Tolerance analysis for comb-drive actuator using DRIE fabrication

Deep reactive ion etching (DRIE) process is specially invented for bulk micromachining fabrication with the objective of realizing high aspect ratio microstructures. However, various tolerances, such as slanted etched profile, uneven deep beams and undercut, cannot be avoided during the fabrication process. In this paper, the origins of various fabrication tolerances together with its effects on the performances of lateral comb-drive actuator, in terms of electrostatic force, mechanical stiffness, stability and displacement, are discussed. It shows that comb finger with positive slope generates larger electrostatic force. The mechanical stiffness along lateral direction increases when the folded beam slants negatively. The displacement is 4.832 times larger if the comb finger and folded beam are tapered to +1° and −1°, respectively. The uneven deep fingers generate an abrupt force and displacement when the motion distance reaches the initial overlap length. The undercut reduces both the driving force and the mechanical stiffness of the lateral comb-drive actuator. The fabricated comb-drive actuator, with comb finger of +1° profile and 0.025 μm undercut, and folded beam of −1° slope and 0.075 μm undercut, is measured and compared with the models where both show consistent results. These analytical results can be used to compensate the fabrication tolerances at design stage and allow the actuators to provide more predictable performance.     

Fringing capacitance and tolerance of DRIE effect on the performance of bulk silicon comb-drive actuator

A bulk silicon comb-drive actuator with low driving voltage and large displacement is presented in this paper. The bulk silicon comb-drive actuator is fabricated by a simple bulk micromachining process based on the low temperature Au–Au bonding technology. A cascade folded beam is designed to improve the displacement of comb-drive actuator at low driving voltages. The instability of the whole system decreases by utilizing unequal wide comb fingers design. The fringing capacitance and the fabrication tolerances together with their effects on the performances of the comb-drive actuators are also discussed. The measurement results show that the capacitance change rate and the displacement change rate of the comb-drive actuator are 1.5 fF/V² and 0.125 μm/V², respectively. The displacement of the actuator can reach 28.5 μm at 15 V driving voltages. The experimental results of the comb-drive actuator are in good agreement with the modified theoretical predictions.

     

Hybrid micro electrostatic actuator

A hybrid micro-electrostatic actuator is presented. The actuator integrates a vertical comb driving (VCD) unit and a parallel-plate driving (PPD) unit. The hybrid actuator is fabricated using a one structural layer microfabrication process, i.e., MetalMUMPs instead of a two-layer microfabrication process needed for traditional vertical comb-drive actuators by taking advantage of the residual stress gradient in the MetalMUMPs nickel layer, which raises the moving parts of the actuator above the substrate after release. The hybrid actuator significantly simplifies the fabrication process for vertical comb-drive actuators, i.e., turning a process requiring two structural layers into a process requiring only one structural layer and thus avoids any misalignment between the two layers. The hybrid actuator can generate larger force and then a larger displacement than the actuator having only the VCD with the same area since no extra space is needed for the PPD unit which uses the moving electrode existing in the VCD unit and a fixed electrode under the VCD unit. The VCD and PPD units in the hybrid actuator are subject to the same driving voltage and work together to pull the moving parts of the actuator downward. A model is established for the hybrid actuator to analyze its displacement. The analytical results show that displacement of the moving part of the hybrid actuator is about half of the gap between the electrodes of the PPD unit. Prototypes are fabricated and tested. With a driving voltage of 150 V, the hybrid actuator achieved a measured displacement of 6.48 µm.     

Fabrication of high aspect ratio comb-drive actuator using deep X-ray lithography at Indus-2

We report microfabrication of high aspect ratio comb-drive using deep X-ray lithography at Indus-2 synchrotron radiation source. Analysis shows that the comb-drive actuator of aspect ratio 32 will produce nearly 2.5 μm displacement when 100 V DC is applied. The displacement increases as the gap between the comb finger decreases. For fabrication of comb-drive, polyimide–gold X-ray mask using UV lithography is made for the first time in India. To pattern on an 800 μm thick X-ray photoresist (PMMA) exposures are performed using our deep X-ray lithography beamline (BL-07) at Indus-2. Metallization on the selective regions of the developed X-ray photoresist with comb-drive pattern was carried out by RF sputtering. Following this the comb-drive actuator of PMMA was fabricated by one-step X-ray lithography. The comb-drive can also be used as a sensor, energy harvester, resonator and filter.     

A design method of comb-drive actuators for linear tuning characteristics in mechanically tunable optical filters

A new method is proposed in design of comb-drive actuators for specific voltage-displacement characteristics with finger gaps as the design parameters. The design method proposed by the author previously is further refined by adopting a more accurate model which considers fringe electric fields. The proposed method is applied to design comb-drive actuators with an aim to achieve linear tuning characteristics in mechanically tunable optical add-drop filters with microring resonators. To make an assessment of the accuracy of the proposed design method, three-dimensional electrostatic numerical analysis is conducted to obtain capacitances of the designed comb-drive actuators as functions of the moving finger displacement. Obtained capacitances are used to find the tuning characteristics (resonant wavelength vs. voltage) of the filter, in combination with the results from the author’s other work where a relationship between the resonant wavelength and the displacement of an index modulator was studied. It is found that by employing the actuators designed by the proposed method, the maximum deviation from linearity (MDL) can be reduced by 17.2 % points (from 25.7 % of the conventional design to 8.5 % of the new design). MDL is further reduced to 4.4 % by making a few modifications in the design.

     

A self-aligned fabrication method of dual comb drive using multilayers SOI process for optical MEMS applications

A novel method for fabricating a self-aligned electrostatic dual comb drive using a multi-layer SOI process is developed. The present method utilizes four aligned masks, greatly simplify the existing SOI-MEMS fabrication methods in manufacturing optical MEMS devices. Here, the actuating structure consists of fixed combs and moving combs that are composed of single crystal silicon, nitride and polysilicon. One mask is used to provide a deep etching to etch polysilicon, nitride and single crystal silicon respectively. The nitride separates polysilicon and single crystal silicon and provides an additional dielectric for the purpose of producing bi- directional motion upon applying electrostatic forces. A dual comb drive actuator with optical structures was fabricated with the developed process. The actuator is capable of motion 250 nm downward and 480 nm upward with 30 V applied voltage at 4 kHz frequency. The dynamic characteristics of the first and the second resonant frequency of the dual comb-drive actuator are 10.5 kHz and 23 kHz respectively. Experimental results indicated that the measured data agreed well with simulation results using the ANSOFT Maxwell^® 2D field simulator, ANSYS^® and Coventor Ware^®.     

A new MEMS based variable capacitor using electrostatic vertical comb drive actuator and auxiliary cantilever beams

We have proposed a new wide tunable MEMS variable capacitor. In the proposed structure, an electrostatic vertical comb drive actuator is used to extend the tuning range. Moreover, the auxiliary cantilever-beams are used in the electrostatic comb drive actuator to delay the front sticking (Pull in) and increase the tunability. The effect of lateral gap distance between the fingers in the capacitance tunability is investigated. Not only a full review of electrostatic actuator portion is done but also the electric fields related to lateral gap changes are simulated by COMSOL software and its results are compared with theoretical results as well. The structure is calculated using MATLAB software. To verify, the calculated results are compared with simulated results using Intellisuite software. According to calculation and simulation results the achieved tuning range is 285%.

     

用于硅基氮化镓可调微镜的静电梳齿型微驱动器设计

提出并设计了一种用于硅基氮化镓(GaN)可调微镜的静电梳齿型微驱动器.利用有限元软件建立了该器件的几何结构模型,对器件的结构进行了仿真优化.此外,采用微机电系统(MEMS)加工工艺,制作出了用于硅基氮化镓可调微镜的梳齿型微驱动器,并对其驱动特性进行测试.测试结果表明:所制作的微驱动器的位移随着电压的变化呈二次方关系,与仿真结果基本一致.当加载驱动电压为200 V时,微驱动器的驱动位移可达到1.08 μm.     

Design, fabrication, and operation of submicron gap comb-drivemicroactuators

Making submicron interelectrode gaps is the key to reducing the driving voltage of a micro comb-drive electrostatic actuator. Two new fabrication technologies, oxidation machining and a post-release positioning method, are proposed to realize submicron gaps. Two types of actuator (a resonant type and a nonresonant type) with submicron gaps were successfully fabricated and their operational characteristics were tested experimentally. The drive voltage was found to be lower than that of existing actuators. The stability of comb-drive actuators is discussed     

A micro gearing system based on a ratchet mechanism and electrostatic actuation

This paper presents the design and fabrication of a silicon micro gearing system (MGS) that utilizes electrostatic comb-drive actuators to rotate a gear ring through a ratchet mechanism. The rotational comb-drive actuator is engaged with the gear ring through a spring system and ratchet teeth at one end, reciprocally rotates around an elastic point at the other end based on the electrostatic force. Rotational motion and torque from the driving gear ring are transmitted smoothly to driven gears through involute-shaped gear teeth. Smart design of anti-gap structures helps to overcome the unavoidable gap problem occurred in deep reactive ion etching (deep-RIE) process of silicon. The MGS has been fabricated and tested successfully by using SOI (silicon-on-insulator) wafer and one mask only. The angular velocity of the gear ring is proportional to the driving frequency up to 40 Hz.     

Electrostatic comb-drive actuators made of polyimide for actuating micromotion convert mechanisms

 For conventional micromachines, in particular, micromotion convert mechanisms, the output points of the mechanism can move horizontally when input points move in the same direction. Therefore, we have proposed a three-dimensional motion convert mechanism whose output points can move vertically when the input points move in the horizontal direction. This 2-degree-of-freedom (DOF) mechanism consists of electrostatic comb-drive actuators and a basic mechanism with large-deflective elastic hinges. In this study, the characteristics of comb-drive actuators are analyzed. The electrostatic comb-drive actuator which is made up of polyimide is fabricated by CVD, RIE, Wet etching, etc., technologies. The relationship between the input (voltage) and the output (displacement) of the drive has been analyzed both theoretically and experimentally. Received: 26 December 1998 / Accepted: 4 January 1999     

A Model for Electrostatic Actuation in Conducting Liquids

This paper presents a generalized model that describes the behavior of micromachined electrostatic actuators in conducting liquids and provides a guideline for designing electrostatic actuators to operate in aqueous electrolytes such as biological media. The model predicts static actuator displacement as a function of device parameters and applied frequency and potential for the typical case of negligible double-layer impedance and dynamic response. Model results are compared to the experimentally measured displacement of electrostatic comb-drive and parallel-plate actuators and exhibit good qualitative agreement with experimental observations. The model is applied to show that the pull-in instability of a parallel-plate actuator is frequency dependent near the critical frequency for actuation and can be eliminated for any actuator design by tuning the applied frequency. In addition, the model is applied to establish a frequency-dependent theoretical upper bound on the voltage that can be applied across passivated electrodes without electrolysis.     

Impact of design parameters on working stability of the electrothermal V-shaped actuator

This paper mentions a detail calculation of the equivalent dynamic parameters in differential equations of motion of the electrothermal V-shaped actuator. A heat transfer model for a thin beam (including the dependence of material properties on the temperature) is applied in order to solve more exactly temperature distribution and displacement of V-shaped beam system. Comparing the values of displacement in both calculation and simulation confirmed a higher accuracy of proposed equations. Moreover, a related formula between the minimum conversion stiffness and driving voltage amplitude is analyzed and examined to avoid the buckling phenomenon may occur in V-shaped beam system while working at a high voltage.

     

Design of large deflection electrostatic actuators

Electrostatic, comb-drive actuators have been designed for applications requiring displacements of up to 150 /spl mu/m in less than 1 ms. A nonlinear model of the actuator relates the resonant frequency and the maximum stable deflection to the actuator dimensions. A suite of experiments that were carried out on deep reactive ion etched (DRIE), single-crystal silicon, comb-drive actuators confirm the validity of the model. Four actuator design improvements were implemented. First, a folded-flexure suspension consisting of two folded beams rather than four and a U-shaped shuttle allowed the actuator area to be cut in half without degrading its performance. Second, the comb teeth were designed with linearly increasing lengths to reduce side instability by a factor of two. Third, the folded-flexure suspensions were fabricated in an initially bent configuration, improving the suspension stiffness ratio and reducing side instability by an additional factor of 30. Finally, additional actuation range was achieved using a launch and capture actuation scheme in which the actuator was allowed to swing backward after full forward deflection; the shuttle was captured and held using the backs of the comb banks as high-force, parallel-plate actuators.     

静电梳齿驱动结构的稳定性分析

静电梳齿驱动结构的最大驱动位移主要受限于其侧向不稳定性,即当驱动电压接近吸合电压时,静电梳齿驱动结构的活动梳齿与固定梳齿发生吸合,导致静电梳齿驱动器失效.建立典型静电梳齿驱动结构的稳定性分析模型,研究梳齿驱动结构稳定性的影响因素,并进行理论分析、仿真分析和实验验证.结果表明:支撑梁结构的纵/横刚度比是影响静电梳齿驱动结...     

Development of copper based miniature electrostatic actuator using WEDM with low actuation voltage

Fabricating electrostatic micro actuator, such as comb-drive actuator, is one of the demanding areas of the MEMS technology because of the promising applications in modern engineering, such as, micro-switches, attenuators, filters, micro-lenses, optical waveguide couplers, modulation, interferometer, dynamic focus mirror, and chopper. For the fabrication, most of the cases silicon monocrystalline wafers are used through complex process. To etch the silicon substrates, researchers often use deep reactive-ion etching or anisotropic wet etching procedure which are time consuming and unsuitable for batch fabrication process. Again, resent research shows that comb-drive actuators need comparatively high voltage for actuation. In solving these problems, the study presents a copper based electrostatic micro actuator with low actuation voltage. Using wire electrical discharge machine (WEDM), the actuator is fabricated where a light weight flexible spring model is introduced. Capacitor design model is applied to present a voltage controlling electronic circuit using Arduino micro controller unit. The experimental result shows that the actuator is able to produce 1.38 mN force for 15 V DC. The experiment also proves that coper based actuator design using WEDM technology is much easier for batch processing and could provide the advantages in rapid prototyping.     

MEMS Electrostatic Actuation in Conducting Biological Media

We present design and experimental implementation of electrostatic comb-drive actuators in solutions of high conductivity relevant for biological cells. The actuators are operated in the frequency range 1-10 MHz in ionic and biological cell culture media, with ionic strengths up to 150 mmol/L. Typical displacement is 3.5 mum at an applied peak-to-peak signal of 5 V. Two different actuation schemes are presented and tested for performance at high frequency. A differential drive design is demonstrated to overcome the attenuation due to losses in parasitic impedances. The frequency dependence of the electrostatic force has been characterized in media of different ionic strengths. Circuit models for the electric double layer phenomena are used to understand and predict the actuator behavior. The actuator is integrated into a planar force sensing system to measure the stiffness of cells cultured on suspended structures.     

Micro robot system with moving micro-car driven by electrostatic comb-drive actuators

This paper describes a silicon micro robot system (MRS) that is capable of driving micro-cars in different directions based on a ratchet mechanism and electrostatic comb-drive actuators. Lateral movement of the ratchet racks makes the micro-car move in the perpendicular direction with different velocities. Based on MEMS technology, the MRS described in this article was fabricated from a silicon on insulator wafer by using only one photo mask. In our experiments, various driving frequencies ranging from 1 to 20 Hz were used to accelerate the micro-car up to 200 μm/s. It was observed that the velocity of the micro-car was proportional to the driving frequency used in the experiments. This relation was also confirmed with our theoretical calculation. When combined with microscopes, this MRS can be applied in bio-medical analysis for transportation and classification of small samples.     

Fabrication of distributed electrostatic micro actuator (DEMA)

A distributed electrostatic micro actuator (DEMA) has been proposed. The actuator has many small driving units which consist of two wave-like insulated electrodes. Both ends of insulated electrodes are connected to each other, and the driving unit has narrow gap for deformation caused by electrostatic forces. The driving units have large area of electrodes and are distributed in series and in parallel. So, a strong electrostatic force can be obtained, and the deformation and the generated force of the actuator would be large. Macro model of the DEMA was fabricated with polyimide films, and the deformation of the actuator was measured. When the applied voltage was 200 V, the deformation ratio was 36%. A micro actuator was fabricated by use of photolithography and electroplating. The displacement of 28 μm was observed when applied voltage was 160 V. Experimental results of the micro actuator were compared with the results simulated by finite element method (FEM) analysis     

The electromechanical response of a symmetric electret parallel-plates actuator

The electromechanical response of a symmetric electret parallel-plates actuator is analyzed. The actuator is constructed from a dielectric plate that is suspended by a linear spring between two electrodes of a planar capacitor. The dielectric plate is loaded with fixed charge, and is displaced due to the interaction between this charge and the electrostatic field. The electrostatic field that displaces the charged dielectric has three components: a field induced by the voltage difference across the capacitor plates, a field induced by the anti-symmetric part of charge, and a field induced by the combined effect of the symmetric part of charge and the displacement of the plate itself. The analysis shows that the displacement of the electret actuator is a linear function of the driving voltage, and that a full range of stable motion can be achieved. Furthermore, it is shown that all important characteristics of the fixed charge can be deduced from simple measurements.