CAVITY STRUCTURE OF BULK ACOUSTIC RESONATOR, AND MANUFACTURING PROCESS
20230238933 · 2023-07-27
Inventors
- Linping LI (Huzhou, Zhejiang, CN)
- Jinghao SHENG (Hangzhou, Zhejiang, CN)
- Zhou JIANG (Huzhou, Zhejiang, CN)
Cpc classification
H03H2003/023
ELECTRICITY
International classification
Abstract
A cavity structure of a bulk acoustic resonator and a manufacturing process. The cavity structure comprises a substrate and a cavity formed on the substrate, a support layer is arranged on the substrate to form the cavity in a surrounding manner, a release channel in communication with the cavity is formed above the substrate in a same layer with the cavity, and the release channel extends, in parallel to the substrate, in a peripheral area of the cavity. There is no need to manufacture a release hole, which simplifies the manufacturing process of the resonator, thereby avoiding weakening the performance of the resonator due to damage to the structure of the piezoelectric layer around the electrode layer when manufacturing the release hole.
Claims
1. A cavity structure of a bulk acoustic resonator, comprising: a substrate; and a cavity formed on the substrate; wherein a support layer is arranged on the substrate to form the cavity in a surrounding manner, a release channel in communication with the cavity is formed above the substrate in a same layer with the cavity, and the release channel extends in a peripheral area of the cavity in parallel to the substrate, and the release channel extends laterally between the substrate and a piezoelectric layer.
2. The cavity structure of a bulk acoustic resonator according to claim 1, wherein the release channel comprises a first release channel extending outward from the cavity and a second release channel extending among cavities of a plurality of resonators to be in communication with the first release channel, and a projection of the first release channel and/or the second release channel on the substrate is of a shape of a trapezoid, an arc or a rectangle.
3. (canceled)
4. The cavity structure of a bulk acoustic resonator according to claim 1, wherein a groove in communication with the release channel is formed on the substrate in a peripheral area of a filter formed by a plurality of resonators being connected, and the groove is a channel without a film covering on top.
5. The cavity structure of a bulk acoustic resonator according to claim 4, wherein the groove is a channel without a film covering on top.
6. A bulk acoustic resonator, comprising: a bottom electrode layer, a piezoelectric layer and a top electrode layer sequentially stacked and formed above a cavity; wherein the bottom electrode layer is spanned on the support layer; wherein the bulk acoustic resonator further comprises the cavity structure, the cavity structure comprises a substrate and a cavity formed on the substrate, a support layer is arranged on the substrate to form the cavity in a surrounding manner, a release channel in communication with the cavity is formed above the substrate in a same layer with the cavity, the release channel extends in a peripheral area of the cavity in parallel to the substrate, and the release channel extends laterally between the substrate and the piezoelectric layer.
7. The bulk acoustic resonator according to claim 6, wherein the release channel is a channel extends between the substrate and the piezoelectric layer.
8. The bulk acoustic resonator according to claim 6, wherein a release hole is arranged in an area away from the bottom electrode layer and the top electrode layer of the resonator, and the release hole is in communication with at least one of the release channel.
9. A process for manufacturing a cavity structure of a bulk acoustic resonator, comprising: S1, manufacturing a patterned support layer on a substrate to form a cavity surrounded by the support layer, and forming, above the substrate, a release channel in communication with the cavity in a same layer with the cavity, wherein the release channel extends, in parallel to the substrate, in a peripheral area of the cavity; S2, filling the cavity and the release channel with a sacrificial material; S3, manufacturing a bottom electrode layer on the support layer and the sacrificial material, wherein the bottom electrode layer is spanned on the support layer and covers the cavity; S4, manufacturing a piezoelectric layer and a top electrode layer on the bottom electrode layer; and S5, removing the sacrificial material, wherein the release channel extends laterally between the substrate and the piezoelectric layer.
10. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 9, wherein the release channel comprises a first release channel extending outward from the cavity and a second release channel extending among cavities of a plurality of resonators to be in communication with the first release channel.
11. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 10, wherein a projection of the first release channel and/or the second release channel on the substrate is of a shape of a trapezoid, an arc or a rectangle.
12. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 9, wherein the step S1 further comprises: patterning the substrate in a peripheral area of a filter formed by a plurality of resonators being connected, to form a groove in communication with the release channel.
13. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 12, wherein the step S2 further comprises: filling the groove with the sacrificial material.
14. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 9, wherein the step S1 comprises: depositing the support layer on the substrate through a PVD process, and patterning the support layer through photolithography and etching processes.
15. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 9, wherein the step S1 comprises: forming a patterned support layer on the substrate through an etching process.
16. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 9, wherein a surface of the sacrificial material and a surface of the support layer are made flush through a polishing step in the step S2.
17. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 9, wherein the step S5 further comprises: manufacturing a release hole on the support layer and the piezoelectric layer in an area away from the bottom electrode layer and the top electrode layer of the resonator, wherein the release hole extends downward to the substrate and is communication with at least one of the release channel.
18. The process for manufacturing a cavity structure of a bulk acoustic resonator according to claim 12, wherein the groove is a channel without a film covering on top, and the release channel is a channel extends between the substrate and the piezoelectric layer.
19. The bulk acoustic resonator according to claim 6, wherein the release channel comprises a first release channel extending outward from the cavity and a second release channel extending among cavities of a plurality of resonators to be in communication with the first release channel, and a projection of the first release channel and/or the second release channel on the substrate is of a shape of a trapezoid, an arc or a rectangle.
20. The bulk acoustic resonator according to claim 6, wherein a groove in communication with the release channel is formed on the substrate in a peripheral area of a filter formed by a plurality of resonators being connected, and the groove is a channel without a film covering on top.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0032] The accompanying drawings are included to provide a further understanding of the embodiments and are incorporated into and constitute a part of the specification. The drawings illustrate embodiments and serve to explain the principles of the present disclosure together with the description. Other embodiments and many of the intended advantages of the embodiments will be readily recognized, and are better understood by reference to the following detailed description. The elements of the drawings are not necessarily to scale to each other. Like reference numerals designate corresponding similar parts.
[0033]
[0034]
[0035]
[0036]
[0037]
[0038]
DETAILED DESCRIPTION
[0039] The present disclosure will be further described in detail below with reference to the accompanying drawings and embodiments. It should be understood that the specific embodiments described herein are only used to explain the related content of the present disclosure, but not to limit the present disclosure. In addition, it should be noted that, for the convenience of description, only the parts related to the related content of the present disclosure are shown in the drawings. It should be noted that the dimensions and sizes of components in the drawings are not to scale and the size of some components may be highlighted for clarity.
[0040] It should be noted that the embodiments in the present disclosure and the features of the embodiments may be combined with each other without conflict. The present disclosure will be described in detail below with reference to the accompanying drawings and in conjunction with the embodiments.
[0041] A cavity structure of a bulk acoustic resonator is provided according to an embodiment of the present disclosure.
[0042] in a specific embodiment, the release channel 401 includes a first release channel 402 extending outward from the cavity 201 and a second release channel 403 extending among cavities 201 of multiple resonators to be in communication with the first release channel 402. The first release channel 402 and the second release channel 403 are criss-crossed around the cavities 201 of multiple resonators to ensure that the release liquid can flow from the first release channel 402 and the second release channel 403 into the cavity 201 to quickly sacrifice the sacrificial material and to ensure that the stress uniformity of the piezoelectric layer 701 is not affected. In a preferred embodiment, the criss-crossed release channels 401 may be designed based on the distribution of the resonators, thereby eliminating the need to manufacture the release hole and simplifying the process for manufacturing the resonator.
[0043] In a specific embodiment, a projection of the first release channel 402 and/or the second release channel 403 on the substrate 101 is of a shape of a trapezoid, an arc or a rectangle. The shape of the projection, when viewed from the top view, includes, but is not limited to, a trapezoid, an arc, or a rectangle. By changing the shape of the first release channel 402 and/or the second release channel 403 around the electrode layer, the stress of the piezoelectric layer 701 covering on the first release channel 402 and/or the second release channel 403 is adjusted, thereby effectively improving the performance of the resonator. Since the stress of the piezoelectric layer 701 around the electrode layer affects a resonance area above the cavity 201, the performance of the resonator can be improved by adjusting the stress of the piezoelectric layer 701 around the electrode layer.
[0044] In a specific embodiment, a filter is formed by multiple resonators being connected, and a groove 501 in communication with the release channel 401 is formed on the substrate 101 in a peripheral area of the filter. One end of all of the release channels 401 may be in communication to the groove 501, and the other end may be in communication to the cavity 201, thereby avoiding weakening the performance of the resonator due to damage to the structure of the piezoelectric layer 701 around the electrode layer when manufacturing a release hole (a hole in an AlN film layer). In a preferred embodiment, the groove 501 is a channel without a film covering on top. The release liquid may be directly injected from the groove 501 and then circulated from the release channel 401 into the cavity 201. Therefore, in the present disclosure, it is not necessary to manufacture a release hole around the electrode layer, and the cavity 201 can be released by communicating the internal criss-crossed release channels 401 with the groove 501, In other embodiments, other methods other than the groove 501 may be selected to inject the release liquid into the release channel 401 to release the cavity 201.
[0045] In a specific embodiment, each of the release channel 401 is a channel extends between the substrate 101 and the piezoelectric layer 701. Different from the use of the release hole extending longitudinally through the electrode layer and the piezoelectric layer to the substrate in the conventional technology, the release channel 401 extends laterally between the substrate 101 and the piezoelectric layer 701, so that the release liquid can flow through the release channel 401. In addition, the cavity 201 is also formed on the substrate 101. In this case, the bottom surface of the release channel 401 and the bottom surface of the cavity 201 are flush, therefore, the release liquid can flow to the release channel 401 and the cavity 201 more quickly and conveniently through the fluidity.
[0046] In a specific embodiment, as shown in
[0047] In a specific embodiment, as shown in
[0048] In a case that resonators are manufactured into an interconnected structure, when there is no release channel in a middle part where the two resonators are connected, cross-sectional views taken along A1-A2 as shown in
[0049] In correspondence to the cavity structure of the bulk acoustic resonator according to the above embodiments, a process for manufacturing a cavity structure of a bulk acoustic resonator is further provided according to an embodiment of the present disclosure. As shown in
[0050] In step S1, a patterned support layer is manufactured on a substrate to form a cavity surrounded by the support layer and a release channel in communication with the cavity is formed above the substrate in the same layer with the cavity, where the release channel extends, in parallel to the substrate, in a peripheral area of the cavity.
[0051] In step S2, the cavity and the release channel are filled with a sacrificial material.
[0052] in step S3, a bottom electrode layer is manufactured on the support layer and the sacrificial material, where the bottom electrode layer is spanned on the support layer and covers the cavity.
[0053] In step S4, a piezoelectric layer and a top electrode layer are manufactured on the bottom electrode layer.
[0054] In step S5, the sacrificial material is removed.
[0055] In a specific embodiment,
[0056] In one embodiment, as shown in
[0057] In step S2, as shown in
[0058] In a specific embodiment, the release channel 401 includes a first release channel 402 extending outward from the cavity 201 and a second release channel 403 extending among cavities 201 of multiple resonators to be in communication with the first release channel 402. The first release channel 402 and the second release channel 403 are criss-crossed in a peripheral area of cavities 201 of multiple resonators to ensure that the release liquid can flow from the first release channel 402 and the second release channel 403 to the cavity 201 to quickly scarify the sacrificial material 202, and to ensure that the stress uniformity of the piezoelectric layer 701 will not be affected. In a preferred embodiment, the criss-crossed release channels 401 may be designed based on the distribution of the resonators. In this case, there is no need to manufacture the release hole and the process for manufacturing the resonator can be simplified.
[0059] In a specific embodiment, a projection of the first release channel 402 and/or the second release channel 403 on the substrate 101 is of a shape of a trapezoid, an arc or a
[0060] rectangle. The shape of the projection, when viewed from the top view, includes, but is not limited to, a trapezoid, an arc, or a rectangle. By changing the shape of the first release channel 402 and/or the second release channel 403 around the electrode layer, the stress of the piezoelectric layer 701 covering on the first release channel 402 and/or the second release channel 403 is adjusted, thereby effectively improving the performance of the resonator. Since the stress of the piezoelectric layer 701 around the electrode layer will affect a resonance area above the cavity 201, the performance of the resonator can be improved by adjusting the stress of the piezoelectric layer 701 around the electrode layer.
[0061] In a specific embodiment, a filter is formed by multiple resonators being connected, and a groove 501 in communication with the release channel 401 is formed on the support layer 301 in a peripheral area of the filter. One end of all of the release channels 401 may be in communication to the groove 501, and the other end may be in communication to the cavity 201, thereby avoiding weakening the performance of the resonator due to damage to the structure of the piezoelectric layer 701 around the electrode layer when manufacturing a release hole (a hole in an AlN film layer). In a preferred embodiment, the groove 501 is a channel without a film covering on top. The release liquid may be directly injected from the groove 501 and then circulated from the release channel 401 into the cavity 201. Therefore, in the present disclosure, it is not necessary to manufacture a release hole around the electrode layer, and the cavity 201 can be released by communicating the internal criss-crossed release channels 401 with the groove 501.
[0062] In a specific embodiment, the release channel 401 is a channel extends between the substrate 101 and the piezoelectric layer 701. Different from the use of the release hole extending longitudinally through the electrode layer and the piezoelectric layer to the substrate in the conventional technology, the release channel 401 extends laterally between the substrate 101 and the piezoelectric layer 701, so that the release liquid can flow through the release channel 401. In addition, the cavity 201 is also formed on the substrate 101. In this case, the bottom surface of the release channel 401 and the bottom surface of the cavity 201 are flush, therefore, the release liquid can flow to the release channel 401 and the cavity 201 more quickly and conveniently through the fluidity.
[0063] In a specific embodiment, as shown in
[0064] In a specific embodiment, S5 further includes: forming a release hole 901 on the support layer 301 and the piezoelectric layer 701 in an area away from the bottom electrode layer 601 and the top electrode layer 801 of the resonator, where the release hole 901 extends downward to the substrate 101 and is in communication with at least one of the release channel 401. In terms of too many criss-crossed release channels 401, the release hole 901 is added, and a release efficiency of the cavity 201 can be improved by injecting the release liquid into the release hole 901, so that the cavity 201 can he released more quickly. In addition, the release hole 901 is thrilled in the area away from the bottom electrode layer 601 and the top electrode layer 801 of the resonator, which will not affect the stress of the piezoelectric layer 701 around the electrode layer, and not weaken the performance of the resonator. In a preferred embodiment, the distances between the release hole 901 and the bottom electrode layer 601 and the top electrode layer 801 of the resonator are equal to or greater than 5 μm. The release hole 901 manufactured at the distances will not affect the stress of the piezoelectric layer 701 around the electrode layer.
[0065] Finally, as shown in
[0066] A cavity structure of a bulk acoustic resonator and a process for manufacturing the same are disclosed in the present disclosure. By manufacturing, on the support layer, the release channel in communication with the cavity, the groove in communication with the release channel is arranged in a peripheral area of a filter formed by multiple resonators being connected, where the criss-crossed release channels may be designed based on the distribution of the resonators. In addition, there is no need to manufacture a release hole, which simplifies the manufacturing process of the resonator, thereby avoiding weakening the performance of the resonator due to damage to the structure of the piezoelectric layer around the electrode layer when manufacturing a release hole (a hole in an AlN film layer), The performance of the resonator can be improved by designing a shape of the release channel around the electrode layer and adjusting the stress of the piezoelectric layer around the electrode layer. Therefore, the cavity can be released without damaging the structure of the piezoelectric layer, and the stress of the piezoelectric layer can be adjusted through the design of the cavity structure.
[0067] The specific embodiments of the present disclosure have been described above, but the protection scope of the present disclosure is not limited to this. Changes or substitutions may be easily envisaged by those familiar with the technical field within the technical scope disclosed in the present disclosure, and should be included in the protection scope of the present disclosure. Therefore, the protection scope of the present disclosure should be subject to the protection scope of the claims.
[0068] In the description of the present disclosure, it should be noted that the orientation or positional relationship indicated by the terms, such as “upper”, “lower”, “inner”, and “outer”, are based on the orientation or positional relationship shown in the drawings, which are only to facilitate the description of the present disclosure and to simplify the description, rather than indicating or implying that the device or element referred to must have a specific orientation, or can only be configured and operated in a particular orientation. Therefore the above-mentioned terms should not be construed as a limitation to the present disclosure. The wording ‘including’ does not exclude the presence of elements or steps not listed in a claim. The preceding wording ‘a’ or ‘an’ of an element does not exclude the existence of multiple such elements. The mere fact that certain measures are recited in mutually different dependent claims does not indicate that a combination of these measures cannot be used to advantage. Any reference signs in the claims should not be construed as limiting the scope.
INDUSTRIAL APPLICABILITY
[0069] In the embodiments of the present disclosure, the release channel in communication with the cavity are manufactured on the support layer, and the groove in communication with the release channel is arranged in a peripheral area of a filter formed by multiple resonators being connected, where the criss-crossed release channel may be arranged based on the distribution of the resonators. In addition, there is no need to manufacture a release hole, which simplifies the process for manufacturing the resonator, thereby avoiding weakening the performance of the resonator due to damage to the structure of the piezoelectric layer around the electrode layer when manufacturing a release hole (a hole in an AlN film layer). The manufacturing process is simple, the manufacturing cost is low, which facilitates industrial production in large-scale.