EE 446 MEMS Microelectromechanical Systems Spring 2020 Homew ✓ Solved

1ee 446 Mems Microelectromechanical Systems Spring 2020 Homework

1. Thermal oxide growth of Si in high temperature (>1000°C) is shown in a figure along with the chemical reaction Si + O2 → SiO2. Given atomic weights of Si and O as 28 and 16 respectively, and densities of silicon and SiO2, determine the total mass of Si consumed during oxidation and the mass of the generated SiO2 based on surface area. Calculate the thickness of the SiO2 layer formed and the ratio of silicon thickness to oxide thickness.

2. In the anisotropic etching of (100) silicon wafers in KOH solution, determine the etching depth required to form a 10 μm thick silicon membrane, the width of the window in SiO2 needed in the process, and the etching time based on the given etching rates. Also, find the minimum SiO2 mask thickness necessary for protection during the process, considering native oxide and oxidation parameters at 1100°C and the required oxide thickness obtained during wet oxidation.

3. List the ten basic steps of photolithography and explain PVD and CVD for thin film deposition. Provide four vaporization methods used in evaporation techniques. Describe one chemical reaction for CVD of polysilicon, and two for SiO2, along with the necessary temperatures. Explain the requirements for successful silicon-glass anodic bonding, and differentiate between bulk and surface micromachining.

4. Compare surface-micromachining and Silicon-on-Glass bulk-micromachining approaches for creating free-standing microstructures, highlighting how they achieve this. Briefly define the concepts of photolithography mask, etching mask, oxidation mask, and implantation mask. Explain lag and loading effects in Deep Reactive Ion Etching (DRIE) and their causes.

5. For a bulk-micromachined silicon-on-glass MEMS accelerometer, outline the fabrication steps, including the pattern design for four photolithography masks used in the process. Additionally, to understand the device's schematic, draw the simplified spring-mass model and explain its working principle, including actuation, sensing techniques, and the importance of matching resonant frequencies.

Calculate the velocity of the sensing mass during vibration, the Coriolis force produced by a specified angular velocity, and the resulting displacement of the sensing mass. Discuss how the sensing mass responds to the Coriolis force triggered by external angular velocity.

6. For a surface-micromachined poly-Si MEMS bridge, develop the fabrication flow chart, showing the layers and their thicknesses. Draw the photolithography masks for patterning the anchors and microbridge, indicating the dark and transparent regions. Describe the process steps involved and their purposes.

7. Regarding a surface-micromachined MEMS comb gyroscope, sketch the simplified spring-mass model, describe its working principle, and identify the actuation and sensing methods. Explain the significance of matching the resonant frequencies of drive and sense modes. Compute the velocity of the sensing mass during operation, the Coriolis force experienced, and the consequent displacement in the sense direction.

8. For a 2×2 binary reflective MEMS optical switch, determine the spring constant of each beam, the total device stiffness, and calculate the required DC driving voltage to achieve a 30 μm mirror displacement. If scaling to a 128×128 switch network, estimate the number of switches needed and suggest potential solutions to reduce complexity and improve yield.

Sample Paper For Above instruction

The thermal oxidation of silicon at high temperatures is a fundamental process in fabricating MEMS devices, serving as both an electrical insulator and a protective layer. During oxidation, silicon react with oxygen to form silicon dioxide (SiO2), which influences device dimensions and performance. Calculating the mass of silicon consumed and the resulting oxide thickness provides critical insights in process engineering and device design.

Calculation of Silicon Consumption and SiO2 Formation

The key chemical reaction, Si + O2 → SiO2, indicates that 28 grams of silicon reacts with 32 grams of oxygen to produce 60 grams of SiO2. Given a silicon wafer with surface area determined by the last two digits of a student ID, for example, 67 cm², the total mass of silicon consumed can be calculated. The mass of Si is obtained by multiplying the volume (area multiplied by thickness) by the density. Assuming a silicon layer thickness of t_Si, we calculate the volume:

V_Si = area × thickness = 67 cm² × t_Si μm

Converting μm to cm (1 μm = 10^-4 cm):

V_Si = 67 cm² × t_Si × 10^-4 cm = 67 × t_Si × 10^-4 cm³

Mass of silicon: m_Si = V_Si × density_Si.

Using the density of silicon, 2.33 g/cm³, we get:

m_Si = 67 × t_Si × 10^-4 cm³ × 2.33 g/cm³ = 0.0156 × t_Si grams.

From the chemical reaction, 28 g of silicon produces 60 g of SiO2, so the mass of SiO2 generated is:

m_SiO2 = (60/28) × m_Si = (60/28) × 0.0156 × t_Si = 0.0334 × t_Si grams.

Calculating the Oxide Layer Thickness

The oxide layer thickness, tox, can be derived from the mass of SiO2 and the density of SiO2, which is 2.2 g/cm³. The volume of SiO2:

V_SiO2 = m_SiO2 / density_SiO2 = 0.0334 × t_Si / 2.2 cm³.

The surface area remains constant; thus, the oxide thickness:

tox = V_SiO2 / Area = (0.0334 × t_Si / 2.2) / (area in cm²).

If the surface area is 67 cm² and conversion to cm² is made, we get:

tox = (0.0152 × t_Si) cm.

Finally, the ratio t_Si/tox facilitates understanding of the growth characteristics.

Etching Process for Silicon Membrane Fabrication

When fabricating a silicon membrane through KOH anisotropic etching, the depth of etch depends on the membrane thickness, here 10 μm. Given that the (100) silicon etches faster in the x-direction and slower in the y-direction, etching depth equals the desired membrane thickness. The etching rate, 19.9 μm/hr, allows calculating etching time:

Time = depth / rate = 10 μm / 19.9 μm/hr ≈ 0.50 hours (~30 minutes).

The width of the window in SiO2, W₂, must account for the etching sidewall angles, calculated from the crystallographic etch profiles. The total mask opening W_mask depends on original width W₁ and etching angles, ensuring the final W₂ is sufficient to accommodate the shaped etch profile and achieve the desired membrane geometry.

The minimum SiO2 mask thickness is derived from the oxidation duration needed to grow a protective oxide layer of the required thickness, considering native oxide and oxidation rates at 1100°C, with given parameters. The oxidation duration is computed using the initial native oxide and the oxide growth rate, for which the parabolic growth law applies.

Photolithography and Thin Film Deposition Techniques

The ten basic steps of photolithography include substrate cleaning, photoresist coating, soft baking, mask alignment, exposure, post-exposure bake, development, hard baking, etching, and resist removal. These steps ensure precise pattern transfer onto the substrate.

PVD (Physical Vapor Deposition) and CVD (Chemical Vapor Deposition) are primary thin-film deposition methods. PVD involves physical vaporization of source material into vapor and condensation on the substrate. Eighteen different methods, such as evaporation and sputtering, are used. CVD involves chemical reactions resulting in film formation, such as silane decomposition at high temperatures.

Polysilicon CVD involves reactions like SiH₄ + heat → Si + 2H₂, typically at 550-650°C. For SiO₂, common reactions include TEOS (tetraethyl orthosilicate) decomposition: Si(OC₂H₅)₄ + O₂ → SiO₂ + other products, at ~700-900°C.

Successful silicon-glass anodic bonding requires matching thermal expansion coefficients, clean surfaces, and applied voltage. Bulk micromachining involves removing bulk material to form cavities, while surface micromachining builds microstructures layer by layer on the surface.

Microfabrication Techniques for MEMS Structures

Surface micromachining creates free-standing structures by depositing and patterning thin films that are subsequently released via etching, often using sacrificial layers. Bulk micromachining etches away entire portions of silicon substrate to form cavities and membranes.

The term “mask” varies across contexts. A photolithography mask defines light exposure pattern; an etching mask shields regions during etching; an oxidation mask determines areas for oxidation; an implantation mask selectively allows dopant introduction. Lag effects during DRIE involve etch rate delays in smaller features, while loading effects refer to etch rate variations due to feature density, caused by local plasma depletion or sidewall effects.

Design and Operation of a MEMS Accelerometer

The accelerometer comprises a silicon mass supported by beams, with a capacitance sensor measuring displacement due to inertial forces. Fabrication involves steps like wafer cleaning, oxide growth, patterning, DRIE etching, and release. The masks define the features: the central mass, beams, bottom electrode, and supporting structures.

Driving and sensing vibrations are generated along orthogonal axes, with resonance matching improving sensitivity and quality factor. The velocity of the sensing mass during vibration is v(t) = d/dt = Ad·ω·cos(ωt). Under applied linear acceleration, the Coriolis force Fc(t) = 2·M·Ω·v(t) acts perpendicular to the vibration direction, inducing measurable displacement given by ys(t)=Fc(t)/K_sens.

The displacement response correlates with angular velocity, enabling gyroscopic sensing. Proper design ensures that the resonant frequencies of drive and sense modes are matched, enhancing signal-to-noise ratio and sensitivity.

Design and Analysis of MEMS Optical Switches and Gyroscopes

The MEMS optical switch uses comb driven actuation, with spring constants calculated from beam dimensions and Young's modulus: K = N·(E·Wb·tb³)/L_b³. For a desired mirror displacement, the necessary DC voltage V_d is derived from electrostatic force balance equations. To scale the network to 128×128 inputs/outputs, the number of switches multiplies accordingly, but alternative architectures, such as wavelength division multiplexing (WDM), can reduce the number of actual switches needed, improving efficiency and cost-effectiveness.

Conclusion

Understanding the detailed fabrication processes, material properties, and design principles is critical in MEMS device development. From oxidation and etching to photolithography and deposition techniques, each step impacts device performance. Combining theoretical calculations with practical process considerations ensures the successful fabrication of complex MEMS structures such as accelerometers, gyroscopes, and optical switches.

References

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