Sealing of micromachined cavities using chemical vapor deposition methods: characterization and optimization

This paper presents results of a systematic investigation to characterize the sealing of micromachined cavities using chemical vapor deposition (CVD) methods. We have designed and fabricated a large number and variety of surface-micromachined test structures with different etch-channel dimensions. Each cavity is then subjected to a number of sequential CVD deposition steps with incremental thickness until the cavity is successfully sealed. At etch deposition interval, the sealing status of every test structure is experimentally obtained and the percentage of structures that are sealed is recorded. Four CVD sealing materials have been incorporated in our studies: LPCVD silicon nitride, LPCVD polycrystalline silicon (polysilicon), LPCVD phosphosilicate glass (PSG), and PECVD silicon nitride. The minimum CVD deposition thickness that is required to successfully seal a microstructure is obtained for the first time. For a typical Type-1 test structure that has eight etch channels-each 10 μm long, 4 μm wide, and 0.42 μm tall-the minimum required thickness (normalized with respect to the height of etch channels) is 0.67 for LPCVD silicon nitride, 0.62 for LPCVD polysilicon, 4.5 for LPCVD PSG, and 5.2 for PECVD nitride. LPCVD silicon nitride and polysilicon are the most efficient sealing materials. Sealing results with respect to etch-channel dimensions (length and width) are evaluated (within the range of current design). When LPCVD silicon nitride is used as the sealing material, test structures with the longest (38 μm) and widest (16 μm) etch channels exhibit the highest probability of sealing. Cavities with a reduced number of etch channels seal more easily. For LPCVD PSG sealing, on the other hand, the sealing performance improves with decreasing width but is not affected by length of etch channels

Surface micromachined mechanisms and micromotors

Electric micromotors are sub-millimeter sized actuators capable of unrestrained motion in at least one degree of freedom. Polysilicon surface micromachining using heavily phosphorus-doped LPCVD polysilicon for the structural material, LPCVD silicon nitride for the electrical isolation and deposited silicon dioxide for the sacrificial material has formed the fabrication technology base for the development of these micromotors. Two polysilicon surface micromachining processes, referred to here as the center-pin and flange, have been demonstrated for the fabrication of passive mechanisms and micromotors. Passive mechanisms such as gear trains, cranks and manipulators have been implemented on silicon. Reported operational micromotors have been of the rotary variable-capacitance salient-pole and harmonic (or wobble) side-drive designs. These micromotors are capable of motive torques in the 10 pN m order of magnitude range. Preliminary progress has been made in studying the operational, friction and wear characteristics of these micromechanical devices. Typical operational voltages have been as low as 37 V and 26 V across 1.5 mu m air gap salient-pole and harmonic micromotors. These excitations correspond to electric field intensities above 10(8) Vm-1 in the micromotor air gaps. Salient-pole and wobble micromotors have been reported to operate at speeds as high as 15000 rpm and 700 rpm, respectively. Micromotor lifetimes of at least many millions of cycles over a period of several days have been reported

Micromachined High-Aspect-Ratio Parylene Spring and Its Application to Low-Frequency Accelerometers

A new microfabrication technology for high-aspect-ratio parylene structure has been developed for soft spring applications. Free-standing parylene beams with widths of 10–40 µm and aspect ratios of 10–20 have been successfully fabricated. Since parylene has a small Young's modulus, a high-aspect-ratio beam with a spring constant of the order of 1 × 10^(-3) N/m has been realized. The large yield strain of parylene enables a test structure to have a large-amplitude oscillation of 600 µm_(p-p), without any failure of the high-aspect-ratio springs. An early prototype of in-plane capacitive accelerometer was also developed. It was found that its resonant frequency is as low as 37 Hz, and the noise spectral density is 64 µg/(Hz)^(0.5)

Design and fabrication of a micro Coulter counter with thin film electrodes

We report a new approach for micro Coulter counter with thin film electrodes. Traditional Coulter counter measures DC resistance change to sense particles passing through an aperture between two flow chambers. One of the, biggest challenges to miniaturize the device is to overcome the large resistance encountered. We propose a new approach to use thin film metal electrodes in micron size range for sensing. Resolution can be improved and it's easy for system integration. A device based on this approach was built and tested

A Micromechanical Parylene Spiral-Tube Sensor and Its Applications of Unpowered Environmental Pressure/Temperature Sensing

A multi-function micromechanical pressure/temperature sensor incorporating a microfabricated parylene spiral tube is presented. Its visible responses in expression of in situ rotational tube deformation enable unpowered sensing directly from optical device observation without electrical or any powered signal transduction. Sensor characterizations show promising pressure (14.46°/kPa sensitivity, 0.11 kPa resolution) and temperature (6.28°/°C sensitivity, 0.24 °C resolution) responses. Depending on different application requests, this sensor can be individually utilized to measure pressure/temperature of systems having one property varying while the other stabilized, such as intraocular or other in vivo pressure sensing of certain apparatus inside human bodies or other biological targets. A straightforward sensor-pair configuration has also been implemented to retrieve the decoupled pressure and temperature readouts, hence ultimately realizes a convenient environmental pressure and temperature sensing in various systems

Parylene-HT-based electret rotor generator

A new micro power generator with parylene HT electret rotor is made. This generator uses parylene HT as a new electret material with a much superior charge density compared to teflon and CYTOP. The highest surface potential observed is 204.58 V/mum, equivalent to a surface charge density of 3.69 mC/m^2. The generator uses an electret rotor. The rotor is a piece of PEEK insulator block coated with a layer of corona-charged parylene HT. Both output electrodes are on the stator. The generator produces 17.98 µW with 80MΩ load at 50Hz and 7.77 µW with an 800MΩ load at 10Hz

Floating-disk parylene micro check valve

A novel micro check valve which has nearly ideal fluidic shunting behaviors is presented. Featuring a parylene-based floating disk, this surface-micromachined check valve ultimately realizes both zero forward cracking pressure and zero reverse leakage in fluidic operations. Two different floating disk designs have been implemented to demonstrate functionality of the microvalve. Experimental data of underwater testing successfully show that in-channel floating-disk valves in both designs have great fluidic performance close to an ideal check valve, except the additional fluidic resistance in the order of 10^(13) N-s/m^5 based on dimensions of the fabricated devices. Their pressure loading limit have been confirmed to be higher than 300 kPa without water leakage. This type of micro check valve is believed to have great use of flow control in integrated microfluidics and lab-on-a-chip applications

Parylene-based electret power generators

n electret power generator is developed using a new electret made of a charged parylene HT® thin-film polymer. Here, parylene HT® is a room-temperature chemical-vapor-deposited thin-film polymer that is MEMS and CMOS compatible. With corona charge implantation, the surface charge density of parylene HT® is measured as high as 3.69 mC m^−2. Moreover, it is found that, with annealing at 400 °C for 1 h before charge implantation, both the long-term stability and the high-temperature reliability of the electret are improved. For the generator, a new design of the stator/rotor is also developed. The new micro electret generator does not require any sophisticated gap-controlling structure such as tethers. With the conformal coating capability of parylene HT®, it is also feasible to have the electret on the rotors, which is made of either a piece of metal or an insulator. The maximum power output, 17.98 µW, is obtained at 50 Hz with an external load of 80 MΩ. For low frequencies, the generator can harvest 7.7 µW at 10 Hz and 8.23 µW at 20 Hz

Parylene BioMEMS

This paper describes parylene as an emerging bioMEMS material. Parylene has the unique feature of room-temperature, pinhole-free conformal CVD deposition. It is chemically inert and biocompatible. More interestingly, it is found that parylene thin film usually possesses a tensile intrinsic stress, controlled by the last thermal steps. These features allow free-standing parylene MEMS structures in many designs. Parylene MEMS is also a suitable technology for post-CMOS integration. As a result, multi-layer parylene MEMS technology has been developed, especially for bioMEMS applications. This paper also gives examples of integrated parylene microfluidics and HPLC on-a-chip

Cracking pressure control of parylene checkvalve using slanted tensile tethers

MEMS check valves with fixed cracking pressures are important in micro-fluidic applications where the pressure, flow directions and flow rates all need to be carefully controlled. This work presents a new surface-micromachined parylene check valve that uses residual thermal stress in the parylene to control its cracking pressure. The new check valve uses slanted tethers to allow the parylene tensile stress to apply a net downward force on the valving seat against the orifice. The angle of the slanted tethers is made using a gray-scale mask to create a sloped sacrificial photoresist with the following tether parylene deposition. The resulted check valves have both the cracking pressures and flow profiles agreeable well with our theoretical analysis