Additively Manufactured Flexible Hybrid Electronics (FHE) Enabled On-Package Phased Arrays for 5G/mmWave Wearable and Conformal Applications
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Hu, Kexin
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Abstract
As we step into the era of 5G/B5G, mmWave frequencies have been widely explored, providing broadband operation, high data throughput, and low latency to support multi-user, multi-point, multi-platform communication scenarios. This advancement utilizing higher frequencies comes with increasing free-space path loss, as well as greater diffraction and penetration losses for non-line-of-sight applications. To overcome these issues, high gain and beam scanning antennas, such as phased arrays, are imperative for future mmWave wireless communication. Electronically scanned arrays or phased arrays offer rapid beam switching, low profile, and high gain with large array aperture. However, the performance of phased arrays can be hindered by several challenges. The complexity of the systems and the need for large-scale arrays bring high manufacturing costs and limited scalability. Traditional rigid and bulky systems are difficult to integrate and adapt to different platforms, especially in conformal applications. In addition, their radiation performance degrades at large angles due to reduced effective antenna aperture and impedance mismatch caused by mutual coupling. There is a demand for low-cost, highly scalable, flexible/conformal phased arrays with high gain and wide scanning range.
The work presented in this thesis aims to address the aforementioned challenges by utilizing additive manufacturing technologies and flexible hybrid electronics designs. Additively manufactured phased arrays provide a low-cost and customized solution with high adaptability and scalability. The proposed research first investigated and characterized 3D printing and inkjet printing techniques, and printed flexible materials to evaluate their potential for mmWave designs and applications. Various interconnects are fabricated and tested for their reliability under mechanical deformation for flexible or deployable systems. Then, various types of additively manufactured phased arrays, including flexible on-package phased arrays, conformal tile-based phased arrays, and lens-loaded phased arrays, are developed and implemented to demonstrate their potential in 5G mmWave applications.
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Date
2024-08-26
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Dissertation