Rectilinearly deflectable element fabricated from a single wafer

Abstract: A suspended element (12) etched in a silicon substrate (28) which is deflected in linear proportion to an applied force. A pair of flexing means (16,18,20,22,­ 24,26) symmetrically positioned around the suspended element (12) provides rectilinear movement of the suspended element in response to the applied force. In one embodiment of the invention, the flexing means is formed in a single etchant step by concurrently etching nearly identical recesses (66,68,74,76) into opposing planar surfaces of the silicon substrate (28). In this embodiment, the portions of silicon remaining between the recesses and planar surfaces define the flexing means.

Description: The present invention relates to deflectable elements which are suitable for use, with appropriate electronics, as either force transducers or actuators. It is known to fabricate force transducers from silicon substrates by etching suspended beams, or similar structures, which deflect in response to the application of a force to be measured. The deflection may be electronically measured by conventional means such as resistive strain gauges or piezoelectric elements. Typical applications of these force transducers include accelerometers, pressure sensors, gravity sensors, and microphones. A difficulty encountered with many known devices is that internal bending moments of the suspended structure are cancelled by reactions at the fixed boundary which prohibit flexure with simultaneous boundary displacement. Stated another way, these devices typically have not provided rectilinear displacement of the suspended structure. Accordingly, a nonlinearity has been introduced into the electrical representation of the applied force. Another problem is that the amount of flexure is limited by the amount of bending a given dimension of a silicon structure is able to withstand before fracturing. A prior approach to provide rectilinear displacement of a suspended element is disclosed in U.S. patent 4,071,838. More specifically, a structure is disclosed which may be characterized as a pair of opposing E-shaped springs joined together at their arm extremities and fabricated from a single monocrystalline wafer. The resulting center arm allegedly deflects in a rectilinear relationship to the applied force. A disadvantage of this approach is the complexity of the structure and associated complexity in fabricating. Another disadvantage is that the range of rectilinear displacement is limited by the amount of bending the silicon segments are able to withstand before fracturing. In another approach, U.S. patent 4,144,516 discloses a multiple wafer structure, each wafer having a pair of opposing E-shaped springs. The two wafers are bonded together to extend the range of rectilinear deflection of the E-shaped springs. A disadvantage of this approach is the added complexity of the two wafer design. DE-A-36 20 368 discloses a transducer in which a beam is formed from an n⁺-doped surface layer of a silicon substrate by locally etching a recess beneath it, a recess above it and slits on either side, so that it is supported only at its ends on the remaining substrate. US-A-3 505 875 discloses a pressure transducer comprising a bending beam having on either side of it a diaphragm formed of a metal disc having on opposite faces offset annular grooves around its periphery so that the central area of the disc can move in a direction normal to its plane in response to fluid pressure. US-A-4 236 133 discloses a pressure transducer made by forming a single flexure groove, which may be trapezoidal in section, around a central area in the surface of a silicon wafer by anisotropic etching from one face of the wafer. The groove is to act as a stress-concentrating area to increase the sensitivity of sensors placed adjacent the inner and outer edges of the groove. FR-A-2 559 899 discloses a similar pressure transducer comprising a thin membrane formed in a silicon wafer by machining a recess from one face of the wafer and anisotropically etching a recess from the other face, the membrane being surrounded by a groove formed in the machined face such that the thickness of the central wall between the groove and the etched recess is not less than that of the membrane. An object of the present invention is to provide a method of forming from a single wafer of silicon a suspended element having an extended range of deflection and, more particularly, an extended range of rectilinear deflection. According to the invention, a method of forming such a suspended element comprises the steps of etching two cavities in a {110} or {100} wafer of a silicon substrate, thereby defining a center member between said cavities having a first planar face and an opposing second planar face, said cavities also defining a supporting frame connected to opposing ends of said center member, forming in a passivation layer on said first planar face a first pair of passivation openings symmetrically positioned on said first planar face and forming in a passivation layer on said second planar face a second pair of passivation openings symmetrically positioned on said second planar face and offset from said first pair of passivation openings; applying an anisotropic etchant to said passivation openings for forming, in a single etching step, a first pair of recesses through said first planar face and a second pair of recesses through said second planar face, whereby said suspended element is defined as the portion of said center member between said first pair of recesses; and timing said step of anisotropic etching to form narrowed portions of said center member between corresponding recesses of said first and second pairs of recesses and between the bottoms of said recesses and the respective opposed planar face, said narrowed portions defining a pair of flexing means at the opposing ends of said center member for providing rectilinear deflection of said suspended element. Since the structure is constructed of a material, namely silicon, wherein strain is a linear function of applied stress, the deflection of the suspended member is also linearly proportional to the applied force. As will be explained hereafter, the flexing means are made from flexible members the thickness of which is defined by the amount of offset between the first recess and the second recess, and the depth of the recesses. Each flexible member defines a spring having a spring constant related to the substrate material and the cross sectional dimension of the flexible member. The invention enables apparatus to be obtained which exhibits the advantage of providing a greater range of rectilinear movement from a single substrate than heretofore possible. Further, the range of deflection may be increased by simply etching additional flexible members. Since the recesses may be etched to the same depth, they all may be fabricated in one step thereby obtaining another advantage. The invention will now be described further by way of example, with reference to the accompanying drawings in which: Figure 1 is a perspective view of an embodiment in which the invention is used to advantage; Figure 2 is a cross-sectional view taken along line 2-2 of Figure 1; Figures 3A-3C illustrate sequential fabrication steps for fabricating the embodiment shown in Figure 1; Figure 4 is a cross-sectional view of an alternate embodiment in which the invention is used to advantage; and Figure 5 is a cross-sectional view of another alternate embodiment in which the invention is used to advantage. In general terms, with reference to Figure 1, suspended element 12 is shown integrally connected to supporting frame 14 by flexible members 16, 18, 20, 22, 24 and 26. Suspended element 12, frame 14, and each of the flexible members are fabricated from a single wafer or substrate 28 (Figure 3A) as described in greater detail hereinafter with particular reference to Figures 3A through 3C. Continuing with Figure 1, and also referring to Figure 2, flexible member 16 and nearly identical flexible member 18 define a pair of flexible members shown connected to respective opposing outer ends 30 and 32 of suspended element 12 forming respective angles A and B therebetween. Similarly, flexible member 20 and nearly identical flexible member 22 define another pair of flexible members connected to respective opposing inner ends 34 and 36 of frame 14 forming respective angles C and D therebetween. Flexible member 24 is shown interconnecting flexible members 16 and 20 thereby forming respective alternate angles E and F. Similarly, flexible member 26 is shown interconnecting flexible members 18 and 22 thereby forming respective alternate angles G and H. The symmetrical positioning, with respect to suspended element 12, of each flexible member of a respective flexible member pair provides rectilinear movement in response to a force applied against suspended element 12. For example, in the event that a force such as an inertial force deflects suspended element 12 in an upward direction, the bending moments at each boundary of the flexible member cause : angles A and B to decrease by the same degree; angles E and G to increase by the same degree; angles F and H to increase by the same degree; and angles C and D to decrease by the same degree. Accordingly, the boundary between suspended element 12 and flexible member 16 is displaced directly upward; the boundary between flexible members 16 and 24 is displaced upward and toward suspended element 12; and the boundary between flexible members 24 and 20 is displaced upward and away from the suspended element 12. Likewise, the boundaries between suspended element 12, flexible member 18, flexible member 26, and flexible member 22 are displaced in the same manner. This symmetrical movement of the flexible members permits rectilinear deflection of suspended element 12. Further, by the use of appropriate flexible member materials, such as silicon, wherein any strain in the flexible members caused by an applied stress is within their linear range, the deflection of suspended element 12 is in direct linear proportion to the applied force. Referring to Figures 3A through 3C, wherein like numerals refer to like parts shown in Figures 1 and 2, the fabrication of suspended element 12, support frame 14, and flexible members 16, 18, 20, 22, 24 and 26 is now described. The fabrication described herein utilizes photolithographic and etching techniques well-known in the microelectronics industry. Substrate 28 is illustrated in Figure 3A as a silicon wafer, preferably having a thickness of approximately 200 to 500 microns, with major surfaces lying substantially in the {110} plane. Top and bottom silicon oxide layers 38 and 40, respectively, are grown on substrate 28 using conventional techniques well known in the semi-conductor industry. Layer of silicon nitride 42 and layer of silicon nitride 44 are the deposited over respective silicon oxide layers 38 and 40, respectively, using conventional vapor deposition techniques. Layer of silicon oxide 38 and layer of silicon nitride 42 form a conventional passivation layer 43. Similarly, layer of silicon oxide 40 and layer of silicon nitride 44 form passivation layer 45. Referring now Figure 3B, center member 60 and frame 14 are formed by etching a pair of openings or cavities 62 and 64 (Figure 1) through substrate 28 by use of well-known photolithographic technology and wet etching with an anisotropic etchant solution, such as aqueous potassium hydroxide solution or ethylene diamine pyrocatechol solutions. It is to be understood that dry etching techniques utilizing a gas may also be used, but the intrinsically slower etch rates may be useful only in thin materials. Photo resist layers 46 and 48 are deposited over respective passivation layers 43 and 45, and passivation openings 50, 52, 54 and 56 are delineated utilizing conventional photolithographic techniques. Passivation openings 50, 52, 54 and 56 are extended through the passivation layers 43 and 45 to expose respective portions of surfaces 70 and 78 of center member 60 as shown in Fig. 3B. Thus, passivation openings 50, 52, 54 and 56 form conventional mask openings for subsequent etching of center member 60. A wet anisotropic etchant, such as described hereinabove, is applied to etch the exposed portions of surfaces 70 and 78 of center member 60 such that respective recesses 66 and 68 are formed in surface 70 extending from passivation openings 50 and 52; and, respective recesses 74 and 76 are formed in surface 78 extending from passivation openings 54 and 56 as shown in Fig. 3C. Etching of the {110} plane is timed such that flexible members 16, 18, 20 and 22 have a thickness, and accordingly the related flexibility or spring constant desired. Since the anisotropic etchant acts against the {110} planes at a rate approximately 100 times greater than the etchant acts against the lateral {111} planes, the final shape of the etched areas is determined by the slowly etched {111} surfaces and the remaining unetched {110} surfaces which bound the etched volume. Thus, for the illustrated {110} wafer, recesses 66, 68, 74 and 76 each define a substantially rectangular recess extending inwardly from the passivation openings. The spacing between the recesses 66 and 74, as determined by the offset between passivation openings 50 and 54, substantially defines the thickness of flexible member 24. Similarly, the spacing between recesses 68 and 76, as substantially determined by the offset between passivation openings 52 and 56, defines the thickness of flexible member 26. Figure 3C illustrates the resulting structure after the photo resist material has been removed. For clarity in illustration, passivation layers 43 and 45 are now shown in Figure 3C. Those skilled in the art will recognize that different crystalline structures will result in recessed of different shapes. In another embodiment of the invention a silicon wafer having a {100} crystalline structure is used, which results in the formation of the recesses as described later herein with particular reference to Figures 4 and 5. It should also be noted that the formation of multiple flexible members, as described herein, provides the advantage of requiring only a single etching step from a single substrate. Referring now to Figures 4 and 5, wherein like numerals relate to like parts shown in figures 1 and 2, wet etching in {100} wafers of silicon is shown. In a {100} crystalline structure, the lateral {111} planes intersect the normal {100} plane at an angle of 54.7°. An anisotropic etchant, as described hereinabove, acts against the (10) planes at a rate approximately 100 times greater than the {111} planes. Accordingly, the etchant acts against the {100} planes leaving etched volumes bounded by the {111} planes. For the embodiment shown in figure 4, the etchant step is timed such that the etching against the {100} planes defines the thickness of flexible members 16', 18', 20' and 22'. Flexible members 24' and 26', however, have a thickness essentially determined by the positioning of the passivation openings (not shown) with respect to one another. That is, since the etchant acts against the {111} planes at a rate approximately only 1/100th the {100} planes, the spacing of those {111} planes extending from the opposing passivation openings essentially determines the thickness of flexible members 24' and 26'. It is to be noted, however, that some etching against the {111} planes will occur dependent upon the etching time. Accordingly, the thickness of flexible members 24′ and 26′ is not perfectly defined by the spacing of the passivation openings with respect to one another. Although the photo resist openings are not shown in Figure 4, it is apparent to one skilled in the art that they may be defined as the intersection of recesses 66′ and 68′ with surface 70′, and recesses 74′ and 76′ with surface 78′. Referring now to the embodiment shown in Figure 5, wherein another {100} silicon substrate is illustrated, it is seen that the {111} planes defining the outer walls of recesses 66″, 68″, 74″ and 76″ intersect or converge within the silicon substrate. That is, the {111} planes extending from the perimeter of each passivation opening (not shown) intersect within the silicon substrate. Since the anisotropic etchant etches against the {100} plane at a rate approximately 100 times greater than the {111} planes, the anisotropic etchant etches against the {100} plane to the intersection of the {111} planes as illustrated in Fig. 5. At the intersecting point the etch rate drops drastically giving the operator more than sufficient time to remove the wafer from the etchant and wash the wafer clean of etchant chemicals. It is to be noted that extending the perimeter of the passivation openings (not shown) such that the {111} planes extending therefrom would converge off the substrate, would result in a structure similar to that shown in Figure 4; provided, however, that the etching time is controlled to prevent etching of the {100} plane through the substrate. Accordingly, an advantage provided by the embodiment shown in Figure 5 is that the etching time does not require strict control. As previously described with respect to the embodiment shown in Figure 1, another advantage obtained by the embodiments shown in both Figures 4 and 5 is that multiple flexible members are obtained on a single substrate by a single etching step. A silicon substrate is advantageous to use in applications wherein electronic circuitry is fabricated on the same silicon substrate using techniques well known in the microelectronics industry. Further, the silicon may be doped to carry electrical current thereby minimizing the need for external electronic circuitry.

Claims: A method of forming a suspended element (12) from a silicon substrate which comprises the steps of etching two cavities (62, 64) in a {110} or {100} wafer (28) of said substrate, thereby defining a center member (60) between said cavities having a first planar face (70) and an opposing second planar face (78), said cavities also defining a supporting frame (14) connected to opposing ends of said center member, forming in a passivation layer (48) on said first planar (70) face a first pair of passivation openings (50, 52) symmetrically positioned on said first planar face (70) and forming in a passivation layer (46) on said second planar face (78) a second pair of passivation openings (54, 56) symmetrically positioned on said second planar face (78) and offset from said first pair of passivation openings (50, 52); applying an anisotropic etchant to said passivation openings (50, 52, 54, 56) for forming, in a single etching step, a first pair of recesses (66, 68) through said first planar face (70) and a second pair of recesses (74, 76) through said second planar face (78), whereby said suspended element (12) is defined as the portion of said center member (60) between said first pair of recesses (66, 68); and timing said step of anisotropic etching to form narrowed portions (24, 26) of said center member between corresponding recesses (66, 74; 68; 76) of said first and second pairs of recesses and between the bottoms of said recesses and the respective opposed planar face, said narrowed portions (24, 26) defining a pair of flexing means (16, 24, 20; 18, 26, 22) at the opposing ends of said center member (60) for providing rectilinear deflection of said suspended element (12) in linear proportion to an applied force. A method according to claim 1 wherein said silicon substrate is a {110} wafer of silicon and said recesses (66, 68; 74, 76) are essentially rectangular in cross-section. A method according to claim 1 wherein said silicon substrate is a {100} wafer of silicon and the cross section of said recesses is V-shaped (66'', 68'', 74'', 76'') or truncated V-shaped (66', 68', 74', 76').

Inventors: SICKAFUS EDWARD N, SICKAFUS, EDWARD N.
Applicants: FORD FRANCE, FORD MOTOR CO, FORD WERKE AG, FORD FRANCE SOCIETE ANONYME, FORD MOTOR COMPANY LIMITED, FORD-WERKE AKTIENGESELLSCHAFT
Application year: 1988
Main classification: G01L1
IPC codes: G01L1, G01P15