U.S. patent application number 16/998300 was filed with the patent office on 2020-12-03 for transversely-excited film bulk acoustic resonator.
The applicant listed for this patent is Resonant Inc.. Invention is credited to Charles Chung, Mike Eddy, Andrew Kay, Patrick Turner, Ventsislav Yantchev.
Application Number | 20200382101 16/998300 |
Document ID | / |
Family ID | 1000005030802 |
Filed Date | 2020-12-03 |
View All Diagrams
United States Patent
Application |
20200382101 |
Kind Code |
A1 |
Turner; Patrick ; et
al. |
December 3, 2020 |
TRANSVERSELY-EXCITED FILM BULK ACOUSTIC RESONATOR
Abstract
Acoustic resonator devices and filters are disclosed. A
piezoelectric plate is attached to a substrate, a portion of the
piezoelectric plate forming a diaphragm spanning a cavity in the
substrate. A first conductor pattern is formed on a surface of the
piezoelectric plate. The first conductor pattern includes
interleaved fingers of an interdigital transducer disposed on the
diaphragm, and a first plurality of contact pads. A second
conductor pattern is formed on a surface of a base, the second
conductor pattern including a second plurality of contact pads.
Each pad of the first plurality of contact pads is directly bonded
to a respective pad of the second plurality of contact pads. A
ring-shaped seal is form between a perimeter of the piezoelectric
plate and a perimeter of the base.
Inventors: |
Turner; Patrick; (San Bruno,
CA) ; Eddy; Mike; (Santa Barbara, CA) ; Kay;
Andrew; (Irvine, CA) ; Yantchev; Ventsislav;
(Sofia, BG) ; Chung; Charles; (San Francisco,
CA) |
|
Applicant: |
Name |
City |
State |
Country |
Type |
Resonant Inc. |
Goleta |
CA |
US |
|
|
Family ID: |
1000005030802 |
Appl. No.: |
16/998300 |
Filed: |
August 20, 2020 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
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16841134 |
Apr 6, 2020 |
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16998300 |
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62830258 |
Apr 5, 2019 |
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62881749 |
Aug 1, 2019 |
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62904416 |
Sep 23, 2019 |
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Current U.S.
Class: |
1/1 |
Current CPC
Class: |
H03H 9/1085 20130101;
H03H 9/02228 20130101; H03H 9/6406 20130101; H03H 9/105 20130101;
H03H 9/02992 20130101; H03H 9/25 20130101; H03H 9/586 20130101 |
International
Class: |
H03H 9/25 20060101
H03H009/25; H03H 9/58 20060101 H03H009/58; H03H 9/10 20060101
H03H009/10; H03H 9/64 20060101 H03H009/64; H03H 9/02 20060101
H03H009/02 |
Claims
1. A method of fabricating an acoustic resonator device,
comprising: fabricating an acoustic resonator chip, comprising:
bonding a back surface of a piezoelectric plate to a substrate;
forming a cavity in the substrate such that a portion of the
piezoelectric plate forms a diaphragm spanning the cavity; and
forming a first conductor pattern as one or more conductor layers
on a front surface of the single-crystal piezoelectric plate, the
first conductor pattern including: an interdigital transducer
(IDT), interleaved fingers of the IDT are disposed on the
diaphragm, and a first plurality of contact pads; forming a second
conductor pattern on a back surface of a base, the second conductor
pattern including: a second plurality of contact pads; attaching
the back surface of the base to the front surface of the
piezoelectric plate by directly bonding each contact pad of the
first plurality of contact pads to a respective contact pads of the
second plurality of contact pads; and forming a ring-shaped seal
between a perimeter of the piezoelectric plate and a perimeter of
the base.
2. The method of claim 1, wherein the cavity is a hole passing
through a thickness of the substrate, and the method further
comprises bonding a cap to a back surface of the substrate.
3. The method of claim 1, wherein the first conductor pattern
further includes a first conductor ring about the perimeter of the
piezoelectric plate, the second conductor pattern further includes
a second conductor ring about the perimeter of the base, and
forming a ring-shaped seal comprises directly bonding the first
conductor ring to the second conductor ring.
4. The method of claim 1, wherein forming a ring-shaped seal
further comprises: applying a ring of adhesive material around one
or both of a perimeter of the piezoelectric plate and a perimeter
of the base; and curing the adhesive material after or concurrent
with directly bonding the first plurality of contact pads to the
second plurality of contact pads.
5. The method of claim 1, wherein the method further comprises
forming vias to connect the second plurality of contact pads to a
third plurality of contact pads formed on the front surface of the
base.
6. The method of claim 1, further comprising: prior to attaching
the base to the piezoelectric plate, forming a recess in the back
surface of the base, the recess located in an area of the back
surface of the base that will face the diaphragm.
7. The method of claim 6, wherein forming a recess in the back
surface of the base further comprises: forming a recess having a
depth such that, after attaching the base to the piezoelectric
plate, a distance from a bottom of the recess to the diaphragm is
greater than or equal to 15 microns and less than or equal to 100
microns.
8. The method of claim 1, wherein the acoustic resonator device is
a bandpass filter; forming a cavity in the substrate comprises
forming a plurality of cavities such that a plurality of portions
of the piezoelectric plate form a corresponding plurality of
diaphragms spanning respective cavities of the plurality of
cavities; and the first conductor pattern includes a plurality of
IDTs, interleaved fingers of each IDT disposed on a respective
diaphragm of the plurality of diaphragms.
9. The method of claim 1, wherein the method further comprises
forming vias to connect the second plurality of contact pads to a
third plurality of contact pads formed on the front surface of the
base; and wherein the base is silicon and the vias are
through-silicon-vias (TSVs).
10. The method of claim 1, wherein the IDT and piezoelectric plate
are configured such that a radio frequency signal applied to the
IDT excites a bulk shear acoustic wave in the diaphragm.
11. A method of fabricating an acoustic resonator device,
comprising: fabricating an acoustic resonator chip, comprising:
bonding a back surface of a piezoelectric plate to a substrate;
forming a cavity in the substrate such that a portion of the
piezoelectric plate forms a diaphragm spanning the cavity; and
forming a first conductor pattern as one or more conductor layers
on a front surface of the single-crystal piezoelectric plate, the
first conductor pattern including: an interdigitated transducer
(IDT) comprising two bus bars and interleaved fingers, the
interleaved fingers of the IDT disposed on the diaphragm, the
piezoelectric plate and IDT configured so that a radio frequency or
microwave signal applied between the two busbars excites a bulk
shear acoustic wave within the diaphragm; and a first plurality of
contact pads; forming a second conductor pattern on a back surface
of a base of an interposer, the second conductor pattern including:
a second plurality of contact pads; attaching the back surface of
the base to the front surface of the piezoelectric plate by
directly bonding each contact pad of the first plurality of contact
pads to a respective contact pads of the second plurality of
contact pads; and forming a ring-shaped seal between a perimeter of
the piezoelectric plate and a perimeter of the base.
12. The method of claim 11, wherein the first conductor pattern
further includes a first conductor ring about the perimeter of the
piezoelectric plate, the second conductor pattern further includes
a second conductor ring about the perimeter of the base, and
forming a ring-shaped seal comprises directly bonding the first
conductor ring to the second conductor ring.
13. The method of claim 11, wherein the interposer further
comprises through-silicon-vias (TSVs) connecting the second
plurality of contact pads to a third plurality of contact pads
formed on the front surface of the base; and the base is
silicon.
14. The method of claim 11, further comprising: prior to attaching
the base to the piezoelectric plate, forming a recess in the back
surface of the base, the recess located in an area of the back
surface of the base that will face the diaphragm; and wherein
forming a recess in the back surface of the base further comprises
forming a recess having a depth such that, after attaching the base
to the piezoelectric plate, a distance from a bottom of the recess
to the diaphragm is greater than or equal to 15 microns and less
than or equal to 100 microns.
15. The method of claim 11, wherein the acoustic resonator device
is a bandpass filter; forming a cavity in the substrate comprises
forming a plurality of cavities such that a plurality of portions
of the piezoelectric plate form a corresponding plurality of
diaphragms spanning respective cavities of the plurality of
cavities; and the first conductor pattern includes a plurality of
IDTs, interleaved fingers of each IDT disposed on a respective
diaphragm of the plurality of diaphragms.
16. A method of fabricating a filter device, comprising:
fabricating an acoustic resonator chip, comprising: bonding a back
surface of a piezoelectric plate to a substrate; forming one or
more cavities in the substrate such that a portion of the
piezoelectric plate forms a diaphragm spanning the cavities; and
forming a conductor pattern on a front surface of the
single-crystal piezoelectric plate, the conductor pattern
including: a plurality of interdigitated transducer (IDTs) of a
respective plurality of resonators and a first plurality of contact
pads; wherein interleaved fingers of each of the plurality of IDTs
are disposed on respective portions of the piezoelectric plate
suspended over the one or more cavities; depositing a first
thickness of a first dielectric layer between the fingers of the
IDT of a first resonator of a respective plurality of resonators;
and depositing a second thickness of a second dielectric layer
between the fingers of the IDT of a second resonator of a
respective plurality of resonators; and forming a second conductor
pattern on a back surface of a base of an interposer, the second
conductor pattern including: a second plurality of contact pads;
and attaching the back surface of the base to the front surface of
the piezoelectric plate by directly bonding each contact pad of the
first plurality of contact pads to a respective contact pads of the
second plurality of contact pads; and forming a ring-shaped seal
between a perimeter of the piezoelectric plate and a perimeter of
the base.
17. The method of claim 16, wherein the plurality of resonators
includes at least five resonators, each resonator having: a recess
in the base facing the diaphragm; and a distance from a bottom of
the recess to the diaphragm is greater than or equal to 15 microns
and less than or equal to 100 microns.
18. The method of claim 16, wherein all of the plurality of IDTs
are configured to excite shear acoustic waves in the piezoelectric
plate in response to respective radio frequency signals applied to
each IDT; the interposer further comprises through-silicon-vias
(TSVs) connecting the second plurality of contact pads to a third
plurality of contact pads formed on the front surface of the base;
and the base is silicon.
Description
NOTICE OF COPYRIGHTS AND TRADE DRESS
[0001] A portion of the disclosure of this patent document contains
material which is subject to copyright protection. This patent
document may show and/or describe matter which is or may become
trade dress of the owner. The copyright and trade dress owner has
no objection to the facsimile reproduction by anyone of the patent
disclosure as it appears in the Patent and Trademark Office patent
files or records, but otherwise reserves all copyright and trade
dress rights whatsoever.
RELATED APPLICATION INFORMATION
[0002] This patent application is a divisional of copending U.S.
application Ser. No. 16/841,134 titled TRANSVERSELY-EXCITED FILM
BULK ACOUSTIC RESONATOR PACKAGE AND METHOD, filed Apr. 6, 2020,
which claims priority to the following provisional patent
applications: application 62/830,258, titled XBAR PACKAGING, filed
Apr. 5, 2019; application 62/881,749, titled XBAR PACKAGING
INCLUDING CAP PLATE, filed Aug. 1, 2019; and application
62/904,416, titled XBAR WAFER-LEVEL PACKAGING, filed Sep. 23, 2019,
all of which are incorporated herein by reference in their
entirety.
[0003] This patent is related to application Ser. No. 16/230,443,
filed Dec. 21, 2018, entitled TRANSVERSELY-EXCITED FILM BULK
ACOUSTIC RESONATOR, now U.S. Pat. No. 10,491,192.
BACKGROUND
Field
[0004] This disclosure relates to radio frequency filters using
acoustic wave resonators, and specifically to filters for use in
communications equipment.
Description of the Related Art
[0005] A radio frequency (RF) filter is a two-port device
configured to pass some frequencies and to stop other frequencies,
where "pass" means transmit with relatively low signal loss and
"stop" means block or substantially attenuate. The range of
frequencies passed by a filter is referred to as the "pass-band" of
the filter. The range of frequencies stopped by such a filter is
referred to as the "stop-band" of the filter. A typical RF filter
has at least one pass-band and at least one stop-band. Specific
requirements on a pass-band or stop-band depend on the specific
application. For example, a "pass-band" may be defined as a
frequency range where the insertion loss of a filter is better than
a defined value such as 1 dB, 2 dB, or 3 dB. A "stop-band" may be
defined as a frequency range where the rejection of a filter is
greater than a defined value such as 20 dB, 30 dB, 40 dB, or
greater depending on application.
[0006] RF filters are used in communications systems where
information is transmitted over wireless links. For example, RF
filters may be found in the RF front-ends of cellular base
stations, mobile telephone and computing devices, satellite
transceivers and ground stations, IoT (Internet of Things) devices,
laptop computers and tablets, fixed point radio links, and other
communications systems. RF filters are also used in radar and
electronic and information warfare systems.
[0007] RF filters typically require many design trade-offs to
achieve, for each specific application, the best compromise between
performance parameters such as insertion loss, rejection,
isolation, power handling, linearity, size and cost. Specific
design and manufacturing methods and enhancements can benefit
simultaneously one or several of these requirements.
[0008] Performance enhancements to the RF filters in a wireless
system can have broad impact to system performance. Improvements in
RF filters can be leveraged to provide system performance
improvements such as larger cell size, longer battery life, higher
data rates, greater network capacity, lower cost, enhanced
security, higher reliability, etc. These improvements can be
realized at many levels of the wireless system both separately and
in combination, for example at the RF module, RF transceiver,
mobile or fixed sub-system, or network levels.
[0009] The desire for wider communication channel bandwidths will
inevitably lead to the use of higher frequency communications
bands. The current LTE.TM. (Long Term Evolution) specification
defines frequency bands from 3.3 GHz to 5.9 GHz. These bands are
not presently used. Future proposals for wireless communications
include millimeter wave communication bands with frequencies up to
28 GHz.
[0010] High performance RF filters for present communication
systems commonly incorporate acoustic wave resonators including
surface acoustic wave (SAW) resonators, bulk acoustic wave (BAW)
resonators, film bulk acoustic wave resonators (FBAR), and other
types of acoustic resonators. However, these existing technologies
are not well-suited for use at the higher frequencies proposed for
future communications networks.
DESCRIPTION OF THE DRAWINGS
[0011] FIG. 1 includes a schematic plan view and two schematic
cross-sectional views of a transversely-excited film bulk acoustic
resonator (XBAR).
[0012] FIG. 2 is an expanded schematic cross-sectional view of a
portion of the XBAR of FIG. 1.
[0013] FIG. 3 is an alternative schematic cross-sectional view of
the XBAR of FIG. 1.
[0014] FIG. 4A is a schematic cross-sectional view of a packaged
XBAR.
[0015] FIG. 4B is a schematic cross-sectional view of another
packaged XBAR.
[0016] FIG. 5 is a graph of the transmission S21 through a bandpass
filter using XBARs with a distance between the XBARs and a silicon
cover as a parameter.
[0017] FIG. 6A is a schematic cross-sectional view of an XBAR
filter chip and an interposer prior to bonding.
[0018] FIG. 6B is a schematic cross-sectional view of a packaged
XBAR filter.
[0019] FIG. 7A is a schematic cross-sectional view of another
packaged XBAR filter.
[0020] FIG. 7B is a schematic cross-sectional view of another
packaged XBAR filter.
[0021] FIG. 8 is a schematic cross-sectional view of another
packaged XBAR filter.
[0022] FIG. 9 is a schematic cross-sectional view of another
packaged XBAR filter.
[0023] FIG. 10 is a schematic cross-sectional view of another
packaged XBAR filter.
[0024] FIG. 11 is a flow chart of a process for fabricating an XBAR
chip.
[0025] FIG. 12A, FIG. 12B, and FIG. 12C are, in combination, a flow
chart of process for packaging an XBAR filter.
[0026] FIG. 13 is a flow chart of another process for packaging an
XBAR filter.
[0027] FIG. 14 is a flow chart of another process for packaging an
XBAR filter.
[0028] Throughout this description, elements appearing in figures
are assigned three-digit or four-digit reference designators, where
the two least significant digits are specific to the element and
the one or two most significant digit is the figure number where
the element is first introduced. An element that is not described
in conjunction with a figure may be presumed to have the same
characteristics and function as a previously-described element
having the same reference designator.
DETAILED DESCRIPTION
[0029] Description of Apparatus
[0030] FIG. 1 shows a simplified schematic top view and orthogonal
cross-sectional views of a transversely-excited film bulk acoustic
resonator (XBAR) 100. XBAR resonators such as the resonator 100 may
be used in a variety of RF filters including band-reject filters,
band-pass filters, duplexers, and multiplexers. XBARs are
particularly suited for use in filters for communications bands
with frequencies above 3 GHz.
[0031] The XBAR 100 is made up of a thin film conductor pattern
formed on a surface of a piezoelectric plate 110 having parallel
front and back surfaces 112, 114, respectively. The piezoelectric
plate is a thin single-crystal layer of a piezoelectric material
such as lithium niobate, lithium tantalate, lanthanum gallium
silicate, gallium nitride, or aluminum nitride. The piezoelectric
plate is cut such that the orientation of the X, Y, and Z
crystalline axes with respect to the front and back surfaces is
known and consistent. In the examples presented in this patent, the
piezoelectric plates are Z-cut, which is to say the Z axis is
normal to the surfaces. However, XBARs may be fabricated on
piezoelectric plates with other crystallographic orientations.
[0032] The back surface 114 of the piezoelectric plate 110 is
attached to a substrate 120 that provides mechanical support to the
piezoelectric plate 110. The substrate 120 may be, for example,
silicon, sapphire, quartz, or some other material. The
piezoelectric plate 110 may be bonded to the substrate 120 using a
wafer bonding process, or grown on the substrate 120, or attached
to the substrate in some other manner. The piezoelectric plate may
be attached directly to the substrate, or may be attached to the
substrate via one or more intermediate material layers.
[0033] The conductor pattern of the XBAR 100 includes an
interdigital transducer (IDT) 130. The IDT 130 includes a first
plurality of parallel fingers, such as finger 136, extending from a
first busbar 132 and a second plurality of fingers extending from a
second busbar 134. The first and second pluralities of parallel
fingers are interleaved. The interleaved fingers overlap for a
distance AP, commonly referred to as the "aperture" of the IDT. The
center-to-center distance L between the outermost fingers of the
IDT 130 is the "length" of the IDT.
[0034] The first and second busbars 132, 134 serve as the terminals
of the XBAR 100. A radio frequency or microwave signal applied
between the two busbars 132, 134 of the IDT 130 excites an acoustic
wave within the piezoelectric plate 110. As will be discussed in
further detail, the excited acoustic wave is a bulk shear wave that
propagates in the direction normal to the surface of the
piezoelectric plate 110, which is also normal, or transverse, to
the direction of the electric field created by the IDT fingers.
Thus, the XBAR is considered a transversely-excited film bulk wave
resonator.
[0035] A cavity 140 is formed in the substrate 120 such that a
portion 115 of the piezoelectric plate 110 containing the IDT 130
is suspended over the cavity 140 without contacting the substrate
120. "Cavity" has its conventional meaning of "an empty space
within a solid body." The cavity 140 may be a hole completely
through the substrate 120 (as shown in Section A-A and Section B-B)
or a recess in the substrate 120 (as shown subsequently in FIG. 3).
The cavity 140 may be formed, for example, by selective etching of
the substrate 120 before or after the piezoelectric plate 110 and
the substrate 120 are attached. As shown in FIG. 1, the cavity 140
has a rectangular shape with an extent greater than the aperture AP
and length L of the IDT 130. A cavity of an XBAR may have a
different shape, such as a regular or irregular polygon. The cavity
of an XBAR may more or fewer than four sides, which may be straight
or curved.
[0036] The portion 115 of the piezoelectric plate suspended over
the cavity 140 will be referred to herein as the "diaphragm" (for
lack of a better term) due to its physical resemblance to the
diaphragm of a microphone. The diaphragm may be continuously and
seamlessly connected to the rest of the piezoelectric plate 110
around all, or nearly all, of perimeter of the cavity 140.
[0037] For ease of presentation in FIG. 1, the geometric pitch and
width of the IDT fingers is greatly exaggerated with respect to the
length (dimension L) and aperture (dimension AP) of the XBAR. A
typical XBAR has more than ten parallel fingers in the IDT 110. An
XBAR may have hundreds, possibly thousands, of parallel fingers in
the IDT 110. Similarly, the thickness of the fingers in the
cross-sectional views is greatly exaggerated.
[0038] FIG. 2 shows a detailed schematic cross-sectional view of
the XBAR 100 of FIG. 1. The piezoelectric plate 110 is a
single-crystal layer of piezoelectrical material having a thickness
ts. ts may be, for example, 100 nm to 1500 nm. When used in filters
for LTE.TM. bands from 3.4 GHZ to 6 GHz (e.g. bands 42, 43, 46),
the thickness ts may be, for example, 200 nm to 1000 nm.
[0039] A front-side dielectric layer 214 may optionally be formed
on the front side of the piezoelectric plate 110. The "front side"
of the XBAR is, by definition, the surface facing away from the
substrate. The front-side dielectric layer 214 has a thickness tfd.
The front-side dielectric layer 214 is formed between the IDT
fingers 238. Although not shown in FIG. 2, the front side
dielectric layer 214 may also be deposited over the IDT fingers
238. A back-side dielectric layer 216 may optionally be formed on
the back side of the piezoelectric plate 110. The back-side
dielectric layer 216 has a thickness tbd. The front-side and
back-side dielectric layers 214, 216 may be a non-piezoelectric
dielectric material, such as silicon dioxide or silicon nitride.
tfd and tbd may be, for example, 0 to 500 nm. tfd and tbd are
typically less than the thickness is of the piezoelectric plate.
tfd and tbd are not necessarily equal, and the front-side and
back-side dielectric layers 214, 216 are not necessarily the same
material. Either or both of the front-side and back-side dielectric
layers 214, 216 may be formed of multiple layers of two or more
materials.
[0040] The IDT fingers 238 may be aluminum or a substantially
aluminum alloy, copper or a substantially copper alloy, beryllium,
gold, or some other conductive material. Thin (relative to the
total thickness of the conductors) layers of other metals, such as
chromium or titanium, may be formed under and/or over the fingers
to improve adhesion between the fingers and the piezoelectric plate
110 and/or to passivate or encapsulate the fingers. The busbars
(132, 134 in FIG. 1) of the IDT may be made of the same or
different materials as the fingers.
[0041] Dimension p is the center-to-center spacing or "pitch" of
the IDT fingers, which may be referred to as the pitch of the IDT
and/or the pitch of the XBAR. Dimension w is the width or "mark" of
the IDT fingers. The IDT of an XBAR differs substantially from the
IDTs used in surface acoustic wave (SAW) resonators. In a SAW
resonator, the pitch of the IDT is one-half of the acoustic
wavelength at the resonance frequency. Additionally, the
mark-to-pitch ratio of a SAW resonator IDT is typically close to
0.5 (i.e. the mark or finger width is about one-fourth of the
acoustic wavelength at resonance). In an XBAR, the pitch p of the
IDT is typically 2 to 20 times the width w of the fingers. In
addition, the pitch p of the IDT is typically 2 to 20 times the
thickness is of the piezoelectric slab 212. The width of the IDT
fingers in an XBAR is not constrained to one-fourth of the acoustic
wavelength at resonance. For example, the width of XBAR IDT fingers
may be 500 nm or greater, such that the IDT can be fabricated using
optical lithography. The thickness tm of the IDT fingers may be
from 100 nm to about equal to the width w. The thickness of the
busbars (132, 134 in FIG. 1) of the IDT may be the same as, or
greater than, the thickness tm of the IDT fingers.
[0042] FIG. 3 is an alternative cross-sectional view along the
section plane A-A defined in FIG. 1. In FIG. 3, a piezoelectric
plate 310 is attached to a substrate 320. A cavity 340, which does
not fully penetrate the substrate 320, is formed in the substrate
under the portion of the piezoelectric plate 310 containing the IDT
of an XBAR. The cavity 340 may be formed, for example, by etching
the substrate 320 before attaching the piezoelectric plate 310.
Alternatively, the cavity 340 may be formed by etching the
substrate 320 with a selective etchant that reaches the substrate
through one or more openings 342 provided in the piezoelectric
plate 310.
[0043] The XBAR 300 shown in FIG. 3 will be referred to herein as a
"front-side etch" configuration since the cavity 340 is etched from
the front side of the substrate 320 (before or after attaching the
piezoelectric plate 310). The XBAR 100 of FIG. 1 will be referred
to herein as a "back-side etch" configuration since the cavity 140
is etched from the back side of the substrate 120 after attaching
the piezoelectric plate 110.
[0044] The XBARs of FIG. 1 and FIG. 3 and filter devices using
XBARs must be encased in a package. The package for an XBAR must
perform the following functions: [0045] Provide mechanical
protection for the diaphragms and conductor patterns; [0046]
Provide cavities facing the diaphragms comparable to the cavity 340
in the substrate 320; [0047] Provide a seal to prevent intrusion of
humidity and/or fluids that may be encountered during subsequent
assembly of the packaged filter into an electronic device; and
[0048] Provide means for connecting the conductor patterns of the
XBARs to circuitry external to the packaged filter device.
[0049] FIG. 4A and FIG. 4B are schematic cross-sectional views of
packaged XBAR filters, each of which comprises an XBAR filter chip
405 and an interposer 450. While the cross-sectional views of FIG.
4A and FIG. 4B show the XBAR filter chips 405 containing two XBARs,
filters may commonly include five to nine XBARs. Specifically, FIG.
4A is a schematic cross-sectional view of a packaged filter 400A
using front-side etched XBARs, and FIG. 4B is a schematic
cross-section view of a packaged XBAR filter 400B using back-side
etched XBARs. FIG. 4A and FIG. 4B are intended to illustrate the
requirements on the package for an XBAR filter but do not
necessarily represent practical package structures.
[0050] Referring to FIG. 4A, the XBAR filter chip 405 includes a
piezoelectric plate 410 attached to a substrate 420. Portions of
the piezoelectric plate form diaphragms spanning respective
cavities 440 in the substrate 420. Commonly, one or more
intermediate layers, which are shown in FIG. 4A but not identified,
may be disposed between the piezoelectric plate 410 and the
substrate 420. Conductor patterns including IDTs are formed on the
surface of the piezoelectric plate 410 such that interleaved IDT
fingers, such as fingers 430, are disposed on the diaphragms.
[0051] The interposer 450 also includes a base 452 and conductive
vias 454 to provide electrical connections between the conductor
patters on the piezoelectric plate 410 and circuitry external to
the filter (not shown). The term "interposer" is generally used to
describe a passive circuit device that provides electrical
connections between two different interfaces. The interposer 450
fulfills this function but also forms a structural part of the
package of the packaged XBAR filter 400A. The interposer may be,
for example, a printed circuit board (PCB), a low temperature
cofired ceramic (LTCC) circuit card, a silicon wafer, or some other
structure that provides mechanical protection to the diaphragms of
the XBARs.
[0052] In FIG. 4A, the conductive vias 454 are illustrated
schematically as simple pins extending though the base to the
piezoelectric plate. As will be discuss subsequently, physically
realizable vias have more complex structures.
[0053] As shown in FIG. 4A, the interposer 450 includes recesses
455 facing the diaphragms of the XBARs. Such recesses may be
required to ensure sufficient spacing between the diaphragms and
the surfaces of the interposer facing the diaphragms (i.e. the
bottom surfaces of the cavities 440). The required spacing
(dimension cd in the FIG. 4A) depends on the material of the
interposer.
[0054] FIG. 5 is a plot of the transmission (S21) through a
bandpass filter including five XBARs in a package including a base
made from a high resistivity silicon wafer. The silicon wafer has
high dielectric permittivity and finite conductivity that can
distort the electric fields created by the IDTs within the XBARs
and introduce electrical losses, and thus impact the filter
performance. The solid line 510 is a plot of S12 for a filter where
the dimension cd is 50 microns. The dashed line 520 is a plot of
S12 for the same filter where the dimension cd is 15 microns. The
dotted line 530 is a plot of S12 for the same filter where the
dimension cd is 5 microns. Reducing the spacing between the surface
of the interposer and the diaphragms from 50 microns to 15 microns
reduces the transmission of the filter in the passband by about 0.5
dB. Further reducing the spacing between the surface of the
interposer and the diaphragms to 5 microns results in an addition
reduction in transmission by about 1.0 dB. 15 microns may be a
practical minimum for the dimension cd. Increasing the spacing
between the surface of the interposer beyond 50 microns, for
example to 100 microns, may offer a small addition improvement in
transmission. All transmission plots are based on simulations of
packaged filters using finite element methods.
[0055] Referring back to FIG. 4A, the interposer 450 is attached to
the piezoelectric plate 410 by a seal 460. The seal 460 provides
mechanical attachment and prevents intrusion of humidity and other
fluids into the interior of the packaged XBAR filter 400A. As shown
in FIG. 4A, the seal 460 is a distinct structure having a finite
thickness which contributes to the total spacing cd between the
diaphragms and the facing surfaces of the interposer 450. The seal
460 may be, for example, a thermocompression or ultrasonic bond
between metal layers deposited on the piezoelectric plate and the
interposer, a polymer or adhesive bond, a eutectic or solder bond,
a glass frit bond, or some other bonding method and structure.
Alternatively, the seal may be a bond, such as a plasma activated
or surface activated wafer bond, directly between the interposer
450 and the piezoelectric plate 410. In this case (not shown in
FIG. 4A), the thickness of the seal 460 may be negligible. In all
cases, the seal 460 is present around the entire perimeter of the
packaged XBAR filter 400A. In addition, the same sealing mechanism
may attach the piezoelectric plate 410 to the interposer 450 at
locations, such as location 465, in the interior of the packaged
XBAR filter 400A.
[0056] FIG. 4B is a schematic cross-section view of a packaged XBAR
filter 400B using back-side etched XBARs. Except for the depth of
the cavities 440, the structure of the XBAR filter chip 405, the
interposer 450, and the seal 460 between the interposer and the
piezoelectric plate are identical to the comparable elements in
FIG. 4A. The descriptions of these elements will not be
repeated.
[0057] In addition, the package XBAR filter 400B includes a cap 480
attached to the substrate 420 by a cap seal 485. The cap 480 may be
any material suitable to cover the openings where the cavities 440
intersect the surface of the substrate 420. For example, the cap
480 may be silicon, glass, quartz, or a polymer plate or film. The
cap seal 485 may be any of the materials and sealing methods
previously described with respect to the seal 460.
[0058] FIG. 4B also illustrates the packaged XBAR filter 400B
attached and electrically connected to a radio module circuit board
490 by means of solder balls 495. This is an example of the use of
the packaged filter device. The radio module circuit board 490 and
the solder balls 495 are not part of the filter device 400B.
[0059] FIG. 6A is an exploded schematic cross-sectional view of a
packaged XBAR filter 600. More specifically, FIG. 6A shows
schematic cross-sectional views of an XBAR filter chip 605
including front-side etched XBARs and an interposer 650 prior to
bonding.
[0060] The XBAR filter chip 605 includes a piezoelectric plate 610
attached to a substrate 620. The substrate 620 may be high
resistivity silicon or some other material. Portions of the
piezoelectric plate 610 form diaphragms spanning respective
cavities 640 in the substrate 620. Commonly, one or more
intermediate layers, which are shown in FIG. 6A but not identified,
may be disposed between the piezoelectric plate 610 and the
substrate 620. A first conductor pattern is formed on the surface
of the piezoelectric plate 610. The first conductor pattern
includes IDTs with interleaved IDT fingers, such as fingers 630,
disposed on the diaphragms. The first conductor pattern may be
aluminum, copper, molybdenum, or some other metal with a thickness
of about 100 nm to 1000 nm.
[0061] A second conductor pattern is formed on the surface of the
piezoelectric plate 610. The second conductor pattern, which may
overlay portions of the first conductor pattern, may be gold,
aluminum, copper or some other metal. The second conductor pattern
includes a continuous metal ring 662 around the perimeter of the
XBAR filter chip 605. The second conductor pattern also includes
pads, such as pad 672, in locations where portions of the first
conductor pattern must be connected to circuitry external to the
packaged XBAR filter.
[0062] The interposer 650 includes a base 652, which may be high
resistivity silicon or some other material. The base 652 may have
recesses 655 so that the surfaces of the base 652 facing the
diaphragms (i.e. the bottoms of the recesses 655) are sufficiently
far from the diaphragms. A third conductor pattern is formed on the
surface of the base 652 facing the XBAR filter chip 605. The third
conductor pattern may be the same material as the second conductor
pattern. The third conductor pattern includes a continuous metal
ring 664 around the perimeter of the base 652. The third conductor
pattern also includes pads, such as pad 674, in locations where
portions of the first conductor pattern must be connected to
circuitry external to the packaged XBAR filter. The arrangement of
ring 664 and pads 674 of third conductor pattern is typically a
mirror image of the arrangement of the ring 662 and pads 672 of the
second conductor pattern.
[0063] The interposer 650 also includes vias such as via 676. When
the base is silicon, such vias are commonly referred to as "through
silicon vias" (TSVs). Vias consist of a metal-coated or
metal-filled hole through the base 652. Each via provides an
electrical connection between one of the pads, such as pad 674, of
the third conductor pattern and a corresponding pad on the external
surface (i.e. the lower surface as shown in the figure) of the base
652. While FIG. 6A, which is intended to illustrate the structure
of the packaged XBAR filter 600, shows the TSVs formed prior to
bonding the XBAR filter chip 605 and the interposer 650, the vias
may be formed after bonding.
[0064] FIG. 6B is a schematic cross-sectional view of the packaged
XBAR filter 600 after the XBAR filter chip 605 and the interposer
650 of FIG. 6A are bonded to each other. Descriptions of all of the
identified elements in FIG. 6B were previously provided in the
discussion of FIG. 6A and will not be repeated.
[0065] As shown in FIG. 6B, the ring 662 around the perimeter of
the XBAR filter chip 605 has been directly bonded to the ring 664
around the perimeter of the interposer 650 to create a hermetic
seal around the perimeter of the package XBAR filter 600. In this
context, the term "directly bonded" means bonded without any
intervening adhesive. Simultaneously, the pads, such as pad 672, of
the second conductor pattern have been directly bonded to the pads,
such as pad 674, of the third conductor pattern to create
electrical connections between the XBAR filter chip 605 and the
interposer 650. The bonds between the rings and pads of the second
and third conductor patterns may be accomplished by, for example,
thermocompression bonding or ultrasonic bonding.
[0066] FIG. 7A is a schematic cross-sectional view of a packaged
XBAR filter 700A including an XBAR filter chip 705 bonded to an
interposer 750. With the exception of elements 780 and 785, the
identified elements in FIG. 7A have the structure and function as
the corresponding elements of FIG. 6A and FIG. 6B. Descriptions of
these elements will not be repeated.
[0067] A cap 780 is sealed to the substrate 720 by a cap seal 785.
When the substrate 720 of the XBAR filter chip 705 and the base 752
of the interposer 750 are both silicon, the cap 780 may also be
silicon to maintain consistency of thermal expansion coefficients.
In other cases, the cap 780 may be silicon, borosilicate or other
glass, plastic, or some other material. The cap 780 may be attached
to the substrate 720 using any of the previously described sealing
methods and materials. Typically, the cap 780 will be attached to
the substrate 720 immediately after forming the cavities 740 in the
substrate. The cap 780 may be attached to the substrate 720 before
bonding the XBAR filter chip 705 to the interposer 750.
[0068] FIG. 7B is a schematic cross-sectional view of a packaged
XBAR filter 700B including an XBAR filter chip 705 bonded to an
interposer 750. With the exception of element 768, the identified
elements in FIG. 7B have the structure and function as the
corresponding elements of FIG. 6A and FIG. 6B. Descriptions of
these elements will not be repeated.
[0069] In the packaged XBAR filter 700B, a perimeter seal between
the piezoelectric plate 710 and the base 752 is not made by bonding
conductor rings (i.e. conductor rings 762, 772 in FIG. 7A).
Instead, a ring of cured adhesive material 768 forms a perimeter
seal between the piezoelectric plate 710 and the base 752. The
cured adhesive material 768 may be, for example, an epoxy resin or
other thermosetting adhesive. The adhesive material (in an uncured
state) may be applied to either or both of the piezoelectric plate
710 and the base 752 before the piezoelectric plate 710 and the
base 752 are assembled. The adhesive material may be cured after or
concurrent with bonding the pads 772 to the pads 774.
[0070] The XBAR filter chips 605 and 705 shown in FIG. 6B, FIG. 7A,
and FIG. 7B may be portions of large wafers containing many filter
chips. Similarly, the interposers 650 and 750 may be portions of
large wafers containing a corresponding number on interposers. An
XBAR wafer and an interposer wafer may be bonded and individual
packaged XBAR filters may be excised from the bonded wafers.
[0071] FIG. 8 is a schematic cross-sectional view of another
packaged XBAR filter 800 including an XBAR filter chip 805 with
front-side etched cavities 840 and a low temperature cofired
ceramic (LTCC) interposer 850. As in the previous examples, the
XBAR filter chip 805 includes a piezoelectric plate 810 attached to
a substrate 820. The substrate 820 may be high resistivity silicon
or some other material. Portions of the piezoelectric plate 810
form diaphragms spanning respective cavities 840 in the substrate
820. Commonly, one or more intermediate layers, which are shown in
FIG. 8 but not identified, may be disposed between the
piezoelectric plate 810 and the substrate 820. A conductor pattern
is formed on the surface of the piezoelectric plate 810. The
conductor pattern includes IDTs with interleaved IDT fingers, such
as fingers 830, disposed on the diaphragms.
[0072] The LTCC interposer 850 comprises layers of thin ceramic
tape, some or all of which bear printed conductors, that are
assembled and then fired to form a rigid multilayer circuit board.
In the example of FIG. 8, the interposer has three conductor layers
874, 876, 878. An LTCC interposer for an XBAR filter may have more
than three layers. The availability of multiple conductor layers
allows incorporation of passive components, such as inductors, into
the interposer.
[0073] The LTCC interposer 850 may have recesses 855 to ensure
sufficient spacing between the diaphragms and the surfaces of the
interposer facing the diaphragms. Such recess may be formed, for
example, by punching openings in one or more of the ceramic layers
prior to cofiring the layers of the interposer.
[0074] The XBAR filter chip 805 is flip-chip mounted to the
interposer 850. Flip-chip mounting establishes physical and
electric connections between the XBAR filter chip 805 and the
interposer 850. As shown in FIG. 8, the connections are made by
means of solder balls such as solder ball 872. Alternatively, the
connections made be made by thermocompression or ultrasonic bonding
of gold bumps on the XBAR filter chip 805 and the interposer 850
(not shown).
[0075] Since flip-chip mounting does not establish a seal between
the XBAR filter chip 805 and the interposer 850, a polymer cover
860 is molded over the assembly to provide a near-hermetic
seal.
[0076] FIG. 9 is a schematic cross-sectional view of another
packaged XBAR filter 900 including an XBAR filter chip 905 with
back-side etched cavities and a low temperature cofired ceramic
(LTCC) interposer 950. With the exception of element 980, the
identified elements in FIG. 9 have the structure and function as
the corresponding elements of FIG. 8. Descriptions of these
elements will not be repeated.
[0077] A cap 980 is sealed to the substrate 920. Since the cap 980
is eventually enclosed by the molded cover 970, the cap's primary
function is to prevent intrusion of materials, including the
molding compound used for the cover 970, into the cavities 940.
This function may be satisfied by a very thin cap, such as a
plastic film.
[0078] FIG. 10 is a schematic cross-sectional view of another
packaged XBAR filter 1000 including an XBAR filter chip 1005 with
back-side etched cavities and an interposer 1050 formed by layers
built up on the surface of the XBAR filter chip. The XBAR filter
chip 1005 is a portion of a wafer (not shown) containing multiple
XBAR filter chips. The build up of the interposer layers is done on
all of the XBAR filter chips simultaneously. Individual packaged
XBAR filters are then excised from the wafer.
[0079] As in previous examples, the XBAR filter chip 1005 includes
a piezoelectric plate 1010 attached to a substrate 1020. The
substrate 1020 may be high resistivity silicon or some other
material. Portions of the piezoelectric plate 1010 form diaphragms
spanning respective cavities 1040 in the substrate 1020. Commonly,
one or more intermediate layers, which are shown in FIG. 10 but not
identified, may be disposed between the piezoelectric plate 1010
and the substrate 1020. A conductor pattern is formed on the
surface of the piezoelectric plate 1010. The conductor pattern
includes IDTs with interleaved IDT fingers, such as fingers 1030,
disposed on the diaphragms. A cap 1080 is sealed to the substrate
1020 by a cap seal 1085 as previously described.
[0080] The interposer 1050 includes at least three layers
sequentially formed on the piezoelectric plate 1010. Walls 1052
surround the diaphragms of the XBAR devices. The thickness of the
walls 1052 defines the distance between the diaphragms and a cover
layer 1054 that spans the walls creating an enclosed cavity 1055
over each diaphragm. Both the walls 1052 and the cover layer 1054
may be polymer materials. An interposer conductor pattern 1070
includes pads 1072 on the external surface of the cover layer 1054
for connection to circuitry external to the packaged XBAR filter.
The conductor pattern 1070 connects the pads 1072 to connection
points 1074 on the XBAR filer chip 1005. The conductor pattern 1070
may be aluminum, copper, gold, or a combination of materials.
[0081] Description of Methods
[0082] FIG. 11 is a simplified flow chart showing a process 1100
for making an XBAR filter chip. The process 1100 starts at 1105
with a substrate and a plate of piezoelectric material and ends at
1195 with a completed XBAR filter chip. The flow chart of FIG. 11
includes only major process steps. Various conventional process
steps (e.g. surface preparation, cleaning, inspection, baking,
annealing, monitoring, testing, etc.) may be performed before,
between, after, and during the steps shown in FIG. 11.
[0083] The flow chart of FIG. 11 captures three variations of the
process 1100 for making an XBAR filter chip which differ in when
and how cavities are formed in the substrate. The cavities may be
formed at steps 1110A, 1110B, or 1110C. Only one of these steps is
performed in each of the three variations of the process 1100.
[0084] The piezoelectric plate may be, for example, Z-cut lithium
niobate or lithium tantalate as used in the previously presented
examples. The piezoelectric plate may be some other material and/or
some other cut. The substrate may preferably be silicon. The
substrate may be some other material that allows formation of deep
cavities by etching or other processing.
[0085] In one variation of the process 1100, one or more cavities
are formed in the substrate at 1110A, before the piezoelectric
plate is bonded to the substrate at 1120. A separate cavity may be
formed for each resonator in a filter device. The one or more
cavities may be formed using conventional photolithographic and
etching techniques. Typically, the cavities formed at 1110A will
not penetrate through the substrate, and the resulting resonator
devices will have a cross-section as shown in FIG. 3A or FIG.
3B.
[0086] At 1120, the piezoelectric plate is bonded to the substrate.
The piezoelectric plate and the substrate may be bonded by a wafer
bonding process. Typically, the mating surfaces of the substrate
and the piezoelectric plate are highly polished. One or more layers
of intermediate materials, such as an oxide or metal, may be formed
or deposited on the mating surface of one or both of the
piezoelectric plate and the substrate. One or both mating surfaces
may be activated using, for example, a plasma process. The mating
surfaces may then be pressed together with considerable force to
establish molecular bonds between the piezoelectric plate and the
substrate or intermediate material layers.
[0087] A conductor pattern, including IDTs of each XBAR, is formed
at 1130 by depositing and patterning one or more conductor layer on
the front side of the piezoelectric plate. The conductor layer may
be, for example, aluminum, an aluminum alloy, copper, a copper
alloy, or some other conductive metal. Optionally, one or more
layers of other materials may be disposed below (i.e. between the
conductor layer and the piezoelectric plate) and/or on top of the
conductor layer. For example, a thin film of titanium, chrome, or
other metal may be used to improve the adhesion between the
conductor layer and the piezoelectric plate. A conduction
enhancement layer of gold, aluminum, copper or other higher
conductivity metal may be formed over portions of the conductor
pattern (for example the IDT bus bars and interconnections between
the IDTs).
[0088] The conductor pattern may be formed at 1130 by depositing
the conductor layer and, optionally, one or more other metal layers
in sequence over the surface of the piezoelectric plate. The excess
metal may then be removed by etching through patterned photoresist.
The conductor layer can be etched, for example, by plasma etching,
reactive ion etching, wet chemical etching, and other etching
techniques.
[0089] Alternatively, the conductor pattern may be formed at 1130
using a lift-off process. Photoresist may be deposited over the
piezoelectric plate. and patterned to define the conductor pattern.
The conductor layer and, optionally, one or more other layers may
be deposited in sequence over the surface of the piezoelectric
plate. The photoresist may then be removed, which removes the
excess material, leaving the conductor pattern.
[0090] At 1140, a front-side dielectric layer may be formed by
depositing one or more layers of dielectric material on the front
side of the piezoelectric plate. The one or more dielectric layers
may be deposited using a conventional deposition technique such as
sputtering, evaporation, or chemical vapor deposition. The one or
more dielectric layers may be deposited over the entire surface of
the piezoelectric plate, including on top of the conductor pattern.
Alternatively, one or more lithography processes (using photomasks)
may be used to limit the deposition of the dielectric layers to
selected areas of the piezoelectric plate, such as only between the
interleaved fingers of the IDTs. Masks may also be used to allow
deposition of different thicknesses of dielectric materials on
different portions of the piezoelectric plate.
[0091] In a second variation of the process 1100, one or more
cavities are formed in the back-side of the substrate at 1110B. A
separate cavity may be formed for each resonator in a filter
device. The one or more cavities may be formed using an anisotropic
or orientation-dependent dry or wet etch to open holes through the
back-side of the substrate to the piezoelectric plate. In this
case, the resulting resonator devices will have a cross-section as
shown in FIG. 1.
[0092] In the second variation of the process 1100, a cap, such as
the caps 480, 780, 980, 1080, may be attached to the substrate at
1150 to cover and seal the cavities formed at 1110B. The cap may a
plate of silicon, glass, or some other material or a plate or film
of a polymer material. The cap may be attached to the substrate
using any of the previously discussed bonding techniques.
[0093] In a third variation of the process 1100, one or more
cavities in the form of recesses in the substrate may be formed at
1110C by etching the substrate using an etchant introduced through
openings in the piezoelectric plate. A separate cavity may be
formed for each resonator in a filter device. The one or more
cavities formed at 1110C will not penetrate through the substrate,
and the resulting resonator devices will have a cross-section as
shown in FIG. 3.
[0094] In all variations of the process 1100, the XBAR filter chip
is completed at 1160. Actions that may occur at 1160 include
depositing an encapsulation/passivation layer such as SiO.sub.2 or
Si.sub.3O.sub.4 over all or a portion of the device; forming
bonding pads or solder bumps or other means for making connection
between the device and external circuitry; and, if necessary,
tuning the resonant frequencies of the resonators within the device
by adding or removing metal or dielectric material from the front
side of the device. At the conclusion of 1160, the XBAR filter chip
is ready to be packaged. The process 1100 then ends at 1195.
[0095] FIG. 12A, FIG. 12B, and FIG. 12C are, in combination, a flow
chart of process 1200 for fabricating a package XBAR filter using a
silicon interposer with TSVs (through silicon vias). While FIG.
12A, FIG. 12B, and FIG. 12C illustrate the process 1200 with an
XBAR filter chip with front-side etched cavities, the process 1200
may also use an XBAR filter chip with back-side etched
cavities.
[0096] The process 1200 starts at 1205 and ends at 1295 with a
completed packaged XBAR filter. FIG. 12A, FIG. 12B, and FIG. 12C
show major process actions, each of which may involve multiple
steps. Various conventional process steps (e.g. surface
preparation, cleaning, inspection, baking, annealing, monitoring,
testing, etc.) may be performed before, between, after, and during
the steps shown in FIG. 12A, FIG. 12B, and FIG. 12C. For each major
process action, a corresponding schematic cross-sectional view is
provided to illustrate the configuration of the work-in-progress at
the conclusion of the action. Where appropriate, reference
designators previously used in FIG. 6 are used to identify elements
of the work-in-progress.
[0097] Referring to FIG. 12A, at 1210, a XBAR filter chip 605 is
fabricated using, for example, the process 1100 of FIG. 11. The
XBAR filter chip 605 includes a piezoelectric plate 610 attached to
a substrate 620. The substrate 620 may be high resistivity silicon
or some other material. Portions of the piezoelectric plate 610
form diaphragms spanning respective cavities 640 in the substrate
620. A first conductor pattern is formed on the surface of the
piezoelectric plate 610. The first conductor pattern includes IDTs
with interleaved IDT fingers, such as fingers 630, disposed on the
diaphragms.
[0098] When the XBAR filter chip 605 has back-side etched cavities
(as shown by the dot-dash lines), a cover 680 is sealed to the back
side of the substrate 620. While the cover 680 is not shown in
subsequent cross-sectional views in FIG. 12A, FIG. 12B, and FIG.
12C, it must be understood that all of the actions in the process
1200 are compatible with a XBAR filter chip having a cover over
back-side etched cavities.
[0099] A second conductor pattern is formed on the surface of the
piezoelectric plate 610. The second conductor pattern, which may
overlay portions of the first conductor pattern, may be gold,
aluminum, copper or some other metal. The second conductor pattern
includes a continuous metal ring 662 around the perimeter of the
XBAR filter chip 605. The second conductor pattern also includes
pads, such as pad 672, in locations where portions of the first
conductor pattern must be connected to circuitry external to the
packaged XBAR filter.
[0100] At 1220, a partially-completed interposer is prepared. The
partially-completed interposer includes a base 652, which may be
high resistivity silicon or some other material. A dielectric layer
654, such as silicon dioxide, is formed on the surface of the base
that will face the XBAR filter chip. The base 652 may have recesses
655 so that the surfaces of the base 652 that will face the
diaphragms (i.e. the bottoms of the recesses 655) are sufficiently
far from the diaphragms. The dielectric layer 654 may or may not
cover the recesses 655. A third conductor pattern is formed on top
of the dielectric layer 654. The third conductor pattern may be the
same material as the second conductor pattern. The third conductor
pattern includes a continuous metal ring 664 around the perimeter
of the base 652. The third conductor pattern also includes pads,
such as pad 674, in locations where portions of the first conductor
pattern must be connected to circuitry external to the packaged
XBAR filter. The arrangement of ring 664 and pads 674 of third
conductor pattern is typically a mirror image of the arrangement of
the ring 662 and pads 672 of the second conductor pattern.
[0101] At 1230, the XBAR filter chip 605 is bonded to the
partially-completed interposer. Specifically, the ring 662 of the
second conductor pattern is bonded to the ring 664 of the third
conductor pattern, forming a hermetic seal around the perimeter of
the XBAR filter chip and partially-completed interposer.
Simultaneously, pads, such as pad 672, on the XBAR filter chip are
bonded to corresponding pads, such as pad 674, on the
partially-completed interposer. A preferred method of bonding the
XBAR filter chip to the partially competed interposer is
thermocompression bonding, which uses a combination of heat and
pressure to make bonds between metallic layers. Other methods,
including ultrasonic bonding, and solder or eutectic bonding may be
used.
[0102] Referring now to FIG. 12B, at 1240, one or both of the
substrate 620 and the XBAR filter chip, and the base 652 of the
partially-completed interposer may be thinned to reduce the overall
height of the package XBAR filter. The substrate 620 and/or the
base 652 may be thinned, for example, by mechanical or
chemo-mechanical polishing.
[0103] After the optional thinning of one or both of the substrate
620 and the base 652, through silicon via are formed in a sequence
of actions from 1250 to 1280.
[0104] At 1250, deep reactive ion etching (DRIE) is used to etch
holes 1252 from the back side (the lower side as shown in FIG. 12B)
of the base 652 through the base 652 to the dielectric layer 654.
The dielectric layer 654 is not affected by the DRIE process, so
the depth of the etch holes will be precisely controlled and
uniform. The locations of the etched holes 1252 correspond to the
locations of the pads, such as pad 674, of the third conductor
pattern.
[0105] At 1260, a dielectric layer 1262 is deposited over the back
side of the base 652 and the interiors of the holes 1252. The
dielectric layer may be silicon dioxide, silicon nitride, aluminum
oxide, or some other dielectric material. The dielectric layer may
be deposited by a conventional process such as evaporation,
sputtering, chemical vapor deposition, or some other process.
[0106] Referring now to FIG. 12C, at 1270, the oxide layer at the
ends of the holes 1252 is etched through a patterned photoresist
mask to expose at least a portion of each contact pad (such as pad
674) of the third conductor pattern.
[0107] At 1280, a fourth conductor pattern 1256 is formed to create
electric connections from the pads, such as pad 674 of the third
conductor pattern, to corresponding pads, such as pad 676 on the
exterior surface (the lower surface as shown in FIG. 12C) of the
base 652. The fourth conductor pattern may include a primary
conductive layer of gold, aluminum, copper or some other highly
conductive material. A thin layer of some other metal, such as
titanium or nickel may be disposed between the primary conductive
layer and the base 652 to improve adhesion. The structures
including the holes 1252 and the fourth conductor pattern is
commonly referred to as "through silicon vias". Once the through
silicon vias are complete, the process 1200 ends at 1295.
[0108] The entire process 1200 may be, and commonly will be,
performed on whole wafers. A whole wafer containing multiple XBARs
filter chips will be bonded to another wafer containing a
corresponding number of partially-completed interposers at 1230.
The subsequent actions form TSVs for all of the interposers
simultaneously. Individual packaged XBAR filters may then be
excised by dicing the bonded wafers after action 1230.
[0109] FIG. 13 is a flow chart of another process 1300 for
fabricating a package XBAR filter using a LTCC interposer. While
FIG. 13 illustrates the process 1300 with an XBAR filter chip with
front-side etched cavities, the process 1300 may also use an XBAR
filter chip with back-side etched cavities.
[0110] The process 1300 starts at 1305 and ends at 1395 with a
completed packaged XBAR filter. FIG. 13 shows major process
actions, each of which may involve multiple steps. Various
conventional process steps (e.g. surface preparation, cleaning,
inspection, baking, annealing, monitoring, testing, etc.) may be
performed before, between, after, and during the steps shown in
FIG. 13. For each major process action, a corresponding schematic
cross-sectional view is provided to illustrate the configuration of
the work-in-progress at the conclusion of the action. Where
appropriate, reference designators previously used in FIG. 8 are
used to identify elements of the work-in-progress.
[0111] At 1310, a XBAR filter chip 805 is fabricated using, for
example, the process 1100 of FIG. 11. The XBAR filter chip 805 will
typically be a portion of a wafer containing multiple XBAR filter
chips. The XBAR filter chip 805 includes a piezoelectric plate 810
attached to a substrate 820. The substrate 820 may be high
resistivity silicon or some other material. Portions of the
piezoelectric plate 810 form diaphragms spanning respective
cavities 840 in the substrate 820. A first conductor pattern is
formed on the surface of the piezoelectric plate 810. The first
conductor pattern includes IDTs with interleaved IDT fingers, such
as fingers 830, disposed on the diaphragms.
[0112] When the XBAR filter chip 805 has back-side etched cavities
(as shown by the dot-dash lines), a cover 880 is sealed to the back
side of the substrate 820. While the cover 880 is not shown in
subsequent cross-sectional views in FIG. 13, it must be understood
that all of the actions in the process 1300 are compatible with a
XBAR filter chip having a cover over back-side etched cavities.
[0113] A second conductor pattern is formed on the surface of the
piezoelectric plate 810. The second conductor pattern, which may
overlay portions of the first conductor pattern, may be gold,
aluminum, copper or some other metal. The second conductor pattern
may include pads (not identified) in locations where portions of
the first conductor pattern must be connected to circuitry external
to the packaged XBAR filter. Solder balls or bumps 872 may be
formed on the pads to allow the XBAR filter chip 805 to be reflow
soldered to an interposer. Alternatively, gold bumps may be formed
on the pads to allow the XBAR filter chip 805 to be
thermocompression bonded or ultrasonic bonded to an interposer.
[0114] At 1320, a LTCC interposer 850 is fabricated by cofiring
thin ceramic layers, some or all of which bear printed conductors.
The LTCC interposer 850 will typically be a portion of a larger
panel including multiple interposers, An LTCC interposer has at
least an upper (as shown in FIG. 13) conductor pattern 874 that
includes pads for connections to the XBAR filter chip and a lower
conductor pattern 878 that includes pads for connection to
circuitry external to the package XBAR filter. In the example of
FIG. 13, the interposer 850 includes one intermediate conductor
layer. An LTCC interposer for an XBAR filter may have more than
three conductor layers. The availability of multiple conductor
layers allows incorporation of passive components, such as
inductors, into the interposer.
[0115] The LTCC interposer 850 may have recesses 855 to ensure
sufficient spacing between the diaphragms and the surfaces of the
interposer facing the diaphragms. Such recess may be formed, for
example, by punching openings in one or more of the ceramic layers
prior to cofiring the layers of the interposer.
[0116] At 1330, the XBAR filter chip 850 is flip-chip bonded to the
interposer 850. First the XBAR filter chips within a wafer are
tested, and good chips are excised from the wafer. The good chips
are then bonded to the LTCC interposer 850 by soldering,
thermocompression bonding, ultrasonic bonding, or some other
bonding method. The bonding physically attaches the XBAR filter
chip 805 to the interposer 850 and makes electrical connections
between the XBAR filter chip 805 and the interposer 850. The
bonding typically does not make a seal to protect the diaphragms of
the XBAR filter chip 805.
[0117] At 1340, a polymer cover 860 is formed over the XBAR filter
chip 805 to seal the space between the XBAR filter chip 805 and the
interposer 850. The cover 850 may be formed by injection molding or
casting, for example. Individual covers may be formed over each
XBAR filter chip, or a unitary cover 850 may be formed over the
entire LTCC panel. In either case, packages XBAR filters may be
excised from the panel by, for example, sawing. The process 1300
then ends at 1395.
[0118] FIG. 14 is a flow chart of another process 1400 for
fabricating a package XBAR filter using a wafer-level built up
interposer. The process 1400 starts at 1405 and ends at 1495 with a
completed packaged XBAR filter. FIG. 14 shows major process
actions, each of which may involve multiple steps. Various
conventional process steps (e.g. surface preparation, cleaning,
inspection, baking, annealing, monitoring, testing, etc.) may be
performed before, between, after, and during the steps shown in
FIG. 14. For each major process action, a corresponding schematic
cross-sectional view is provided to illustrate the configuration of
the work-in-progress at the conclusion of the action. Where
appropriate, reference designators previously used in FIG. 10 are
used to identify elements of the work-in-progress.
[0119] At 1410, a XBAR filter chip 1005 is fabricated using, for
example, the process 1100 of FIG. 11. The XBAR filter chip 1005
will typically be a portion of a wafer containing multiple XBAR
filter chips. The XBAR filter chip 1005 includes a piezoelectric
plate 1010 attached to a substrate 1020. The substrate 1020 may be
high resistivity silicon or some other material. Portions of the
piezoelectric plate 1010 form diaphragms spanning respective
cavities 1040 in the substrate 1020. A first conductor pattern is
formed on the surface of the piezoelectric plate 1010. The first
conductor pattern includes IDTs with interleaved IDT fingers, such
as fingers 1030, disposed on the diaphragms.
[0120] The subsequent actions in the process require liquid
materials, such as solvents, photoresist, or photopolymerizable
monomers, to be applied to the front side of the piezoelectric
plate 1010 after the cavities 1040 have been etched. The process
1400 is not suitable for XBAR filter chips with front-side etched
cavities because the liquid materials may pass into the cavities
through the etch holes in the diaphragms. Thus, the XBAR filter
chip 1005 has back-side etched cavities with a cover 1080 sealed to
the back side of the substrate 1020.
[0121] At 1420, walls 1052 are formed on the piezoelectric plate
1010. The walls 1052 may be formed with openings over the XBAR
diaphragms and openings where electrical connections to the XBAR
filter chip will be made in a subsequent process action. The walls
1052 may be formed, for example, by coating the piezoelectric plate
1010 with a photopolymerizable material and then exposing the
photopolymerizable material through a suitable mask. Depending on
the required thickness of the walls, multiple layers of material
may be coated and patterned in succession.
[0122] A 1430, a cover layer 1054 is applied over the walls 1052.
The cover layer 1054 may be applied, for example, as a continuous
film bonded to the walls 1052 by an adhesive. The cover layer 1054
spans the openings in the walls 1052 over the XBAR diaphragms,
forming an enclosed cavity 1055 over each diaphragm. The cover
layer is pattered to form openings where electrical connections to
the XBAR filter chip will be made in a subsequent process
action.
[0123] At 1440, a conductor pattern 1070 is formed. The conductor
pattern 1070 includes pads 1072 on the external surface of the
cover layer 1054 for connection to circuitry external to the
packaged XBAR filter. The conductor pattern 1070 connects the pads
1072 to connection points 1074 on the XBAR filer chip 1005. The
conductor pattern 1070 may be aluminum, copper, gold, or a
combination of materials deposited and patterned using conventional
techniques. Once the conductor pattern is formed, the process 1400
ends at 1495.
[0124] The entire process 1400 may be, and commonly will be,
performed on whole wafers. Individual packaged XBAR filters may
then be excised by sawing through the bonded wafers after the
conductor pattern is formed at 1440.
[0125] Closing Comments
[0126] Throughout this description, the embodiments and examples
shown should be considered as exemplars, rather than limitations on
the apparatus and procedures disclosed or claimed. Although many of
the examples presented herein involve specific combinations of
method acts or system elements, it should be understood that those
acts and those elements may be combined in other ways to accomplish
the same objectives. With regard to flowcharts, additional and
fewer steps may be taken, and the steps as shown may be combined or
further refined to achieve the methods described herein. Acts,
elements and features discussed only in connection with one
embodiment are not intended to be excluded from a similar role in
other embodiments.
[0127] As used herein, "plurality" means two or more. As used
herein, a "set" of items may include one or more of such items. As
used herein, whether in the written description or the claims, the
terms "comprising", "including", "carrying", "having",
"containing", "involving", and the like are to be understood to be
open-ended, i.e., to mean including but not limited to. Only the
transitional phrases "consisting of" and "consisting essentially
of", respectively, are closed or semi-closed transitional phrases
with respect to claims. Use of ordinal terms such as "first",
"second", "third", etc., in the claims to modify a claim element
does not by itself connote any priority, precedence, or order of
one claim element over another or the temporal order in which acts
of a method are performed, but are used merely as labels to
distinguish one claim element having a certain name from another
element having a same name (but for use of the ordinal term) to
distinguish the claim elements. As used herein, "and/or" means that
the listed items are alternatives, but the alternatives also
include any combination of the listed items.
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