A temperature probe includes a substrate, a cantilever body portion formed on the substrate, having an anchor portion held in contact to the substrate and a free end portion extending out of the surface of the substrate, and a sputter-deposited thermistor sensor portion located at the free end portion of the cantilever body portion.

INCORPORATION BY REFERENCE

BACKGROUND

This application relates generally to a device and method for making the device for improved temperature sensing and more specifically to improved high-sensitivity thermal sensing on the micro-scale and nano-scale by improved temperature sensors.

Photo-lithographically patterned spring structures (sometimes referred to as “micro-springs”) represent one type of micro-machined structure that has been developed, for example, to produce low cost temperature probes. Such structures have also been used as probe cards, and to provide electrical connections between integrated circuits, circuit boards, and electrode arrays, and for producing other devices such as inductors, variable capacitors, and actuated mirrors, among other uses. Conventional spring structures include a spring metal finger (beam) having a flat anchor portion secured to a substrate, and a curved free cantilever portion extending from the anchor portion and bending away or coming out from the substrate (i.e., such that an air-gap is defined between the tip of the spring metal finger and the substrate to which the anchor portion is attached).

The spring metal finger is formed from a stress-engineered metal film (i.e., a metal film fabricated such that its lower portions have a different internal stress than its upper portions) that is at least partially formed on a release material layer. The free cantilever portion of the spring metal finger bends away from the substrate when the release material located under the spring finger is etched away. The internal stress gradient is produced in the spring metal by layering different metals having the desired stress characteristics, or using a single metal by altering the fabrication parameters. The stress-engineered metal films used to form spring structures are processed by sputtering deposition methods, and/or plating deposition methods

It is considered that additional advances to the spring structures previously disclosed, when used in connection with temperature probes would be useful in a number of environments. The following therefore discloses advances to temperature probes employing processing methods used in making spring structures.

BRIEF DESCRIPTION

A temperature probe includes a substrate, a cantilever body portion formed on the substrate, having an anchor portion held in contact to the substrate and a free end portion extending out of the surface of the substrate, and a sputter-deposited thermistor sensor portion located at the free end portion of the cantilever body portion.

DETAILED DESCRIPTION

Turning now toFIGS. 1A-1E, depicted is a process100to form a monolithic cantilever structure. In this embodiment stress-engineered sputter-deposited vanadium oxide (VOx) cantilever probes are formed, which can be used as temperature sensing components. As depicted inFIG. 2a cantilever temperature probe200formed by this process is in one embodiment formed on a substrate202, with two connected legs204a,204b, connected by a tip portion206. Also included are two anchor points208a,208b. The probe is a monolithic probe as it consists entirely of a sputter-deposited semiconductor material, such as sputtered vanadium oxide, and which at the same time forms the curved cantilever structure defined by legs204a,204b, anchor points208a,208band tip portion206. As also illustrated inFIG. 2, on top of anchor points208aand208bare electric contact pads210a,210b, which provide input for electrical power to probe200. By this design probe200defines an electrical resistor used as temperature sensor (thermistor). In operation, a sensing current is sent through the two legs of the cantilever portion and the tip portion, and an output voltage is proportional to the electrical resistance of the structure, which is a function of the temperature along the beams (i.e., legs).

The combination of the high temperature coefficient of resistance and low 1/f noise of vanadium oxide results in superior thermal sensing specifications. In this embodiment the shorter width of tip portion206compared to legs204a,204bact to increase the resistance in the tip portion. Alternative embodiments include designing the tip portion to have a point or other configuration to increase the resistance at the tip portion.

With continuing attention toFIGS. 1A-1E, in a step102a thin sacrificial film layer, such as amorphous silicon, titanium or other appropriate material, is deposited on an appropriate substrate, such as silicon. In step104the sacrificial layer is patterned, and then in step106a first layer of vanadium oxide and a second layer of vanadium oxide are, in one embodiment, sputter-deposited in a low temperature DC-sputtering process. After the deposition of the vanadium oxide layers, the layers are patterned, in one embodiment by a wet etching process, in step108. Thereafter, the sacrificial layer is etched in step110to release the cantilever structure consisting of two layers of stressed vanadium oxide. In one embodiment a gaseous xenon difluoride release etch process is used to release the components. The released structure is a monolithic temperature probe, which is at one end anchored to the substrate while a free end extends out of the substrate.

In process100, two lithography steps are performed in the patterning operation in steps104and108to form the cantilever shape. While the cantilever shape is shown as a two-legged configuration, by altering the patterning operation other configurations are obtained, such as a single leg structure, or structures having multiple (more than two legs). Also, the tip portion can also be patterned into alternative designs, including a pointed structure, among others. In addition, alternative embodiments including evaporation or chemical vapor deposition are used in place of the sputtering processes. The following sputtering conditions are employed in at least one embodiment:For the first VOxlayer: 600 W DC power, 10:1 Ar:O2ratio, 1.6 mTorr total pressure, 250 nm thickness (±25 min); andFor the second VOxlayer: 600 W DC power, 10:1 Ar:O2ratio, 7.6 mTorr total pressure, 400 nm thickness (±40 min)
It is noted the target material is 99.9% pure (metallic) vanadium.

These conditions result in cantilever lift heights of about 70 um for single cantilevers 300 um long and 30 um wide. Measured stress values were 245 MPa compressive stress in the first layer and 48 MPa tensile stress in the second layer. Of course it is to be appreciated the above operational conditions, values and measured results are one set of parameters using certain sizes and amounts of materials. It is to be appreciated these parameters, sizes and amounts can be adjusted depending on the probes being designed, resulting in differing results and parameters. For example, While the above description notes the Argon (Ar) to Oxygen (O2) ratio is 10 to 1, in other embodiments the amount of Argon may be in a range of 20:1 (Ar:O2) to 5:1 (Ar:O2) times more prevalent than the Oxygen. It is also noted the other above recited conditions will also operate in ranges other than the specific numbers which have been recited, such as the 600 W DC power, may range from 100 W to 800 W DC for particular operations, and the pressure applied during the depositing may range between 1 mTorr to 10 mTorr.

Sputtered vanadium oxide films show a behavior similar to the ‘traditional’ stressed metal materials such as molybdenum and chromium alloy (MoCr) or Nickel and Zirconium alloy (NiZr), where lower sputtering pressures result in denser layers with compressive stress, and higher sputtering pressure values lead to tensile stress in the film. A particular point of difference between process100(and of the to be described process300) of the present application and existing stress generating processes, is that in the case of the sputtered vanadium, the vanadium is being oxidized in situ, due to the presence of oxygen in the chamber.

Vanadium oxide has properties that make it an excellent candidate material for thermistors, these include a combination of relatively high temperature coefficient of resistance (TCR) and low resistivity, as well as low electrical 1/f noise.

The thermistor material (e.g., vanadium oxide) is also employed here as a structural material. It's unique compared to other micromachined materials as its TCR is higher, for resistivities that are comparable or even much higher: lowly p-doped single crystalline silicon for instance has a TCR of up to 0.48%/K, versus about 3% for vanadium oxide. At the same time, the 1/f noise of vanadium oxide is very low, e.g., within a factor of three of the Johnson noise over a typical measurement bandwidth for a nanocalorimeter. Johnson noise is the random variation of voltage due to thermal agitation of charge carriers in an electrical conductor (e.g., a resistor).

Dual beam structures such as formed by processes100and the to be described process300ofFIG. 3A-3J(as well as variants on these processes) will be highly sensitive to the temperature measured along the beams (legs). Also, due to the fact the beams are lifted out of the plane of the substrate and they are very thin, necessary thermal insulation from the substrate is provided.

If it is assumed heat conduction through the solid legs (beams) is dominant, the thermal RC time constant can be estimated as follows: assuming values for VOxheat conductivity, heat capacity and density of 0.75 W/m·K, 487 J/kg·K and 5800 kg/m3respectively, the heat resistance of one leg of length 800 um, width 10 um and thickness 1 um is 1.1E8 K/W; the heat resistance between the tip and the substrate is then 1.1E8/2; the heat capacitance of the dual beam structure is about 2.8E-8 J/K and the thermal time constant hence about 1.5 seconds.

This thermal time constant determines the lower limit of the bandwidth of the sensor (slowest changes that can still be detected). The time constant increases linearly with the length of the beams.

Prototypes of the monolithic vanadium oxide beams formed by process100and measurements of the temperature coefficient of resistance (TCR) and the Noise Equivalent Temperature Difference (NETD) have been performed and are similar to the values measured on an integrated nanocalorimeter vanadium oxide (VOx) devices (such as described in U.S. Pat. No. 7,473,031, the TCR is about 3%, and the NETD is about 10 to 30 uK (Kelvin).

FIGS. 3A-3Jillustrate the process300used to form a hybrid temperature probe, such as probe400shown inFIG. 4, having a thermal sensor carried on a cantilever. Initially, a silicon or other appropriate substrate is provided (step302), then a sacrificial layer of titanium, amorphous silicon or other appropriate sacrificial material is deposited onto the substrate (step304). Next a dielectric layer is deposited and patterned, which will serve to electrically passivate the thermistor material (step306). In this embodiment, a thermistor material (e.g., vanadium oxide (VOx) or p+ amorphous silicon (p+ a-Si)) is deposited (step308). Following this step, a stressed metal (e.g., an alloy of molybdenum and chromium, denoted as MoCr, or an alloy of nickel and zirconium, denoted as NiZr) is deposited and patterned to form a two-leg component (step310). The stressed metal contacts the vanadium oxide, which forms a bridge between the two legs. In step312a top passivation dielectric is deposited, and in step314a thin gold layer is deposited to provide a good electrical contact to the sensor. In steps316,318and320the sacrificial layer is selectively etched away, resulting in the release of the cantilever structure, which in this case is a hybrid cantilever temperature (thermistor) probe, with one end attached to the substrate and a free end extending out of the substrate, and carrying the thermistor tip portion. The above process may optionally incorporate a load layer.

With attention toFIG. 4, probe400may be considered to have been manufactured by the process ofFIG. 3A-3J, resulting is a hybrid vanadium oxide thermal temperature probe, carried on a substrate402. Probe400includes two separate legs404a,404b, bridged by vanadium oxide tip portion406, and anchor portions408a,408b. Electrical pad contacts420a,410bare located to allow electrical input to the probe400. The probe consists of a tip of vanadium oxide and a different stressed material such as MoCr or NiZr. The optional load layer is used to control lift height and/or to provide strength and robustness to the probe structure.

The thermal sensor, in the form of the vanadium oxide thermistor tip406carried on a cantilever legs404a,404bformed by the process ofFIGS. 3A-3Jis essentially a resistor, where current flows in through one leg of the cantilever structure and flows out of the other leg. Since the current passes through the vanadium oxide tip406, probe400it will be highly sensitive to temperature changes at the tip406.

There is evidence the sensitivity of vanadium oxide thermistors increase when fabricated at higher temperatures. One such fabrication technique which can employ higher temperatures is when the thermistors are fabricated on thick glass substrates made out of p+ amorphous silicon. This fabrication process enables higher temperature fabrication for more sensitive thermal sensors, as well as enabling tighter tolerances that will result in better balanced resistivity, an additional avenue for sensitivity improvement.

In one embodiment cantilever fabrication according to processes100and300, and variations thereof, are enabled by StressedMetal® technology invented and developed at Palo Alto Research Center (PARC) in Palo Alto, Calif. StressedMetal® is a registered trademark of PARC.

StressedMetal® technology is based on micro-fabrication techniques that take advantage of the stress that occurs in the thin film deposition process. In thin film deposition, extremely thin layers of metal film are deposited onto a substrate, such as silicon or glass. To create StressedMetal® micro-structures, films are sputter deposited with an engineered built-in stress gradient, on top of a sacrificial layer. After lithographic patterning, the sacrificial layer is etched away and the micro-structures are released. The metal's inherent stress causes it to lift or curl into a designed radius of curvature, creating 3D structures such as tiny coils, springs, or cantilevers. An example of a plurality or array of two-legged cantilever probes500formed by this process is shown inFIG. 5. The process ofFIGS. 1A-1E, as understood by one of skill in the art, is adjustable to manufacture alternatively formed probes. For exampleFIG. 6depicts probes600having a single leg602.

As previously mentioned the cantilever probes (or sensors) depicted inFIGS. 2 and 4are made using a fabrication process that combines these techniques with the high quality, low-noise vanadium oxide thermistor material. The process is also used to fabricate and test higher sensitivity p+ amorphous silicon thermistors, as well as higher temperature processes for vanadium oxide that have an improved sensitivity. Preliminary data on p+ amorphous silicon shows a temperature coefficient of resistance as high as 4%/K for this material, compared with 2.8%/K. Literature on vanadium oxide suggests values as high as 5.2%/K are feasible with modified deposition.

Temperature probes manufactured according to the described processes (e.g.,100,300) and variations thereof, find use in a variety of applications.FIG. 7illustrates one such use, where the probes are used in a non-integrated nanocalorimeter (e.g., a thermal sensing cell) device700. As described in more detail by U.S. patent application Ser. No. 12/467,072, titled Nanocalorimeter Based On Thermal Probes, filed May 15, 2009. Device700includes a drop merging layer702, having a thin thermally insulating substrate (e.g., plastic film, Kapton membrane, PEN membrane, or other appropriate thermally insulating material)704carried on a frame (or stiffener)706. On the surface of thin substrate704are activation contact pads708arranged to receive energy (from a power source710) to implement the merging operation. Conductive lines (not shown) are formed to carry the activation energy, to drop mergers (or drop merging areas)712which receive the energy from the conductive lines (not shown) to perform a merging operation to form drops714. Drop merging layer702also includes thermal equilibration areas716. The thermal equilibration areas are thermally conductive areas of the merging layer702that conduct heat well enough that lateral temperature non-uniformities are minimized across the drop merging areas.

A bottom (or measurement) layer718of device700includes a substrate720which carries cantilever temperature probes722, constructed according to the concepts of the present application, which in one embodiment has a thermal sensor at a tip portion724and cantilever portion726. Also carried on measurement layer718are temperature measurement contact pads728and conductive lines (not shown) which connect the cantilever thermistor probes700to the temperature measurement contact pads728. As illustrated byFIG. 7the independent construction of the drop merging layer702and layer718separates the surface of the thin substrate704(which carries the drop mergers712and cantilever temperature probes726from each other.

In this embodiment the thermal sensor is on the tip of a ≈3 μm thin cantilever that is located in operative contact with the backplane island portion of thermal equilibration area716. It is to be understood that operative contact includes having the thermal sensor tip724in actual physical contact with the thermal equilibration areas716, as well as coming within sufficient proximity of the thermal equilibration areas716to allow for the transfer of heat but without actual physical contact with the thermal equilibration areas. This close proximity is achieved in some embodiments when the thermal sensor is less than 1 micron away (but still not in actual physical contact) and up to about 5 microns away from a thermal equilibration area. Heat is transferred to thermal equilibration areas716and is sensed by thermal sensor tip724carried on cantilever726, and is then passed to measurement electronics710.

Heat conduction along the cantilever is small compared with the heat conduction through the air because the cantilever is kept thin, so the thermal time constant of the detector is not reduced, as desired. COMSOL® calculations presented below provide more detail. COMSOL® is a registered trademark of COMSOL AB Corporation of Sweden, for a finite element analysis and solver software package for various physics and engineering applications.

The surface of the cantilevers of temperature probes can be coated (after release) with a thin layer of for instance parylene in order to chemically and electrically passivate the cantilevers. It is also noted, the cantilever temperature probes, are self-heated by the electrical current flowing through them. Also, by altering the patterning steps of the described processes, and as previously mentioned, devices with multiple legs, microbridges or doubly clamped cantilevers, membranes, etc. may be formed. Still further multi-layered composite beams can be realized by employing the present concepts; for instance, in one embodiment a dual beam device consisting of a stressed metal layer, an insulating dielectric layer, and a VOxlayer on top may be built. Still further, a reference device (unreleased cantilever) can be used in conjunction in order to realize a half- or full Wheatstone bridge configuration for differential temperature measurements.

It is mentioned here that the probes (or microprobes) as described herein should be generally understood as temperature (thermometer, thermal, etc.) probes, as opposed to bimorph components where the cantilever deflection is used as a measure for temperature change.