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.     

An Electrothermal Tip–Tilt–Piston Micromirror Based on Folded Dual S-Shaped Bimorphs

This paper presents the design, optimization, fabrication, and test results of an electrothermally actuated tip-tilt-piston micromirror with a large optical aperture of 1 mm. The fabrication of the device is a combination of thin-film surface micromachining and bulk silicon micromachining based on silicon-on-insulator wafers. The device has 3-DOF of actuations, including rotations around two axes in the mirror plane, and out-of-plane piston actuation. The micromirror shows an optical scan range of plusmn30^deg about both x- and y-axes and displaces 480 mum in the z-axis, all at dc voltages that are less than 8 V. Dynamic testing of the micromirror shows that the thermal response time of each actuator is about 10 ms. Resonant frequencies of the piston and rotation motion are 336 and 488 Hz, respectively. The unique structural design of the device ensures that there is no lateral shift for the piston motion and no rotation-axis shift for the rotation scanning. With the large tip-tilt-piston scan ranges and low driving voltage, this type of device is very suitable for biomedical imaging and laser beam steering applications.     

A self-retracting fully compliant bistable micromechanism

A new class of fully compliant bistable mechanisms with the added benefit of integrated self-retraction has been developed (hereafter identified as Self-Retracting Fully compliant Bistable Mechanism or SRFBM). A technique using tensural pivots to manage compressive loading in compliant mechanisms is introduced and implemented in the SRFBM. The elimination of traditional kinematic joints and their associated clearance allows a total displacement between stable positions of 8.5 /spl mu/m, and the mechanism size is less than 300 /spl mu/m square when using 2.0 /spl mu/m minimum line widths. Maximum actuation force is approximately 500 /spl mu/N. The SRFBM's small linear displacement and reasonable actuation force facilitate integration with efficient thermal actuators. Furthermore, fully compliant mechanisms allow greater freedom in fabrication as only one mechanical layer is needed. Systems with on-chip actuation have been fabricated and tested, demonstrating bistability and on-chip actuation, which requires approximately 150 mW. A single fatigue test has been completed, during which the SRFBM endured approximately 2 million duty cycles without failure.     

Design, Modeling, and Demonstration of a MEMS Repulsive-Force Out-of-Plane Electrostatic Micro Actuator

An analytical model is developed for a two-layer repulsive-force out-of-plane micro electrostatic actuator by using conformal mapping techniques. The model provides the means to establish the performance characteristics in terms of stroke and generated force of the actuator and is used to develop design and optimization rules for the actuator. Numerical simulations were conducted in order to verify the analytical model. A simple physical model is also presented that explains the mechanism for generating the repulsive force. A Multi-User-MEMS-Processes repulsive-force out-of-plane rotation micromirror is developed to experimentally verify the analytical model and to demonstrate the repulsive-force actuator's capability of driving large-size rotation plates by using surface micromachining technology. Experimental measurements show that the repulsive-force rotation micromirror with a size of 312 mum times 312 mum achieved a mechanical rotation of 0deg-2.1deg at a dc driving voltage of 0-200 V. The micromirror achieved an open-loop settling time of 2.9 ms for a mechanical rotation of 2.3deg and an open-loop bandwidth of 150 Hz (-3 dB).     

Optical and mechanical performance of a novel magnetically actuated MEMS-based optical switch

A novel magnetically actuated 8/spl times/8-port MEMS-based fiber-optic switch is described. Fiber-to-fiber insertion loss measurements of six 8/spl times/8 switch units show average and worst-case insertion loss of 1.3 dB and 2 dB, respectively. Low insertion loss is achieved through a unique MEMS design that uses anisotropically etched single-crystal silicon sidewalls to provide a global mechanical alignment stop for an array of MEMS mirrors. This alignment surface produces a uniform and repeatable mirror angle across the mirror array. Mirror misalignment is attributed to the surface roughness of the silicon sidewalls. Repeated interferometric measurements of the mirrors of 24 8/spl times/8 switch units show repeatability of the mirror angle of 3/spl times/10/sup -3/ degrees, while the uniformity of the mirror angle across the MEMS array is 2/spl times/10/sup -2/ degrees, in agreement with the angular error predicted from measurements of sidewall surface roughness. In turn, the average repeatability and uniformity of the insertion loss are 0.01 dB and 1 dB, respectively, in agreement with predictions based on the interferometric measurements. Finally, the unique dynamics of the magnetic actuation and electrostatic addressing scheme are described. Measurements show that fast switching can be achieved by driving the mirrors with a magnetic pulse that is faster than the mechanical resonant frequency of the mirror, relying on an electrostatic clamping force to capture the mirror as it overshoots the magnetic field angle. This actuation scheme is shown to result in switching times of 8.5 ms to 13.5 ms, but requires accurate control of the kinetic energy of the mirror.     

Trench filling characteristics of low stress TEOS/ozone oxide deposited by PECVD and SACVD

In this paper low stress silicon oxide was deposited with tetraethylorthosilicate (TEOS, Si(OC₂H₅)₄)/ozone by plasma enhanced chemical vapor deposition (PECVD) and sub-atmospheric chemical vapor deposition (SACVD) for deep trench filling. Two kinds of PECVD oxide were fabricated: Coil antenna inductively coupled plasma (ICP) oxide and parallel plates capacitive coupled plasma (CCP) oxide. Adding ozone into the deposition process enhances the trench filling capability. Oxide filling in a deep trench (5 m wide, 52 m deep) was carried out using the SACVD process, which gave excellent conformal step coverage. However, the coil antenna ICP oxide was suitable as a sealing material. The effects of argon ion sputtering and magnetic field in the PECVD for the trench filling are discussed in this paper. Because the low temperature processes of PECVD and SACVD, the thermal residual stress was reduced and a low stress film of 85 MPa compression is available.This work is supported by a Grant-in-Aid (No. 13305010) from Japanese Ministry of Education, Culture, Sports, Science and Technology. A part of this work has been performed in Venture Business Laboratory, Tohoku University.     

Design and Characterization of Single-Layer Step-Bridge Structure for Out-of-Plane Thermal Actuator

This paper presents the design and fabrication of a single-layer out-of-plane thermal actuator. The step-bridge structure design enables bending and then buckling of the actuator in the out-of-plane direction by Joule heating. Moreover, the moving direction of the actuator can be specified by the step structure. In summary, the step-bridge actuator design has the following five merits: (1) The load-deflection relation is easily tuned; (2) the bistable buckling behavior is prevented; (3) the unwanted vibration modes can be suppressed; (4) the delamination problem is prevented; and (5) the bridge structure is stiffer and more stable. The actuator and its application on a lens positioning stage have been implemented using p⁺⁺ Si layer by bulk micromachining. It demonstrates that a typical actuator would move upward with an amplitude near 13 mum when driven at 54 mW.     

Microengineered Two-Dimensional Arrays of Monomode Optical Fibers

In this paper, a method to manufacture 2-D bundles of single-mode optical fibers of highly accurate pitch is presented. Electrostatic actuation of the metal-clad optical fibers is performed to align the fibers with submicrometer translational alignment accuracy. The manufacturing and alignment performance characteristics of the fiber holder are fully described. The sensitivity of the active-alignment procedure for a maximum displacement up to 90 mum is between 0.125 and 1.1 mum, depending on the clamping distance. An alignment accuracy of around 0.2 mum can be achieved with this alignment method. The combination of the electrostatic actuation with the optical monitoring of the fiber pitch in a closed-loop feedback system provides a highly accurate and sensitive alignment system.     

Electrostatically actuated metal-droplet microswitches integrated on CMOS chip

The dominance of surface tension over inertia in microscale and favorable scale effect for electrostatic actuation allow electrostatically driven metal-droplet systems practical. Because of such potential advantages as low contact resistance, naturally bistable operation, and high switch density, the liquid-metal droplet switch is an excellent candidate for reconfigurable circuit interconnections. Following earlier droplet microswitch examples and related studies of metal-droplet behavior, we report the first functioning droplet switch directly integrated on top of a functional CMOS circuit. While the surface tension dominance makes the droplet switches practical as a mechanical system and also brings bistability, it also requires a high electric field to move the droplet. We implement the concept of physical surface modification to lower the driving voltage to a value that a commercial CMOS process can provide. Unlike previous droplet switches, the reported device is planar-processed to allow the integration with the underlying CMOS circuits. The integrated switch is made functional by such provisions as self-limiting actuation and by optimizing the electrostatic force in the planar configuration and avoiding liquid-metal "flooding" into surface patterns. A fabrication process for low driving voltage and high compatibility is developed to integrate the droplet switch on the custom-developed CMOS chip. A packaging method adapted from well-established microelectronic packaging isolates the active switch space from the surrounding environment. Low driving voltage (as low as 15 V) and millisecond switching speed are achieved by the current on-chip device. While the current device uses /spl sim/150 /spl mu/m droplets for demonstration, additional theoretical and experimental results indicate that further miniaturization would lead to smaller devices and lower operation voltage.     

Microbridge testing on symmetrical trilayer films

In this paper, we extended the microbridge testing method to characterize the mechanical properties of symmetrical trilayer thin films. Theoretically, we analyzed the deformation of a trilayer microbridge sample with a deformable boundary condition and derived load-deflection formulas in closed-form. The slope of a load-deflection curve under small deformation gives the relationship between the bending stiffness and the residual force of a trilayer microbridge. Taking this relationship, we were able to assess simultaneously the Young's modulus of two kinds of materials composing the symmetrical trilayer film and the thickness-averaged residual stress of the film. Experimentally, we fabricated symmetrical trilayer microbridge samples of SiO/sub 2//Si/sub 3/N/sub 4//SiO/sub 2/ on 4-inch p-type (100) silicon wafers and conducted the microbridge tests with a load and displacement sensing nanoindenter system equipped with a microwedge indenter. The experimental results verified the proposed microbridge testing method. The thickness-averaged residual stress of the 1.1-/spl mu/m trilayer thin films was determined to be 8.8 MPa, while the Young's modulus of the 0.3-/spl mu/m silicon oxide layers and the Young's modulus of the 0.5-/spl mu/m silicon nitride layer were evaluated to be 31 GPa and 294 GPa, respectively.     

Resistive damping implementation as a method to improve controllability in stiff ohmic RF-MEMS switches

This paper presents in detail the entire procedure of calculating the bias resistance of an ohmic RF-MEMS switch, controlled under resistive damping (charge drive technique). In case of a very stiff device, like the North Eastern University switch, the actuation control under resistive damping is the only way to achieve controllability. Due to the short switching time as well as the high actuation voltage, it is not practical to apply a tailored control pulse (voltage drive control technique). Implementing a bias resistor of 33 MΩ in series with the voltage source, the impact velocity of the cantilever has been reduced 80 % (13.2 from 65.9 cm/s), eliminating bouncing and high initial impact force during the pull-down phase. However, this results in an affordable cost of switching time increase from 2.38 to 4.34 μs. During the release phase the amplitude of bouncing has also been reduced 34 % (174 from 255 nm), providing significant improvement in both switching operation phases of the switch.     

Analog piezoelectric-driven tunable gratings with nanometer resolution

This work presents the design, fabrication, and characterization of a piezoelectrically actuated MEMS diffractive optical grating, whose spatial periodicity can be tuned in analog fashion to within a fraction of a nanometer. The fine control of the diffracted beams permits applications in dense wavelength-division multiplexing (DWDM) optical telecommunications and high-resolution miniaturized spectrometers. The design concept consists of a diffractive grating defined on a deformable membrane, strained in the direction perpendicular to the gratings grooves via thin-film piezoelectric actuators. The tunable angular range for the first diffracted order is up to 400 /spl mu/rad with 0.2% strain (/spl sim/8 nm change in grating periodicity) at 10 V actuation, as predicted by device modeling. The actuators demonstrate a piezoelectric d/sub 31/ coefficient of -100 pC/N and dielectric constant /spl epsiv//sub r/ of 1200. Uniformity across the tunable grating and the out-of-plane deflections are also characterized and discussed.     

Frequency-dependent electrostatic actuation in microfluidic MEMS

Electrostatic actuators exhibit fast response times and are easily integrated into microsystems because they can be fabricated with standard IC micromachining processes and materials. Although electrostatic actuators have been used extensively in "dry" MEMS, they have received less attention in microfluidic systems probably because of challenges such as electrolysis, anodization, and electrode polarization. Here we demonstrate that ac drive signals can be used to prevent electrode polarization, and thus enable electrostatic actuation in many liquids, at potentials low enough to avoid electrochemistry. We measure the frequency response of an interdigitated silicon comb-drive actuator in liquids spanning a decade of dielectric permittivities and four decades of conductivity, and present a simple theory that predicts the characteristic actuation frequency. The analysis demonstrates the importance of the native oxide on silicon actuator response, and suggests that the actuation frequency can be shifted by controlling the thickness of the oxide. For native silicon devices, actuation is predicted at frequencies less than 10 MHz, in electrolytes of ionic strength up to 100 mmol/L, and thus electrostatic actuation may be feasible in many bioMEMS and other microfluidic applications.     

Microsized Piston-Cylinder Pneumatic and Hydraulic Actuators Fabricated by Lithography

Future microrobotic applications require actuators that can generate a high actuation force in a limited volume. Up to now, little research has been performed on the development of pneumatic or hydraulic microactuators, although they offer great prospects in achieving high force densities. In addition, large actuation strokes and high actuation speeds can be achieved by these actuators. This paper describes a fabrication process for piston-cylinder pneumatic and hydraulic actuators based on etching techniques, UV-definable polymers, and low-temperature bonding. Prototype actuators with a piston area of 0.15 mm² have been fabricated in order to validate the production process. These actuators achieve actuation forces of more than 0.1 N and strokes of 750 mum using pressurized air or water as driving fluid.     

Seal Formation in Silicon Planar Patch-Clamp Microstructures

This paper presents a microfabricated planar patch-clamp electrode design and looks at the impact of several physical characteristics on seal formation. The device consists of a patch aperture, 1.5–2.5 $muhbox{m}$ in diameter and 7–12 $muhbox{m}$ in depth, with a reverse-side deep-etched 80- $muhbox{m}$ well. The patch aperture was coated with either thermal oxide or plasma-enhanced chemical vapor deposited (PECVD) $ hbox{SiO}_{2}$. Some of the thermal oxide devices were converted into protruding nozzle structures, and some were boron-doped. Seal formation was tested with cultured N2a neuroblastoma cells. The PECVD oxide devices produced an average seal resistance of 34 $hbox{M}Omega (n = 24)$ , and the thermal oxide devices produced an average seal resistance of 96 $hbox{M}Omega (n = 59)$. Seal resistance was found to positively correlate with patch aperture depth. Whole-cell recordings were obtained from 14% of cells tested with the thermal oxide devices, including a single recording where a gigaohm seal was obtained.$hfill$ [2007-0159]      

Performance of GaAs microbridge thermocouple infrared detectors

GaAs microbridge thermocouples with lengths ranging from 40 to 650 μm and operating at room temperature have been fabricated for the detection of infrared radiation. A CO₂ laser of a 10.6 μm wavelength was used to characterize the performance of the detectors in air and in vacuum. A responsivity of 4.2 V/W with a corresponding detectivity D*=8×10⁶ cm Hz^1/2/W and a time constant of 2.2 ms have been measured in vacuum for 650-μm-long bridges, and a shorter time constant of 50 μs was obtained for 40-μm-long bridges. An analytic thermal transport model has been used to simulate the operation of the sensors. The heat-transfer coefficient has been evaluated by comparing the data from air and vacuum measurements. The spectral response and the absorbance of the microbridge have also been presented     

微型风速风向传感器研制

阐述了微型风速风向传感器的工作原理,结构设计及工艺研究,该传感器采用硅微机械加工技术制成微悬桥结构,将加热电阻器与感温电阻器排布在悬桥上,降低了功耗,提高了传感器灵敏度,实现低风速风场测量。     

Dynamical switching of an electromagnetically driven compliant bistable mechanism

Dynamical switching behaviors of a compliant bistable mechanism driven by electromagnetic force are investigated. The bistability of the mechanism originates from combined tension and bending of the beam structures. Finite element analyses are used to characterize the bistability of the mechanism under static loading. An analytical model is developed to analyze the dynamic behaviors of the mechanism. The main advantage of this dynamic actuation method is the absence of on-chip driving mechanisms. The dynamical switching characteristics of the bistable mechanism are examined. Microscale prototypes are fabricated and tested. Using the driving technique, we demonstrate dynamical switching in the fabricated device and verify that the performance predicted by theory is attained.     

Reliability design of thermally actuated MEMS switches based on V-shape beams

This paper presents the design and fabrication of the thermally actuated MEMS switches based on out-of-plane V-beams. The purpose of this research is to analyze the mechanical response of a V-thermal actuator fabricated from aluminum in order to improve the accuracy in response and to increase the switch lifetime. The actuation of this kind of switches is based on the thermal displacement of the mobile electrode under thermal load that is generated when the actuation voltage is applied. It can be used either as a capacitive switch or as a metal-to-metal one. The displacement of the mobile electrode for a given temperature is analytically calculated and validated both numerically and experimentally. Experimental investigations are performed on a macro-scale sample using a 3D digital image correlation measuring system, a heating source and a thermal camera for temperature monitoring. The first fabrication steps of the MEMS switch based on the V-beam thermal actuator are presented. The out-of-plane V-beams thermal MEMS switches can be monolithically integrated in RF applications.

     

Vertical mirrors fabricated by deep reactive ion etching forfiber-optic switching applications

We report on vertical mirrors fabricated by deep reactive ion etching of silicon. The mirror height is 75 μm, covering the fiber core of a single-mode fiber when the latter is placed into a groove of equal depth and etched simultaneously with the mirror. To obtain a uniform etch depth, etching is stopped on a buried oxide layer. Using the buried oxide as a sacrificial layer allows to fabricate mirrors with suspension and actuation structures as well as fiber-alignment grooves in one and the same processing step. A minimal mirror thickness of 2.3 μm was achieved, resulting in an aspect ratio higher than 30. The verticality was better than 89.3°. In the upper part of the mirror a surface roughness below 40 nm rms was obtained. At a wavelength of 1300 nm the reflectivity of the aluminum-coated mirrors was measured to be higher than 76%. Using a reactive ion etched mirror we have fabricated an optical fiber switch with electrostatic actuation. The coupling loss in the bar state of two packaged prototypes was between 0.6 and 1.7 dB and between 1.4 and 3.4 dB in the cross state. The switching time is below 0.2 ms