U.S. patent application number 13/941619 was filed with the patent office on 2013-11-14 for protected resonator.
This patent application is currently assigned to CYMATICS LABORATORIES CORP.. The applicant listed for this patent is L. Richard Carley, Louis Caley Chomas, Hugo Safar, Rajarishi Sinha. Invention is credited to L. Richard Carley, Louis Caley Chomas, Hugo Safar, Rajarishi Sinha.
Application Number | 20130300259 13/941619 |
Document ID | / |
Family ID | 42353604 |
Filed Date | 2013-11-14 |
United States Patent
Application |
20130300259 |
Kind Code |
A1 |
Sinha; Rajarishi ; et
al. |
November 14, 2013 |
PROTECTED RESONATOR
Abstract
A bulk acoustic wave resonator structure that isolates the core
resonator from both environmental effects and aging effects. The
structure has a piezoelectric layer at least partially disposed
between two electrodes. The structure is protected against
contamination, package leaks, and changes to the piezoelectric
material due to external effects while still providing inertial
resistance. The structure has one or more protective elements that
limit aging effects to at or below a specified threshold. The
resonator behavior is stabilized across the entire bandwidth of the
resonance, not just at the series resonance. Examples of protective
elements include a collar of material around the core resonator so
that perimeter and edge-related environmental and aging phenomena
are kept away from the core resonator, a Bragg reflector formed
above or below the piezoelectric layer and a cap formed over the
piezoelectric layer.
Inventors: |
Sinha; Rajarishi;
(Pittsburgh, PA) ; Carley; L. Richard; (Sewickley,
PA) ; Chomas; Louis Caley; (Pittsburgh, PA) ;
Safar; Hugo; (Westfield, NJ) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Sinha; Rajarishi
Carley; L. Richard
Chomas; Louis Caley
Safar; Hugo |
Pittsburgh
Sewickley
Pittsburgh
Westfield |
PA
PA
PA
NJ |
US
US
US
US |
|
|
Assignee: |
CYMATICS LABORATORIES CORP.
Pittsburgh
PA
|
Family ID: |
42353604 |
Appl. No.: |
13/941619 |
Filed: |
July 15, 2013 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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13549676 |
Jul 16, 2012 |
8487511 |
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13941619 |
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|
13246304 |
Sep 27, 2011 |
8222795 |
|
|
13549676 |
|
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|
12321860 |
Jan 26, 2009 |
8030823 |
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13246304 |
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Current U.S.
Class: |
310/340 |
Current CPC
Class: |
H03H 9/0557 20130101;
H03H 9/02086 20130101; H03H 9/1007 20130101; H03H 9/02133 20130101;
H03H 9/105 20130101; H03H 9/02149 20130101; H03H 9/02102 20130101;
H03H 9/175 20130101; H01L 41/0533 20130101 |
Class at
Publication: |
310/340 |
International
Class: |
H01L 41/053 20060101
H01L041/053 |
Claims
1. A resonator comprising: a substrate; a piezoelectric layer
formed over said substrate a least a portion of the piezoelectric
layer being disposed between two electrodes; the piezoelectric
layer having two defined regions, an active interior region and a
perimeter collar region; a Bragg structure formed either above the
piezoelectric layer, below the piezoelectric layer or both above
and below the piezoelectric layer wherein the Bragg structure has a
lateral extent that is at least coextensive with the piezoelectric
layer; and a dielectric spacer that defines the lateral extent of
the active interior region.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a continuation of U.S. application Ser.
No. 13/549,676, which was filed on Jul. 16, 2012 and is scheduled
to issue as U.S. Pat. No. 8,487,511 on Jul. 16, 2013, which is a
continuation of U.S. application Ser. No. 13/246,304, which was
filed on Sep. 27, 2011 and has issued as U.S. Pat. No. 8,222,795 on
Jul. 17, 2012, which is a divisional of U.S. application Ser. No.
12/321,860, filed on Jan. 26, 2009, which has issued as U.S. Pat.
No. 8,030,823 on Oct. 4, 2011, the disclosures of which are
incorporated herein by reference.
FIELD OF THE INVENTION
[0002] High-stability resonators and, more particularly, thin-film
bulk acoustic wave resonators that are largely immune to
environmental effects and aging are disclosed herein.
BACKGROUND OF THE INVENTION
[0003] The response of a bulk-acoustic wave resonator (FBARs, SMRs,
HBARs, etc.) exhibits long term drift in its characteristics,
particularly in frequency. This time-dependent long-term change is
known as drift of the resonator. The drift is caused by both
intrinsic and extrinsic factors and the intrinsic instability is
often called as aging of the resonator. Aging occurs even when
external environmental factors are kept constant. An example of an
SMR structure from the prior art is illustrated in FIG. 1.
[0004] In the literature, Walls and Vig, "Fundamental Limits on the
Frequency Stabilities of Crystal Oscillators," IEEE Transactions On
Ultrasonics, Ferroelectrics, And Frequency Control, 42(4):576-589,
July 1995 (referred to herein as Walls and Vig, 1995) and Vig and
Meeker, "The Aging of Bulk Acoustic Wave Resonators, Filters, and
Oscillators," Proc. 45.sup.th Ann. Symp. Frequency Control, IEEE
Cat. No. 91 CH2965-2, pp. 77-101, (1991) (referred to herein as Vig
and Meeker 1991) present a taxonomy of mechanisms that cause aging
in resonators and oscillators. These mechanisms include mass
transfer to or from the resonator's surfaces due to deposition or
removal of contaminants, stress relief in the mounting structure of
the crystal, changes in the electrodes, leaks in the package, and
changes in the piezoelectric material. Other mechanisms include
external environmental effects like temperature and stress cycling
(hysteresis) and inertial effects.
[0005] In general, previous attempts in making a resonator stable
against environmental effects and aging have focused on frequency
stability. This effort has focused on packaging and mounting
structure design.
[0006] Usually, packaging of the resonator has been the primary
method of protecting it against aging that is caused by
contamination and leaks. Also, packaging partially insulates the
resonator from external environmental effects.
[0007] Quartz resonators have traditionally been packaged within
containers to protect them from certain aging phenomena. Many
examples exist in the prior art. For example, see U.S. Pat. No.
5,640,746 entitled "Method of Hermetically Encapsulating a Crystal
Oscillator Using a Thermoplastic Shell" to Knecht et al. that
issued on Jun. 24, 1997.
[0008] Micromachined thin film resonators are packaged using
wafer-scale or device-scale encapsulation techniques. Many examples
exist in the prior art. Micromachined thin film resonators like
silicon resonators and thin-film bulk acoustic wave resonators
(FBARs) use micromechanical support structures such as posts and
suspensions. These structures are also designed to minimize the
transfer of stress, including temperature-induced stress to the
crystal resonator. For example, see Kim et al. "Frequency stability
of wafer-scale film encapsulated silicon-based MEMS resonators,"
Sensors and Actuators A 136 (2007) 125-131. Also see U.S. Pat. No.
7,153,717 entitled "Encapsulation of MEMS Devices Using
Pillar-Supported Caps" to Carley et al. that issued on Dec. 26,
2006.
[0009] The current methods of packaging are either high profile
(the case with quartz), which makes them difficult to integrate in
a product; or they encapsulate thin-film structures like released
inertial resonators or FBARs that are susceptible to other forms of
instability such as acceleration or shock.
[0010] The mounting structure is another location for possible
aging. Stress introduced by packaging and transmitted to the
crystal causes long-term frequency aging.
[0011] Quartz resonators have been mounted via support legs before
being sealed under a cap. The support structure is carefully
designed to minimize stress transfer (hence aging) to the crystal.
Many examples exist in the prior art. For example, see U.S. Pat.
No. 4,642,510 entitled "Mount for quartz crystal oscillator device"
to Yamashita that issued on Feb. 10, 1987. See also U.S. Pat. No.
5,030,875 entitled "Sacrificial Quartz Crystal Mount" to Knecht,
that issued on Jul. 9, 1991. Levitating the crystal using
electrostatic levitation so that aging effects related to a
mechanical mounting structure are minimized has also been
suggested. See Wall and Vig, 1995.
[0012] The current methods of mounting of the resonator are
susceptible to inertial and thermal fatigue, hence aging. None of
these approaches, however, address the protection of the crystal
and/or electrode material itself. The current approaches do not
protect the crystal or electrode material from environmental
effects, including aging.
[0013] The research focus to date on frequency stability is
appropriate for certain applications. However, a more general focus
on the entire behavior of the resonator around the primary
resonance, in both frequency (f) and over time is desired.
SUMMARY OF THE INVENTION
[0014] The present invention is directed to a bulk acoustic wave
resonator structure that isolates the core resonator from both
environmental effects and aging effects. The structure protects
against contamination, package leaks, and changes to the
piezoelectric material due to external effects like ionizing
radiation and package stress, while still providing excellent
inertial resistance. In preferred embodiments of the present
invention the structure has one or more protective elements that
limit aging effects to at or below a specified threshold. That
threshold is expressed herein as a shift in the impedance response
of the resonator as a function of frequency that is at or below a
certain value. As one skilled in the art will appreciate, an
acoustic resonator device has an impedance value for each frequency
value. As the resonator ages, the impedance value associated with a
frequency value may change over time. Thus, the impedance value (Z)
associated with a frequency f for the acoustic resonator as
designed may change to the value Z.sub.i over time. The present
invention limits the rate of the change of frequency to at or below
a certain level.
[0015] More specifically, an acoustic resonator, when configured in
an oscillator, oscillates at a frequency f.sub.osc that is
associated with a complex-valued impedance Z=(Za, Z.phi.). This
complex-value impedance is initially determined when a value of a
function g (Z) equals a specified design value g.sub.0. Drift in
the resonator behavior in its bandwidth occurs when the
complex-valued impedance changes from the value associated with
g.sub.0. This drift manifests itself as shift in the oscillator
frequency (f.sub.osc) associated with the complex-valued impedance
from the (f.sub.osc) associated with the complex-valued impedance
at g.sub.0. The drift in f.sub.osc is expressed herein as a ppm
change in frequency associated with a specific complex-value
impedance per unit time. As used herein "ppm" is Hz on a MHz scale.
That is, a change of 5 Hz is a 5 ppm change in an f.sub.osc of 1
MHz. The rate of change in f.sub.osc is at or below about 5
ppm/year.
[0016] In other embodiments, this drift can be measured as a change
series or parallel resonance of the resonator. One skilled in the
art will appreciate that, over the resonator bandwidth, the
impedance response exhibits a minimum in amplitude that is
associated with a particular frequency. The frequency associated
with this minimum in amplitude is termed the series resonance. The
frequency associated with the maximum in amplitude is the parallel
resonance. The effects of aging also manifest themselves as a
change in the frequencies associated with the series and parallel
resonance. In these preferred embodiments, the shift in at least
one of the series or parallel resonance frequency of the device is
at or below about 5 ppm per year.
[0017] According to the embodiments described herein, mitigation of
the effects that cause aging is more than simply minimizing
frequency drift of the series or parallel resonance. For example,
series resonance frequency depends on the acoustic path and any
parasitics. Therefore the electromechanical coupling coefficient
and dielectric constant of the resonator materials (and changes
thereto over time) play no role in determining the series resonance
frequency, and any subsequent drift in that frequency.
[0018] Consequently, in certain embodiments the resonator behavior
is stabilized across the entire resonator bandwidth, not just at
the series resonance. In order to achieve such stabilization, the
electromechanical coupling coefficient and the dielectric constant
of resonator materials must be stable over time. Embodiments of the
present invention address short-term environmentally-driven
instabilities as well as long-term aging effects on frequency
drift. However, in certain preferred embodiments, the resonator
behavior is stabilized such that the shift in the resonance
frequency for at least one the series resonance and the parallel
resonance is less than 5 ppm per year of device operation.
[0019] The resonator is protected from the effects of degradation
of the material due to environmental and/or aging processes, by
providing protective element that is a collar of material, in one
particular embodiment a piezoelectric material, around the core
resonator so that perimeter and edge-related environmental and
aging phenomena are kept away from the core resonator.
[0020] In certain embodiments the resonator is protected against
the effect of contamination on the surface by surrounding it on all
sides by a protective element that is a plurality of
energy-confining Bragg layers.
[0021] In certain embodiments the package and environmental
stresses are attenuated and thereby prevented from reaching the
main resonator structure. Attenuation is accomplished by providing
a protective element that is one or more layers formed over and
around the resonator function. These layers are Bragg layers,
spacer layers, stress relief layers or sealing layers, or some
combination thereof, as described more fully herein.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] FIG. 1 is a cross section view of a thin-film solidly
mounted prior art SMR (solidly mounted resonator);
[0023] FIG. 2 is a frequency spectrum of an electrical impedance of
a resonator;
[0024] FIG. 3 is a cross section view of an alternative embodiment
of the present invention with the core resonator surrounded by the
collar;
[0025] FIG. 4 is a cross section view of alternative embodiment
with the core resonator surrounded by the collar;
[0026] FIG. 5 is a frequency spectrum view of a prior art SMR (FIG.
1);
[0027] FIG. 6 is a frequency spectrum view of an alternative
embodiment;
[0028] FIG. 7 is a frequency spectrum view of a prior art SMR (FIG.
1) with the same material as the SMR in FIG. 5;
[0029] FIG. 8 is a frequency spectrum view of an alternative
embodiment with the same materials from the SMR of FIG. 5;
[0030] FIG. 9 is a cross section view of an alternative embodiment
with the core resonator surrounded by the collar;
[0031] FIG. 10 is a cross section view of another alternate
embodiment in a FBAR configuration with a core resonator, a collar
and a spacer, under a cap;
[0032] FIG. 11 is a cross section view of an alternate embodiment
in a FBAR configuration with a core resonator, a collar and spacer,
under a cap, where the FBAR is supported at the center of the
structure;
[0033] FIG. 12 is a cross section view of an alternate embodiment
with an inverted SMR configuration having a core resonator and a
collar and encapsulated under a cap that is constructed as a Bragg
reflector;
[0034] FIG. 13 is a cross section view of an alternate embodiment
with an inverted SMR configuration having a core resonator and a
collar and encapsulated under a cap that is constructed as a Bragg
reflector with an alternative electrode configuration; and
[0035] FIG. 14 illustrates the complex impedance response of a
resonator as a function of f.sub.osc,
[0036] For purposes of clarity and brevity, like elements and
components will bear the same designations and numbering throughout
the Figures.
DESCRIPTION OF THE PREFERRED EMBODIMENTS
[0037] FIG. 1 is a cross section view of a thin-film solidly
mounted prior art SMR (solidly mounted resonator) 10. The SMR has a
lower Bragg reflector 12, a lower electrode 14, a piezoelectric 16
layer, and an upper electrode 18. The lower Bragg reflector 12 has
a plurality of pairs of high acoustic impedance layer 24 and low
acoustic impedance layers 22. Each layer (22, 24) has a thickness
approximately equal to an odd multiple of the quarter acoustic
wavelength of the operational mode in the material. The operational
mode is one of several resonant modes that are supported by the
structure, and include the thickness-extensional mode, the
thickness-shear mode, etc. For each of these modes, a resonant
spectrum such as that shown in FIG. 2 can be realized. Selection of
an odd multiple of the quarter acoustic wavelength thickness based
on a particular mode results in maximum reflection of the perfect
reflection of the acoustic energy in that mode. It is also possible
to optimize the thickness to values different from the quarter
wavelength thickness to obtain good reflection of acoustic energy
in two or more different modes.
[0038] Embodiments of the present invention reduce the drift of the
impedance of the entire resonator around the primary resonance. The
primary resonance, referring to FIG. 2, is the region of the
spectrum from just before the series resonance 28 to just after the
peak of the parallel resonance 30 of the device. The series
resonance is typically defined as the frequency at which the
impedance is a minimum. The parallel resonance is often defined as
the frequency at which the impedance is at a maximum. The frequency
range between the two is known as the bandwidth of the
resonator.
[0039] Embodiments of the present invention provide a protective
element that mitigates the drift in at least one of and preferably
both, the series resonance and the parallel resonance over time.
Preferred embodiments of the present invention have at least one of
three features, collectively referred to as protective elements,
which address several of the most important environmental effects
and aging mechanisms that are the root cause of these undesirable
shifts in series resonance and/or parallel resonance. One such
embodiment is illustrated in FIG. 3. The first exemplary protective
element is a collar 44 formed around the core resonator 42. The
collar 44 as illustrated in FIG. 3 is a region surrounding the core
resonator and includes layers of material that form the core
region. For example, peripheral portions of the piezoelectric layer
16 extend into and are part of the collar 44. The collar 44 ensures
that perimeter and edge-related environmental and aging phenomena
are kept away from the core resonator 42.
[0040] The core resonator 42 is immune to the deposition of
contaminants because it is surrounded on all sides by Bragg layers
(22, 24). Such Bragg layers are described in previously cited U.S.
patent application Ser. No. 12/002,524.
[0041] In an alternative embodiment (FIG. 4), the entire structure
52 is encapsulated in a protective element that is a low
acoustic-impedance, low-density encapsulant 50 material such as
aerogel. In this embodiment, the package and external stresses are
not transmitted to the structure 52.
[0042] Referring again to FIG. 3, the cross section of 52 has a
core resonator 42 surrounded by the collar 44. The structure 52 has
an energy-confining Bragg reflector 48 both below (12) and above
(40) the piezoelectric layer 16. The structure also has a lower
electrode 14, a spacer 38 layer, an optional temperature
compensating layer 32, an upper electrode 18, an optional
interconnect 34 layer, and a passivation 36 layer. Each reflector
has a plurality of pairs of high acoustic impedance layers 24 and
low acoustic impedance layers 22. Each of these Bragg material
layers (22, 24) has a thickness equal to an odd integer multiple of
the quarter acoustic wavelength of the operational mode in the
material. The spacer 38 layer can have a thickness equal to an odd
integer multiple of the quarter acoustic wavelength of the
operational mode in the material. The optional interconnect 34
layer electrically connects the resonator electrodes (14, 18) to
pads (49) or to a via 46 down to CMOS circuits (not shown) in the
substrate 20. The present invention contemplates both single-ended
and differential embodiments. As used herein, a single-ended
embodiment is one in which each of the top and bottom electrodes
are electrically connected to a circuit. A differential embodiment,
both of the electrodes that go to circuits are located on one side
of the device. The electrode on the other side is left
floating.
[0043] The structure illustrated in FIG. 3 is formed in the
following illustrative manner. The layered structure 52 is formed
on substrate 20 by depositing and patterning layers of material as
follows. Layers are deposited to form a lower Bragg reflector 12
(formed from alternating high 24 and low 22 acoustic impedance
layers) and a lower electrode 14. The piezoelectric 16 material is
deposited on the lower electrode 14. The piezoelectric 16 material
is patterned by photolithography and etching. Then, the electrode
14 and, in some cases, the reflector 12 are also patterned by
photolithography followed by one or more etch steps. An insulating
spacer 38 layer is then deposited and patterned, thereby removing
spacer material from over the portion of the piezoelectric 16
material from the core resonator region 42 where the device will be
formed. The spacer layer therefore defines the core and collar
regions in this embodiment. An upper electrode 18 is formed over
the exposed region of the piezoelectric 16 material to create the
active portion of the device. In products where integration of
resonators on a substrate having CMOS devices is desired, ohmic
contact to the lower electrode 14 is provided. In the illustrated
embodiment, vias 46 and 146 are formed in the insulating spacer
layer 38 down to CMOS circuits (for via 46) and down to the lower
electrode 14 (for via 146) by photolithography and etching. A
conducting interconnect 34 is then formed to electrically connect
the electrodes 14 and 18 to the CMOS devices formed in the
substrate as required. The energy-confining Bragg reflector layers
22 and 24 that form the upper Bragg structure are then deposited in
sequence and, subsequently, patterned. Preferably such patterning
will provide access to the interconnect layer 34 for subsequent
packaging. A sealing layer 36 is then formed over the structure to
further protect and isolated the active structure from the
environment and the effects thereof. Layer 36 is referred to as a
passivation layer or sealing layer herein. Examples of materials
suitable for use as a passivation or sealing layer include silicon
nitride, polyimide, or benzocyclobutene (BCB).
[0044] FIG. 4 is a cross section view of a preferred embodiment of
the present invention again having the structure 52 having the core
resonator 42 surrounded by the protective element collar 44. A
protective element that is a low-acoustic impedance material 50 is
placed over the entire structure 52. This material encapsulates the
device and attenuates the transmission of external and package
stress to the device. As with the embodiment illustrated in FIG. 3,
this embodiment can also be single-ended or differential. To
further reduce the transmission of package stresses that will
change over time, an additional layer of soft material such as an
encapsulation resin (e.g. silicone) commonly known as "glop top"
may be deposited over the resonator after it is assembled into a
package and before overmolding of the package with plastic.
Encapsulation resins are well known to one skilled in the art and
are not described in detail herein.
[0045] The material formed over structure 52 is a low-density,
low-acoustic impedance encapsulant 50 material such as aerogel.
Layer 50 is deposited on structure 52 before plastic packaging.
Layer 52 ensures that external and package stresses are not
transmitted to the core resonator structure 42.
[0046] As previously noted, the collar 44 around the core resonator
42 illustrated in FIGS. 3 and 4 isolates the core resonator 42 from
most environmental effects. The collar attenuates temperature,
stress or aging effects before they reach the core resonator 42.
Although applicants do not wish to be held to a particular theory,
applicants believe that the collar 44 acts like a parasitic
resonator on the core resonator 42. Advantageously, the size of the
parasitic resonance can be customized during device design to meet
product performance requirements.
[0047] Also as previously noted, the use of energy-confining Bragg
reflector 48 is a protective element that isolates the core
resonator 42 from external contaminants released by the
environment, as well as providing additional shielding for the core
resonator 42 against temperature and/or stress effects. Protective
element 50 is a stress barrier that protects the core resonator
from external sources (e.g., the package, the environment) to
prevent these stresses from propagating to the core resonator
42.
[0048] The spacer 38 is another protective element that is also
used to electrically isolate the lower electrode 14 from the upper
electrode 18 in addition to providing extra material in the collar
44 region to attenuate environmental effects. In this regard it is
advantageous if the spacer layer 38 is a dielectric material (e.g.,
silicon dioxide). In a preferred embodiment the spacer 38 layer
thickness is approximately equal to an odd integer multiple of the
Bragg wavelength in the material. Bragg wavelength is defined by
the following equation:
v=v(c33/d) (1)
[0049] where v is the acoustic velocity in the material, c33 is the
stiffness coefficient of the material in the direction of wave
propagation, and d is the material density. The layer thickness is
calculated by the following equation:
t=N.times.(v/f)/4 (2)
[0050] where t is the layer thickness and f is the Bragg center
frequency. N is an odd integer 1.
[0051] Referring to FIG. 14, the impedance response for an
oscillator is illustrated as a function of f.sub.osc. The impedance
response is illustrated for an oscillator type resonator device.
The device oscillates at a frequency f.sub.osc that is determined
by the complex-valued impedance Z=(Za, Z.phi.). This impedance
value is determined when a value of a function g(Z) equals a
specified design value g.sub.0. Drift in the resonator behavior in
its bandwidth results in a drift in the value of f.sub.osc where
resonator impedance becomes equal to (Za, Z.phi.). The drift in
f.sub.osc can be quantified in ppm/time. According to the present
invention, aging effects are controlled so that the change in
frequency associated with a complex-valued impedance Z=(Za, Z.phi.)
changes at a rate of 5 ppm/per year or less.
[0052] External stress and/or ionizing radiation are examples of
environmental conditions that can change material properties of the
resonator. Piezoelectric 16 properties, in particular, are
susceptible to change due to external factors. FIG. 5 illustrates
the resonance spectrum of an SMR from the prior art (the SMR
illustrated in FIG. 1). As noted above, ionizing radiation or other
external process can change the material structure of the resonator
layers, and hence their electromechanical properties. These changes
manifest themselves as a change or shift in the resonator spectrum.
When there is a 10% decrease in the piezoelectric 16 coupling
coefficient in an SMR such as the one shown in FIG. 1, there is a
large shift in the resonance spectrum. The FIG. 1 structure has 3.5
pairs of tungsten/oxide Bragg reflector layers, an AlN (aluminum
nitride) piezoelectric layer 16 and molybdenum (MO) electrodes
(14,18). The series and parallel resonance was modeled over time
for this structure using a 1-D acoustical and 3-D electrical model
implemented in Agilent Advanced Design System (ADS) 2006. For the
prior art structure illustrated in FIG. 1, the effect of a 10%
decrease in the coupling coefficient on the resonance spectrum was
modeled. For this FIG. 1 structure, FIG. 5 illustrates that there
is a -510 ppm (i.e. an 870,570 Hz shift downward) shift in the
series resonance 54, and a -2200 ppm (i.e. a 3,790,600 Hz shift
downward) shift in the parallel resonance 56 as illustrated in FIG.
5. The greater decrease of the parallel resonance 30 compared to
the series resonance 28 results in a lowered k2 or bandwidth for
the resonator. For many applications, such a shift in behavior can
severely and negatively impact performance.
[0053] FIG. 6 illustrates a frequency spectrum view of the
structure 52 (e.g., FIGS. 3 and 4) with the same materials from the
prior art example of FIG. 5 for the Bragg layers, piezoelectric
layer and electrodes, but with a 10% decrease in the piezoelectric
16 coupling of the collar 44 material. This change, caused by the
same environmental condition that caused the shift illustrated in
FIG. 5, results in a negligible shift in the resonance spectrum,
with a +32 ppm shift in the parallel resonance 56 (i.e. a 54,624 Hz
shift upward), and 0 ppm shift (no shift) in the series resonance
28. The reason for the difference observed in effect of the
coupling coefficient on the frequency shift of the two devices is
that, in the device in FIGS. 3 and 4, the change in coupling
coefficient of the piezoelectric material was largely confined to
the collar region 42. The piezoelectric material in the core
resonator 44 had very little change in coupling coefficient.
[0054] In the example illustrated in FIG. 6, the shift of the
resonance is barely visible in a narrow band frequency sweep. A
very narrow band sweep reveals that there is negligible shift in
the parallel resonance 56 and no shift in the series resonance 28.
This illustrates the ability of the structure described herein to
protect the core resonator 42 by providing a collar 44 that
mitigates adverse effects of the environment on material properties
without affecting the performance of the core resonator 42.
[0055] FIG. 7 is a frequency spectrum view of the SMR of FIG. 1
using the same materials as those identified in the discussion of
FIG. 5. FIG. 7 illustrates the shift in the resonance spectrum of
an SMR due to a 0.1 um thick layer of oxide contaminant on the top
surface of the device (piezoelectric layer 16 in FIG. 1). The
series and parallel resonance was modeled over time for this
structure using the software tools previously described. For the
prior art structure illustrated in FIG. 1, as an example of the
physical effects of aging in one scenario, a 0.1 um thick layer of
oxide contaminant on the top surface of the device is expected to
form over the first year of use. Contaminants can be any material,
deposited at any rate over some time period. This was just used to
illustrate the concept and the benefit of the upper bragg. This
causes a -1143 ppm shift in the series resonance (i.e. a 1,939,671
Hz shift downward) 54 and a -2461 ppm shift in the parallel
resonance 56 (i.e. a 4,199,697 Hz shift downward). Additionally, a
spurious mode 58 is introduced adjacent to the main resonance in
the spectrum.
[0056] FIG. 7 illustrates the large changes that occur in the
resonator response as a result of the deposition of contaminants on
the structure. The large negative shift in the series resonance 54
and the even larger negative shift in the parallel resonance 56
results in a lowered k2 or bandwidth for the resonator.
Additionally, a spurious mode 58 is introduced near the main
resonance, further altering the behavior from the baseline. For
many applications, such a shift in performance is unacceptable.
[0057] FIG. 8 is a frequency spectrum view for the structure 52,
made from the same materials set forth in the description of FIG.
5. The structure has a 0.1 um thick layer of oxide contaminant on
the top surface of the device. Contrary to the shift in spectrum
caused by this layer on prior art devices, the oxide contaminant
causes a negligible shift in the resonance spectrum of the device
with structure 52.
[0058] Specifically, when the structure 52 is subjected to the same
environmental contaminant effect as the FIG. 1 prior art structure,
the shift of the resonance is barely visible in a narrow band
frequency sweep. As illustrated in FIG. 8, there is a +1 ppm shift
in the series resonance 54 (i.e. a 1,697 Hz shift upward), and +1.2
ppm shift in the parallel resonance 56 (i.e. a 2,047.8 Hz shift
upward). This illustrates that the resonator is protected by the
energy-confining Bragg structure that attenuates the acoustic and
electrical effect of contaminants that deposit on the device
surface.
[0059] Introducing an aerogel-like encapsulant 50 around the device
(FIG. 4) as an additional protective element further attenuates
package stresses and inertial stresses by making them more remote
from the resonator device.
[0060] FIG. 9 is another embodiment of the present invention. This
embodiment is also configured to protect the resonator from
external stresses. An SMR structure is equipped with a protective
element collar 44 as previously described. The resulting structure
is then covered with another protective element. That protective
element is a device-level thin-film cap 60 structure that can
attenuate package stress as well as isolate the resonator from the
effects of contaminants. In this structure, the stress management
function of the structure is separated from the acoustic resonator
function.
[0061] The structure in FIG. 9 is fabricated in the following
sequence. A lower Bragg reflector 12 (alternating high 24 and low
22 acoustic impedance layers) is formed by depositing a plurality
of alternating layers 22 and 24 on substrate 20. A lower electrode
14 and piezoelectric 16 material layer are deposited on the Bragg
reflector 12. The piezoelectric 16 material is patterned by
photolithography and etching. Then, the electrode 14 and, in some
embodiments, the reflector 12 are patterned by photolithography and
one or more etch steps. An insulating spacer 38 layer is then
deposited and patterned, to remove it from the portion of the
piezoelectric 16 material in region 42. An upper electrode 18 is
formed over the exposed region of the piezoelectric material 16 to
create the active portion of the device. In products where
integration of resonators with CMOS devices is desired, (therefore
requiring ohmic contact to the lower electrode 14), a via 46 is
formed in the insulating layer to the lower electrode 14 by
photolithography and etching. A conducting interconnect layer 34 is
formed for electrical connection to each of the electrodes. Up to
this point, the manufacturing process follows that described for
the embodiments illustrated in FIGS. 3 and 4.
[0062] The protective element cap 60 structure is formed over the
above-described structure by first depositing a sacrificial layer
over the structure, forming the cap 60 structure thereover and then
patterning the structure to remove the sacrificial layer. The
resulting space houses a vacuum or a noble gas in the completed
device. Sacrificial layers may be made out of any material that can
use underlying exposed material as an etch stop. Silicon is one
example of a suitable sacrificial material. The cap layer as
illustrated is a two layer structure; an inner protective layer 62
and an outer seal layer 64. An inner protective layer 62 is
deposited over the above described sacrificial layer. The
sacrificial layer has vias formed therein that are filled with the
protective layer material when the protective layer is formed on
the sacrificial layer. Since these vias are filled with the
protective layer material, the protective layer material remains
when the sacrificial layer is removed. The inner protective layer
is patterned such that it remains over the device region 42,
anchored to the substrate 20 by the protective layer material that
remains after the sacrificial layer is removed. The sacrificial
layers are then completely etched away, leaving the device and the
protective layer 62 as freestanding, released structures. This is
observed by the gap 63 between the device structure and the
protective layer 62. A seal layer 64 is deposited over the
structure encapsulating the device beneath the cap 60. Layer 62 can
be any structurally stiff material such as alumina, silicon
nitride, gold, etc. In certain embodiments, layer 62 is configured
as a Bragg structure such as previously described. Layer 64 can be
a material that provides a hermetic seal to the underlying
structure. Alumina and silicon nitride are examples of suitable
materials.
[0063] FIG. 9 is a cross section view of the alternate embodiment
66 described above with the core resonator 42 surrounded by the
collar 44. Structure 66 has a lower Bragg reflector 12, a lower
electrode 14, a piezoelectric 16 layer, a spacer 38 layer, an
optional temperature compensating layer 32, an upper electrode 18,
and an optional interconnect 34 layer. The Bragg reflector 12 has
alternating layers of high acoustic impedance layer 24 and low
acoustic impedance layer 22. The Bragg reflector has a plurality of
pairs of these layers. Each of these material layers has a
thickness equal to a quarter acoustic wavelength of the operational
mode in the material. The cap 60 that is formed over the resonator
structure has an inner protective layer 62 and an over seal layer
64. As with the other embodiments described herein, the structure
in FIG. 9 can be single-ended or differential.
[0064] For certain applications, stresses originating from the
wafer itself are significant enough to justify released (FBAR)
structure even though these structures exhibit decreased inertial
resistance. FIGS. 10 and 11 illustrate another alternate embodiment
66. The released FBARs have the collar 44 and spacer 38 that
protect the core resonator 42. The FBARs are covered with a cap 60
structure as described above for FIG. 9.
[0065] The structures illustrated in FIGS. 10 and 11 are formed as
follows. A sacrificial release layer is deposited and patterned
such that it remains under the device region 42. On the substrate
20 is formed a temperature compensating layer 32, lower electrode
14, piezoelectric 16 material, and upper electrode 18. The upper
electrode 18 is patterned by photolithography and etching. The
piezoelectric 16 material, the lower electrode 14, and the
temperature compensation layer are all patterned (preferably with
the same mask) using photolithography and a sequence of etches. A
second temperature compensation layer 32 is deposited and
patterned, sealing both regions 42 and 44 of the device except
electrical interconnects to the upper electrode 18. A conductive
layer 70 is then deposited and patterned that electrically connects
the device and mechanically supports the structure after
release.
[0066] The cap 60 structure is formed over the above structure. A
second sacrificial layer (not shown) is deposited and patterned. An
inner protective layer 62 is deposited and patterned such that it
remains over the device region, anchored to the substrate 20
through holes in the second sacrificial layer only. The sacrificial
layers are etched away, leaving the device and the protective layer
as freestanding, released structures. A seal layer 64 is deposited,
encapsulating the device beneath the protective membrane.
[0067] Referring to FIG. 10, the structure has a core resonator 42,
a collar 44 and a spacer 38, under a cap 60. The structure 66 has a
lower electrode 14, a piezoelectric 16 layer, a spacer 38 layer, an
optional temperature compensating layer 32, an upper electrode 18,
and an interconnect layer 70. The interconnect 70 layer is also a
suspension support. The suspension 70 supports the FBAR and is
connected to the substrate 20 by the anchor 72. The
interconnect/suspension 70 is made of a metal such as aluminum or
copper. In situations when the resonator is built directly on top
of a previously fabricated circuit wafer, the anchor 72 material is
also a metal, to facilitate interconnect with underlying circuitry.
The cap 60 formed over the resonator structure consists of an inner
protective layer 62 and a seal layer 64.
[0068] FIG. 11 shows a variant of the FBAR embodiment illustrated
in FIG. 10 where the FBAR is supported by a center post 72 instead
of side supports. The advantage of this embodiment is that
temperature-related stresses and other environmental effects (one
of the major reasons for device aging) do not introduce changes in
the FBAR performance. This is because the mismatch in the
temperature coefficient of the different materials in the resonator
structure, in particular the piezoelectric and the oxides cannot
cause stress at the material interfaces.
[0069] FIG. 11 is a cross section view of this alternate center
post embodiment. FIG. 11 illustrates a core resonator 42, a collar
44, and spacer 38, formed under a cap 60, where the FBAR is
supported at the center of the structure. The structure has a lower
electrode 14, a piezoelectric 16 layer, a spacer 38 layer, an
optional temperature compensating layer 32, an upper electrode 18,
and an interconnect (not shown) layer. The upper electrode 18 and
the interconnect 34 layer form the suspension 70 in the illustrated
embodiment. The suspension 70 supports the FBAR and is connected to
the substrate 20 by the anchor 72. Substrate 20 has a barrier layer
78 formed thereon. The barrier layer is any suitable material such
as, for example, silicon nitride. The cap 60 is formed over the
resonator structure. The cap 60 has an inner protective layer 62
and a seal layer 64.
[0070] An alternative FBAR configuration is illustrated in FIG. 13.
In this embodiment, an interconnect 76 is disposed underneath the
cap 60, and specifically under the protective layer 62 of the cap
60. In this embodiment the top electrode 18 is capacitively or
inductively coupled to the interconnect 76 disposed underneath the
cap. An alternative configuration is not illustrated where the
interconnect 76 is disposed on the barrier layer 78. In this
configuration, the bottom electrode 14 is capacitively or
inductively coupled to the interconnect 76. Therefore, the bottom
electrode 14 is the two part electrode in this alternative
configuration. The top electrode in the alternative configuration
is one part (as the bottom electrode 14 illustrated in FIG. 13).
The interconnect is also in two parts in this alternate
configuration, one part each being disposed on either side of the
temperature compensating layer disposed on the barrier layer. The
advantage of this structure is that neither the bottom electrode 14
nor the top electrode is performing a support function. Therefore
degradation in their mechanical properties due to environmental
effects or aging have no effect on resonator performance.
[0071] FIG. 12 is a cross section view of an alternate embodiment
74. This embodiment is an inverted SMR with a core resonator 42,
collar 44, both of which are encapsulated under a cap 40 that is
constructed as a Bragg reflector. The structure 74 has a lower
electrode 14, a piezoelectric 16 layer, and an upper electrode 18.
A temperature-compensating layer is optional and not illustrated.
The cap 40 formed over the resonator structure consists of an inner
protective layer 62 and a seal layer 64. The seal layer 64 is
configured as an energy-confining upper Bragg reflector. As
previously described such a layer has multiple pairs of layers,
each pair having a high acoustic impedance layer 24 and low
acoustic impedance layer 22. As described above, each of these
materials has a thickness equal to a quarter acoustic wavelength of
the operational mode in the material. Individual reflector layers
are not shown but illustrated as one monolithic layer 40. As with
other embodiments, this embodiment can be single-ended or
differential.
[0072] This embodiment can be thought of as an inverted SMR hanging
from the cap 40, with cap 40 constructed as a Bragg reflector.
There is no lower Bragg reflector (e.g. 12 in the structure
illustrated in FIG. 9); instead there is a cavity 80 created when a
sacrificial layer is etched away by a release process.
[0073] For products that require extremely low-profile packaging,
the aerogel-like encapsulant material in other embodiments may not
be suitable. For other products that require a high degree of
inertial shock resistance, a released FBAR structure may be
unsuitable. The cap 40 is able to protect the device 42 from
package and external stress while still providing an extremely
low-profile. Since the resonator is a part of the cap 40, it
benefits from the mechanical strength of the cap 40 while still
being acoustically isolated from the environment by the Bragg
reflector characteristic of the cap 40.
[0074] Although the invention herein has been described with
reference to particular embodiments, it is to be understood that
these embodiments are merely illustrative of the principles and
applications of the present invention. It is therefore to be
understood that numerous modifications may be made to the
illustrative embodiments and that other arrangements may be devised
without departing from the spirit and scope of the present
invention as defined by the appended claims.
[0075] Since other modifications and changes varied to fit
particular operating requirements and environments will be apparent
to those skilled in the art, the invention is not considered
limited to the example chosen for purposes of disclosure, and
covers all changes and modifications which do not constitute
departures from the true spirit and scope of this invention.
* * * * *