Rob N. Candler

Long-Term and Accelerated Life Testing of a Novel Single-Wafer Vacuum Encapsulation for MEMS Resonators

We have developed a single-wafer vacuum encapsulation for microelectromechanical systems (MEMS), using a thick (20-mum) polysilicon encapsulation to package micromechanical resonators in a pressure <1 Pa. The encapsulation is robust enough to withstand standard back-end processing steps, such as wafer dicing, die handling, and injection molding of plastic. We have continuously monitored the pressure of encapsulated resonators at ambient temperature for more than 10 000 h and have seen no measurable change of pressure inside the encapsulation. We have subjected packaged resonators to >600 cycles of -50 to 80degC, and no measurable change in cavity pressure was seen. We have also performed accelerated leakage tests by driving hydrogen gas in and out of the encapsulation at elevated temperature. Two results have come from these hydrogen diffusion tests. First, hydrogen diffusion rates through the encapsulation at temperatures 300-400degC have been determined. Second, the package was shown to withstand multiple temperature cycles between room and 300-400degC without showing any adverse affects. The high robustness and stability of the encapsulation can be attributed to the clean, high-temperature environment during the sealing process

Single wafer encapsulation of MEMS devices

Packaging of micro-electro-mechanical systems (MEMS) devices has proven to be costly and complex, and it has been a significant barrier to the commercialization of MEMS. We present a packaging solution applicable to several common MEMS devices, such as inertial sensors and micromechanical resonators. It involves deposition of a 20 /spl mu/m layer of epi-polysilicon over unreleased devices to act as a sealing cap, release of the encapsulated parts via an HF vapor release process, and a final seal of the parts in 7 mbar (700 Pa) vacuum. Two types of accelerometers, piezoresistive and capacitive sensing, were fabricated. Piezoresistive accelerometers with a footprint smaller than 3 mm/sup 2/ had a resolution of 10 /spl mu/g//spl radic/Hz at 250 Hz. Capacitive accelerometers with a 1 mm/sup 2/ footprint had a resolution of 1 mg/spl radic/Hz over its 5 kHz bandwidth. Resonators with a quality factor as high as 14,000 and resonant frequency from 50 kHz to 10 MHz have also been built. More than 100 capacitive accelerometers and 100 resonators were tested, and greater than 90% of the resonators and accelerometers were functional.

Engineering MEMS Resonators With Low Thermoelastic Damping

This paper presents two approaches to analyzing and calculating thermoelastic damping in micromechanical resonators. The first approach solves the fully coupled thermomechanical equations that capture the physics of thermoelastic damping in both two and three dimensions for arbitrary structures. The second approach uses the eigenvalues and eigenvectors of the uncoupled thermal and mechanical dynamics equations to calculate damping. We demonstrate the use of the latter approach to identify the thermal modes that contribute most to damping, and present an example that illustrates how this information may be used to design devices with higher quality factors. Both approaches are numerically implemented using a finite-element solver (Comsol Multiphysics). We calculate damping in typical micromechanical resonator structures using Comsol Multiphysics and compare the results with experimental data reported in literature for these devices

Limits of quality factor in bulk-mode micromechanical resonators

In this paper we present the dominant energy loss mechanisms and quality factor (Q) limits in bulk mode micromechanical resonators. We demonstrate that in resonators with an appropriately designed stem connection to anchor the maximum achievable Q limit is set by either Thermoelastic dissipation (TED) or the Akhieser effect (AKE). Furthermore, we suggest a choice of materials for achieving maximum Qs in micromechanical resonators. It is established here that silicon resonators can theoretically achieve higher Qs than quartz and we predict that by using alternative materials, such as silicon carbide, it is possible to surpass the Q of quartz by more than an order of magnitude.

Frequency stability of wafer-scale encapsulated MEMS resonators

This paper presents an investigation of the long-term frequency stability of wafer-scale encapsulated silicon MEMS resonators. Two aspects of stability were examined: long-term stability over time and temperature-related hysteresis. Encapsulated resonators were tested over a period of 8,000 hours in constant environmental temperature of 25/spl deg/C /spl plusmn/ 0.1/spl deg/C. No measurable drift, burn-in time, or other changes in resonant frequencies were detected. Another experiment was performed to investigate the stability of the resonators with temperature cycling. The resonant frequency was measured between each cycle for more than 450 temperature cycles from -50/spl deg/C to +80/spl deg/C. Additional data is presented for short-term hysteresis measurements -10/spl deg/C to +80/spl deg/C temperature cycle. No detectable hysteresis was observed in either of the temperature cycle experiments. These series of experiments demonstrate resonant frequency stability of wafer-scale silicon based MEMS resonators.

Impact of geometry on thermoelastic dissipation in micromechanical resonant beams

Thermoelastic dissipation (TED) is analyzed for complex geometries of micromechanical resonators, demonstrating the impact of resonator design (i.e., slots machined into flexural beams) on TED-limited quality factor. Zener first described TED for simple beams in 1937. This work extends beyond simple beams into arbitrary geometries, verifying simulations that completely capture the coupled physics that occur. Novel geometries of slots engineered at specific locations within the flexural resonator beams are utilized. These slots drastically affect the thermal-mechanical coupling and have an impact on the quality factor, providing resonators with quality factors higher than those predicted by simple Zener theory. The ideal location for maximum impact of slots is determined to be in regions of high strain. We have demonstrated the ability to predict and control the quality factor of micromechanical resonators limited by thermoelastic dissipation. This enables tuning of the quality factor by structure design without the need to scale its size, thus allowing for enhanced design optimization

Thermal Isolation of Encapsulated MEMS Resonators

This paper presents an in-chip thermal-isolation technique for a micro-ovenized microelectromechanical-system resonator. Resonators with a microoven can be used for high-precision feedback control of temperature to compensate for the temperature dependence of resonator frequency over a wide temperature range. However, ovenization requires power consumption for heating, and the thermal time constant must be minimized for effective temperature control. This paper demonstrates an efficient local-thermal-isolation mechanism, which can reduce the power requirement to a few milliwatts and the thermal time constant to a few milliseconds. In this method, the mechanical suspension of the resonator is modified to provide thermal isolation and include an integrated resistive heater. This combination provides mechanical suspension, electrical heating, and thermal isolation in a compact structure that requires low heating power and has a small thermal time constant. A power consumption of approximately 12 mW for a 125degC temperature rise and a thermal time constant ranging from 7 to 10 ms is reported in this paper, which is orders of magnitude lower than that of commercially available ovenized quartz resonators. A CMOS-compatible wafer-scale encapsulation process is used to fabricate this device, and the thermal-isolation design is achieved without any modification to the existing resonator fabrication process.

Energy loss in MEMS resonators and the impact on inertial and RF devices

In this paper, we review the current understanding of energy loss mechanisms in micromachined (MEMS and NEMS) devices. We describe the importance of high quality factor (Q) to the performance of MEMS gyros and MEMS resonators used in radio-frequency applications.

Using the temperature dependence of resonator quality factor as a thermometer

Silicon micromechanical resonators have been designed to have a quality factor (Q) that is a strong function of temperature. This is an ideal sensor for the temperature of the resonator—it is instantaneous, consumes no power, and indicates the temperature of the resonator structure with high sensitivity. The authors present a practical implementation of an oscillator system using these resonators with a temperature resolution of better than 0.002°C. The Q(T) signal is uniquely suited for implementing feedback control of the resonator temperature, thereby stabilizing the frequency silicon micromechanical resonators and enabling their use in high-stability frequency reference applications.

A stacked memory device on logic 3D technology for ultra-high-density data storage

We have demonstrated, for the first time, a novel three-dimensional (3D) memory chip architecture of stacked-memory-devices-on-logic (SMOL) achieving up to 95% of cell-area efficiency by directly building up memory devices on top of front-end CMOS devices. In order to realize the SMOL, a unique 3D Flash memory device and vertical integration structure have been successfully developed. The SMOL architecture has great potential to achieve tera-bit level memory density by stacking memory devices vertically and maximizing cell-area efficiency. Furthermore, various emerging devices could replace the 3D memory device to develop new 3D chip architectures.