. The equation clearly demonstrates that the SNR is proportional to output power and inversely proportional to noise factor. One may ascertain the maximum range by assuming a minimum acceptable SNR (e.g., 15 dB) and other parameter values, and then computing the range using formula (1) above.
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(27) According to embodiments of this presentation and as illustrated in
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(29) Method 50 then comprises forming conductors between portions of circuit 14 and the discrete transistor chips 18, for example to form power amplifiers with the transistors in chips 18 as detailed in relation with
(30) Method 50 can be modified, mutatis mutandis, to fabricate a circuit such as illustrated in
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(34) Advantageously, as both the chips 18 and substrate 12+16+28 are attached by their top surfaces to carrier wafer 62 when metal filling 21 is formed, the top surfaces of chips 18 and substrate 12+16+28 are essentially flush once carrier wafer 62 is removed, which facilitates forming conductors 19 and 24.
(35) It is to be noted that
(36) All elements, parts and steps described herein are preferably included. It is to be understood that any of these elements, parts and steps may be replaced by other elements, parts and steps or deleted altogether as will be obvious to those skilled in the art
(37) The foregoing description has been presented for purposes of illustration and description and is not intended to be exhaustive or to limit the invention to the precise form disclosed. Many modifications and variations are possible in light of the above teaching. The embodiments disclosed were meant only to explain the principles of the invention and its practical application to thereby enable others skilled in the art to best use the invention in various embodiments and with various modifications suited to the particular use contemplated. The scope of the invention is to be defined by the following claims.