Microelectromechanical Systems (MEMS) based advanced high performance Radio Frequency (RF) systems Outline •• •• Introduction Introduction What What are are MEMS MEMS –– Why Why use use MEMS MEMS –– advantages advantages –– How How are MEMS MEMS fabricated fabricated –– MEMS MEMS actuation actuation techniques techniques •• RF RF MEMS MEMS –– Fabrication Fabrication –– Applications Applications –– Advantages Advantages –– MEMS MEMS switch switch library library –– Design Design and and analysis analysis –– Failure Failure mechanisms mechanisms –– Challenges Challenges –– Conclusions Conclusions What are MEMS? •• MEMS MEMS are are Micro Micro Electro-Mechanical Electro-Mechanical Systems Systems •• MEMS MEMS typically typically have have both both electrical electrical and and mechanical mechanical components components •• As As microelectronics microelectronics has has shown, shown, size size doesn’t doesn’t necessarily necessarily matter matter •• Envisioned Envisioned by by Sci-Fi Sci-Fi authors authors •• R.P. R.P. Feynman Feynman –– “There’s “There’s lots lots of of room room at at the the bottom” bottom” •• First First MEMS MEMS Publication Publication :: –– H.C. H.C. Nathanson, Nathanson, et et al., al., The The Resonant Resonant Gate Gate Transistor, Transistor, IEEE IEEE Trans. Trans. Electron Electron Devices, Devices, March March 1967, 1967, vol. vol. 14, 14, no. no. 3, 3, pp pp 117-133 117-133 •• Pressure Pressure sensors sensors were were the the first first MEMS MEMS products products –– Si Si diaphragms diaphragms and and diffused diffused piezo-resistors piezo-resistors •• Surface Surface m-machined m-machined accelerometers accelerometers and and flow flow sensors sensors Why MEMS? • • • • • • • • Miniaturization with no loss of functionality Integration to form a monolithic system Improved reproducibility, reliability and accuracy Exploitation of new physics domains Low power Fast actuation techniques Improved selectivity and sensitivity MEMS may be the ONLY solution MEMS enables advances in many business areas… Optics • Micromirrors • Silicon Benches • Waveguided structures • Integrated subsystems • Optical transparency • Ease of manufacture • High precision • High reliability • Integration of multiple subsystems Life Sciences & Laboratory Equipment • Micronozzles • Micropumps • Membranes • Microfluidic channels • Wells & reservoirs • Waveguides • Lab-on-a-chip • Economical use of samples • Low cost assays • Quick turnaround on sample analysis • Reduction in equipment footprint RF • Capacitors • High-Q inductors • Resonators • Relays and Switches • Integrated subsystems • Low weight • Low insertion loss • High off-state isolation • High precision • Low power consumption • High reliability Some MEMS Applications Ultrasound Transducer Gyroscope Optical Scanner Microphone Accelerometer 2-Axis Micromirror Overall, the market is poised for breakaway growth $30 $20 $10 $ US Billions Growth of International MEMS Market 2008 2005 2002 1999 1996 1993 1990 $0 Year Source: Aggregate of data presented in MST News 5/01, including data from SPC, SRI, NEXUS, Batelle, VDC, and other research organizations New applications for MEMS emerge and grow quickly 2001 Industrial 25% Consumer 1% Medical 16% Automotive 31% 2006 Comm. 1% Computer 26% Medical 11% Industrial 22% Consumer 3% Comm. 21% Source: In-stat 2002 Automotive 17% Computer 26% Fabrication of MEMS •• Typically Typically the the fabrication fabrication of of MEMS MEMS uses uses tools tools from from the the semiconductor semiconductor industry, industry, plus plus many many other other tools: tools: –– Photolithography Photolithography –– Diffusion Diffusion –– Oxidation Oxidation –– Etching Etching (isotropic (isotropic and and anisotropic, anisotropic, wet wet and and plasma) plasma) –– Chemical Chemical Vapor Vapor Deposition Deposition (Si3N4, (Si3N4, SiO2, SiO2, Polysilicon, Polysilicon, etc.) etc.) –– Vacuum Vacuum Metal Metal Deposition Deposition (sputtering, (sputtering, evaporation) evaporation) –– Electroplating Electroplating (LIGA, Ni, Au, Cu microstructures) –– Chemical Chemical Mechanical Mechanical Polishing Polishing to to produce produce flat flat surfaces surfaces –– Wafer Wafer Bonding, Bonding, SOI SOI wafers wafers –– Deep Deep Plasma Plasma Etching Etching (Inductively (Inductively Coupled Coupled Plasma) Plasma) –– Sol-Gel Sol-Gel deposition deposition (PZT) (PZT) Bulk Micromachining •• •• •• Single Single Crystalline Crystalline Silicon Silicon Isotropic Isotropic Etching Etching (HNA etc.) Anisotropic Anisotropic Etching (KOH, TMAH, EDP EDP etc.) etc.) •• Reactive Reactive Ion Ion Etching Etching (RIE (RIE & & DRIE) DRIE) •• Accommodates Accommodates sharp sharp corners, corners, small small features features and and very very smooth smooth surfaces surfaces LIGA Process •• •• •• •• •• Electroplated Electroplated microstructures microstructures X-ray X-ray Photolithography Photolithography in in PMMA PMMA polymer polymer resist resist Very Very high high aspect aspect ratio ratio microstructures microstructures with with smooth smooth surfaces surfaces Used Used to to create create molds molds for for low low cost cost replication replication of of precision precision shapes shapes Molded Molded diffraction diffraction grating grating for for match-box match-box spectrometer spectrometer Surface Micromachining •• •• •• •• Primarily Primarily Poly-Si Poly-Si thin-film thin-film structures structures Make Make structures structures horizontally horizontally and and erect erect them them on on aa hinge hinge MUMPS, MUMPS, SUMMIT, SUMMIT, HEXSIL HEXSIL etc. etc. Applications Applications –– Pop-up Pop-up micro-mirrors micro-mirrors –– Pressure Pressure sensors sensors –– RF RF switches switches A B C D E Si Phosphosilicate glass Polysilicon Capacitive MEMS RF Switch Fabrication •• Surface Surface micromachining based fabrication fabrication process process –– oxide oxide deposition, deposition, electrode, electrode, dielectric dielectric deposition deposition and and patterning patterning –– metal metal posts posts deposition deposition and and patterning patterning –– spacer spacer coating coating and and patterning patterning –– membrane membrane deposition deposition and and patterning patterning –– removal removal of of spacer spacer layer layer by by dry dry or or wet wet etching* etching* *Yao, Z., Chen, S., Eshelman, S., Goldsmith, C., “Micromachined low-loss microwave switches”, IEEE, J. MEMS, Vol 8, pp 129–34, 1999 MEMS Actuation Techniques Mechanism Advantage Disadvantage Rockwell Electrostatic Fast High voltage Cronos Georgia Tech Thermal Magnetostatic High force, Fast, bi-directional high force, Quiescent bi-directional power, Quiescent slow power Marconi Piezoelectric Fast Small throw Microlab Latching Magnetic Fast, high force, bi-directional Construction Series Switches Rebeiz/Muldavin/Rizk Shunt Capacitive Switches Rs1 G Rs1 Zo, a, bl L W C Zo, a, bl L CPW Rs L MEMS bridge g w Rs1 w G Microstrip Rs1 Zo, a, bl L W C L Rs via Rebeiz/Muldavin/Rizk Lvia Rvia Zo, a, bl G Circuit metal W Thin dielectric layer MEMS Ohmic Switch Technology HRL Laboratories Rockwell Analog Devices Motorola Chronos Microlab Ohmic Contact Switch Companies Rockwell Scientific HRL Laboratories Analog Devices Motorola Chronos Omron Microlab Several standard MEMS fabs Switch Construction Metallizations Gold, aluminum, nickel Substrates Silicon, gallium arsenide Actuation Mechanisms Electrostatic, thermal, magnetic CoCo-integration microwave electronics MEMS Capacitive Switch Technology Raytheon MIT Lincoln Labs Bosch Capacitive Contact Switch Companies Raytheon NorthropNorthrop-Grumman Samsung LG Electronics MIT Lincoln Labs DaimlerDaimler-Chrysler Bosch Samsung LG Electronics DaimlerDaimler-Chrysler Switch Construction Metallizations Gold, aluminum, copper Substrates Silicon, quartz, gallium arsenide CoCo-integration CMOS Radio Frequency Applications Technology Bulk Micromachining Surface Micromachining Micromachining - fab of 3D structures on an IC MEMS - movable structure micromachined into an IC Cornell Rockwell DaimlerDaimler-Chrysler U Michigan Transmission Lines Variable Capacitor Switch Filter Devices These devices are the “transistor” of a new generation of mechanical IC devices! Rockwell Raytheon Circuits 5-Pole Bandpass Filter Electronic Phase Shifter MEMS are creating a revolutionary impact on RF technology! Opportunity for Applications of RF MEMS Application Areas for MEMS RF Comparison: MEMS versus Solid-state switches Advantages of RF MEMS Performance Performance Ultra-low Ultra-low RF RF loss loss –– Beats Beats any any available available electronics electronics technology technology for for switching switching or or tuning tuning of of RF RF signals signals Essentially Essentially no no DC DC power power consumption consumption –– Perfect Perfect for for battery battery and and low low powerpowerconsumption consumption applications applications Extremely Extremely high high linearity linearity –– Creates Creates no no harmonics harmonics or or distortion, distortion, excellent excellent for for broadband broadband communications communications Size Size Microminiature Microminiature size size –– Reduced Reduced size size with with unmatched unmatched performance, performance, able able to to work work at at very very high high frequencies frequencies (> (> 50 50 GHz) GHz) Tunability Tunability –– Supports Supports reduction reduction in in number number of of passive passive components, components, combines combines numerous numerous switched switched parts parts into into one one tunable tunable chip chip Cost Cost Reduced Reduced IC IC costs costs –– Low Low cost, cost, batch batch fabrication. fabrication. Much Much less less expensive expensive than than competing competing exotic exotic semiconductor semiconductor technologies. technologies. Significant Significant system system cost cost impact impact -- Able Able to to be be combined combined with with other other electronics electronics for for “system-on-a-chip.” “system-on-a-chip.” Improved Improved functionality functionality can can greatly greatly reduce reduce cost. cost. RF MEMS Switches Are Much Simpler than PIN Diode Switches PIN Diode Switch Circuit RF MEMS Switch Circuit +Vcontrol DC Control Voltage –Vcontrol C In Out L In C L C C R 0.0025 sq inch One < 1 nanowatt Area DC Control Voltages DC Control Power 0.25 sq inch Two: + and – ~300 milliwatts Out Companies/ Univ./Labs Developing MEMS switches •• •• •• •• •• •• •• •• •• •• •• •• •• Raytheon Raytheon // (Texas (Texas Instruments) Instruments) Raytheon Raytheon // (HRL) (HRL) Rockwell Rockwell Science Science Center Center Northrop Northrop Grumman Grumman Motorola Motorola Analog Analog Devices Devices Lincoln Lincoln Labs Labs Dow-Key Dow-Key Microwave Microwave (with (with HRL) HRL) Sarnoff Sarnoff Labs Labs Sandia Sandia Labs Labs Bosch, Bosch, Germany Germany DaimlerChrysler, DaimlerChrysler, Germany Germany Thompson-CSF, Thompson-CSF, France France •• •• •• •• •• •• •• •• •• •• •• University University of of Michigan Michigan Univ. Univ. of of Illinois, Illinois, Urbana Urbana Univ. Univ. of of California, California, Berkeley Berkeley Northeastern Northeastern University University And And other other small small efforts efforts at at many many European European and and Japanese Japanese Univ. Univ. Samsung, Samsung, Korea Korea Sony, Sony, Japan Japan MEMSCAP, MEMSCAP, France France Corning Corning IntelliSense IntelliSense LG-Corporate LG-Corporate Research, Research, Korea Korea NEC, NEC, Japan Japan Raytheon 0 0 -5 -1 -10 -1.5 -15 -2 -20 -2.5 -25 -3 Return Loss (dB) Insertion Loss (dB) -0.5 -30 Capacitor Up -3.5 -35 -4 -40 0 5 10 15 20 25 30 35 40 Frequency (GHz) 0 0 -5 Capacitor Down -10 -10 -15 -15 -20 -20 -25 -25 -30 -30 -35 -35 -40 -40 -45 -45 -50 -50 0 5 10 15 20 25 Frequency (GHz) 30 35 40 Return Loss (dB) Isolation (dB) -5 Insertion Loss @ 40 GHz Isolation @ 40 GHz <0.07 >35 Model Values Rs 0.11 0.2 Rsh CON/OFF 0.03-0.045 Coff 3.4 Con RSH RSH 0.25 Ron Capacitance Ratio 70-110 Cutoff Frequency 18,000 Switching Speed < 10 Intercept Point > +66 Switching Voltage 30-50 Size 280 × 170 RSE RSE dB dB Ohms Ohms pF pF Ohms GHz µs dBm volts µm HRL Top View Side View RF Out Switch Open (Signal Isolation) h Anchor Bias Electrode RF Contact h = 2 µm (0.08 mil) 500 µm (20 mil) Switch Closed (Signal Transmission) Gold 700 µm (28 mil) • Metal-Metal contact series switch • Electrostatic actuation: 20–40 V • Switching time: 20–40 µsec – Depends on gap and voltage RF In Silicon Nitride GaAs Substrate • Nitride/gold/nitride tri-layer prevents creep • Fabrication process is compatible with other substrate materials like high resistivity silicon 0 -15 -0.2 -20 insertion loss (dB) -25 -0.4 ON return loss (dB) -0.6 -35 -0.8 -40 -1 0 10 20 30 40 freq (GHz) -10 -20 isolation (dB) -30 -30 isolation (dB) -40 -50 OFF -60 -70 0 10 20 freq (GHz) 30 40 return loss (dB) insertion loss (dB) Rockwell Science Center • • • • • • Low insertion loss: 0.1 dB @ 2GHz Excellent Isolation: -56dB @2 GHz Turn-on time <10ms +28dBm power handling capability Third order intercept 80dBm Implementation on Si, GaAs, Quartz Analog Devices •• •• •• •• •• •• •• DC DC Contact Contact Series Series switch switch Vp Vp = 50-60 50-60 V V Isolation: Isolation: -40 -40 dB dB (4 (4 GHz) GHz) tt == 0.5-3 0.5-3 ms ms Isolation: Isolation: -27 -27 dB dB (20 (20 GHz) GHz) Cu Cu == 44 fF fF Loss Loss :: -0.1 -0.1 to to –0.2 –0.2 dB dB (DC-20 (DC-20 GHz) GHz) •• Rs Rs == 1-2 1-2 W W •• (Electrode (Electrode does does not not touch touch cantilever) cantilever) Muldavin/Rebeiz MIT Lincoln Lab 0 -0.1 2 thru lines -0.2 S21 (dB) -0.3 -0.4 -0.5 -0.6 -0.7 -0.8 9 switches Vact = 80 V -0.9 -1 0 5 10 15 20 25 30 35 Frequency (GHz) RF Measurement (9 Switches) Contact Resistance: DC Contact single switch in CPW configuration Switch Speed: 95% yield < 2 W 60% yield < 1 W Closing time: < 1 ms Opening time: < 1 ms 40 University of Michigan •• •• •• •• •• •• All All metal series series switch switch Vp=20-25 Vp=20-25 V Switching Switching speed speed == 10 10 us us Cu=4-8 Cu=4-8 fF, fF, Ron=0.5-2 Ron=0.5-2 Ohms Ohms Isolation: Isolation: -36 -36 to to –40 –40 dB dB (4 (4 GHz) GHz) Compact Compact Geometry Geometry –– 300 300 um um by by 100 100 um um •• CPW CPW or or Micro-strip Micro-strip •• High High Impedance Impedance Bias Bias Line Line –– 11 kOhm kOhm // square square SiCr SiCr Muldavin/Rebeiz LG Korea •• •• •• •• •• •• •• •• •• •• High High Capacitance Capacitance shunt shunt Isolation: Isolation: -40 dB (3-5 GHz) Isolation: Isolation: -30 -30 dB dB (10 (10 GHz) GHz) Isolation: Isolation: -20 -20 dB dB (20 (20 GHz) GHz) Loss Loss :: -0.1 -0.1 dB dB (10 (10 GHz) GHz) (LCd (LCd Resonance Resonance effect at at 3-5 3-5 GHz) GHz) Vp Vp = 8-20 8-20 V V tt == N/A N/A Dielectric: Dielectric: SrTiO3 SrTiO3 Cd Cd == 50 50 pF pF Movable Plate RF input Hinge Ground RF output Dielectric Metal Post MEMS Physics is Multi-Disciplinary: Mechanics, Electrostatics, Fluidics, Ionics etc. C-C Beam Center Cap Top Stress in CC Beam Charge injection into insulator or contact erosion Charge migration over surface Formation of induced channel on semiconductors Distributed Mass and Spring Large Surface Tension formation forces + + + + + ® ... 2m 200m Cap Base Design and Analysis of MEMS RF Switches • Electrostatic domain – to solve for electrostatic pressure due to parallel surfaces. • Mechanical domain – to solve for mechanical deformation, contact, stresses, heat generation etc. • Fluidic domain – to solve for squeeze film dampening effect when the bridge moves. • Electromagnetic domain – to solve for S, Y, Z parameters in order to obtain insertion loss, isolation and current distribution. Electromechanical Analysis Capacitance versus voltage Deflection versus voltage 1.4000 Deflection ( m) 0 2 4 6 8 10 12 14 16 18 20 - 0.5 -1 - 1.5 -2 22 24 26 28 30 Capacitance (pf) 0 1.2000 1.0000 0.8000 0.6000 0.4000 0.2000 0.0000 - 2.5 0 Voltage (V) 2 4 6 8 10 12 14 16 18 20 22 24 26 28 30 Voltage (V) Electromagnetic Analysis 0 0 DB(|S[2,1]|) Measured -5 -10 -0.1 DB(|S[2,1]|) Theoretical -15 -20 -0.2 -0.3 -25 -30 -0.4 -35 DB(|S[2,1]|) Theoretical -0.5 -40 -45 -0.6 -50 DB(|S[2,1]|) Measurement (On) -0.7 -55 -60 -0.8 2 6 10 14 18 22 26 Frequency (GHz) 30 34 38 40 2 6 10 14 18 22 26 Frequency (GHz) 30 34 Electromagnetic (RF) analysis showing S parameters and current distribution for a capacitive switch in OFF (left) and ON (right) positions 38 40 Failure Mechanisms in MEMS Devices Class I No Moving parts Class II Moving Parts, No Rubbing or Impacting Surfaces Class III Moving Parts, Impacting Surfaces Class IV Moving Parts, Impacting and Rubbing Surfaces Applications Accelerometers Pressure Sensors Ink Jet Print Heads Strain Gauge Integrated Circuits Particle Contamination Shock Induced Stiction Gyros Comb Drives Resonators Filters TI DMD Relays Valves Pumps RF Switches Optical Switches Shutters Scanners Failure Mechanisms Particle Contamination Shock Induced Stiction Mechanical Fatigue Particle Contamination Shock Induced Stiction Stiction Mechanical Fatigue Impact Damage Particle Contamination Shock Induced Stiction Stiction Mechanical Fatigue Friction Wear Challenges • • • • Lifetime and reliability Packaging Cost Speed Switch Lifetimes: Capacitive Switches •• •• Stiction Stiction –– Metal-to-dielectric Metal-to-dielectric stiction stiction –– Large Large contact contact area area resulting resulting in in stiction stiction due due to to dielectric dielectric charging charging –– Water Water particle particle (water (water is is aa polar polar molecule) molecule) –– Organic Organic materials materials on on the the metalmetaldielectric dielectric interface interface Possible Possible solutions solutions –– Package Package device device in in Nitrogen Nitrogen atmosphere atmosphere (makes (makes itit very very expensive) expensive) –– Better Better design design and and dielectrics dielectrics by by reducing reducing actuation actuation voltage voltage –– Use Use bipolar bipolar voltage voltage so so as as not not to to charge charge the the dielectric dielectric (cost (cost may may be be high high preventing preventing use use in in various various portable portable applications) applications) Packaging Considerations in MEMS Circuits •• •• •• •• •• Wafer Wafer level level packaging packaging will will result result in in lowest lowest cost cost for for MEMS MEMS switches. switches. Packaging Packaging gas gas has has large large effect effect on on reliability. reliability. Hermetic Hermetic sealing sealing is is essential essential since since MEMS MEMS switches switches are are sensitive sensitive to to humidity. humidity. For For high high performance, performance, low low quantities, quantities, packaging packaging can can be be done done using using standard standard techniques. techniques. The The highest highest cost cost will will be be the the package package in in single single MEMS MEMS switches. switches. This This is is not not the the case case in in phase phase shifters shifters or or filters, filters, or or high high isolation isolation switch switch networks. networks. Conclusions •• Virtually Virtually every every MEMS MEMS switch switch configuration configuration is is available available today. today. The The main main question question now now is is reliability reliability and and packaging. packaging. 11 mechanically. •• Reliability electrically, and and 10 1011 mechanically. Reliability is is currently currently in in the the 10 1088 electrically, •• Failure Failure mechanisms mechanisms are: are: –– Resistive Resistive failure failure in in DC-contact DC-contact switches switches (metallurgy, (metallurgy, contact contact forces) forces) –– Stiction Stiction due to humidity and/or charging of the dielectric (capacitive switches) switches) –– Stiction Stiction due to metal-to-metal contacts (contact physics) –– Microwelding Microwelding due due to to large large currents currents •• To To combat combat failures, failures, industry industry is is doing doing the the following: following: –– Packaging Packaging in inert inert atmosphere atmosphere such such as as Nitrogen Nitrogen and/or and/or hermetic hermetic sealing sealing –– Large Large voltage voltage and and large large spring spring constant constant structures structures –– Development Development of of better better metal metal contacts contacts –– Designs Designs with with no no contact contact between between the the pull-down pull-down electrode and the bottom bottom metal metal (not (not applicable applicable for for current current capacitive capacitive switches) switches) Conclusions •• Today, Today, most most MEMS MEMS switches switches are are being being developed developed for for phase phase shifters shifters and and defense defense applications. applications. •• Tomorrow, Tomorrow, which which is is today, today, most most MEMS MEMS switches will be developed for wireless wireless applications applications and and low-power low-power applications: applications: –– Single-Pole Single-Pole Multiple-Throw Multiple-Throw Switches Switches –– Switched Switched Filter Banks for portable and basestations (receive) –– Switched Switched Attenuators for High Dynamic Range Receivers and Instrumentation Instrumentation –– Switch Switch Matrices Matrices (Basestations (Basestations and and Satellite Satellite Applications) Applications) –– Tunable Tunable Filters Filters (High-Q (High-Q Varactors) Varactors) –– Tunable Tunable Networks Networks for for Wideband Wideband Applications Applications (Switched (Switched Capacitors, Capacitors, Medium Medium Q Q needed) needed) •• There There are are currently currently no no high high power power (100 (100 mW mW to to 10 10 W) W) MEMS MEMS switches. switches. •• There There are are currently currently no no services services or or foundries foundries for for RF RF MEMS MEMS switches. switches.