基于硅塑性变形的蛇形梁垂直梳齿驱动器

设计了基于硅塑性变形的垂直梳齿驱动器,中央可动微镜由四组蛇形曲折梁支撑。驱动器的制作采用硅—硅键合技术,首先利用DRIE干法刻蚀技术释放可动梳齿与固定梳齿,然后通过各向异性湿法腐蚀制作的施压凸台实现可动梳齿和固定梳齿的精确自对准,最后利用硅塑性变形使可动梳齿和固定梳齿在垂直方向上产生位错,成功制作出在Z方向依靠位错梳齿实现垂直驱动的蛇形梁静电梳齿驱动器。     

Initial deflection of silicon-on-insulator thin membrane micro-mirror and fabrication of varifocal mirror

Thin membranes fabricated from silicon-on-insulator (SOI) wafer are valuable for deformable mirrors. The mirror is controlled to generate a specific wave-front with precision smaller than a wavelength. Here, we investigate quantitatively the initial deflection of the thin membrane mirrors fabricated from SOI wafer, which are often used in micro-electro-mechanical systems. A 1-μm-thick and 450-μm-diameter mirror fabricated from SOI wafer deflects upward around the circumference at an angle of 0.12°. The maximum deflection of the mirror is 320 nm at the center. The stress conditions of the mirrors are analyzed on the basis of material strength theory. The deflection is explained by the residual stress of the buried oxide layer of SOI wafer. The in-plane stresses of the micro-mirrors of diameters from 450 μm to 860 μm range from compressive stress of 1.2 MPa to tensile stress of 2.1 MPa. Furthermore, based on the above experimental and theoretical analyses, a 1-μm-thick varifocal micro-mirror of the diameter of 400 μm is fabricated. The focus of the mirror is varied from −28 mm to 21 mm with the deviation smaller than 4 nm from parabola in the mirror central region.     

Polymeric (SU-8) optical microscanner driven by electrostatic actuation

A torsional micromechanical scanner was fabricated using photosensitive polymer (SU-8). The proposed polymer-based optical microscanner with reduced torsional stiffness offers a new approach to increase scanning angles. The scanner consists of two parts; the top layer (micro mirror and electrodes) and the bottom layer (anchors and electrodes). The SU-8 scanner is actuated by electrostatic force generated by gap-closing electrodes. For the fabricated optical scanner with the mirror size of 3 × 3 mm², the experimentally obtained scanning angles were 0.43° for 60 Hz (non-resonant) and 1.54° for 1.13 kHz (resonant) at the input voltage of 160 V. This paper also proposes a simple and new fabrication method, which can effectively control the stiffness of the torsional springs by molding SU-8 photoresist through V-groove on the silicon substrate, thereby increasing the scanning angles.     

Varifocal liquid lenses with integrated actuator, high focusing power and low operating voltage fabricated on 200 mm wafers

We developed an innovative type of varifocal liquid lens actuated by electrostatic parallel plates. The 3 mm diameter lens is made of a polymer membrane that encapsulates a high permittivity liquid in a cavity on top of a glass wafer. Annular electrodes situated below the membrane and on the glass wafer form the electrostatic parallel plates actuator. By applying a voltage between the electrodes, the electrostatic actuation generated reduces the gap and pushes the liquid towards the center of the lens changing the curvature of the membrane.Compared to previous liquid lenses, very compact devices (≤6 mm × 6 mm × 0.7 mm) working at a reduced supply voltage (<25 V) are demonstrated. Wave front measurements indicate an optical power change of 8 m⁻¹ at 22 V_RMS that can be further improved. The lenses were fabricated on 200 mm wafers using standard microelectronics processes that make our solution a promising small outline, low voltage and low cost candidate for auto-focus devices in camera phones.     

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.

     

A MEMS-based tracking milli-mirror for high-density optical disk drives

We present a new MEMS-based milli-mirror for precise tracking in high-density optical disk drives (ODDs). The device consists of a torsionally suspended mirror plate, one pair of torsion springs, which support the mirror plate and offer a restoring torque, and two pairs of electrodes attached to the mirror plate and glass substrate. The dimensions of mirror plate and torsion springs were determined so that a 5 V dc bias ±4.5 V ac drive voltage would provide the mirror with ±0.02° rotation to transmit laser beam spot on spinning disk. The MEMS-based milli-mirror was successfully fabricated using MEMS technology. Displacement–voltage linearization scheme was implemented by differential voltage driving. The static and dynamic performances of mirror prototype, such as capacitance versus driving voltage, rotation angle versus driving voltage, and resonant frequency were characterized and compared well with the simulation solutions. The mechanical resonant frequency of the mirror is expected to be high enough to satisfy the requirement of the servo bandwidth of precise tracking-control in high-density blue-laser optical disk drive.     

Miniature orthogonal optical scanning mirror excited by torsional piezoelectric fiber actuator

A novel optical scanner excited by a torsional piezoelectric fiber actuator is presented. The device consists of a piezoelectric fiber actuator generating torsional and longitudinal vibrations simultaneously and a specially designed metal frame transforming the two vibrations to orthogonal deflections of the mirror. Theoretical and experimental studies were performed on the structure. The changing trends of the vibration modes and resonant frequencies were obtained from finite element simulations. Samples with 1 mm × 1 mm mirrors were fabricated from PZT hollow fibers with a diameter of 1 mm and a stainless steel sheet with a thickness of 50 μm. A horizontal scanning angle of 17.9° and a vertical scanning angle of 2.6° were achieved at 6780 and 10,330 Hz under an applied voltage of 400 V_p–p.     

Design and experiment of an electromagnetic levitation system for a micro mirror

In this paper, the design and characterization of a contactless electromagnetic levitation and electrostatic driven microsystem is presented, which has applications for example for large scale angle rotation micro mirrors. The proposed design can levitate a fabricated aluminum micro rotor which can incorporate a mirror and control it to rotate around the vertical axis within the range of ± 180°, which enlarges the scanning angle dramatically compared with conventional torsion micro mirrors. The rotation angle of the micro rotor is detected by the change of capacitance and controlled by the electrostatic force produced by variable capacitors. The levitation of the micro rotor is realized by utilizing electromagnetic inductions. The rotation is achieved through electrostatic forces generated by a digital controller. The hybrid system design for a micro rotor, combining magnetic and electrostatic forces is introduced. The digital control strategy is based on a PID controller with bias voltage. The detection interface circuit, which is based on frequency multiplexing, is also presented in this paper. It has been experimentally shown that the proposed design can levitate a 1.65 mm radius and 8 µm thickness aluminum micro rotor to 100 µm height with 20 MHz frequency and 0.5A p-p input current. Square and slope wave input experiments were carried out. The experimental results show that the control principal is in good agreement with the simulation models and this applies as well to the time-response performance and stability.

     

A new scanning MEMS mirror

This paper introduces the development of a new MEMS-based optical mirror, which performs optical scanning function with discrete reflection angles in an out-of-plane configuration. The device was fabricated through Deep Reactive Ion Etching (DRIE) process on silicon-on-insulator (SOI) wafer, followed by assembly with two metalised glass dies. The optical mirrors can be tilted by electrostatic forces between the opposite electrodes on the SOI and glass dies. The most outstanding performance that can be expected from the device is the discrete and therefore, reliable tilting angle of the mirror, which is guaranteed by its unique mechanical structure and the electrostatically driven mechanism. In this paper, the working principle of the new MEMS mirror was presented, followed by the introduction of device design, mechanical simulation, microfabrication process, assembly solution, and some testing results. The potential application of this new MEMS mirror is for light beam scanning or optical sensing (detection).     

Analysis of the dynamic behaviour of a torsional micro-mirror

In this paper, the results of the dynamic pull-in voltage characteristics of a micro-mirror using electrostatic actuation are analyzed. Based on torsional dynamic theory, appropriate equations are developed that allowed to give insight into the actuating voltage, switching time and other dynamic parameters. The analytical results are discussed in detail without and with considering air squeeze film damping, respectively. This is equivalent to assuming the mirror is operated in vacuum or at ambient pressure. When the effect of the damping is considered, the movement trajectory of the cantilever beam is changed, and the calculated results of the pull-in voltage and switching time are considerably different compared to those without considering damping. Therefore, the effect of the air squeeze film damping is an important factor in the design and fabrication of micro-electro-mechanical systems. Finally, the experimental results in the air environment are discussed and compared to the theoretical analysis.     

高速MEMS扫描微镜动态变形特性研究

扭转镜面的动态形变是影响显示成像用MEMS扫描微镜光学分辨率的主导因素,研究了高速转动的MEMS扫描微镜的动态形变特性,得到了相关有用的结论。结果表明当MEMS扫描微镜镜面几何尺寸一定时,如果要获得系统衍射极限光学分辨率,需要对转动频率,扭转角度和镜面厚度进行优化设计和选择,简单通过增加镜面厚度保证光学分辨率的方法不利于MEMS扫描微镜综合性能的改善和提高。     

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.     

RMS voltage sensor based on a variable parallel-plate capacitor made of electroplated copper

We present an advanced RMS voltage sensor based on a variable parallel-plate capacitor using the principle of electrostatic force. The device is fabricated in a micromechanical surface process with a high-aspect ratio actuator, reinforced by copper electroplating employing a sacrificial photo-resist layer. Another copper layer with a coplanar waveguide below the actuator provides separated excitation and sensing electrodes. Flip-chip technology is employed for low-loss electrical connectivity. The presented design has a plate area of up to 3 × 3 mm² and an initial gap distance of only 1.5 μm. We present results achieving a pull-in voltage below 1 V at frequencies from DC up to 1 GHz and sensitivities up to 1 fF/mV.     

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.     

Design and fabrication of a resonant scanning micromirror suspended by V shaped beams with vertical electrostatic comb drives

A scanning micromirror suspended by a pair of V-shaped beams with vertical electrostatic comb drives was designed, modeled, fabricated and characterized. The dynamic analyses were carried out by both theory calculation and FEM simulation to obtain frequency response, stiffness characteristics, oscillation modes and their resonance frequencies. The device was fabricated using the silicon-on-insulator process by only two photolithography masks. Some problems during the process such as the micromirror distortion and the side sticking of the comb fingers were effectively solved by thermal annealing and alcohol-replacement methods, respectively. Based on the fabricated device, the typical scanning patterns for 1-D and 2-D operation were obtained. The experimental results reveal that the micromirror can work in resonant mode with the resonant frequency of 2.38 kHz. The maximum deflection angles can reach ±4.8°, corresponding to a total optical scanning range of 19.2° at a driving voltage of 21 V.     

Design,fabrication and vacuum operation characteristics of two-dimensional comb-drive micro-scanner

We present design, fabrication, and characteristics of two-dimensional micro-machined comb-drive scanner to operate in vacuum. The scanner can be actuated in two orthogonal axes using the slanted electrostatic comb-drive and silicon conductive V-shaped torsion hinges fabricated from a silicon-on-insulator wafer. The resonant frequencies of the inner mirror and the gimbal frame are 40 kHz and 162 Hz, respectively. The resonant frequency ratio is 247. The optical scanning angles for the inner mirror and the gimbal frame are 11.5° and 14° at the operation voltages of 12 and 10 V in 1 Pa vacuum, respectively. These driving voltages are smaller by the factors of about 21 and 3 than those in atmosphere, respectively. The dependence of quality factor on pressure for the inner mirror and the gimbal frame is also experimentally investigated and compared with the theoretical calculation based on air-friction models.     

Variable optical attenuator using planar light attenuation scheme based on rotational and translational misalignment

In the last decade, extensive developments of microelectromechanical systems based thermal actuator and/or electrothermal actuators have been dedicated to the applications, such as data storage devices, relays and optical switches, etc. In this paper, we demonstrated a novel planar micromechanism comprising a tilted mirror driven by a V-beam electrothermal actuator via a link beam. This electrothermally driven tilted mirror can have static displacement with a motion trace including rotational and translational movement. The rotational and translational misalignment of reflected light spot toward the core of output port fiber will lead to light attenuation. In other words, the attenuation is controlled in terms of the position of tilted mirror depending on driving dc voltage. This new micromechanism has granted us a more efficient way to perform the light attenuation regarding to the other kinds of planar variable optical attenuators. These devices were fabricated by the deep reactive ion etching process and can reach 30-dB attenuation at 7.5 V driving voltage. The polarization dependant loss is less than 0.1 dB within the 30-dB attenuation region. The static and transient characteristics of devices operated at ambient room temperature environment show good repeatability and stability.     

A single-layer PDMS-on-silicon hybrid microactuator with multi-axis out-of-plane motion capabilities-part II: fabrication and characterization

This paper reports on fabrication and characterization of a new electrostatic microactuator that achieves out-of-plane multi-axis motion with a single silicon device layer. The multi-axis motion with the simple actuator design is possible by incorporating a three-dimensional (3-D) polydimethylsiloxane (PDMS) microstructure. This paper develops a new device processing method named "Soft-Lithographic Lift-Off and Grafting (SLLOG)" to fabricate the previously designed PDMS-on-silicon hybrid actuator structure. SLLOG is a low-temperature (less than 150/spl deg/C) process that allows replica molded PDMS microstructures to be integrated in silicon micromachined device patterns. The fabricated actuator is characterized using laser vibrometry. The experimental results demonstrate actuation motions achieved in three independent axes with fast dynamic response reaching a bandwidth of about 5 kHz. The fabricated PDMS-on-silicon actuator yields a vertical displacement up to 5 /spl mu/m and rotational motions with a 0.6-/spl deg/ tilting angle at a 40-V peak-to-peak ac actuation voltage.     

Rotary electrostatic micromirror switches using wafer-scale processing and assembly

The design, micromachining process, wafer-scale assembly, and experimental characterization of our rotary electrostatic micromirrors for optical switching applications are reported in this paper. Some of the proposed microelectromechanical systems (MEMS) optical switches utilize surface-micromachined thin films as the reflection micromirrors which might result in optical degradation due to dynamic warping. Some of these devices fabricated by bulk micromachining highly rely on a delicate post-assembly process to assemble the micromirrors onto the top of MEMS actuators. In this research, we focus on developing rotary electrostatic micromirror switches without the requirement of delicate post-assembly processes. We use the spin-on-glass, which is used as an intermediate layer in a 280°C low-temperature wafer-bonding process, to fabricate our rotary optical switches with a wafer-scale assembly process. The rotary electrostatic actuator and the vertical micromirror are fabricated simultaneously by the same deep RIE process in our design. We have successfully demonstrated the rotary electrostatic micromirror switches via the wafer-scale assembly process with a yield rate of above 70%. Experimental results show that our rotary vertical micromirrors rotate about 1.5° under an applied voltage of 150 V for steady-state measurements. For dynamic measurements, the rotary vertical micromirrors rotate about 3.6° under an applied voltage of 30 V at the resonant frequency. The first vibration mode of our rotary switch is an in-plane rotational mode and appears around 3.4 kHz, which is characterized via a Polytec laser doppler vibrometer.

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High-aspect-ratio Si vertical micromirror arrays for opticalswitching

Arrays of bulk-micromachined high-aspect-ratio vertical Si mirrors were designed, fabricated, and characterized for optical switching applications. These 50-μm-tall vertical mirrors were fabricated by the deep-etch shallow-diffusion process. The released Si mirrors have smooth sidewalls with 5-nm surface roughness. An electrostatic comb drive applied to actuate the mirrors which were supported by folded or serpentine beams. For 800-μm-long, 3-μm-wide, and 50-μm-thick folded suspension beams, a lateral mirror movement of 34 μm was achieved by a driving voltage of 30 V. Resonant frequency of 987 Hz was obtained for similar devices at atmospheric pressure. There are tradeoffs between mirror displacement and resonant frequency. The mirror displacement increases with beam length (BL) and decreases with beam width (BW). However, the resonant frequency increases with BW, but decreases with BL, which is in agreement with the theoretical calculations. These vertical Si micromirrors were coated with Au to increase the reflectivity. Magnetron sputtering of Au at low pressure was applied to achieve uniform and smooth sidewall coverage. Optical measurement on 50-μm-tall Au-coated Si mirrors showed a reflectivity of 85% (-0.71 dB). Dynamic response of the Si micromirror switches was measured, and the switching function was successfully demonstrated at a frequency up to 1.2 KHz