3D Structuration Techniques of LTCC for Microsystems Applications

This thesis aimed at developing new 3D structuration techniques for a relatively recent new ceramic technology called LTCC, which stands for Low Temperature, Co-fired Ceramic. It is a material originally developed for the microelectronic packaging industry; its chemical and thermal stabilities make it suitable to military-grade and automotive applications, such as car ignition systems and Wi-Fi antennae (GHz frequencies). In recent years however, the research in ceramic microsystems has seen a growing interest for microfluidics, packaging, MEMS and sensors. Positioned at the crossing of classical thick-film technology on alumina substrate and of high temperature ceramics, this new kind of easily structurable ceramic is filling the technological and dimensional gap between microsystems in Silicon and classical "macro microsystems", in the sense that we can now structure microdevices in the range from 150 mm to 150 mm. In effect, LTCC technology allows printing conductors and other inks from 30 mm to many mm, structuration from 150 mm to 150 mm, and suspended structures with gaps down to 30 mm thanks to sacrificial materials. Sensors and their packaging are now merged in what we can call "functional packaging". The contributions of this thesis lie both in the technological aspects we brought, and in the innovative microfluidic sensors and devices created using our developed methods. These realizations would not have been possible with the standard lamination and firing techniques used so far. Hence, we allow circumventing the problems related to microfluidics circuitry: for instance, the difficulty to control final fired dimensions, the burden to produce cavities or open structures and the associated delaminations of tapes, and the absence of "recipe" for the industrialization of fluidic devices. The achievements of the presented research can be summarized as follows: The control of final dimensions is mastered after having studied the influence of lamination parameters, proving they have a considerable impact. It is now possible to have a set of design rules for a given material, deviating from suppliers' recommendations for the manufacture of slender structures requiring reduced lamination. A new lamination method was set up, permitting the assembly of complex microfluidic circuits that would normally not sustain standard lamination. The method is based on partial pseudo-isostatic sub-laminations, with the help of a constrained rubber, subsequently consolidated together with a final standard uniaxial lamination. The conflict between well bonded tapes and acceptable output geometry is greatly attenuated. We achieved the formulation of a new class of Sacrificial Volume Materials (SVM) to allow the fabrication of open structures on LTCC and on standard alumina substrates; these are indeed screen-printable inks made by mixing together mineral compounds, a glassy phase and experimental organic binders. This is an appreciable improvement over the so-far existing SVMs for LTCC, limited to closed structures such as thin membranes. An innovative industrial-grade potentially low-cost diagnostics multisensor for the pneumatic industry was developed, allowing the measurement of compressed air pressure, flow and temperature. The device is entirely mounted by soldering onto an electro-fluidic platform, de facto making it a true electro-fluidic SMD component in itself. It comprises additionally its own integrated SMD electronics, and thanks to standard hybrid assembly techniques, gets rid of external wires and tubings – this prowess was never achieved before. This opens the way for in situ diagnostics of industrial systems through the use of low-cost integrated sensors that directly output conditioned signals. In addition to the abovementioned developments, we propose an extensive review of existing Sacrificial Volume Materials, and we present numerous applications of LTCC to sensors and microsystems, such as capacitive microforce sensors, a chemical microreactor and microthrusters. In conclusion, LTCC is a technology adapted to the industrial production of microfluidic sensors and devices: the fabrication steps are all industrializable, with an easy transition from prototyping to mass production. Nonetheless, the structuration of channels, cavities and membranes obey complex rules; it is for the moment not yet possible to choose with accuracy the right manufacturing parameters without testing. Consequently, thorough engineering and mastering of the know-how of the whole manufacturing process is still necessary to produce efficient LTCC electro-fluidic circuits, in contrast with older techniques such as classical thick-film technology on alumina substrates or PCBs in FR-4. Notwithstanding its lack of maturity, the still young LTCC technology is promising in both the microelectronics and microfluidics domains. Engineers have a better understanding of the structuration possibilities, of the implications of lamination, and of the most common problems; they have now all the tools in hand to create complex microfluidics circuits

Macro-meso-microsystems integration in LTCC : LDRD report.

Low Temperature Cofired Ceramic (LTCC) has proven to be an enabling medium for microsystem technologies, because of its desirable electrical, physical, and chemical properties coupled with its capability for rapid prototyping and scalable manufacturing of components. LTCC is viewed as an extension of hybrid microcircuits, and in that function it enables development, testing, and deployment of silicon microsystems. However, its versatility has allowed it to succeed as a microsystem medium in its own right, with applications in non-microelectronic meso-scale devices and in a range of sensor devices. Applications include silicon microfluidic ''chip-and-wire'' systems and fluid grid array (FGA)/microfluidic multichip modules using embedded channels in LTCC, and cofired electro-mechanical systems with moving parts. Both the microfluidic and mechanical system applications are enabled by sacrificial volume materials (SVM), which serve to create and maintain cavities and separation gaps during the lamination and cofiring process. SVMs consisting of thermally fugitive or partially inert materials are easily incorporated. Recognizing the premium on devices that are cofired rather than assembled, we report on functional-as-released and functional-as-fired moving parts. Additional applications for cofired transparent windows, some as small as an optical fiber, are also described. The applications described help pave the way for widespread application of LTCC to biomedical, control, analysis, characterization, and radio frequency (RF) functions for macro-meso-microsystems

Integrated packaging solutions and hotplates for a miniature atomic clock and other microsystems

This thesis aimed at developing innovative packaging solutions for a miniature atomic clock and other microsystems in the cm-scale, i.e. somewhat larger than what is practical for full "chip-scale" device-package integration using clean-room technologies for fabrication of microelectromechanical systems (MEMS). Besides well-defined and robust mechanical attachment, such packaging solutions must provide reliable electrical interconnection with the other system components, and, if needed, additional functions such as local temperature control, insulation from electrical magnetic or temperature perturbations, chemical separation (hermeticity). In order to accomplish this objective, different packaging technologies and modules were developed, fabricated and characterized in the frame of this thesis, with particular emphasis on the packaging of a miniature double-resonance (DR) rubidium atomic clock, which is an ideal demonstration platform given the associated large variety of requirements. First, the possibility of encapsulating the reactive Rb metal in ceramic / glass substrates using soldering was explored, with the aim to achieve simple and reliable fabrication of miniature atomic clock elements such as the reference cell and the Rb lamp. After a thorough literature review investigation of the metallurgical interactions between rubidium and materials used in packaging such as solder (Sn, Pb, Bi..) and thick-film metallizations metals (Ag, Pd, Au, 2 Pt...), an innovative design for a Rb reference cell (dimensions 10 × 12 mm ) is presented. The cell is based on a multifunctional low-temperature cofired ceramic (LTCC) spacer, closed by two glass windows allowing light transmission and acting as lids. Bonding is achieved by low-temperature soldering, avoiding exposing Rb to high temperatures. The use of LTCC as the main substrate material for Rb vapor cells in principle allows further integration of necessary functions for the Rb lamp and reference cell, such as temperature regulation, excitation / microwave resonator electrodes, impedance-matching passive components (lamp), and coil for static magnetic field generation (reference). In this work, to test the hermeticity of the bonding, a pressure sensor was integrated into the cell by replacing one of the glass windows by a membrane comprising an integrated piezoresistive Wheatstone bridge. In this frame, a new lamination technique for LTCC is proposed. The technique consists in applying a hot-melt adhesive on top of the LTCC green tape, and allows good bonding of the tapes even at low lamination pressure. This technique is particularly attractive for the lamination of LTCC microfluidic devices or membrane pressure sensors, because the low pressure applied during lamination does not affect the shape of the channels in a microfluidic device, or the membrane of the sensor. The resulting cells are shown to be hermetic, and a Rb response could be measured by the project partners. However, heating resulted in loss of this response, indicating Rb depletion by undesired reactions between Rb and the sealing metals or contaminants. This result is somewhat in line with studies made in parallel with the present work on low-temperature indium thermocompression bonding. Therefore, although the results are promising, further optimisation of metallizations, solders and package design is required. An important generic function that may be integrated into LTCC is temperature control. In this frame, a multifunctional LTCC hotplate was designed, fabricated and studied. This device allows controlling the temperature of any object in the cm-scale, such as the abovementioned Rb vapor cells (reference or lamp) and other temperature-sensitive elements used in miniature atomic clocks such as lasers and impedance-matching passive components. Full thermal analysis, mathematical calculations, finite-element simulations and laboratory experiments were performed. The excellent structurability and modest thermal conductivity of LTCC make it much better suited than standard alumina for integrated hotplates, resulting in conduction losses in the LTCC structure being small compared to surface losses by conduction and convection. It is therefore concluded that insulation and/or vacuum packaging techniques are necessary to achieve optimized low-power operation. Although we have seen that LTCC is an excellent integrated packaging platform, there are some limitations for carrying relatively massive components such as the DR atomic clock resonator cavity structure, which in general is a solid metal part. Therefore, an alternative hotplate technology platform, was developed, based on the combination of standard fiberglass-reinforced organic-matrix printed-circuit board (PCB), combined with thick-film alumina heaters. The PCB acts as high-strength, low-cost and readily available mechanical carrier, electrical interconnect and thermal insulator, and the thick-film heaters provide local temperature regulation, with the high thermal conductivity of alumina ensuring good local temperature uniformity. Therefore, such a hybrid PCB-Al2O3 platform constitutes an attractive alternative to LTCC hotplates for benign operating conditions. In conclusion, this work introduced several innovative packaging solutions and techniques, which were successfully applied to various dedicated modules carrying the elements of miniature atomic clocks. Beyond this application, these developments allow us to envision efficient packaging of a wide variety of new miniature devices. Also, new areas for further investigations are suggested, such as long-term metallurgical interactions of alkali metals with solders, hermeticity, optimization of temperature distribution and thermal insulation techniques, as well as reliability at high-temperatures and under severe thermal cycling.This thesis aimed at developing innovative packaging solutions for a miniature atomic clock and other microsystems in the cm-scale, i.e. somewhat larger than what is practical for full "chip-scale" device-package integration using clean-room technologies for fabrication of microelectromechanical systems (MEMS). Besides well-defined and robust mechanical attachment, such packaging solutions must provide reliable electrical interconnection with the other system components, and, if needed, additional functions such as local temperature control, insulation from electrical magnetic or temperature perturbations, chemical separation (hermeticity). In order to accomplish this objective, different packaging technologies and modules were developed, fabricated and characterized in the frame of this thesis, with particular emphasis on the packaging of a miniature double-resonance (DR) rubidium atomic clock, which is an ideal demonstration platform given the associated large variety of requirements. First, the possibility of encapsulating the reactive Rb metal in ceramic / glass substrates using soldering was explored, with the aim to achieve simple and reliable fabrication of miniature atomic clock elements such as the reference cell and the Rb lamp. After a thorough literature review investigation of the metallurgical interactions between rubidium and materials used in packaging such as solder (Sn, Pb, Bi..) and thick-film metallizations metals (Ag, Pd, Au, 2 Pt...), an innovative design for a Rb reference cell (dimensions 10 × 12 mm ) is presented. The cell is based on a multifunctional low-temperature cofired ceramic (LTCC) spacer, closed by two glass windows allowing light transmission and acting as lids. Bonding is achieved by low-temperature soldering, avoiding exposing Rb to high temperatures. The use of LTCC as the main substrate material for Rb vapor cells in principle allows further integration of necessary functions for the Rb lamp and reference cell, such as temperature regulation, excitation / microwave resonator electrodes, impedance-matching passive components (lamp), and coil for static magnetic field generation (reference). In this work, to test the hermeticity of the bonding, a pressure sensor was integrated into the cell by replacing one of the glass windows by a membrane comprising an integrated piezoresistive Wheatstone bridge. In this frame, a new lamination technique for LTCC is proposed. The technique consists in applying a hot-melt adhesive on top of the LTCC green tape, and allows good bonding of the tapes even at low lamination pressure. This technique is particularly attractive for the lamination of LTCC microfluidic devices or membrane pressure sensors, because the low pressure applied during lamination does not affect the shape of the channels in a microfluidic device, or the membrane of the sensor. The resulting cells are shown to be hermetic, and a Rb response could be measured by the project partners. However, heating resulted in loss of this response, indicating Rb depletion by undesired reactions between Rb and the sealing metals or contaminants. This result is somewhat in line with studies made in parallel with the present work on low-temperature indium thermocompression bonding. Therefore, although the results are promising, further optimisation of metallizations, solders and package design is required. An important generic function that may be integrated into LTCC is temperature control. In this frame, a multifunctional LTCC hotplate was designed, fabricated and studied. This device allows controlling the temperature of any object in the cm-scale, such as the abovementioned Rb vapor cells (reference or lamp) and other temperature-sensitive elements used in miniature atomic clocks such as lasers and impedance-matching passive components. Full thermal analysis, mathematical calculations, finite-element simulations and laboratory experiments were performed. The excellent structurability and modest thermal conductivity of LTCC make it much better suited than standard alumina for integrated hotplates, resulting in conduction losses in the LTCC structure being small compared to surface losses by conduction and convection. It is therefore concluded that insulation and/or vacuum packaging techniques are necessary to achieve optimized low-power operation. Although we have seen that LTCC is an excellent integrated packaging platform, there are some limitations for carrying relatively massive components such as the DR atomic clock resonator cavity structure, which in general is a solid metal part. Therefore, an alternative hotplate technology platform, was developed, based on the combination of standard fiberglass-reinforced organic-matrix printed-circuit board (PCB), combined with thick-film alumina heaters. The PCB acts as high-strength, low-cost and readily available mechanical carrier, electrical interconnect and thermal insulator, and the thick-film heaters provide local temperature regulation, with the high thermal conductivity of alumina ensuring good local temperature uniformity. Therefore, such a hybrid PCB-Al2O3 platform constitutes an attractive alternative to LTCC hotplates for benign operating conditions. In conclusion, this work introduced several innovative packaging solutions and techniques, which were successfully applied to various dedicated modules carrying the elements of miniature atomic clocks. Beyond this application, these developments allow us to envision efficient packaging of a wide variety of new miniature devices. Also, new areas for further investigations are suggested, such as long-term metallurgical interactions of alkali metals with solders, hermeticity, optimization of temperature distribution and thermal insulation techniques, as well as reliability at high-temperatures and under severe thermal cycling

The Design, Fabrication, and Pressure Testing of a Low-Temperature Co-Fired Ceramic Electric Propulsion Thruster

Electric thrusters have been used for many years for orbital station-keeping and propulsion. As technology advances, smaller satellites are possible that require less thrust. The resulting miniature electric thrusters need low-weight and compact designs. This thesis specifies the design, fabrication, and testing of a thruster and its fluid delivery system designed for use with a micro-satellite weighing less than fifty kilograms. The advent of Micro-Electro-Mechanical Systems (MEMS) has sparked a new market with incredibly small scale designs. Using this technology with Low-Temperature Co-fired Ceramic (LTCC) materials has spawned the new distinction of Ceramic Micro-Electro-Mechanical Systems (C-MEMS). The thruster body is made entirely out of LTCC and it has embedded electrical connections and gas delivery channels integrated wholly within the thruster. These thrusters are tested inside a vacuum chamber system set up at Boise State University to simulate the pressure ranges seen in typical space applications. Plasma generation requires adequate gas pressures localized to the time-varying electric field inside of a vacuum. Prior testing for prototype thrusters at Boise State University proved that a single hole central gas injection point was not taking full advantage of the locations of high electric field intensity. This was the driving force to generate a computational fluid dynamics (CFD) model to simulate the pressure ranges as they applied to the areas of high electric field intensity. ANSYS Fluent was used as the modeling software to simulate the pressure ranges of the gas seen inside the thruster body. Experimental testing was done to verify the validity of the Fluent modeling. Electric field intensity was used as a driving force for the design of the gas outlets and their locations. The resulting thruster design demonstrated the successful ability to use LTCC as a substrate for a miniature thruster with fully embedded electrical components and gas channels. Experimental testing showed that a multiple hole gas injection concept created a higher localized pressure within the thruster cylinder, which increases plasma efficiency. The increase in localized pressure was as high as 49.8% larger than a single injection hole design. The experimental tests were also used as a method of validation for a CFD model that could be used in future iterations of the thruster to improve the locations of the thruster gas injection holes. Further work should be done with the external connections to the LTCC body to improve long-term durability. These results imply that LTCC is a viable medium for creating miniature thrusters for micro-satellites. The LTCC creates a hermetically sealed fluidic pathway for neutral gas to travel through, which reduces the size of the overall thruster considerably. A thruster made out of LTCC is both small in size and has excellent qualities to survive the harsh environment of space

Conception et réalisation d'un capteur MEMS multifonctions

La problématique entourant la mise en oeuvre, la conception et le conditionnement de micro-capteurs au sein d'une application embarquée représente un enjeu industriel majeur, consiste en un vaste ensemble de défis techniques et touche à de nombreux champs de recherche scientifiques comme d'applications commerciales. Ce mémoire de thèse compile de manière pédagogique et détaillée la conception, la réalisation et l'évaluation expérimentale d'un capteur MEMS constitué d'un simple micro-filament destiné à la mesure, mutuellement, de la température, de la pression et de l'humidité d'une ambiance gazeuse, en utilisant un même et mutuel étage de conditionnement du signal ce qui en tant que tel constitue une méthode d'intégration particulièrement originale qui est arbitrairement référencée comme "intégration totale". Aussi, le principe physique sous jacent à ce triplet de mesurage est la diffusion par conduction de la chaleur, produite par effet Joule dans l'élément sensible, à travers l'échantillon gazeux l'environnant. Ainsi, le principe de fonctionnement consiste en ce que, la réponse transitoire d'un tel ensemble permet d'une part de mettre en évidence, simultanément et de manière diagonalisable, à une température donnée, l'influence de la pression et de l'humidité sur la conductivité thermique et la capacité calorifique du couple sonde/échantillon. D'autre part, l'élément sensible est spécifiquement prévu pour que dans les conditions initiales du régime transitoire de l'échauffement, sa résistance électrique ne soit sensible qu'à la seule température ambiante, indépendamment des deux mesurandes.Integration of micro sensors within an embedded system is a challenging task in terms of commercial application and deals with many fields of research. This report compiles a novel methodology of multi-sensor integration, from the design to the experimental evaluation. The reported MEMS gas sensor is made from a resistive micro-wire. It is designed to the sensing of temperature, pressure and humidity of a gaseous sample, at the same time, in using only a single sensing part as well as a single conditioning principle which is by itself a new feature arbitrarily called "total integration". The physical principle involved here is heat-diffusion, where heat is produced by Joule effect within the resistive sensing part, sinking through the gaseous sample. The key is that the transient response of such a sensor enables the reading of both the sample thermal conductivity and heat capacity, depending on both humidity and pressure at a given temperature, the later being only depending upon the initial response of the sensor transient response.PARIS11-SCD-Bib. électronique (914719901) / SudocSudocFranceF