MEMS MICROPHONE AND METHOD OF MANUFACTURING THE SAME
20220417632 · 2022-12-29
Inventors
Cpc classification
B81C1/00182
PERFORMING OPERATIONS; TRANSPORTING
International classification
B81C1/00
PERFORMING OPERATIONS; TRANSPORTING
H04R31/00
ELECTRICITY
Abstract
A MEMS microphone includes a substrate having a cavity, a diaphragm disposed above the substrate to correspond to the cavity, and a back plate disposed above the diaphragm. The diaphragm includes a concave-convex structure, and the back plate includes a second concave-convex structure corresponding to the concave-convex structure.
Claims
1. A MEMS microphone comprising: a substrate having a cavity; a diaphragm disposed above the substrate to correspond to the cavity; and a back plate disposed above the diaphragm, wherein the diaphragm comprises a concave-convex structure.
2. The MEMS microphone of claim 1, wherein the diaphragm comprises a lower electrode layer made of a conductive material and having the concave-convex structure, and the back plate comprises a support layer made of an insulating material and an upper electrode layer attached to a lower surface of the support layer and made of a conductive material.
3. The MEMS microphone of claim 2, wherein the concave-convex structure comprises convex portions protruding downward.
4. The MEMS microphone of claim 3, wherein each of the convex portions has a shape of a hollow pyramid, a hollow truncated pyramid, a hollow cone, or a hollow truncated cone.
5. The MEMS microphone of claim 2, wherein the diaphragm further comprises a first anchor portion configured to surround the lower electrode layer and to fix the lower electrode layer on the substrate; and the back plate further comprises a second anchor portion configured to fix the support layer on the substrate.
6. The MEMS microphone of claim 2, wherein the support layer comprises protrusions penetrating through the upper electrode layer and protruding toward the lower electrode layer.
7. The MEMS microphone of claim 1, wherein the back plate comprises a second concave-convex structure corresponding to the concave-convex structure.
8. The MEMS microphone of claim 7, wherein the concave-convex structure comprises convex portions protruding downward, and the second concave-convex structure comprises second convex portions corresponding to the convex portions and protruding downward.
9. The MEMS microphone of claim 8, wherein each of the convex portions has an upper inclined surface, and each of the second convex portions has a lower inclined surface corresponding to the upper inclined surface.
10. The MEMS microphone of claim 8, wherein each of the second convex portions has a shape of a hollow pyramid, a hollow truncated pyramid, a hollow cone, or a hollow truncated cone.
11. A method of manufacturing a MEMS microphone, the method comprising: forming a diaphragm comprising a concave-convex structure above a substrate; forming a back plate above the diaphragm; and forming a cavity through the substrate to expose a lower surface of the diaphragm.
12. The method of claim 11, wherein the forming the diaphragm comprises: forming a mask layer exposing surface portions of the substrate; forming concave portions by performing an etching process using the mask layer as an etching mask; removing the mask layer; forming a lower insulating layer having second concave portions on the substrate; forming a lower silicon layer having the concave-convex structure on the lower insulating layer; and forming the diaphragm by patterning the lower silicon layer.
13. The method of claim 12, wherein the forming the diaphragm further comprises: forming a portion of the lower silicon layer into a lower electrode layer by performing an ion implantation process.
14. The method of claim 12, wherein the forming the diaphragm further comprises: forming a first anchor channel partially exposing the substrate by partially removing the lower insulating layer, wherein a portion of the lower silicon layer formed in the first anchor channel functions as a first anchor portion for fixing the diaphragm on the substrate.
15. The method of claim 12, wherein the forming the back plate comprises: forming an upper insulating layer on the diaphragm; forming an upper silicon layer on the upper insulating layer; forming a portion of the upper silicon layer into an upper electrode layer by performing an ion implantation process; exposing a portion of the upper insulating layer by removing another portion of the upper silicon layer; and forming a support layer for supporting the upper electrode layer on the upper electrode layer and the exposed portion of the upper insulating layer.
16. The method of claim 15, wherein the forming the back plate further comprises: forming a second anchor channel partially exposing the substrate by partially removing the upper insulating layer and the lower insulating layer, wherein a portion of the support layer formed in the second anchor channel functions as a second anchor portion for fixing the back plate on the substrate.
17. The method of claim 15, wherein the forming the back plate further comprises: forming holes penetrating through the upper electrode layer and removing upper portions of the upper insulating layer, wherein the support layer is formed to fill the holes, thereby forming protrusions penetrating the upper electrode layer and protruding toward the diaphragm.
18. The method of claim 11, wherein the back plate comprises a second concave-convex structure corresponding to the concave-convex structure.
19. The method of claim 18, wherein the concave-convex structure comprises convex portions protruding downward, and the second concave-convex structure comprises second convex portions corresponding to the convex portions and protruding downward.
20. The method of claim 19, wherein each of the convex portions has an upper inclined surface, and each of the second convex portions has a lower inclined surface corresponding to the upper inclined surface.
Description
BRIEF DESCRIPTION OF THE DRAWINGS
[0029] Embodiments can be understood in more detail from the following description taken in conjunction with the accompanying drawings, in which:
[0030]
[0031]
[0032]
[0033]
[0034]
[0035]
[0036] While various embodiments are amenable to various modifications and alternative forms, specifics thereof have been shown by way of example in the drawings and will be described in detail. It should be understood, however, that the intention is not to limit the claimed inventions to the particular embodiments described. On the contrary, the intention is to cover all modifications, equivalents, and alternatives falling within the spirit and scope of the subject matter as defined by the claims.
DETAILED DESCRIPTION
[0037] Hereinafter, embodiments of the present invention are described in more detail with reference to the accompanying drawings. However, the present invention is not limited to the embodiments described below and is implemented in various other forms. Embodiments below are not provided to fully complete the present invention but rather are provided to fully convey the range of the present invention to those skilled in the art.
[0038] In the specification, when one component is referred to as being on or connected to another component or layer, it can be directly on or connected to the other component or layer, or an intervening component or layer may also be present. Unlike this, it will be understood that when one component is referred to as directly being on or directly connected to another component or layer, it means that no intervening component is present. Also, though terms like a first, a second, and a third are used to describe various regions and layers in various embodiments of the present invention, the regions and the layers are not limited to these terms.
[0039] Terminologies used below are used to merely describe specific embodiments, but do not limit the present invention. Additionally, unless otherwise defined here, all the terms including technical or scientific terms, may have the same meaning that is generally understood by those skilled in the art.
[0040] Embodiments of the present invention are described with reference to schematic drawings of ideal embodiments. Accordingly, changes in manufacturing methods and/or allowable errors may be expected from the forms of the drawings. Accordingly, embodiments of the present invention are not described being limited to the specific forms or areas in the drawings and include the deviations of the forms. The areas may be entirely schematic, and their forms may not describe or depict accurate forms or structures in any given area and are not intended to limit the scope of the present invention.
[0041]
[0042] Referring to
[0043] In embodiments, the substrate 102 may be a single-crystal silicon substrate and may include a vibration area (VA), a support area (SA) surrounding the vibration area (VA), and a periphery area (PA) surrounding the support area (SA). In such cases, the cavity 104 may be formed to pass through the vibration area (VA) and the diaphragm 150 may be exposed through the cavity 104.
[0044] In accordance with an embodiment of the present disclosure, the diaphragm 150 may have a concave-convex structure 140 and may be spaced apart from the substrate 102 to be vibrated by an applied sound pressure. In embodiments, the diaphragm 150 may include a lower electrode layer 152 made of a conductive material and having the concave-convex structure 140. The diaphragm 150 may include a first anchor portion 158 configured to surround the lower electrode layer 152 and the lower electrode layer 152 may be fixed on the substrate 102 by the first anchor portion 158. In embodiments, the lower electrode layer 152 may be made of polysilicon doped with impurities and the first anchor portion 158 may be made of undoped polysilicon. Further, the first anchor portion 158 may have a ring shape surrounding the lower electrode layer 152 and may be formed on the support area (SA) of the substrate 102.
[0045] The concave-convex structure 140 may include a plurality of convex portions 142 protruding downward. That is, the concave-convex structure 140 may include a plurality of convex portions 142 protruding toward the cavity 104. In embodiments, as shown in
[0046] Further, the diaphragm 150 may include a first electrode pad 154 electrically connected to the lower electrode layer 152. In embodiments, the first electrode pad 154 may be connected to the lower electrode layer 152 by a first connection pattern 156 as shown in
[0047] The back plate 200 may include a support layer 192 made of an insulating material, and an upper electrode layer 182 attached to a lower surface of the support layer 192 and made of a conductive material. In particular, the back plate 200 may be disposed above the diaphragm 150 so that the upper electrode layer 182 is spaced apart from the lower electrode layer 152 by a predetermined distance. That is, a predetermined air gap (AG) may be provided between the lower electrode layer 152 and the upper electrode layer 182. In embodiments, the upper electrode layer 182 may be made of polysilicon doped with impurities and the support layer 192 may be made of silicon nitride.
[0048] In addition, the back plate 200 may include a second anchor portion 196 for fixing the support layer 192 on the substrate 102 and a second electrode pad 184 electrically connected to the upper electrode layer 182. In embodiments, as shown in
[0049] The first anchor portion 158 may have a circular ring shape surrounding the cavity 104. The second anchor portion 196 may have a circular ring shape surrounding the first anchor portion 158. Further, between the lower electrode layer 152 and the first anchor portion 158, a plurality of ventilation holes 160 for connecting the air gap (AG) between the diaphragm 150 and the back plate 200 with an inner space of the cavity 104 may be formed through the diaphragm 150.
[0050] A lower insulating layer 120 may be disposed on an upper surface of the substrate 102 and an upper insulating layer 170 may be disposed on the lower insulating layer 120. In this case, the first electrode pad 154 may be disposed on the lower insulating layer 120 and the second electrode pad 184 may be disposed on the upper insulating layer 170. In embodiments, the lower insulating layer 120 and the upper insulating layer 170 may be made of silicon oxide and may be formed to surround the second anchor portion 196.
[0051] A first bonding pad 222 may be disposed on the first electrode pad 154 and a second bonding pad 224 may be disposed on the second electrode pad 184. In embodiments, as shown in
[0052] In accordance with an embodiment of the present disclosure, the back plate 200 may include a second concave-convex structure 210 corresponding to the concave-convex structure 140. In embodiments, the second concave-convex structure 210 may include second convex portions 212 respectively corresponding to the convex portions 142 and protruding downward, that is, toward the convex portions 142. In embodiments, each of the second convex portions 212 may have a shape of a hollow pyramid, a hollow truncated pyramid, a hollow cone, or a hollow truncated cone. In particular, each of the convex portions 142 may have an upper inclined surface, and each of the second convex portions 212 may have a lower inclined surface corresponding to the upper inclined surface. As a result, an area of the upper electrode layer 182 may be increased by the second concave-convex structure 210. Accordingly, the capacitance of the MEMS microphone 100 may be increased, and thus, the sensitivity of the MEMS microphone 100 may be improved.
[0053] In addition, the back plate 200 may have a plurality of air holes 230 connected to the air gap (AG). The air holes 230 may be formed through the support layer 192 and the upper electrode layer 182. In embodiments, the air holes 230 may be formed through the second convex portions 212 and the protrusions 194 may be disposed between the second convex portions 212.
[0054]
[0055] Referring to
[0056] Referring to
[0057] Referring to
[0058] Referring to
[0059] After the first anchor channel 124 is formed, a lower silicon layer 130 may be conformally formed on the lower insulating layer 120 to have an approximately uniform thickness. In embodiments, the lower silicon layer 130 may be a polysilicon layer formed by a chemical vapor deposition process. In such cases, a concave-convex structure 140 including convex portions 142 protruding downward may be formed by the second concave portions 122. In addition, a portion of the lower silicon layer 130 formed in the first anchor channel 124 may be used as a first anchor portion 158 for fixing a diaphragm 150 to be formed subsequently on the substrate 102.
[0060] Referring to
[0061] Then, the lower silicon layer 130 may be patterned to form a diaphragm 150 including the lower electrode layer 152, the first electrode pad 154, and the first connection pattern 156. In addition, a first anchor portion 158 for fixing the diaphragm 150 on the substrate 102 may be formed on the portion of the substrate 102 exposed by the first anchor channel 124 and a plurality of ventilation holes 160 may be formed between the lower electrode layer 152 and the first anchor portion 158. In embodiments, a photoresist pattern covering portions where the lower electrode layer 152, the first anchor portion 158, the first electrode pad 154, and the first connection pattern 156 are to be formed may be formed on the lower silicon layer 130. Next, an etching process, using the photoresist pattern as an etching mask, may be performed until the lower insulating layer 120 is exposed.
[0062] Referring to
[0063] Referring to
[0064] Referring to
[0065] Then, a plurality of holes 188 for forming protrusions 194 (refer to
[0066] Referring to
[0067] After the second anchor channel 190 is formed, a support layer 192 may be conformally formed on the upper electrode layer 182 and the upper insulating layer 170 to have an approximately uniform thickness. As a result, a back plate 200, including the upper electrode layer 182 and the support layer 192, may be formed above the substrate 102. In this case, the back plate 200 may have a second concave-convex structure 210 corresponding to the concave-convex structure 140 and the second concave-convex structure 210 may include second convex portions 212 corresponding to the convex portions 142. In embodiments, the support layer 192 may be a silicon nitride layer formed by a chemical vapor deposition process. In particular, the support layer 192 may be formed to fill the holes 188, whereby protrusions 194 extending downward from the support layer 192 through the upper electrode layer 182 may be formed. In addition, a portion of the support layer 192 formed in the second anchor channel 190 may be used as a second anchor portion 196 for fixing the support layer 192 on the substrate 102.
[0068] Referring to
[0069] Subsequently, as shown in
[0070] After forming the first bonding pad 222 and the second bonding pad 224, as shown in
[0071] Referring to
[0072] Referring to
[0073] In accordance with the embodiments of the present disclosure as described above, the diaphragm 150 and the back plate 200 may include a concave-convex structure 140 and a second concave-convex structure 210 corresponding to each other, respectively. Accordingly, areas facing each other of the diaphragm 150 and the back plate 200 may be increased, and thus, the sensitivity of the MEMS microphone 100 may be significantly improved.
[0074] Although the example embodiments of the present disclosure have been described with reference to the specific embodiments, they are not limited thereto. Therefore, it will be readily understood by those skilled in the art that various modifications and changes can be made thereto without departing from the spirit and scope of the present disclosure defined by the appended claims.