U.S. patent application number 09/841234 was filed with the patent office on 2002-10-24 for controlled effective coupling coefficients for film bulk acoustic resonators.
Invention is credited to Bradley, Paul, Figueredo, Domingo, Larson III, John D., Oshmyansky, Yury, Ruby, Richard C..
Application Number | 20020153965 09/841234 |
Document ID | / |
Family ID | 25284367 |
Filed Date | 2002-10-24 |
United States Patent
Application |
20020153965 |
Kind Code |
A1 |
Ruby, Richard C. ; et
al. |
October 24, 2002 |
CONTROLLED EFFECTIVE COUPLING COEFFICIENTS FOR FILM BULK ACOUSTIC
RESONATORS
Abstract
In an array of acoustic resonators, the effective coupling
coefficient of first and second filters are individually tailored
in order to achieve desired frequency responses. In a duplexer
embodiment, the effective coupling coefficient of a transmit
band-pass filter is lower than the effective coupling coefficient
of a receive band-pass filter of the same duplexer. In one
embodiment, the tailoring of the coefficients is achieved by
varying the ratio of the thickness of a piezoelectric layer to the
total thickness of electrode layers. For example, the total
thickness of the electrode layers of the transmit filter may be in
the range of 1.2 to 2.8 times the total thickness of the electrode
layers of the receive filter. In another embodiment, the
coefficient tailoring is achieved by forming a capacitor in
parallel with an acoustic resonator within the filter for which the
effective coupling coefficient is to be degraded. Preferably, the
capacitor is formed of the same materials used to fabricate a film
bulk acoustic resonator (FBAR). The capacitor may be mass loaded to
change its frequency by depositing a metal layer on the capacitor.
Alternatively, the mass loading may be provided by forming the
capacitor directly on a substrate.
Inventors: |
Ruby, Richard C.; (Menlo
Park, CA) ; Bradley, Paul; (Mountain View, CA)
; Figueredo, Domingo; (Livermore, CA) ; Larson
III, John D.; (Palo Alto, CA) ; Oshmyansky, Yury;
(Camarillo, CA) |
Correspondence
Address: |
AGILENT TECHNOLOGIES
Legal Department, 51U-PD
Intellectual Property Administration
P.O. Box 58043
Santa Clara
CA
95052-8043
US
|
Family ID: |
25284367 |
Appl. No.: |
09/841234 |
Filed: |
April 23, 2001 |
Current U.S.
Class: |
333/133 ;
333/188 |
Current CPC
Class: |
H03H 9/706 20130101;
H03H 9/0571 20130101; H03H 3/04 20130101; Y10T 29/42 20150115; H03H
9/587 20130101; H03H 2003/0471 20130101 |
Class at
Publication: |
333/133 ;
333/188 |
International
Class: |
H03H 009/205 |
Claims
What is claimed is:
1. A method of fabricating an array of acoustic resonators
comprising the steps of: selecting a first target frequency
response and a first target effective coupling coefficient for
operation of a first film bulk acoustic resonator (FBAR) filter;
selecting a second target frequency response and a second target
effective coupling coefficient for operation of a second FBAR
filter, said first target effective coupling coefficient being
substantially degraded relative to said second target effective
coupling coefficient; determining thicknesses and materials of
piezoelectric and electrode layers for forming said first and
second FBAR filters so as to achieve said first and second target
frequency responses and said first and second target effective
coupling coefficients, including selecting an increased electrode
layer thickness for at least one electrode layer of said first FBAR
filter, said increased electrode layer thickness being greater than
electrode layer thicknesses selected for said second FBAR filter
such that said substantially degraded first target effective
coupling coefficient is achieved; and forming said first and second
FBAR filters based on said thicknesses and materials.
2. The method of claim 1 wherein said step of determining said
thicknesses and materials includes determining a ratio of a
thickness of a piezoelectric layer to a total thickness of
electrode layers for each of said first and second FBAR filters,
said ratio for said first FBAR filter being less than said ratio
for said second FBAR filter.
3. The method of claim 1 wherein said step of selecting said first
target coefficient includes selecting a value in the range of 2.5
percent to 4.0 percent and said step of selecting said second
target coefficient includes selecting a value in the range of 4.0
percent to 6.0 percent.
4. The method of claim 1 further comprising the step of forming a
duplexer to include each of: said first FBAR filter as a transmit
filter; and said second FBAR filter as a receive filter.
5. The method of claim 1 wherein said step of forming said first
and second FBAR filters includes depositing AIN as said
piezoelectric layer and depositing Mo as said electrode layers,
said electrode layers of said first FBAR filter having a thickness
that is in the range of 1.2 to 2.8 times the thickness of electrode
layers of said second FBAR filter.
6. The method of claim 6 wherein said selecting steps and said step
of forming said first and second FBAR filters includes providing a
first target frequency response having a center frequency that is
within 100 MHz of a center frequency said second target frequency
response.
7. A method of fabricating an array of acoustic resonators
comprising the steps of: selecting a filter arrangement of FBARs to
achieve a target frequency response and a target effective coupling
coefficient; designing at least one FBAR in said filter arrangement
as a power bar in which a target impedance of said FBAR is
substantially maintained while significantly increasing a power
density of said filter arrangement at said power bar, including
configuring said power bar as a pair of large area FBARs that are
connected in series to provide a combined impedance that
corresponds to said target impedance; selecting ratios of
thicknesses of piezoelectric layers to thicknesses of electrode
layers in the fabrication of said filter arrangement to achieve
said target frequency response and said target effective coupling
coefficient, including selecting at least one said ratio to ensure
an effective coupling coefficient that is substantially below an
intrinsic coupling coefficient; and fabricating said filter
arrangement, including forming said power bar and including forming
electrode layers and piezoelectric layers having thicknesses that
are based upon achieving said selected ratios.
8. A duplexer comprising: a transmit film bulk acoustic resonator
(FBAR) array having transmit series FBARs connected in series and
having transmit shunt FBARs; and a receive FBAR array having series
FBARs connected in series and having receive shunt FBARs; wherein
said transmit FBAR array has an effective coupling coefficient that
is substantially less than an effective coupling coefficient of
said receive FBAR array, said substantially less effective coupling
coefficient being realized by providing at least some FBARs of said
transmit FBAR array with substantially thicker electrode layers and
substantially thinner piezoelectric layers than said FBARs of said
receive FBAR array.
9. The duplexer of claim 8 wherein said transmit and receive FBAR
arrays have frequencies compatible with operation in a code
division multiple access (CDMA) personal communication system
(PCS).
10. The duplexer of claim 8 wherein said at least some FBARs of
said transmit FBAR array each have a ratio of thickness of said
piezoelectric layer to total thickness of said electrode layers,
with said ratio being substantially less than ratios of
piezoelectric layer thickness to total electrode layer thickness
for said receive series FBARs and said receive shunt FBARs.
11. The duplexer of claim 10 wherein said total thickness of said
electrode layers of said at least some FBARs is in the range of 1.2
to 2.8 times said total electrode layer thickness for said receive
series FBARs and said receive shunt FBARs.
12. A method of forming an array of acoustic resonators comprising
the steps of: selecting a first target frequency response and a
first target effective coupling coefficient for operation of a
first FBAR filter; selecting a second target frequency response and
a second target effective coupling coefficient for operation of a
second FBAR filter, said first target effective coupling
coefficient being substantially degraded relative to said second
target effective coupling coefficient; forming said first FBAR
filter to seek said first target frequency response and an
effective coupling coefficient greater than said first target
effective coupling coefficient; forming said second FBAR filter to
seek said second target frequency response and to seek said second
effective coupling coefficient; and forming a capacitor in parallel
with said at least one FBAR of said first FBAR filter to degrade
said effective coupling coefficient of said first FBAR filter,
thereby achieving said first target effective coupling
coefficient.
13. The method of claim 12 wherein said step of forming said
capacitor includes fabricating a separate FBAR structure, each of
said FBARs being suspended on a substrate, said separate FBAR
structure being mass loaded by forming an electrode layer of gold
such that said separate FBAR structure has a resonant frequency
substantially below said first and second target frequency
responses.
14. The method of claim 13 wherein: said step of fabricating said
separate FBAR structure includes forming piezoelectric and
electrode layers to have said resonant frequency in the range of
1400 MHz to 1600 MHz; and said steps of forming said first and
second FBAR filters include forming piezoelectric and electrode
layers to have said first and second target resonant frequencies be
compatible with operation of a CDMA PCS.
15. The method of claim 12 wherein said step of forming said
capacitor includes depositing unsuspended piezoelectric and
electrode layers on a substrate, said steps of forming said first
and second FBAR filters including suspending FBARs of said first
and second FBAR filters on said substrate.
Description
TECHNICAL FIELD
[0001] The invention relates generally to acoustic resonators and
more particularly to controlling the effective coupling coefficient
of a film bulk acoustic resonator.
BACKGROUND ART
[0002] In many different communications applications, a common
signal path is coupled to both an input of a receiver and an output
of a transmitter. For example, in a cellular or cordless telephone,
an antenna may be coupled to the receiver and the transmitter. In
such an arrangement, a duplexer is often used to couple the common
signal path to the input and the output. The function of the
duplexer is to provide the necessary coupling to and from the
common signal path, while preventing the signals generated by the
transmitter from being coupled to the input of the receiver.
[0003] One type of duplexer is referred to as the half duplexer. A
half duplexer uses a switch to connect the common signal path to
the receiver or the transmitter on a time division basis. The half
duplexer has the desired coupling and attenuation properties, but
is unacceptable in many telephony applications, since it does not
allow parties of a call to speak and be heard simultaneously.
[0004] A type of duplexer that is more acceptable for telephony
applications is the full duplexer. A full duplexer operates only if
the transmit signal has a frequency that is different than the
frequency of the receive signal. The full duplexer incorporates
band-pass filters that isolate the transmit signal from the receive
signal according to the frequencies. FIG. 1 illustrates a
conventional circuit used in cellular telephones, personal
communication system (PCS) devices and other transmit/receive
devices. A power amplifier 10 of a transmitter is connected to a
transmit port 12 of a full duplexer 14. The duplexer also includes
a receive port 16 that is connected to a low noise amplifier (LNA)
18 of a receiver. In addition to the transmit port and the receive
port, the duplexer 14 includes an antenna port 20, which is
connected to an antenna 22.
[0005] The duplexer 14 is a three-port device having the transmit
port 12, the receive port 16 and the antenna port 20. Internally,
the duplexer includes a transmit band-pass filter 24, a receiver
band-pass filter 26 and a phase shifter 28. The passbands of the
two filters 24 and 26 are respectively centered on the frequency
range of the transmit signal that is input via the power amplifier
10 and the receive signal to which the receiver is tuned.
[0006] The requirements for the band-pass filters 24 and 26 of the
duplexer 14 are stringent. The band-pass filters must isolate low
intensity receive signals generated at the antenna 22 and directed
to the input of the low noise amplifier 18 from the strong transmit
signals generated by the power amplifier 10. In a typical
embodiment, the sensitivity of the low noise amplifier may be in
the order of -100 dBm, while the power amplifier may provide
transmit signals having an intensity of approximately 28 dBm. It is
expected that the duplexer 14 must attenuate the transmit signal by
approximately 50 dB between the antenna port 20 and the receive
port 16 to prevent any residual transmit signal mixed with the
receive signal at the receive port from overloading the low noise
amplifier.
[0007] One type of PCS that is used in a mobile telephone employs
code division multiple access (CDMA). The CDMA PCS wireless bands
are centered at approximately 1920 MHz and have an especially
stringent regulatory requirement for duplexer performance. Some
concerns will be identified with reference to FIG. 2. A passband 30
is defined by several poles and several zeros. The poles and zeros
are equidistantly spaced from a center frequency 32. For the
transmitter passband 30, the transmitter-to-antenna insertion loss
34 is preferably better than -3 dB over most of the band. The
isolation from the transmitter to receiver ports exceeds 50 dB
across most of the transmitter band and 46 dB in the receiver band.
The crossover between the transmitter and receiver bands occurs
around 1920 MHz. The transmitter and receiver bands are
approximately 3.0 percent of the carrier frequency, so that
extremely sharp filter roll-off 36 and 38 is required. As will be
explained more fully below, the lower-frequency poles and zeroes
and the roll-off 36 are determined by the characteristics of shunt
resonators, while the higher-frequency poles and zeroes and the
roll-off 38 are determined by the characteristics of series
resonators.
[0008] Another challenge for the duplexer is achieving power
handling requirements. The power amplifier 10 of FIG. 1 in the
transmitter can deliver 1 Watt of power to the transmit port 12 of
the duplexer 14. The band-pass filter 24 must be capable of
handling such power without being destroyed and without its
performance being degraded.
[0009] The duplexer 14 will be described in greater detail with
reference to FIG. 3. The duplexer includes a transmit film bulk
acoustic resonator (FBAR) array 40 and a receive FBAR array 42. The
transmit FBAR array is a two-stage ladder circuit having two series
FBARs 44 and 46 and two shunt FBARs 50 and 52. The series FBARs are
connected in series between the transmit port 12 and the antenna
port 20, while the shunt FBARs are connected between electrical
ground and nodes between the series FBARs. Each full stage of an
FBAR array is composed of one series FBAR and one shunt FBAR. In
order to handle the high power generated by the power amplifier at
the filter input of the transmit filter, power bars are used for
each of the series elements 44 and 46.
[0010] The receive FBAR array is a 31/2-stage ladder circuit. A
half stage is limited to either one series FBAR or one shunt FBAR.
In the exemplary array 42, the half stage is a shunt FBAR 60. The
FBAR array includes three series FBARs 54, 56 and 58 and four shunt
FBARs 60, 62, 64 and 66. The series FBARs are connected in series
between the ninety degree phase shifter 28 and the receive port 16.
The shunt FBARs are connected between electrical ground and nodes
between the series FBARs.
[0011] Circuits suitable for use as the ninety degree phase shifter
28 are known in the art. As examples, the phase shifter may be
composed of inductors and capacitors or may be a .lambda./4
transmission line.
[0012] Within the transmit FBAR array 40, each series FBAR 44 and
46 may have the same resonant frequency (f.sub.r.sup.Tx), which may
be centered at 1880 MHz. Similarly, the shunt FBARs 50 and 52 may
have the same resonant frequency, but the resonant frequency of the
series FBARs is approximately 1.0 percent to 3.0 percent (typically
1.6 percent) greater than that of the shunt FBARs. As a result, the
poles that were described with reference to FIG. 2 are
provided.
[0013] The receive FBAR array 42 of the receive band-pass filter 26
may also be composed of series FBARs 54, 56 and 58 having the same
f.sub.r.sup.RX and shunt FBARs 60, 62, 64 and 66 having the same
resonant frequency that is 3.0 percent different than the resonant
frequency f.sub.r.sup.Rx of the series FBARs. Here, f.sub.r.sup.Rx
is centered at 1960 MHz.
[0014] Other considerations that affect the shape of the response
shown in FIG. 2 are the figure of merit, which is referred to as Q,
and the effective coupling coefficient, which is also referred to
as kt.sup.2. The effective coupling coefficient may be considered
as being the ratio of electrical energy to acoustic energy in the
operation of a particular FBAR. It has been the goal to maximize
both Q and the effective coupling coefficient. As a result of the
fabrication process, the effective coupling coefficient can be as
high as 8.0 percent. It has been experimentally determined that Q
is dependent upon kt.sup.2 and, in some cases, that it is better to
decrease kt.sup.2 in order to significantly increase Q. The Q
determines the roll-off of the response.
[0015] What is needed is a fabrication method and a resulting
duplexer which provide a very steep roll-off in the operation of an
array of acoustic resonators.
SUMMARY OF THE INVENTION
[0016] The performance of arrays of acoustic resonators is enhanced
by tailoring the effective coupling coefficients of the individual
acoustic resonators on the basis of the functions of the
resonators. In a duplexer embodiment, the effective coupling
coefficients of FBARs in a transmit band-pass filter are fabricated
to have a lower effective coupling coefficient than the FBARs of
the receive band-pass filter of the same duplexer.
[0017] In one embodiment, the difference in the effective coupling
coefficients is achieved by varying the thicknesses of the
electrode layers. For a given frequency, the effective coupling
coefficient of an acoustic resonator is modified by varying the
ratio of the thickness of the piezoelectric layer to the total
thickness of the electrode layers. Typically, a goal in the
fabrication of FBARs is to minimize the thickness of the electrode
layers, thereby providing an "intrinsic" effective coupling
coefficient. For example, this intrinsic coefficient may be in the
range of 7.0 percent to 8.0 percent.
[0018] However, the coupling coefficient of an FBAR filter having a
given resonant frequency can be adjusted downwardly by decreasing
the ratio of the thickness of the piezoelectric layer to the total
thickness of the electrode layers, since the resonant frequency is
dependent upon the "weighted thickness" (i.e., the physical
thickness weighted on the basis of the selection of electrode and
piezoelectric materials) of the electrode-piezoelectric stack. As
one example of a transmit filter, the thickness of molybdenum (Mo)
electrodes can be increased and the thickness of aluminum nitride
(AIN) can be reduced in order to achieve a degraded effective
coupling coefficient in the range of 2.5 percent to 4.0 percent,
while maintaining a targeted resonant frequency. Similarly, a
receive filter can be fabricated to have an effective coupling
coefficient in the range of 4.0 percent to 6.0 percent by selecting
the appropriate thicknesses for the layers that form the FBARs of
the receive filter.
[0019] The method of fabricating an array of acoustic resonators in
accordance with this embodiment includes a step of selecting a
first target frequency range and a first target effective coupling
coefficient for operation of an FBAR transmit (Tx) filter, and
includes selecting a second target frequency and a second target
coupling coefficient for operation of an FBAR receiver (Rx) filter
The thicknesses and materials of the piezoelectric and electrode
layers for forming the two FBAR filters are determined on the basis
of achieving the target resonant frequencies and the target
effective coupling coefficients. The determinations include
selecting an increased electrode layer thickness for at least one
electrode of the Tx FBARs, so that the Tx FBAR filter will have the
degraded coefficient. The two filters are then formed according to
the selected thicknesses and materials.
[0020] In the fabrication of the two filters, the electrode
material may be Mo and the piezoelectric material may be AIN. Using
these materials, the electrode layers of the FBAR Tx filter having
the degraded coupling coefficient will have a thickness that can be
in the range of 1.2 to 2.8 times the thickness of the electrode
layers of the Rx filter with the higher coefficient. For example,
in a communications device that is compatible with the CDMA PCS
standard, the Rx filter may have electrode layer thicknesses of
2200 .ANG. and a piezoelectric thickness of 2.2 microns in order to
achieve a coupling coefficient in the range of 5.6 percent to 5.8
percent, while the Tx filter may have electrode layer thicknesses
of 4500 .ANG. and a piezoelectric thickness of roughly 8000 .ANG.
in order to achieve a coupling coefficient in the range of 3.1
percent to 3.2 percent. The Q (and therefore the steepness of the
roll-off) is almost two times higher for the Tx filter than for the
Rx filter.
[0021] In one application, a desired filter arrangement of FBARs is
designed to include at least one "power bar" in order to increase
the power handling capacity along a path of the filter arrangement.
A "power bar" is defined herein as a pair of large area FBARs which
are connected in series in place of a single target FBAR. Each
large area FBAR occupies an area that is twice the area of the
target FBAR. The parallel-series combination defined by the power
bar (in the series connection of conventional electrical equivalent
circuits) allows the impedance of the power bar to remain at the
target impedance of the target FBAR, but reduces the power density
by a factor of four.
[0022] In a second embodiment of the invention, the degraded
effective coupling coefficient is achieved by forming a capacitor
in parallel with at least some of the resonators of the Tx filter.
Preferably, the capacitor is formed using materials that are
deposited in steps for fabricating the array of acoustic
resonators. For example, the electrodes and the piezoelectric layer
that are deposited to fabricate the FBARs may be utilized in the
formation of a capacitor that is placed in parallel with at least
one FBAR of the Tx filter to degrade the effective coupling
coefficient. However, the concern in using these layers is that a
resonator will be fabricated, rather than a capacitor. One method
for ensuring that the additional component functions as a capacitor
is to fabricate the electrode-piezoelectric stack of the component
directly on the substrate, rather than suspending the stack. In
this manner, the substrate provides the means for mass loading the
capacitor, thereby pulling the frequency off center.
[0023] A second method is to use the gold layer, which is
conventionally used to provide contact pads, as the means to pull
the resonator component off frequency. This second method is
preferred, since the first method may form a high loss capacitor,
while the second method is the one that will form a high Q
component. By utilizing the gold layer and by suspending the
capacitor component as a free-standing membrane in the same manner
as the FBARs, the capacitor functions as a high Q resonator, but at
a much lower frequency than the first and second FBARs. An
advantage is that the frequency of the capacitor can be "tuned" to
not only be displaced from the frequency of interest, but to form a
parasitic resonance at frequencies where the duplexer does not
perform well. As one example, the capacitor may resonate at 1510
MHz, which is a frequency at which existing duplexers do not
perform well in the rejection of energy. Tuning the capacitor to
1510 MHz allows a designer to incorporate specific shunt and series
type resonators that reduce leakage of the 1510 MHz signal. This is
achieved without any additional process steps to the FBAR
fabrication. The tuning of the capacitor can be provided merely by
properly selecting the thickness of the gold and other layers in
the electrode-piezoelectric stack of the capacitor.
[0024] An advantage of the methods described above is that the
performance of an array of acoustic resonators is enhanced without
significantly affecting the fabrication process. By tailoring the
effective coupling coefficients of individual resonators within a
full duplexer, roll-off at the opposite edges of the passband can
be tailored.
BRIEF DESCRIPTION OF THE DRAWINGS
[0025] FIG. 1 is a block diagram of a front-end circuit of a
conventional cellular telephone or similar device.
[0026] FIG. 2 is a graph showing the characteristics of a band-pass
filter of the type used in FIG. 1.
[0027] FIG. 3 is a schematic block diagram of a conventional full
duplexer.
[0028] FIG. 4 is a schematic block diagram of an example of a pair
of passband filters in which the filters have significantly
different effective coupling coefficients in accordance with one
embodiment of the invention.
[0029] FIG. 5 is a cross sectional view of the selected FBARs of
FIG. 4.
[0030] FIG. 6 is a process flow of steps for carrying out the
invention described with reference to FIGS. 4 and 5.
[0031] FIG. 7 is a schematic diagram of the conventional electrical
equivalent circuit of the FBAR formed in accordance with the first
embodiment of the invention.
[0032] FIG. 8 is a schematic diagram of the electrical equivalent
circuit of an FBAR formed in accordance with a second embodiment of
the invention.
[0033] FIG. 9 is a side sectional view of a resonator-capacitor
pair, with the capacitor being formed directly on the substrate in
accordance with the first approach to the second embodiment
represented in FIG. 8.
[0034] FIG. 10 is a side sectional view of a resonator-capacitor
pair, with the capacitor being mass loaded by addition of a top
metal layer in accordance with the second approach to achieving the
second embodiment represented in FIG. 8.
DETAILED DESCRIPTION
[0035] With reference to FIG. 4, a transmit band-pass filter 68 is
shown schematically as including four series FBARs 70, 72, 74 and
76 connected in electrical series from a transmit port 78 to an
antenna port 80. The filter also includes two shunt FBARs 82 and
84. The first shunt FBAR 82 is connected between the two pairs of
series FBARs, while the second shunt FBAR 84 is connected between
the antenna port and the series FBAR 76. FIG. 4 also shows one
stage of a receive filter 73. This stage includes a series FBAR 75
and a shunt FBAR 77. The number of stages in a transmit (Tx) filter
or a receive (Rx) filter is not critical to the invention that will
be described more fully below. The significance of the filters is
that at least one FBAR will have an effective coupling coefficient
that is intentionally degraded relative to at least one other FBAR.
In the preferred embodiment, the FBARs of the Tx filter have
effective coupling coefficients that are intentionally degraded,
while the FBARs of the Rx filter have significantly higher
coefficients.
[0036] The FBAR pair 70 and 72 and the FBAR pair 74 and 76 are
"power bars." The series connection of the two FBARs in each pair
increases the power density by a factor of four relative to a
single target FBAR. Regarding the first pair of FBARs 70 and 72,
each FBAR is fabricated to occupy an area that is twice the area of
the target FBAR. When the two FBARs are connected in series, the
series-parallel arrangement of resistances and capacitances in the
resulting series combination of the conventional electrical
equivalent circuits (which will be described below with reference
to FIG. 7) will achieve the impedance of the target FBAR, but with
the increased power density. The resonant frequencies of the FBARs
in a power bar should be the same as the resonant frequency of the
target FBAR which is "replaced" by the power bar.
[0037] The phase shifter 28 of FIG. 4 is not critical to the
invention and is consistent with the description of the phase
shifter 28 of FIG. 1. As two examples, the phase shifter may be
comprised of inductors and capacitors or may be a one-quarter
wavelength transmission line. Each of the shunt FBARs 82 and 84 is
coupled to ground through an external inductor 86 and 88. The
inductors may be used to position the attenuation poles of the
shunt bars, so that the passband response exhibits the desired
characteristics, such as steep roll-off at the outside edges of the
response.
[0038] Each of the FBARs 70, 72, 74, 75, 76 and 77 includes outside
electrode layers and an interior piezoelectric layer. For example,
the series FBAR 74 of the Tx filter 68 includes electrodes 90 and
92 that sandwich a piezoelectric layer 94. Similarly, the series
FBAR 75 of the Rx filter 73 includes electrodes 96 and 98 and a
center piezoelectric layer 100. The ratio of the thickness of the
piezoelectric layer 94 to the total thickness of the electrode
layers that sandwich the piezoelectric layer is represented as
being much less for the series FBARs of the Tx filter than for the
series FBAR of the Rx filter. As will be explained more fully
below, the increased electrode layer thickness degrades the
coupling coefficient of the Tx filter 68 relative to the Rx filter
73. As a result, the Q of the Tx filter is greater than the Q of
the Rx filter and the steepness at the edges of the passband
response of the Tx filter is greater than that of the Rx
filter.
[0039] FIG. 5 illustrates a side sectional view of the series FBAR
74 of the Tx filter and the series FBAR 75 of the Rx filter. Again,
the electrode layers 90 and 92 of the FBAR 74 are shown as being
significantly thicker than the electrode layers 96 and 98 of the
FBAR 75. Both of the filters 68 and 73 are formed on a single
substrate 102, such as a silicon substrate. However, the filters
may be formed on separate substrates or may be formed on a material
other than silicon. An FBAR is formed where the piezoelectric
material 94 and 100 is sandwiched between two electrodes 90, 92, 96
and 98. Preferably, wells 104 and 106 are etched into the substrate
below the FBARs. As a result, each electrode-piezoelectric stack
that forms an FBAR is a membrane suspended over a well, so as to
provide resonator-to-air interfaces at both sides. Alternatively,
solidly mounted resonators (SMRs) may be used without diverging
from the invention. SMRs typically include acoustic Bragg
reflectors at their bottom surfaces in order to provide a large
acoustic impedance. A Bragg reflector is made of layers of
alternating high and low acoustic impedance materials, with each
layer having a thickness of approximately one-quarter wavelength of
the resonant frequency of the FBAR. In some applications, a number
of FBARs share a single well.
[0040] The characteristics of the individual series FBARs 74 and 75
of FIGS. 4 and 5 depend upon the layer thicknesses and the
materials of the electrode-piezoelectric stacks. The preferred
material for forming the piezoelectric layers 94 and 100 is AIN,
but other materials may be utilized (e.g., zinc oxide). An
acceptable electrode material is Mo, but other metals may be
substituted (e.g., aluminum, tungsten, gold or titanium). For given
electrode and piezoelectric materials, characteristics of an FBAR
are dependent upon geometrical factors such as the thickness of the
piezoelectric layer, the thicknesses of the electrodes and the area
of overlap between the electrodes. For example, the resonant
frequency is dependent upon the "weighted thickness" of the
electrode-piezoelectric stack. The weighted thickness is the
physical thickness with an adjustment that is based upon the
selection of the electrode and piezoelectric materials. The
adjustment is necessary, since the velocity of sound is different
in different materials. Changing the weighted thickness of one or
both of the electrodes changes the weighted thickness of the
electrode-piezoelectric stack, thereby adjusting the resonant
frequency of the stack.
[0041] The layer thicknesses of the electrode-piezoelectric stacks
also affect the effective coupling coefficients (kt.sup.2) of the
Tx and Rx filters 68 and 73. In accordance with the invention, the
effective coupling coefficients of the filters are tailored on the
basis of the functions of the filters. By providing the Tx filter
68 with a lower effective coupling coefficient than the Rx filter
73, a CDMA-compatible duplexer exhibits desirable characteristics.
As noted with reference to FIGS. 1-3, there is a crossover between
the transmitter passband and the receiver passband. The series
FBARs 70, 72, 74 and 76 of the Tx filter significantly influence
the characteristics of the transmitter passband at the crossover.
Intentionally degrading the effective coupling coefficient while
maintaining the specification-required resonant frequency enhances
the duplexer performance. As previously noted, the reduction in the
kt.sup.2 of a Tx filter increases its Q, so that a steeper roll-of
is achieved.
[0042] In FIG. 5, the cross sectional view through the Tx FBAR 74
and the Rx FBAR 75 shows the difference in the ratios of the
thickness of the piezoelectric layer and the total thicknesses of
the electrode layers. For the Tx FBAR 74, the ratio is
significantly less than that of the Rx FBAR 75. Therefore, the
effective coupling coefficient of the Tx filter will be
significantly less than the coupling coefficient for the Rx filter.
Typically a goal in the fabrication of FBARs is to minimize the
thickness of the electrode layers. This provides an intrinsic
effective coupling coefficient in the range of 7.0 percent to 8.0
percent. In FIG. 5, the electrode layers 96 and 98 that are used to
define the Rx FBAR 75 may be formed of Mo having a thickness of
2200 .ANG.. The portion of the piezoelectric layer 100 that forms
the Rx FBAR may be AIN having a thickness of approximately 2.2
microns. This provides the specification-required resonant
frequency for the CDMA-compatible transmit filter and provides an
effective coupling coefficient in the range of 5.6 percent to 5.8
percent.
[0043] The Tx FBAR 74 is formed such that the Tx filter 68 will
have the intentionally degraded effective coupling coefficient. The
Mo top and bottom electrodes 90 and 92 may have a thickness of
approximately 4500 .ANG., while the thickness of the relevant
portion of the piezoelectric layer 94 may be approximately 8000
.ANG.. This provides the specification-required resonant frequency
and provides a degraded effective coupling coefficient in the range
of 3.1 percent to 3.2 percent.
[0044] For Tx and Rx filters 68 and 73 that are formed on the basis
of the identified layer thicknesses, the Tx filter may have a Q
that is approximately twice that of the Rx filter. Consequently,
the steepness at the edges of the Tx filter response will be
significantly greater.
[0045] Referring now to FIG. 6, the process flow of steps for
fabricating coefficient-differentiated FBAR filters in accordance
with the invention will be described. In step 108, a target
frequency response and a target effective coupling coefficient are
selected for a first FBAR filter. In the formation of the transmit
filter 68 of FIG. 4, the first FBAR filter is the Tx filter 68. The
target frequency response will depend upon the desired application.
For example, in a duplexer that is compatible with CDMA
requirements, the target frequency response is likely to be
centered at 1880 MHz (i.e., f.sub.r.sup.Tx =1880 MHz).
[0046] In step 110, a target frequency response and a target
effective coupling efficient are selected for a second FBAR filter.
Again referring to FIG. 4, the second FBAR filter is the Rx FBAR
filter 73, so that f.sub.r.sup.TX=.sub.1960 MHz. In the preferred
embodiment, the first target coupling coefficient is selected to be
in the range of 2.5 percent to 4.0 percent, while the second target
coupling coefficient is selected to be in the range of 4.0 percent
to 6.0 percent.
[0047] The layer thicknesses and materials for fabricating the
transmit and receive FBAR filters are determined at step 112. This
step includes selecting an increased electrode layer thickness for
at least one electrode layer of the Tx FBAR filter 68, thereby
ensuring that the effective coupling coefficient of the Tx FBAR
filter is degraded relative to the coupling coefficient of the Rx
FBAR filter 73. This necessitates identifying ratios of the
piezoelectric layer thickness to the total thickness of the
electrode layers for each of the Tx and Rx FBAR filters. The ratio
for the Tx FBAR filter will be less than the identified ratio for
the Rx FBAR filter, since the target effective coupling coefficient
is reduced for the Tx FBAR filter. For purposes of ease of
fabrication, the materials for forming the Tx and Rx FBAR filters
are preferably the same. However, this is not critical, since the
difference in the coefficients may be partially achieved by
selecting different materials for the two filters.
[0048] In step 114, the FBARs are fabricated. The filters 68 and 73
may be formed on the same substrate 102, such as shown in FIG. 5.
However, there are process advantages to forming the filters on
separate substrates and subsequently interconnecting the filters.
It is difficult to vary the thicknesses of the electrode layers and
the piezoelectric layers on a single substrate. Forming the FBARs
on separate substrates eliminates the difficulties. If the FBARs
are to be formed on the same substrate, portions of increased layer
thickness may be achieved by providing multiple deposition steps.
For example, in the formation of the lower electrode layer 92 of
FIG. 5, the Mo deposition may be temporarily terminated after the
layer has reached its desired thickness for the electrode layer 98.
A masking layer may then be deposited in the area of the FBAR 75,
so that the re-initiating of the deposition of Mo will occur only
in the area of the series FBAR 74. A similar multi-step deposition
process may be provided for the piezoelectric layer 100. The two
top electrodes 90 and 96 may be similarly formed.
[0049] While the first embodiment of the invention has been
described as being used in FBARs having a single piezoelectric
layer, the invention may be extended to stacked FBARs without
diverging from the level of skill in the art. That is, arrays of
FBARs having stacked piezoelectric layers that are separated by
electrode layers may be fabricated to have tailored effective
coupling coefficients, so as to achieve desired filter
characteristics.
[0050] The process of modifying the ratio of the thickness of the
piezoelectric layer to the total thickness of the electrode layers
is one means for tailoring the effective coupling coefficients of
different FBARs in an FBAR array. A second means of tailoring the
effective coupling coefficient is to form capacitors in parallel
with selected FBARs. As will be explained more fully below, the
parallel connection of a capacitor will degrade the effective
coupling coefficient. This use of a capacitor to degrade the
effective coupling coefficient may be used in applications other
than the design and fabrication of Tx and Rx filters.
[0051] FIG. 7 is an electrical equivalent circuit for an FBAR. The
circuit is known in the art as the modified Butterworth-Van Dyke
circuit. The main reactive component is the shunt capacitance
(C.sub.P) 116, which is the capacitance defined by the structure of
the electrodes and the piezoelectric layer. The piezoelectric layer
functions as the dielectric for the shunt capacitance 116. The
plate resistance (R.sub.P) 118 represents the series resistance of
the shunt capacitance 116, while the resistance (R.sub.S) 120
represents the series electrical resistance of the connections
between the contacts 122 and 124 of the electrode-piezoelectric
stack. Conventionally, the contacts 122 and 124 are formed of
gold.
[0052] The series connections of the inductance (L.sub.M) 126,
capacitance (C.sub.M) 128 and resistance (R.sub.M) 130 are the
motional representations of the resonance due to the piezoelectric
properties of the FBAR. In the operation of an FBAR filter having
FBARs that are fabricated using the steps described with reference
to FIGS. 5 and 6, the effective coupling coefficient is directly
related to the ratio of the motional capacitance 128 to the plate
capacitance 116. However, by adding a capacitance (C.sub.NEW) 132
as shown in FIG. 8, the plate capacitance 116 is increased while
the motional capacitance 128 remains constant. By placing the
capacitance 132 in parallel with each targeted FBAR, the effective
coupling coefficient of the FBAR filter is controllably reduced. It
should be noted that by adding another resonator of the same
frequency in parallel with the FBAR, both of the capacitances 116
and 128 of FIG. 7 are increased, so that the ratio will be
unaffected. Clearly, a capacitor rather than a resonator provides
the desired effects.
[0053] Preferably, the added capacitance 132 is fabricated using
the same materials and techniques as used in the fabrication of the
FBAR. The concern with forming a capacitor using the top and bottom
electrode layers as plates and the piezoelectric layer as a
dielectric is that a resonator will be formed, rather than a
capacitor. Thus, the new device should be mass loaded such that it
does not resonate at one of the frequencies of interest. Referring
to FIG. 9, one technique for mass loading the new device is to
fabricate the capacitor stack 134 directly on the surface of the
substrate 136. This pulls the resonant frequency off of the center.
That is, although the layers of the capacitor stack 134 have the
same thicknesses as the layers of the affected FBAR 138, the
frequencies will be different because the capacitor stack is formed
directly on the surface of the substrate 136, while the FBAR is
suspended over the substrate by the formation of a well 140. In
order to properly distinguish the capacitor stack 134 from the FBAR
stack 138, the connections that provide the electrical parallel
arrangement are not shown.
[0054] The technique of forming the capacitor stack 134 directly on
the surface of the substrate 136 allows the tailoring of the
coupling coefficient of the affected FBAR filter, as described with
reference to FIG. 8. The concern with this approach is that the
capacitor stack may act as a transducer which broadcasts energy
into the substrate 136. Since the substrate is relatively thick, a
multitude of frequencies can be transmitted. Thus, the new device
may be undesirably loosy.
[0055] Referring now to FIG. 10, another approach to forming the
capacitance 132 of FIG. 8 is to apply a gold layer 142 to the top
of the capacitor stack that is formed over a well 144. The
components of FIG. 10 that are identical to those of FIG. 9 are
provided with identical reference numerals. Thus, the only
differences between the approaches of FIGS. 9 and 10 are the added
gold layer 142 and the added well 144. Preferably, the gold layer
is the same layer that is conventionally used to form the contact
pads for the array of FBARs. The addition of the gold layer reduces
the resonant frequency of the stack 134, since it increases the
weighted thickness of the top electrode.
[0056] An advantage to the use of the gold from the pad layer metal
level is that the frequency can be "tuned" so that it is not only
off of the frequency of interest, but that it forms a parasitic
resonance at frequencies where the duplexer does not perform well.
As one example, the capacitor may resonate at 1510 MHz, which is a
frequency at which existing duplexers do not perform well in the
rejection of energy. Tuning the capacitor stack 134 to 1510 MHz
allows a designer to incorporate specific shunt resonators and
series resonators that reduce leakage of the 1510 MHz signal. This
is achieved without adding process steps to the FBAR fabrication.
The tuning of the capacitor stack can be achieved merely by
properly selecting the thicknesses of the gold and other layers in
the stack.
* * * * *