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Custom Manufacturing of Multilayer High Frequency Coupler for the Telecom Industry

(click on thumbnail to enlarge)

This multilayer, high-frequency coupler, shown above, is used within a communications application for the telecom industry. Combining a variety of manufacturing services, Standard Printed Circuit Boards built 250 of these couplers for our client. We first sheared the material to size and fabricated the parts' inner layers, which were then laminated. Our CNC drill formed all primary holes, as well as holes for plated castellations. A mixture of sodium and plasma etching was performed to prep the holes' walls. Direct metallization was also carried out, using a polymer to produce conductive drilled hole walls.

After plating the couplers in copper, we etched the PCB, removing all surplus copper material. In addition, we finished the parts with an immersion tin finish and applied all silkscreen graphics. The finished couplers measured 1.25" x 1", and possessed 6 separate layers. We also evaluated the product to ensure that all parts fulfilled client specifications.

  Click to enlarge
Multilayer High Frequency Coupler
Multilayer High Frequency Coupler

The finished units were vacuum packed and shipped to our consumer in the Northeast US. Meeting IPC-6018A Microwave End Product Board Inspection and Test standards, our couplers exceeded customer expectations for both design and quality.

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Multilayer High Frequency Coupler Specifications:

Product Description This Multi-Layer High-Frequency Coupler is used within a communications application.
Capabilities Applied/Processes
Shearing
  • Cut Material To Size
Inner layer Fabrication (Image, Etch)
Multilayer Lamination
CNC Drilling
  • Drill out primary holes and holes for plated castellations
Deburring
Hole Wall Prep
  • Plasma Etch
  • Sodium Etching
Direct Metallization
  • Conductive polymer
Photolithography
Plating
  • Copper, Solder
Etching
Silkscreening (Legend and Nomenclature)
Immersion Tin Finish
Final Fabrication
  • Routing to final shape and size (including creating burr-free plated castellations)
Packaging - Vacuum packed
Equipment Used
CNC Driller
Vacuum Lamination Press
Plasma Etch
Exposure, Developer
Etcher
CNC Router
Overall Part Dimensions Length: 1.25"
Width: 1"
Layers: 6
Tightest Tolerances ±.001 For Line Widths
Material Used Ceramic Filled PTFE
Estimated Part Weight 10 Grams
In process testing performed Line Width Verification
Full Electrical Testing
Cross Section Analysis
Industry for Use Telecom
Quantity Manufactured 250
Delivery Location Metro New York Area
Standards Met IPC-6018A - Microwave End Product Board Inspection and Test
Product Name Multi-Layer High Frequency Couplers

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