TRANSVERSELY-EXCITED FILM BULK ACOUSTIC RESONATOR WITH MULTI-PITCH INTERDIGITAL TRANSDUCER
20200373907 ยท 2020-11-26
Inventors
Cpc classification
H03H9/13
ELECTRICITY
H03H9/54
ELECTRICITY
International classification
Abstract
There are disclosed acoustic resonators and method of fabricating acoustic resonators. An acoustic resonator includes a single-crystal piezoelectric plate having front and back surfaces, the back surface attached to a surface of a substrate except for a portion of the piezoelectric plate forming a diaphragm spanning a cavity in the substrate. A conductor pattern on the front surface includes a multi-pitch interdigital transducer (IDT) with interleaved fingers of the IDT disposed on the diaphragm.
Claims
1. An acoustic resonator, comprising: a single-crystal piezoelectric plate having front and back surfaces, the back surface attached to a surface of a substrate, a portion of the piezoelectric plate forming a diaphragm spanning a cavity in the substrate; a conductor pattern formed on the front surface, the conductor pattern comprising a multi-pitch interdigital transducer (IDT), interleaved fingers of the IDT disposed on the diaphragm.
2. The acoustic resonator of claim 1, wherein the piezoelectric plate and the IDT are configured such that a radio frequency signal applied to the IDT excites a primary shear acoustic mode in the diaphragm.
3. The acoustic resonator of claim 1, wherein, at any point along a length of the IDT, a pitch of the IDT is constant across an aperture of the IDT.
4. The acoustic resonator of claim 1, wherein a mark of the IDT fingers is constant over the entire IDT.
5. The acoustic resonator of claim 1, wherein the multi-pitch IDT is divided along its length into two or more sections, with each section having a respective pitch different from the pitch of each other section.
6. The acoustic resonator of claim 5, wherein a maximum pitch of the multi-pitch IDT is p(1+) for one of the two or more sections, and a minimum pitch of the multi-pitch IDT is p(1) for another of the two or more sections, where p is a nominal pitch and is greater than 0 and less than or equal to 5.0%.
7. The acoustic resonator of claim 6, wherein is less than or equal to 1.0%.
8. The acoustic resonator of claim 6, wherein the multi-pitch IDT is divided into three sections, and the pitches of the three sections are p(1), p, and p(1+), respectively.
9. The acoustic resonator of claim 1, wherein a pitch of the multi-pitch IDT varies continuously along a length of the IDT.
10. The acoustic resonator of claim 8, wherein the pitch of the multi-pitch IDT varies continuously between p(1) and p(1+), where p is the nominal pitch of the IDT and is greater than 0 and less than or equal to 5.0%.
11. The acoustic resonator of claim 10, wherein is less than or equal to 1.0%.
12. A filter device, comprising: a single-crystal piezoelectric plate having front and back surfaces, the back surface attached to a surface of a substrate, portions of the piezoelectric plate forming a plurality of diaphragms spanning respective cavities in the substrate; a conductor pattern formed on the front surface, the conductor pattern comprising a plurality of interdigital transducers (IDTs), interleaved fingers of the IDTs disposed on a respective one of a plurality of diaphragms, wherein a first IDT from the plurality of IDTs is a multi-pitch IDT.
13. The filter device of claim 12, wherein the piezoelectric plate and the plurality of IDTs are configured such that a respective radio frequency signal applied to each IDT excites a primary shear acoustic mode in the respective diaphragm.
14. The filter device of claim 12, wherein all of the plurality of IDTs are multi-pitch IDTs.
15. The filter device of claim 12, wherein the first IDT is divided along its length into two or more sections, with each section having a respective pitch different from the pitch of each other section.
16. The filter device of claim 15, wherein a maximum pitch of the first IDT is p(1+) for one of the sections, and a minimum pitch of the first IDT is p(1) for another of the sections, where p is a nominal pitch and is greater than 0 and less than or equal to 5.0%.
17. The filter device of claim 16, wherein is less than or equal to 1.0%.
18. The filter device of claim 16, wherein the first IDT is divided into three sections, and the pitches of the three sections are p(1), p, and p(1+), respectively.
19. The filter device of claim 12, wherein a pitch of the first IDT varies continuously along a length of the first IDT.
20. The filter device of claim 19, wherein the pitch of the first IDT varies continuously between p(1) and p(1+), where p is the nominal pitch of the first IDT and is greater than 0 and less than or equal to 5%.
21. The filter device of claim 20, wherein is less than or equal to 1.0%.
22. The filter device of claim 12, wherein a second IDT from the plurality of IDTs is a multi-pitch IDT, a variation in pitch of the second IDT being different from a variation in pitch of the first IDT.
23. The filter device of claim 22, wherein the second IDT is part of a shunt resonator and the first IDT is part of a series resonator.
Description
DESCRIPTION OF THE DRAWINGS
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[0021]
[0022] Throughout this description, elements appearing in figures are assigned three-digit or four-digit reference designators, where the two least significant digits are specific to the element and the one or two most significant digit is the figure number where the element is first introduced. An element that is not described in conjunction with a figure may be presumed to have the same characteristics and function as a previously-described element having the same reference designator.
DETAILED DESCRIPTION
[0023] Description of Apparatus
[0024]
[0025] The XBAR 100 is made up of a thin film conductor pattern formed on a surface of a piezoelectric plate 110 having parallel front and back surfaces 112, 114, respectively. The piezoelectric plate is a thin single-crystal layer of a piezoelectric material such as lithium niobate, lithium tantalate, lanthanum gallium silicate, gallium nitride, or aluminum nitride. The piezoelectric plate is cut such that the orientation of the X, Y, and Z crystalline axes with respect to the front and back surfaces is known and consistent. In the examples presented in this patent, the piezoelectric plates are Z-cut, which is to say the Z axis is normal to the front and back surfaces 112, 114. However, XBARs may be fabricated on piezoelectric plates with other crystallographic orientations.
[0026] The back surface 114 of the piezoelectric plate 110 is attached to a surface of the substrate 120 except for a portion of the piezoelectric plate 110 that forms a diaphragm 115 spanning a cavity 140 formed in the substrate. The portion of the piezoelectric plate that spans the cavity is referred to herein as the diaphragm 115 due to its physical resemblance to the diaphragm of a microphone. As shown in
[0027] The substrate 120 provides mechanical support to the piezoelectric plate 110. The substrate 120 may be, for example, silicon, sapphire, quartz, or some other material or combination of materials. The back surface 114 of the piezoelectric plate 110 may be bonded to the substrate 120 using a wafer bonding process. Alternatively, the piezoelectric plate 110 may be grown on the substrate 120 or attached to the substrate in some other manner. The piezoelectric plate 110 may be attached directly to the substrate or may be attached to the substrate 120 via one or more intermediate material layers (not shown in
[0028] Cavity has its conventional meaning of an empty space within a solid body. The cavity 140 may be a hole completely through the substrate 120 (as shown in Section A-A and Section B-B) or a recess in the substrate 120 under the diaphragm 115. The cavity 140 may be formed, for example, by selective etching of the substrate 120 before or after the piezoelectric plate 110 and the substrate 120 are attached.
[0029] The conductor pattern of the XBAR 100 includes an interdigital transducer (IDT) 130. The IDT 130 includes a first plurality of parallel fingers, such as finger 136, extending from a first busbar 132 and a second plurality of fingers extending from a second busbar 134. The first and second pluralities of parallel fingers are interleaved. The interleaved fingers overlap for a distance AP, commonly referred to as the aperture of the IDT. The center-to-center distance L between the outermost fingers of the IDT 130 is the length of the IDT.
[0030] The first and second busbars 132, 134 serve as the terminals of the XBAR 100. A radio frequency or microwave signal applied between the two busbars 132, 134 of the IDT 130 excites a primary acoustic mode within the piezoelectric plate 110. As will be discussed in further detail, the primary acoustic mode is a bulk shear mode where acoustic energy propagates along a direction substantially orthogonal to the surface of the piezoelectric plate 110, which is also normal, or transverse, to the direction of the electric field created by the IDT fingers. Thus, the XBAR is considered a transversely-excited film bulk wave resonator.
[0031] The IDT 130 is positioned on the piezoelectric plate 110 such that at least the fingers of the IDT 130 are disposed on the diaphragm 115 of the piezoelectric plate which spans, or is suspended over, the cavity 140. As shown in
[0032] For ease of presentation in
[0033]
[0034] A front-side dielectric layer 214 may optionally be formed on the front side of the piezoelectric plate 110. The front side of the XBAR is, by definition, the surface facing away from the substrate. The front-side dielectric layer 214 has a thickness tfd. The front-side dielectric layer 214 may be formed only between the IDT fingers (e.g. IDT finger 238b) or may be deposited as a blanket layer such that the dielectric layer is formed both between and over the IDT fingers (e.g. IDT finger 238a). The front-side dielectric layer 214 may be a non-piezoelectric dielectric material, such as silicon dioxide or silicon nitride. tfd may be, for example, 0 to 500 nm. tfd is typically less than the thickness ts of the piezoelectric plate. The front-side dielectric layer 214 may be formed of multiple layers of two or more materials.
[0035] The IDT fingers 238a and 238b may be aluminum, an aluminum alloy, copper, a copper alloy, beryllium, gold, tungsten, molybdenum or some other conductive material. The IDT fingers are considered to be substantially aluminum if they are formed from aluminum or an alloy comprising at least 50% aluminum. The IDT fingers are considered to be substantially copper if they are formed from copper or an alloy comprising at least 50% copper. Thin (relative to the total thickness of the conductors) layers of other metals, such as chromium or titanium, may be formed under and/or over and/or as layers within the fingers to improve adhesion between the fingers and the piezoelectric plate 110 and/or to passivate or encapsulate the fingers and/or to improve power handling. The busbars (132, 134 in
[0036] Dimension p is the center-to-center spacing or pitch of the IDT fingers, which may be referred to as the pitch of the IDT and/or the pitch of the XBAR. Dimension w is the width or mark of the IDT fingers. The geometry of the IDT of an XBAR differs substantially from the IDTs used in surface acoustic wave (SAW) resonators. In a SAW resonator, the pitch of the IDT is one-half of the acoustic wavelength at the resonance frequency. Additionally, the mark-to-pitch ratio of a SAW resonator IDT is typically close to 0.5 (i.e. the mark or finger width is about one-fourth of the acoustic wavelength at resonance). In an XBAR, the pitch p of the IDT is typically 2 to 20 times the width w of the fingers. In addition, the pitch p of the IDT is typically 2 to 20 times the thickness ts of the piezoelectric plate 110. The width of the IDT fingers in an XBAR is not constrained to be near one-fourth of the acoustic wavelength at resonance. For example, the width of XBAR IDT fingers may be 500 nm or greater, such that the IDT can be readily fabricated using optical lithography. The thickness tm of the IDT fingers may be from 100 nm to about equal to the width w. The thickness of the busbars (132, 134 in
[0037]
[0038] In contrast to the XBAR devices shown in
[0039] The acoustic Bragg reflector 340 includes multiple dielectric layers that alternate between materials having high acoustic impedance and materials have low acoustic impedance. High and low are relative terms. For each layer, the standard for comparison is the adjacent layers. Each high acoustic impedance layer has an acoustic impedance higher than that of both the adjacent low acoustic impedance layers. Each low acoustic impedance layer has an acoustic impedance lower than that of both the adjacent high acoustic impedance layers. As will be discussed subsequently, the primary acoustic mode in the piezoelectric plate of an XBAR is a shear bulk wave. Each of the layers of the acoustic Bragg reflector 340 has a thickness equal to, or about, one-fourth of the wavelength of a shear bulk wave having the same polarization as the primary acoustic mode at or near a resonance frequency of the SM XBAR 300. Dielectric materials having comparatively low acoustic impedance include silicon dioxide, carbon-containing silicon oxide, and certain plastics such as cross-linked polyphenylene polymers. Materials having comparatively high acoustic impedance include hafnium oxide, silicon nitride, aluminum nitride, silicon carbide. All of the high acoustic impedance layers of the acoustic Bragg reflector 340 are not necessarily the same material, and all of the low acoustic impedance layers are not necessarily the same material. In the example of
[0040]
[0041] Considering
[0042] An acoustic resonator based on shear acoustic wave resonances can achieve better performance than current state-of-the art film-bulk-acoustic-resonators (FBAR) and solidly-mounted-resonator bulk-acoustic-wave (SMR BAW) devices where the electric field is applied in the thickness direction. In such devices, the acoustic mode is compressive with atomic motions and the direction of acoustic energy flow in the thickness direction. In addition, the piezoelectric coupling for shear wave XBAR resonances can be high (>20%) compared to other acoustic resonators. High piezoelectric coupling enables the design and implementation of microwave and millimeter-wave filters with appreciable bandwidth.
[0043]
[0044] At least some of the spurious modes found in XBARs are traveling plate waves. The frequencies of traveling plate wave modes are proportional to IDT finger pitch. In contrast, the XBAR resonance and anti-resonance frequencies have only a slight dependence on IDT pitch. For example, changing IDT pitch from 7.5 times the piezoelectric plate thickness to 15 times (i.e. a 2:1 change) the piezoelectric plate thickness results in about 3% change in the resonance frequency of an XBAR.
[0045] Slight variations in the pitch of the IDT in an XBAR can result in cancellation or destructive interference of spurious modes with negligible effect on the shear primary mode. This effect is illustrated in
[0046]
[0047] The multi-pitch IDT 700 includes a first busbar 732, and a second busbar 734, and a plurality of interleaved fingers such as finger 736. The interleaved fingers extend alternately from the first and second busbars 732, 734. The multi-pitch IDT 700 is divided into three sections, identified and Section A, Section B, and Section C, along the length L of the IDT. Each of Sections A, B, and C includes 20 fingers, for a total of 60 fingers in the multi-pitch IDT 700. The use of three sections and 60 fingers is exemplary. An IDT may have more than or fewer than 60 total fingers. An IDT may be divided along its length into two or more sections, each of which includes a plurality of adjacent fingers. The total number of fingers may be divided essentially equally between the two or more sections. In this context, essentially means as close as possible. For example, an IDT with 100 fingers divided into three sections with 33, 34, and 33 fingers is considered to be divided essentially equally. The total number of fingers may be divided unequally between the two or more sections.
[0048] In this example, Section B has pitch p, which is the nominal pitch of the IDT. Section A has a pitch of p(1), and Section C has a pitch of p(1+). is greater than 0 and less than or equal to 5%. may typically be less than 1%. may be selected during a filter design to achieve the most effective reduction of spurious modes. At any point along the length L of the IDT 700, the pitch is constant across the aperture A. The mark, or width of the IDT fingers is constant and the same in all sections. When an IDT is divided into two sections or more than three sections, the maximum pitch may be p(1+) and the minimum pitch may be p(1).
[0049] In the example multi-pitch IDT 700, the pitch increases monotonically from left (as seen in the figure) to right. This is not necessarily the case in all multi-pitch IDTs. The sections of a multi-pitch IDT may be arranged in some other order. Further, in the multi-pitch IDT 700, the change in pitch between adjacent sections is constant. This is also not necessarily the case in all multi-pitch IDTs. The change in pitch between adjacent sections may be the same or different.
[0050]
[0051] As shown in
[0052] The IDTs 700 and 800 may be incorporated into an XBAR as shown in
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[0054]
[0055]
[0056] The dashed curve 1120 is a plot of S2,1 for a second bandpass filter that has uniform-pitch IDTs but is otherwise identical the first bandpass filter. Comparison of the curves 1110 and 1120 shows the passbands of the two filters are effectively the same. Compared to the second filter, the first filter with of multi-pitch IDTs exhibits reduced peak admittance of spurious modes by as much as 8 dB.
[0057] The filters used to generate the data shown in
[0058] All of the examples discuss above were for conventional XBARs as shown in
CLOSING COMMENTS
[0059] Throughout this description, the embodiments and examples shown should be considered as exemplars, rather than limitations on the apparatus and procedures disclosed or claimed. Although many of the examples presented herein involve specific combinations of method acts or system elements, it should be understood that those acts and those elements may be combined in other ways to accomplish the same objectives. With regard to flowcharts, additional and fewer steps may be taken, and the steps as shown may be combined or further refined to achieve the methods described herein. Acts, elements and features discussed only in connection with one embodiment are not intended to be excluded from a similar role in other embodiments.
[0060] As used herein, plurality means two or more. As used herein, a set of items may include one or more of such items. As used herein, whether in the written description or the claims, the terms comprising, including, carrying, having, containing, involving, and the like are to be understood to be open-ended, i.e., to mean including but not limited to. Only the transitional phrases consisting of and consisting essentially of, respectively, are closed or semi-closed transitional phrases with respect to claims. Use of ordinal terms such as first, second, third, etc., in the claims to modify a claim element does not by itself connote any priority, precedence, or order of one claim element over another or the temporal order in which acts of a method are performed, but are used merely as labels to distinguish one claim element having a certain name from another element having a same name (but for use of the ordinal term) to distinguish the claim elements. As used herein, and/or means that the listed items are alternatives, but the alternatives also include any combination of the listed items.