METHOD OF PRODUCING MICROMECHANICAL SENSORS FOR THE AFM/STM PROFILOMETRY AND MICROMECHANICAL AFM/STM SENSOR HEAD

Abstract: A method is described for producing micromechanical sensors for the AFM/STM profilometry, which consist of a cantilever beam with at least one tip at its end and a mounting block at the opposite, comprising: 1. bilaterally coating a wafer substrate with an insulating layer; 2. producing a mask in the insulating layer on the top side of the wafer for future trench or groove etching, and a mask in the insulating layer on the bottom side of the wafer, using a first photolithographic step and reactive ion etching: 3. producing a trench or a groove in the wafer substrate by reactive ion or anisotropic wet etching, respectively, followed by removing the insulating layer from the top side by etching: 4. coating the surface of the wafer and the trench or groove with the desired cantilever beam and tip material, respectively; 5. baring cantilever beam and tip in a second photolithographic step and dry or wet etching steps, respectively; and 6. removing the supporting wafer material from the bottom side by anisotropic wet etching through the bottom side mask. In a preferred embodiment the area on the top side of the cantilever beam corresponding to the remaining piece of wafer on the bottom side is bonded with a block of glass via 'mallory' bonding at about 300°C and 1000 V. Furthermore, the surface of the wafer substrate and the trench can be coated in a first step with a material with nonconformal step coverage, and in a second step with a material with conformal step coverage. The cantilever beam and the tip are bared in the layer with conformal step coverage, and the supporting wafer and the layer with nonconformal step coverage are removed by selective etching through the bottom side mask. The invention also comprises a micromechanical sensor for AFM/STM profilometry which is micromechanically manufactured from one piece of material.

Description: The present invention relates to a method of producing micromechanical sensors for the AFM/STM profilometry, which consist of a cantilever beam with at least one tip at its end and a mounting piece at the opposite end. The invention also relates to a sensor head made in accordance with the method of the invention. The scanning tunneling microscope (hereafter abbreviated STM) has stimulated the development of new techniques for microcharacterization of materials which are based on the use of a very fine tip. One of these techniques involves the atomic force microscope (hereafter abbreviated AFM) which has recently demonstrated the capability to profile and image conductors and insulators. In the initial design of the AFM (Binnig G, Quate CF, Gerber Ch, (1986) Atomic Force Microscope, Phys. Rev. Lett. 56, 930 - 933 and EP-A-0 223 918) a sensor consisting of a spring-like cantilever which is rigidly mounted at one end and carries at its free end a dielectric tip profiles the surface of an object. The force between the object's surface and the tip deflects the cantilever, and this deflection can be accurately measured, for example by a second tip which is part of an STM. A lateral spatial resolution of 3 nm has initially been achieved. Another version of the AFM includes optical detection instead of an STM detection. In this version a tungsten tip at the end of a wire is mounted on a piezoelectric transducer. The transducer vibrates the tip at the resonance frequency of the wire which acts as a cantilever, and a laser heterodyne interferometer accurately measures the amplitude of the a. c. vibration. The gradient of the force between the tip and sample modifies the compliance of the lever, hence inducing a change in vibration amplitude due to the shift of the lever resonance. Knowing the lever characteristics, one can measure the vibration amplitude as a function of the tip-sample spacing in order to deduce the gradient of the force, and thus, the force itself (Duerig UT, Gimzewski JK, Pohl DW (1986) Experimental Observation of Forces Acting During Scanning Tunneling Microscopy, Phys. Rev. Lett. 57, 2403 - 2406; and Martin Y, Williams CC, Wickramasinghe HK (1987) Atomic Force Microscope-Force Mapping and Profiling on a sub 100-Å Scale, J. Appl. Phys. 61(10), 4723 - 4729). A most critical component in the AFM is the spring-like cantilever. As a maximum deflection for a given force is needed a cantilever is required which is as soft as possible. At the same time a stiff cantilever with a high eigenfrequency is necessary in order to minimize the sensitivity to vibrational noise from the building. Usually, ambient vibrations, mainly building vibrations, are on the order of <100 Hertz. If the cantilever is chosen such that it has an eigenfrequency f o ≧ 10 kHz, the ambient vibrations will be attenuated to a negligible value. These requirements can only be met by reducing the geometrical dimensions of the cantilever as reflected by the following two equations: The eigenfrequency f o of the cantilever is given by f o = 0,162 t l 2 E ρ K wherein E is Young's modulus of elasticity, ρ is the density, and K is a correction factor close to unity, l is the length, and t is the thickness of the cantilever. The spring constant of the cantilever on which its sensitivity depends is given by c = F y = E w t 3 4 l 3 wherein F is the force which causes the deflection y of the cantilever, E is Young's modulus of elasticity, w is the width, l is the length, and t is the thickness of the cantilever. In accordance with the spring constant term the sensitivity of the cantilever is dependent on its dimensions and on the material of which it consists, with the highest sensitivity being obtained for long, thin and narrow cantilever beams. The width of the cantilever beam should be sufficiently large so that lateral vibrations are suppressed. Also, the width of the beam should permit the fabrication of additional structures, such as tips, thereon. Therefore, a minimum width w of around 10 µm seems reasonable. In practice, C has to be about ≧ 1 N/m in order to avoid instabilities during sensing of attractive forces, to prevent excessive thermal vibrations of the cantilever beam, and to obtain a measurable response. Dimensions of a cantilever beam compatible with C = 1 N/m, and f o = 10 kHz are for example: l = 800 µm, w = 75 µm, and t = 5.5 µm. In the normal deflection mode of the cantilever beam forces in the order of 10⁻¹² N can be detected. The sensitivity of the sensor head can be further enhanced by vibrating the object to be profiled at the resonance frequency f o of the cantilever beam, as described by G. Binnig et al in Phys. Rev. Lett. 56 (1986), pp. 930 - 933. In the AFM realized in accordance with the Binnig et al article and with EP-A-0 223 918 the requirements for cantilever and tip were met by a gold foil of about 25 µm thickness, 800 µm length, and 250 µm width to which a diamond fragment was attached with a small amount of glue. Another proposal used microfabrication techniques to construct thin-film (1.5 µm thick) SiO₂ microcantilevers with very low mass on which miniature cones could be grown by evaporation of material through a very small hole (Albrecht ThR, Quate CF, (1988) Atomic Resolution with the Atomic Force Microscope on Conductors and Nonconductors, J. Vac. Sci. Technol., pp. 271 - 274. With the aforementioned microfabrication techniques microcantilevers are produced, and in the next process step tips are grown on said cantilevers. However, cantilever and tip do not form one integral part. Furthermore, this technique is disadvantageous in that evaporated tips poorly adhere to the substrate, and the tip diameter at its base is limited to some 10 to 20 µm. From the foregoing description of the state of the art it was known to construct, in a first process step, cantilevers, and, in a second process step, to attach tips thereto. It will be obvious to those skilled in the art that the construction of a cantilever with tip of that type is extremely delicate and prone to low yield. It is desirable to provide a method for making a cantilever beam assembly having a microminiature tip fixed to the free end for application in STM or AFM, with said microminiature tip being uniform, sharp, well-formed, durable and inexpensive in fabrication. The cantilever beams with integrated tips are fabricated using microfabrication techniques. This technique allows to shape the tip in any desired mode, and represents a reproducible method for fabricating integrated tips which is a significant contribution to STM/AFM technology. It is, therefore, an object of the invention to teach a method for the construction of microcantilevers with integrated tips, which method uses a suitable combination of deposition, lithography, wet and dry etching process steps. The object of the invention is achieved with a method in accordance with claim 1 and dependant claims 14 and 16. The invention also comprises structures made in accordance with the method of the invention. Prior to starting with the description of the details of the invention reference is made to the following publications relating to micromechanics: Petersen, KE, Dynamic Micromechanics on Silicon: Techniques and Devices, Vol. ED-25, No. 10, October 1978, pp. 1241 - 1250; Petersen, KE, Silicon as a Mechanical Material, Proc. of the IEEE, Vol. 70, No. 5, May 1982, pp. 420 - 457; and Jolly, RD, Muller, RS, Miniature Cantilever Beams Fabricated by Anisotropic Etching of Silicon, J. Electrochem Soc.: Solid-State Science and Technology, December 1980, pp. 2750 - 2754. With the method of the present invention low-mass microcantilever beams with integrated tips can be made carrying at one end a small piece of wafer or, if necessary, a piece of Pyrex* glass (trademark of Corning Glass Works) for mounting the lever in the AFM, and at the opposite end an integrated tip for interaction with the surface of a sample to be profiled. The force and resonance frequency requirements of cantilever beam and integrated tip are met by using the microfabrication techniques. Due to the fact that cantilever and tip are made from one piece of material there are no adhesion problems between cantilever and tip. Details of several embodiments of the present invention will be described by way of example with respect to the accompanying drawings in which: Fig. 1 shows a sequence of process steps for making a cantilever beam with integrated tip with a high aspect ratio via reactive ion etching of a trench into a substrate, which trench serves as a mould for the tip; Fig. 2 shows the mask and a sequence of process steps for making a cantilever beam with integrated tip via anisotropic wet etching of a pyramidal shaped groove into the substrate, which groove serves as a mould for the tip; Fig. 3 shows the novel tip of one preferred example of the invention in comparison with a conventional tip; Fig. 4 shows a sequence of process steps for making the tip in accordance with Fig. 3. This invention is based on an additive method which allows the fabrication of cantilever beam and tip as an integral part. For this purpose a hollow mould for the tip is made in a wafer substrate. This can be realized by reactive ion trench etching or by anisotropic wet etching which uses special crystallographic orientations for making cone- or pyramidal shaped etch pits. Subsequently, the wafer surface including the hollow mould for the tip is coated with the desired cantilever beam and tip material. The coating can consist of one or of several layers of different materials which are applied one after the other. This process step allows the fabrication of cantilever beams of arbitrary thickness and hence of arbitrary spring constant. In the next step which comprises photolithography and subsequent dry or wet etching the cantilever beam including the tip is bared. By means of selective etching through a mask on the bottom side of the wafer the wafer which up to now served as a carrier for cantilever beam and tip is removed. If more than one layer of different materials has been applied the wafer and the respective layers excluding the top layer have to be removed by selective etching through the bottom side mask. With the method of the invention microcantilevers with integrated tips can be made. The tips, depending on their shape, have a high aspect ratio or, owing to the utilization of special crystallographic orientations, have a highly reproducible form, and are realizable with a very low radius of curvature. As the tips are made by coating hollow moulds their mass can be considerably lower than the mass of tips which have been worked out of solid material. One preferred example of the invention is described in accordance with Fig. 1. A silicon wafer (1) is bilaterally coated with silicon dioxide. Both layers (2 and 3) are thermally grown to the preferred layer thickness of about 1 µm. Next, an about 3 µm thick photoresist layer is applied to the silicon dioxide layer (3) on the top side of the wafer (1) (not shown). Well-known positive acting photoresists, such as AZ 1350J of the Shipley Company, or negative acting photoresists can be used for this purpose. In a first photolithographic step the mask pattern for the reactive ion trench etching process is defined in the photoresist layer. This pattern is transferred into the silicon dioxide layer (3) by wet etching or reactive ion etching under the following conditions: etch gas: CF₄ pressure: about 10 µbar. Concurrently with the aforedescribed photolithographic and reactive ion etching steps rectangular openings are made in the oxide layer on the bottom side of the wafer, with the respective masks on the bottom side of the wafer being in alignment with those on the top side. The remaining photoresist is removed. The resulting structure is shown in Fig. 1 a. With the silicon dioxide mask (3) a trench (4) is etched into the silicon substrate (1) to a depth in the range of about 2 to 20 µm under the following conditions: etch gas: 10 % of total flow Cl₂/argon pressure: about 100 µbar. Other processes for etching silicon use gas mixtures such as SF₆, Cl₂ and helium; CCl₂F₂ and O₂; or SiF₄, Cl₂, helium or argon. The resulting structure is shown in Fig. 1 b. After the trench etching the silicon dioxide mask (3) is removed from the top side of the wafer (1) by wet etching in 5 : 1 buffered hydrofluoric acid. The bottom side of the wafer has to be protected during this etching step, e. g. by a baked photoresist layer. Next, as shown in Fig. 1 c, the wafer surface including the deep trench (4) is coated with the desired cantilever beam and tip material (5). Suitable materials for this purpose are thermally grown or PECVD silicon dioxide; diamond-like carbon; silicon nitride, deposited by chemical vapor deposition (CVD); silicon carbide, deposited by chemical (CVD) or plasma enhanced chemical vapor deposition (PECVD), and the like. In this example silicon nitride is deposited by chemical vapor deposition from a SiH₂Cl₂, ammonia and argon containing atmosphere at a pressure of about 0.25 to 1.3 mbar, and a temperature of about 625°C. In the next step the cantilever beam including the tip is bared using photolithography and dry or wet etching steps on the top side of the wafer (Fig. 1d). For the etching of silicon nitride a dry etching step with CF₄ as etch gas and a pressure of about 50 µbar is applied. By means of selective etching with aqueous KOH solution through a mask (2) on the bottom side of the wafer (1) the wafer which up to now served as a carrier for the cantilever beam (5) and tip (6) is removed (Fig. 1e). As it is sometimes more advantageous for the profiling of surfaces to mount the cantilever beam in the AFM via a block of material extending in a direction opposite to that of the wafer piece (1) shown in Fig. 1e, a block of glass (7) (Fig. 1f) is bonded with the corresponding area on the top side of the cantilever beam, and the remaining piece of wafer on the bottom side of the cantilever beam is removed by etching. In a practical example a block of Pyrex* glass (trademark Corning Glass Works) is bonded with the cantilever beam in the area overlying the remaining silicon wafer (1) via 'mallory' bonding at a temperature of about 300°C and by applying a voltage of about 1000 V. Subsequently, the remaining silicon wafer piece is removed by etching with aqueous KOH solution. The resulting structure is shown in Fig. 1f. In a second example a hollow mould for shaping the tip is made by anisotropic wet etching of a pyramidal shaped etch pit into a standard (100) oriented wafer via a mask hole as shown in the plan view above Fig. 2a. The etching is performed with KOH (37.5 wt% aqueous solutions). Aqueous KOH solution is an etchant which is selective with respect to the orientation as well as to the dopant concentration of the silicon crystal. The KOH etches the (111) direction at least some 100 times slower than the other directions. As a consequence by etching three-dimensional structures into bulk silicon a structure is left with etched wells having (111) side walls. As shown in Fig. 2 a, a pyramidal shaped mould is etched with KOH solution into silicon substrate (21) via mask hole (24) in silicon dioxide layer (23) on the top side of the wafer. After silicon etching the silicon dioxide masking material (23) is removed by etching (not shown). Subsequently, the wafer surface including the pyramidal shaped etch pit (24) is coated with the desired cantilever beam and tip material (25) as shown in Fig. 2 b. In the next step the cantilever beam including the tip is exposed using photolithography and dry or wet etching steps on the top side of the wafer (Fig. 2c). By means of selective etching with aqueous KOH solution through the mask (22) on the bottom side of the wafer (21) the wafer which up to now served as a carrier for the cantilever beam (25) and tip (26) is removed (Fig. 2d). All materials and process steps if not otherwise indicated are identical with those of example 1. The resulting tip structure which has been made by coating a hollow mould has a minimum weight compared to a structure which has been worked out of a solid material. A topography, such as a trench, with vertical side walls and rectangular corners cannot be profiled with a conventional tip which is shown in Fig. 3a, left side. A tip of this shape does neither reach the vertical side walls nor the lower corners of the trench. Therefore, the third example describes a process for making a sensor head for AFM/STM profilometry which consists of a shaft with one or several tips pointing downwards. A sensor head of this kind is shown in Fig. 3b, right side. This sensor head allows the profiling of vertical side walls of a 90° edge. By means of reactive ion etching a trench (42) (Fig. 4a) with substantially vertical side walls and rectangular corners is etched into a basis material, say a silicon substrate. Typical gas mixtures for etching trenches into silicon substrates are described in example 1 in accordance with Fig. 1 b. Apart from silicon, silicon dioxide, GaAs, or polyimide may be used as basis materials. Instead of reactive ion etching direct exposure may be used for making trenches with substantially vertical side walls and rectangular corners. After etching the resulting trench (42) is partly filled by chemical vapor deposition (CVD), or plasma enhanced chemical vapor deposition (PECVD), or sputtering of a material (43) which shows nonconformal step coverage (Fig 4b). Examples for materials with nonconformal step coverage during plasma deposition are silicon nitride, silicon dioxide, amorphous silicon, tungsten silicide etc. In this example silicon nitride is deposited by PECVD from a SiCl₂H₂/ammonia or SiCl₂H₂/nitrogen gas mixture at a temperature of about 300°C, and a pressure in the range of about 500 µbar. Next, the trench (42) is completely filled with a material (44) which shows conformal step coverage (Fig. 4c). A material preferred for this purpose is polysilicon which is deposited by pyrolysis of a silane/hydrogen gas mixture at a temperature of about 625°C, and under atmospheric pressure. With respect to conformal and nonconformal step coverage during PECVD of inorganic materials reference is made to Adams AC (1983) "PLASMA DEPOSITION OF INORGANIC FILMS", Solid State Technol., pp. 135 - 139. Next, the cantilever beam including the tip is bared in the top layer by applying photolithography and dry or wet etching steps on the top side of the wafer (not shown). For polysilicon reactive ion etching is applied with CF₄ as etch gas, and with a pressure of about 25 µbar. By selective etching from the bottom side of the topography the wafer (41) and layer (43) are removed (not shown). For the etching of silicon (41) an aqueous KOH solution is used. For the etching of silicon nitride (43) a concentrated aqueous hydrogen fluoride solution is applied. During these etching steps the top side of the topography (consisting of polysilicon) has to be protected, e. g. by a PECVD silicon dioxide layer. For the STM profilometry the tips made in accordance with this invention may carry a metallic coating.

Claims: 1. Method of producing micromechanical sensors for the AFM/STM profilometry, which consist of a cantilever beam with at least one tip at its end and a mounting piece at the opposite, comprising the following steps: 1. bilaterally coating a wafer substrate (1; 21) with an insulating layer (3/2; 23/22); 2. producing a mask in the insulating layer (3; 23) on the top side of the wafer for future trench (4) or groove (24) etching, and a mask in the insulating layer (2; 22) on the bottom side of the wafer, using a first photolithographic step and wet etching or reactive ion etching; 3. producing a trench (4) or a groove (24) in the wafer substrate (1; 21) by reactive ion or anisotropic wet etching, respectively, followed by removing the insulating layer (3; 23) from the top side by etching; 4. coating the surface of the wafer (1; 21) and the trench (4) or groove (24) with the desired cantilever beam and tip material (5; 25), respectively; 5. baring cantilever beam (5; 25) and tip (6; 26) in a second photolithographic step and dry or wet etching steps, respectively; and 6. removing the supporting wafer material (1; 21) from the bottom side by isotropic or anisotropic wet etching through the bottom side mask. 2. Method of claim 1, wherein the wafer substrate consists of monocrystalline silicon, silicon dioxide, GaAs, or polyimide. 3. Method of claim 1, wherein a silicon dioxide layer (3/2; 23/22) is thermally grown on both sides of a silicon wafer substrate (1; 21) to a layer thickness of about 1 µm. 4. Method of claims 1 and 3, wherein an about 3 µm thick photoresist layer is applied to the silicon dioxide layer (3; 23) on the top side of the wafer, and, by a first photolithographic step, the desired mask pattern is defined in said photoresist layer. 5. Method of claim 4, wherein the mask pattern in the photoresist layer is transferred into the silicon dioxide layer (3; 23) by wet etching or reactive ion etching with CF₄ as etch gas, and with a pressure of about 10 µbar. 6. Method of claims 4 and 5, wherein with said first photolithographic step and said reactive ion etching step rectangular openings are simultaneously made in the silicon dioxide layer (2; 22) on the bottom side of the wafer. 7. Method of claim 1, wherein a trench (4) is etched into the silicon wafer substrate (1) to a depth in the range of about 2 to 20 µm by reactive ion etching with 10 % of total flow chlorine/residue argon as etch gas, and with a pressure of about 100 µbar. 8. Method of claim 1, wherein a pyramidal shaped groove (24) is etched into the silicon wafer substrate (21) by anisotropic wet etching with an aqueous KOH solution (37.5 wt%). 9. Method of claim 1, wherein the silicon dioxide layer (3; 23) is removed from the top side of the wafer by wet etching with 5 : 1 buffered hydrofluoric acid. 10. Method of claims 1, 7 and 8, wherein the wafer surface (1; 21) including deep trench (4) or pyramidal shaped groove (24) is coated with the cantilever beam and tip material (5; 25) which is selected from the group of thermally grown or PECVD silicon dioxide, diamond-like carbon, CVD silicon nitride, CVD or PECVD silicon carbide, and the like. 11. Method of claim 10, wherein the wafer surface is coated with silicon nitride which is deposited from a SiCl₂H₂, ammonia, and argon containing atmosphere at a pressure of about 0.25 to 1.3 mbar, and a temperature of about 625°C. 12. Method of claim 11, wherein the silicon nitride cantilever beam including the tip is bared in the second photolithographic step, followed by reactive ion etching with CF₄ as etch gas, and with a pressure of about 50 µbar. 13. Method of claim 1, wherein the supporting silicon wafer material (1; 21) is removed from the bottom side by anisotropic wet etching with an aqueous KOH solution (37.5 wt%). 14. Method of claim 1, further comprising bonding the area on the top side of the cantilever beam (5; 25) corresponding to the remaining piece of wafer on the bottom side with a block of glass (7), and subsequently removing the remaining piece of wafer by selective etching. 15. Method of claim 14, wherein the block of glass is bonded with the cantilever beam via 'mallory' bonding at a temperature of about 300°C and by applying a voltage of about 1000 V. 16. Method of claim 1, further comprising coating the surface of the wafer and the trench with several layers of different materials (step 4); baring cantilever beam and tip in the top layer by a second photolithographic step and dry or wet etching steps, respectively (step 5); and removing the supporting wafer material and the respective layers by selective etching through the bottom side mask (step 6). 17. Method of claim 16, wherein the surface of the wafer substrate (41) and the trench (42) is coated in a first step with a material (43) which shows nonconformal step coverage, and in a second step with a material (44) which shows conformal step coverage. 18. Method of claim 17, wherein the material (43) with nonconformal step coverage during plasma deposition is selected from the group of silicon nitride, silicon dioxide, amorphous silicon, tungsten silicide and the like. 19. Method of claims 16 to 18, wherein the surface of the silicon wafer substrate (41) and the trench (42) is coated in a first step with PECVD silicon nitride (43), and in a second step with polysilicon (44); the cantilever beam and the tip are bared in the polysilicon layer (44) by photolithography and reactive ion etching with CF₄ as etch gas, and with a pressure of about 25 µbar; and wherein the silicon wafer substrate (41) and the silicon nitride layer (42) are removed by wet etching through the bottom side mask with aqueous KOH solution (37.5 wt%), and concentrated aqueous hydrogen fluoride solution, respectively. 20. Micromechanical sensor for AFM/STM profilometry comprising a cantilever beam carrying at one end at least one tip for interaction with the surface of a sample to be profiled, and carrying a mounting block at the opposite end distant from said tip, characterized in that said cantilever beam, said tip and said mounting block are micromechanically manufactured; said cantilever beam and said tip forming one integral part consist of a material selected from the group of thermally grown or PECVD silicon dioxide, diamond-like carbon, CVD silicon nitride, CVD or PECVD silicon carbide and polysilicon; and said mounting block is formed by a piece of the supporting wafer (Fig. 1e). 21. Micromechanical sensor of claim 20, characterized in that the mounting block bonded to the cantilever beam at the opposite end distant from said tip and extending in a direction opposite to that of the remaining wafer piece which is removed by etching consists of glass (Fig. 1f).

Inventors: BARTHA, JOHANN, DR. DIPL.-PHYS., BAYER, THOMAS, GRESCHNER, JOHANN DR. DIPL.-PHYS., KRAUS, GEORG, WEISS, HELGA, WOLTER, OLAF, DR. DIPL.-PHYS.
Applicants: INTERNATIONAL BUSINESS MACHINES CORPORATION
Application year: 1989
Main classification: G01N27
IPC codes: C23F1, G01N13, G01N27, C03C15, G01B7, H01L41, B44C1, H01L21, B81C1, H01J37