MEMS resonator with a high quality factor

Abstract

A symmetrical MEMS resonator is disclosed with a high quality factor. The MEMS resonator includes a silicon layer with a top surface and bottom surface opposite the top surface. A pair of first metal layers is provided above the top surface of the silicon layer and a corresponding pair of second metal layers is symmetrically provided below the second surface of the silicon layer relative to the pair of first metal layers. Furthermore, a first piezoelectric layer is disposed between the pair of first metal layers and a second piezoelectric layer is disposed between the pair of second metal layers.

Claims

1. A MEMS resonator etched to vibrate in a lateral direction, the MEMS resonator comprising: a silicon layer having a first surface and a second surface opposite the first surface; at least one metal layer disposed above the first surface of the silicon layer and at least one corresponding metal layer disposed below the second surface of the silicon layer; and a piezoelectric layer disposed above the first surface of the silicon layer and a corresponding piezoelectric layer disposed below the second surface of the silicon layer, wherein the respective metal layers and the respective piezoelectric layers are symmetrically disposed about the silicon layer such that the MEMS resonator structurally vibrates in the lateral direction that extends parallel to the first and second surfaces of the silicon layer.

2. The MEMS resonator according to claim 1, wherein vertical sides surfaces of the silicon layer are etched to be unobstructed, such that the MEMS resonator is structurally configured to vibrate primarily in the lateral direction.

3. The MEMS resonator according to claim 1, wherein the at least one metal layer comprises a pair of first metal layers with the piezoelectric layer disposed therebetween, and wherein the at least one corresponding metal layer comprises a pair of second metal layers with the corresponding piezoelectric layer disposed therebetween.

4. The MEMS resonator according to claim 3, wherein the silicon layer has a thickness greater than a combined thickness of the pairs of first and second metal layers and the piezoelectric layers.

5. The MEMS resonator according to claim 4, wherein the pair of first metal layers and the piezoelectric layer are symmetrically disposed about the silicon layer with respect to the pair of second metal layers and the corresponding piezoelectric layer.

6. The MEMS resonator according to claim 4, wherein the pair of first metal layers is electrically coupled to a voltage source to actuate the MEMS resonator.

7. The MEMS resonator according to claim 6, wherein the pair of second metal layers is electrically coupled to the voltage source.

8. The MEMS resonator according to claim 6, wherein the pair of second metal layers is electrically insulated from the voltage source.

9. The MEMS resonator according to claim 4, wherein the piezoelectric layer comprises a thickness substantially equal to a thickness of the corresponding piezoelectric layer.

10. The MEMS resonator according to claim 9, wherein the pair of first metal layers each comprises a thickness substantially equal to respective thicknesses of the pair of second metal layers.

11. The MEMS resonator according to claim 1, wherein the piezoelectric layer comprises a thickness substantially equal to a thickness of the corresponding piezoelectric layer, and wherein the at least one metal layer comprises a thickness substantially equal to a thickness of the at least one corresponding metal layer.

12. The MEMS resonator according to claim 1, wherein the silicon layer comprises a thickness between 5 and 30 micrometers.

13. A MEMS resonator etched to vibrate in a lateral direction, the MEMS resonator comprising: a silicon layer having a first and second opposing surfaces and etched vertical sides surfaces that are unobstructed, such that the MEMS resonator structurally vibrates primarily in the lateral direction; a pair of first metal layers disposed above the first surface of the silicon layer; a first piezoelectric layer disposed between the pair of first metal layers; a pair of second metal layers symmetrically disposed below the second surface of the silicon layer relative to the pair of first metal layers; and a second piezoelectric layer disposed between the pair of second metal layers.

14. The MEMS resonator according to claim 13, wherein the respective pairs of metal layers and the respective first and second piezoelectric layers are symmetrically disposed about the silicon layer such that the MEMS resonator is completely symmetrical in a thickness direction and is structurally configured to vibrate primarily in the lateral direction that extends parallel to the first and second opposing surfaces of the silicon layer.

15. The MEMS resonator according to claim 13, wherein the pair of first metal layers is electrically coupled to a voltage source to actuate the MEMS resonator.

16. The MEMS resonator according to claim 15, wherein the pair of second metal layers is electrically insulated from the voltage source.

17. The MEMS resonator according to claim 13, wherein the silicon layer comprises a thickness between 5 and 30 micrometers and that is greater than a combined thickness of the pairs of first and second metal layers and the piezoelectric layers.

18. A MEMS resonator etched to vibrate in a lateral direction, the MEMS resonator comprising: a silicon layer having a first surface, a second surface opposite the first surface, and vertical sides surfaces that are unobstructed, such that the MEMS resonator structurally vibrates primarily in the lateral direction; a pair of first metal layers disposed above the first surface of the silicon layer; a first piezoelectric layer having a first thickness disposed between the pair of first metal layers; and a second piezoelectric layer disposed below the second surface of the silicon layer, wherein the second piezoelectric layer comprises a second thickness greater than the first thickness of the first piezoelectric layer to inhibit vibration in a thickness direction of the MEMS resonator when the pair of first metal layers are excited by a voltage source.

19. The MEMS resonator according to claim 18, wherein the pair of first metal layers and the first piezoelectric layer have a combined mechanical stiffness that is substantially equal to a mechanical stiffness of the second piezoelectric layer.

20. The MEMS resonator according to claim 19, wherein the combined mechanical stiffness of the pair of first metal layers and the first piezoelectric layer is within 10% MPa*m of the mechanical stiffness of the second piezoelectric layer.

21. The MEMS resonator according to claim 1, wherein the silicon layer is directly coupled by at least one connecting arm to a frame that surrounds the silicon layer in the lateral direction.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

(1) The accompanying drawings, which are incorporated into and constitute a part of this specification, illustrate one or more example embodiments of the present disclosure and, together with the detailed description, serve to explain their principles and implementations. The drawings provided are for illustrative purposes only and are therefore not drawn to scale.

(2) FIG. 1 illustrates a conventional micromechanical bulk acoustic resonator.

(3) FIGS. 2A and 2B illustrate a comparison of vibration between a pure silicon resonator and a silicon resonator with thin films disposed on a top surface of the silicon layer.

(4) FIG. 3A illustrates a top view of a MEMS resonator according to a first exemplary embodiment.

(5) FIG. 3B illustrates a cross-sectional view of the MEMS resonator according to the first exemplary embodiment as shown in FIG. 2A.

(6) FIG. 4 illustrates a cross-sectional view of an exemplary MEMS resonator according to another exemplary embodiment.

(7) FIG. 5 illustrates a cross-sectional view of an exemplary MEMS resonator according to another exemplary embodiment.

DETAILED DESCRIPTION OF THE EXEMPLARY EMBODIMENTS

(8) Example aspects are described herein in the context of a MEMS resonator. Those of ordinary skill in the art will realize that the following description is illustrative only and is not intended to be in any way limiting. Other aspects will readily suggest themselves to those skilled in the art having the benefit of this disclosure. Reference will now be made in detail to implementations of the example aspects as illustrated in the accompanying drawings. The same reference indicators will be used to the extent possible throughout the drawings and the following description to refer to the same or like items.

(9) FIG. 3A illustrates a top view of a MEMS resonator according to a first exemplary embodiment. According to the exemplary embodiment, a MEMS resonator 200 is disclosed that provides a high quality factor of silicon by maintaining symmetry of the resonator in the thickness direction. The symmetrical design can readily be seen in FIG. 3B and will be discussed in more detail below.

(10) As shown in FIG. 3A, the MEMS resonator 200 includes a silicon layer 210 with a top or first piezoelectric layer 212 disposed above the silicon layer 210. Furthermore, a top metal layer 214A is disposed on the first piezoelectric layer 212 that serves as one of a pair of electrodes in operation of the MEMS resonator 200 according to the exemplary embodiment. The first piezoelectric layer 212 and the top metal layer 214A are formed on a inner portion of the silicon layer 210 that is coupled to a frame 11 by a pair of connecting arms 213A and 213B in a lateral direction thereof (i.e., the X, Y plane). Due to the symmetrical design that is shown in FIG. 3B discussed below, the MEMS resonator 200 will vibrate in the X and Y plane during operation, but will have reduced or minimal motional impedance. That is, the symmetrical design of the MEMS resonator 200 prevents or reduces vibration in the Z plane.

(11) FIG. 3B illustrates a cross-sectional view of the symmetrical design of the MEMS resonator 200 according to the first exemplary embodiment as shown in FIG. 3A. It should be readily apparent that the cross-sectional view is taken along the dashed lines shown in FIG. 3A.

(12) As described above, the MEMS resonator 200 includes a silicon layer 210, a top piezoelectric layer 212 and a top metal layer 214A. In addition, a bottom metal layer 214B is disposed on the silicon layer 210, which, in conjunction with the top metal layer 214A, collectively form a first pair of electrodes that serve as electrodes to excite and detect the mechanical vibrations of the resonator 200. Thus, according to the exemplary embodiment, a pair of metal layers 214A and 214B is disposed above the silicon layer 210 with the top or first piezoelectric layer 212 disposed therebetween. Preferably, the metal layer 214 is disposed directly on the silicon layer 210, although additional silicon dioxide (SiO.sub.2) films (not shown) can be disposed between the various layers of the MEMS device 200.

(13) Preferably, the MEMS resonator 200 is formed to have a complete symmetrical design in the thickness direction, i.e., in the Z direction as shown in FIG. 3B. To form the symmetrical design of the MEMS resonator 200, additional layers that correspond to the piezoelectric layer 212 and pair of metal layers 214A and 214B are disposed on the opposite side of the silicon layer 210. More particularly, opposite the piezoelectric and metal layers on the first surface of the silicon layer 210, a corresponding second pair of metal layers 218A and 218B are disposed with corresponding a second piezoelectric layer 216 disposed therebetween as shown. In other words, the second pair of metal layers 218A and 218B are symmetrical and directly correspond to the first pair of metal layers 214A and 214B. Likewise, the second piezoelectric layer 216 is symmetrically disposed and directly corresponds to the first piezoelectric layer 212.

(14) As is readily apparent from the cross-sectional view illustrated in FIG. 3B, the MEMS resonator 200 comprises a symmetrical or substantially symmetrical design in the thickness direction, which provides a high quality factor when compared with conventional MEMS resonators because it does not move in the z direction (or has minimal movement compared with conventional designs) during vibration mode. Thus, according to the exemplary embodiment, metal layer 218A corresponds to metal layer 214A, piezoelectric layer 216 corresponds to piezoelectric layer 212, and metal layer 218B corresponds to metal layer 214B.

(15) According to an exemplary embodiment, the metal layers 214A, 214B, 218A and 218B are formed from molybdenum, although other metal layers, such as platinum, aluminum and the like can be deposited as would be understood to one skilled in the art. Moreover, the piezoelectric layers 212 and 216 are each formed from a thin layer of aluminum nitride (AlN) according to the exemplary embodiment, although other piezoelectric materials may be used. It should be understood that the MEMS resonator 200 can be manufactured using conventional sputtering and deposition techniques, the details of which will not be described in detail so as to not unnecessarily obscure the aspects of the invention.

(16) The symmetrical MEMS resonator design shown in FIGS. 3A and 3B provides an increased quality factor that results in lower motional impedance. Moreover, according to the symmetrical design, the MEMS resonator 200 is configured to vibrate in-plane when the electrodes (i.e., either of the pair of metal layers 214A and 214B and/or the pair of metal layers 218A and 218B) are excited during operation of the MEMS resonator 200. As a result, the MEMS resonator 200 will have a primary vibrational mode in the lateral direction, i.e., the in Y direction and in the X/Y plane as shown in either of FIGS. 3A and/or 3B, while minimizing vibration in the vertical direction, i.e., in the Z plane. Thus, in the exemplary embodiment, the MEMS resonator 200 will vibrate in the X/Y plane, which extends in a direction parallel to the first and second principal surfaces of the silicon layer 210.

(17) Moreover, according to the exemplary embodiment, the silicon layer has a thickness between 5-30 micrometers (m), and, preferably between 5-10 micrometers according to a refinement of the embodiment. In contrast, conventional MEMS resonator designs must increase the thickness of the silicon layer, for example, to 50 micrometers or more in order to obtain a resonator with a sufficiently high quality factor for certain applications. Such an increase in size of the silicon layer would significantly increase manufacturing costs as would be understood to one skilled in the art.

(18) For example, an asymmetric resonator with top piezoelectric film and 10 micrometers silicon thickness may have a quality factor of only 10,000 at 24 MHz. In contrast, a pure silicon resonator may have a quality factor of over 100,000. For an asymmetric resonator with a thicker silicon layer and a top piezoelectric film (e.g., a silicon layer of micrometers), the quality factor would be increased to about 20,000, for example, but this quality factor would still be too low for many applications. With symmetric design described in the disclosure herein, the MEMS resonator may achieve a quality factor of 100,000 or higher at 24 MHz while maintaining a silicon layer with a thickness between 5-30 micrometers, for example.

(19) Furthermore, according to the exemplary embodiment, the piezoelectric layers 212 and 216 (e.g., the AlN layers) can have a thickness between 0.5 and 1.0 micrometers according to the exemplary embodiment, but may have thickness between 200 to 300 nanometers. Preferably, the respective thicknesses of the piezoelectric layers 212 and 216 are substantially the same.

(20) According to the exemplary embodiment, the metal layers 214A, 214B, 218A and 218B (e.g., the molybdenum layers) can have a thickness of approximately 200 nanometers according to the exemplary embodiment, but may have a thickness in the range between 50 to 300 nanometers. Preferably, the respective thicknesses of the metal layers 214A and 218A are substantially the same and the respective thicknesses of the metal layers 214B and 218B are substantially the same. Furthermore, it is contemplated that all four metal layers can have substantially the same thickness for uniform symmetry of the MEMS resonator 200. It should be appreciated that based on the exemplary thickness dimensions described above, the silicon layer 210 (i.e., between 5-30 micrometers) that is thicker than the combination of all metal layers (i.e., 50 to 300 nanometers) and all piezoelectric layers (i.e., between 0.5 and 1.0 micrometers).

(21) Moreover, although the thicknesses of the matching or corresponding layers on top and bottom of the silicon layer 210 (i.e., the piezoelectric layers 212 and 216 and the metal layers 214A, 214B, 218A and 218B) are not so limited, symmetrical design lowers motional impedance and improves the quality factor because the resonator 200 has none or limited movement in the z direction (i.e., the thickness direction) during vibration mode. As a result, the MEMS resonator 200 disclosed herein can be used for certain applications, for example timing devices, gyroscopes, bolometers, and the like, while still having a very thin silicon layer (e.g., 5-30 micrometers).

(22) Moreover, it should be appreciated that the embodiment shown in FIG. 3B is provided to illustrate the symmetrical layering that provides the high quality factor for the device. Thus, after the thin film deposition to form the symmetrical layering of the MEMS resonator 200, it should be understood that the device layers including the metal layers, the piezoelectric layer and the silicon layer can be etched to form the specific resonator shape needed for the desired device. That is, the vertical side surfaces of the silicon layer 210 will be etched during the manufacturing process to form the MEMS resonator 200. As a result, the silicon layer 210 for the resonator is not obstructed or restricted (i.e., it is not mounted to the device by its side surfaces), and, therefore, can vibrate primarily in the lateral direction during excitation of the electrodes as described above. Vibration primarily in the lateral direction means that the magnitude of the motion in lateral direction (i.e., in the lateral X/Y plane) is larger than in thickness direction of the resonator. Ideally, the motion in thickness direction should be minimized in order to obtain a highest possible quality factor. However, due to elastic coupling between lateral and thickness motion, some motion will also inevitably occur in thickness direction. For example, if lateral motion amplitude is 100 nm, the motion of in thickness direction may be 1-10 nm, for example.

(23) Thus, according to the exemplary aspect, the primary mode of vibration means that the MEMS resonator is configured to vibrate in the designed direction (i.e., in the lateral X/Y direction) as described above, with no intended vibration in the vertical direction as described above. As a result, the MEMS resonator 200 as described herein provides a much higher quality factor compared with conventional designs, including MEMS resonators structurally configured to vibrate in the thickness (i.e., vertical) direction.

(24) Moreover, it is contemplated that the term substantially as it is used herein takes into account minor variations in the thickness of the corresponding layers that may occur during the manufacturing process. For example, according to one embodiment, the MEMS resonator 200 is designed to have two piezoelectric layers 212 and 216 on opposite sides of the silicon layer 210 that have the same thickness. However, the machines uses to deposit the layers may lead to slight differences in the thickness of the corresponding layers. The use of the term substantially to describe the thickness of the corresponding layers takes into account resulting variances in thickness due to variations in the manufacturing equipment.

(25) Furthermore, according to one embodiment, the pair of metal layers 214A and 214B and the pair of metal layers 218A and 218B, both function as pairs of electrodes according to one embodiment. However, manufacturing a MEMS resonator with electrical contacts on the underside of the resonator can be relatively difficult since the manufacturing process requires manufacturing of electrical connections through the silicon layer 210. More particularly, to manufacture such a design, a hole (i.e., a via) needs to be etched though the silicon layer 210 and then lined with an insulating material, such as silicon dioxide. Next, the hole needs to be filled with a conductive material that forms the electoral via from top to the bottom of the resonator 200. Since the silicon layer 210 comprises a thickness between 5-30 micrometers, for example, and preferably between 5-10 micrometers, the via formation can be a significantly more difficult process than making contacts to the electrodes on the top side of the MEMS resonator 200.

(26) Accordingly, FIG. 4 illustrates a cross-sectional view of an exemplary MEMS resonator 300 according to another exemplary embodiment. As shown, the MEMS resonator 300 according to this embodiment comprises the same symmetrical design discussed above with respect to FIGS. 3A and 3B. Only the points different from the MEMS resonator 200 of the first embodiment will be specifically described.

(27) In particular, as shown in FIG. 4, a voltage source 220 is provided that applies voltage to metal layers 214A and 214B during operation to drive the resonator 300 in continuous motion. The specific operation is known to those skilled in the art and will not be described herein. It should be appreciated that the electronic circuit that provides the voltage source can be in the same physical package (not shown) as the MEMS resonator 300.

(28) As described above, creating electrical connections to the bottom thin films (e.g., metal layers 218A and 218B) is difficult due to manufacturing challenges. Thus, according to the exemplary embodiment of FIG. 4, the thin films 218A and 218B at the bottom of the MEMS resonator 300 are not electrically connected to voltage source 220 or another source. Rather, only the top electrodes (i.e., metal layers 214A and 214B) are electrically connected. As such, the bottom thin films (i.e., metal layers 218A and 218B) are dummy actuators that are provided to maintain the resonator symmetry in the thickness direction described above with respect to FIG. 3B.

(29) According to alternative embodiments, it should be appreciated that the pair of second metal layers 218A and 218B can be connected to the voltage source by one or more vias extending through silicon layer 210 as discussed above or by other means as would be understood to one skilled in the art.

(30) According to yet another embodiment, because the thin films 218A and 218B are not electrically active in the MEMS resonator 300 of FIG. 4, one or more of the thin metal electrodes could be omitted from the underside of the resonator 200 during manufacturing, which would save one or more manufacturing process steps while still improving the symmetry of the MEMS resonator as would be understood to one skilled in the art. FIG. 5 illustrates a cross-sectional view of an exemplary MEMS resonator 400 according to this additional exemplary embodiment.

(31) As shown, the MEMS resonator 400 according to the embodiment shown in FIG. 5 comprises the same symmetrical design discussed above with respect to FIGS. 3A and 3B. Only the points different from the MEMS resonator 200 of the first embodiment will be specifically described. Namely, the MEMS resonator 400 includes a piezoelectric layer 416 at the bottom of the silicon layer 210, but does not include metal films on each side of the piezoelectric layer 416.

(32) Even with no metal films at the bottom, the structure the MEMS resonator 400 provides a design with symmetric characteristics, by selecting film thicknesses above and below the silicon layer 210 such that bottom films combined and top films combined substantially equal mechanical stiffness. In other words, the layers/films deposited on the top and the bottom of the silicon layer are selected so that the combined films have an equal or substantially equal mechanical thickness to create a symmetrical design. Thus, the mechanical stiffness of the top and bottom layers can be selected during the manufacturing process so that the resulting MEMS resonator 400 will not vibrate (or have minimal vibration) in the Z direction when it is excited by a voltage source as described above.

(33) According to an exemplary embodiment, the combined mechanical stiffness can be calculated as K=E1*h1+E2*h2 . . . EN*hN, where Ei is the elastic modulus for each of the films i=1 to N (which can be either the metal films or the piezoelectric layers in the exemplary embodiment) and hi is the respective film thickness for each film. For example, on top of the silicon layer 210, there can be two metal films #1 and #3 with values E1=E3=329 GPa and h1=h3=200 nm and a piezoelectric film disposed therebetween with values of E2=308 GPa and h2=800 nm. As a result, the total stiffness of the combined films on top of the silicon layer 210 will have a value of K=0.378 MPa*m according to this example. Moreover, during the manufacturing process, the similar mechanical film stiffness can be selected at bottom of the silicon layer 210 with a single film (e.g., a piezoelectric film) of E1=308 GPa and h1=1227 nm. In other words, the total stiffness of the combined layers under the silicon (in this case a single layer) is also K=0.378 MPa*m and the elastic modulus and/or thickness can be selected accordingly.

(34) In this exemplary embodiment, since the same material will be used for the piezoelectric layers 212 and 416 (e.g., AlN), the elastic modulus will be the same for the two layers 212 and 416. As a result, only the thickness of the piezoelectric layer 416 will need to be increased to obtain a total thickness that results in a mechanical stiffness that is substantially equal to achieve the symmetrical design of the MEMS resonator 400. In other words, the second piezoelectric layer 416 will have a thickness that is greater than a thickness of the first piezoelectric layer 212 to inhibit (i.e., eliminate or reduce) vibration in a thickness direction (i.e., the z direction) of the MEMS resonator 400 when the pair of first metal layers 214A and 214B are excited by a voltage source. Finally, it should be understood to those skilled in the art that there are many combinations of top and bottom films that achieve the aim of this invention to minimize the z-axis movement by having similar combined film characteristics at the top and bottom of the silicon layer 210.

(35) Again, it is reiterated as described above that the term substantially as it is used to describe the similar mechanical stiffness of the combined top and bottom films takes into account minor variations that may occur in the thickness of the corresponding layers during the deposition process and the like. In the exemplary embodiment, it is contemplated that substantially equal for the mechanical stiffness of the top and bottom combined layers means that the stiffness is within 10% MPa*m of each other.

(36) In the interest of clarity, not all of the routine features of the embodiments are disclosed herein. It would be appreciated that in the development of any actual implementation of the present disclosure, numerous implementation-specific decisions must be made in order to achieve the designer's specific goals, and these specific goals will vary for different implementations and different designers. It is understood that such a design effort might be complex and time-consuming, but would nevertheless be a routine undertaking of engineering for those of ordinary skill in the art, having the benefit of this disclosure.

(37) Furthermore, it is to be understood that the phraseology or terminology used herein is for the purpose of description and not of restriction, such that the terminology or phraseology of the present specification is to be interpreted by those skilled in the art in light of the teachings and guidance presented herein, in combination with the knowledge of the skilled in the relevant art(s). Moreover, it is not intended for any term in the specification or claims to be ascribed an uncommon or special meaning unless explicitly set forth as such.

(38) While the foregoing has been described in conjunction with exemplary embodiments, it is understood that the term exemplary is merely meant as an example. Accordingly, the application is intended to cover alternatives, modifications and equivalents, which may be included within the spirit and scope of the MEMS resonator disclosed herein.

REFERENCE SIGNS LIST

(39) 200, 300, 400: MEMS resonator 210: silicon layer 212, 216, 416: piezoelectric layer(s) 214A, 214B: first metal layer(s) 218A, 218B: second metal layer(s) 220: voltage source