Suspended stripline structures to reduce skin effect and dielectric loss to provide low loss transmission of signals with high data rates or high frequencies

A multi-layer substrate comprising:

• a conductor having a continuous main path and discrete spaced edges protruding from opposing edges of the continuous main path;
• a first spacer layer on a first side of the conductor, the first spacer layer having an air channel substantially coextensive with the continuous main path and a solid portion overlapping with the discrete spaced edges;
• and
• a second spacer layer on a second side of the conductor, the second spacer layer having an air channel substantially coextensive with the continuous main path of the conductor and a solid portion overlapping with the discrete spaced edges.

A conductor within a multi-layer substrate, the conductor comprising:

• a continuous main path having a first elongated edge, a second elongated edge, and a first end and a second end perpendicular to the first and second elongated edges;
• a first set of discrete spaced edges protruding from the first elongated edge at a first set of locations;
• and
• a second set of discrete spaced edges protruding from the second elongated edge at a second set of locations,
• wherein the first set of locations and the second set of locations are selected such that a width of the conductor is constant over a length thereof.

A method for forming a suspended stripline within a multi-layer substrate, the method comprising the step of:

• forming a first substrate with a conductor on one side;
• etching the conductor into a stripline having a continuous main path and discrete spaced edges protruding from opposing edges of the continuous main path;
• applying a second substrate over the etched stripline;
• forming a first air channel in the first substrate substantially coextensive with the continuous main path of the stripline;
• and
• forming a second air channel in the second substrate substantially coextensive with the continuous main path of the stripline;
• wherein the first substrate and the second substrate at least partially cover the discrete spaced edges, but do not touch the continuous main path.