Micromechanical device

Abstract: A pedestal structure and its fabrication method provide a stress release assembly of micromechanical sensors, in particular acceleration sensors, angular rate sensors, inclination sensors or angular acceleration sensors. At least one silicon seismic mass is used as sensing element. The at least one silicon seismic mass is joined to the silicon frame via at least one elongate assembly pedestal, the surface of which is bonded to a covering wafer, either glass or silicon. Signals may be transmitted via buried conductors in the pedestal. The bonding area is reduced by shallow transversal recesses in the surface of the pedestal.

Description: The invention relates to a micromechanical device, such as an acceleration sensor, angular rate sensor, inclination sensor, or angular acceleration sensor, in which a seismic mass is used as sensing element. Many devices having micromechanical structures are currently known. One problem associated with many of such structures is that manufacture of the devices introduces internal stresses in the structure and participating in the components which measure the parameter to which the sensor is sensitive. Generation of such stresses causes problems. It often results in the sensor having an offset or varying unpredictably with temperature or over the sensing range of the sensor. This results in each sensor requiring individual testing and appropriate means, either via mechanical or electrical compensation, to be provided in order for the sensor to operate accurately and consistently. It will be appreciated that this can cause a considerable increase in sensor cost, as well as reducing reliability. Many attempts have been made to overcome the problem associated with induced stress. Most of the approaches are, however, dependent upon employing very specific materials, either in the device components or in the encasing packaging of the device, meaning that they are inflexible and cannot be broadly applied to different device types. Many have an additional problem they in requiring extremely complex and costly manufacturing steps which again increase cost and which can be time consuming and result in many rejected devices. GB-A-2176607 discloses an accelerometer device with beam members with the problem that they are too large to be used in sufficiently small significantly small micromachined sensors. US-A-5484073 discloses a method for fabricating spring members bonded together to form the inertial mass in a sensor. EP-A-742581 discloses a method for making sealed cavities on silicon wafers. According to the present invention there is provided a micromechanical device characterised by: a pedestal member formed from a semiconductor wafer and connected to a support wall structured out of the same wafer; and first and second encasing members which are bonded to a frame member which comprises the support wall: wherein least a portion of the pedestal member has a peripheral portion of reduced thickness defining a rim which extends away from the pedestal member and supports, in use, at least one sensing component of the device; wherein the pedestal member is elongate, with a longer dimension of the pedestal member extending in a direction substantially perpendicular to that of the support wall to which the pedestal member connects; wherein the pedestal member is bonded, inward of the rim, to the first encasing member only; and wherein the pedestal member has a transverse shallow recess, the recess defining an area over which the pedestal is not bonded to the first encasing member. The support wall may be arranged such that it surrounds both the pedestal member and the sensing component. The sensing component may be connected to the pedestal member by one or more planar flexible hinges. The micromechanical device may be an acceleration sensor, an angular rate sensor, an inclination sensor, or an angular acceleration sensor. A gap between the component and the first encasing member may be provided and may be formed by an etched recess in the encasing member. Electrical contacts may be provided with the component or suspension member by the provision of direct electrical contacts located on the edge of the pedestal and on the contact surface of the encasing member. Alternatively, electrical conductors may be provided by implantation of impurities or by sputter deposition of film onto the pedestal structure. Electrical crossings may be provided perpendicular to the direction of elongation of the pedestal member in order to further reduce stresses in the overall device structure. The device may be formed from silicon. According to the invention, there is also provided a method of manufacturing a micromechanical device according to any preceding claim, the method characterised by: structuring of the pedestal member, the support wall, the sensing component(s) and planar hinge(s) in a top layer atop an etch stop layer out of the substrate wafer, by etching the said top layer to provide the said rim and the said transverse shallow recess and wet etching the excess material of the substrate down, from the backside of the substrate wafer, to the said etch stop layer; final shaping of the pedestal member, the sensing component(s), and the frame member by etching; bonding the frame member to the first encasing member; bonding the pedestal member, inward of the rim though outward of the recess, to the first encasing member; and bonding the frame member to a second encasing member. Within this invention, at least one silicon seismic mass may be is joined to a silicon support wall frame via the pedestal structure, the surface of which is bonded to the encasing member which is, either glass or silicon. This pedestal structure and its method of assembly according to the invention has the advantage that the coupling between the sensing element of the sensor and the frame of the sensor is minimised by using the pedestal member, the bearing surfaces of which are small compared to the surface area from which the device is formed. This reduces the assembly-related strains, stress and associated temperature-induced variations of the overall device, thus simplifying the evaluation electronics of the device. Other provisions of the structure and its method of assembly according to the invention are also advantageous. The pedestal member can be fabricated easily, being produced in the same process that structures the micromechanical components of the device, such as a sensing seismic elements and their suspension systems. This structuring process is especially advantageous because well known - and established micromechanical structuring processes, such as wet and dry anisotropic silicon etching, can be used for this purpose. A particular advantage of the pedestal member and its assembly method according to the invention is that the geometry and the manner of its structuring can be selected in accordance with the function of the sensing element and its fabrication sequence. A special advantage of this invention is that any bonding between the covering wafers and the micromachined silicon wafer, which caries the component, the pedestal member and the support wall, takes place at the wafer level, resulting in economical, easy to handle batch processing. According to the invention, a multitude of ready-structured devices, which have not yet been cut in individual devices, can be bonded simultaneously to the encasing member, then separated, for instance by sawing. The bonding technique that forms any sealed cavity and anchors the pedestal member to the encasing member is to be chosen depending on the material of the encasing member. If glass is used for covering, then an anodic bonding technique is suitable; if silicon is used, then silicon-to-silicon bonding techniques are advantageously suited. For other materials, soldering bonding techniques can be successfully employed. The atmosphere composition and its pressure can be freely selected and preserved within any sealed cavity by the anodic bonding technique, which makes this technique particularly attractive. The device and its method of assembly according to the invention allows the optional implementation in its structure of (i) press-contacts, a method of passing electrical conductive paths between the wafers; (ii) buried crossings, a method of passing electrical conductive paths through the bulk of pedestal; (iii) direct crossings, a method of passing electrical conductive paths across the pedestal; and (iv) surface conductors along the pedestal. The invention particularly enables the realisation of a compact sensor as no other stress-releasing structures or mounting techniques, internal or external, being required. The pedestal structure and its method of assembly according to the present invention will now be described, with reference to the accompanying drawings, in which: Figure 1 is a section through a sensor device according to the invention having its sensing components joined to its frame by means of a pedestal member; Figure 2 is a top view of a sensing component attached to the frame by means of a pedestal member structure; Figures 3a and 3b are cross-sectional views taken along lines A-A and B-B respectively in figure 2; Figure 4 is a cross-sectional view taken along A-A in figure 2, during wafer-based processing of a sensor device recording to the invention; Figure 5 is a longitudinal cross-sectional view of a pedestal member structure and the mechanical loads generated by the packaging and/or temperature variations, in an example of the invention; Figures 6a, 6b, 6c and 6d are transverse cross-sectional views of a pedestal member showing various options for structuring. Figures 7a, 7b, 7c and 7d are cross-sectional views taken along line A-A in figure 2, in alternative examples; Figures 8a, 8b, 8c and 8d are transverse cross-sectional views of the pedestal member structure showing various options of structuring, in alternative examples; and Figure 9 is a longitudinal cross-sectional view of the pedestal member taken along line A-A in figure 2, in alternative examples of SOI wafer-based processing. Figure 1 shows a cross-sectional view of an inertial sensor device 10 in accordance with the present invention. The inertial sensor 10 is realised by bonding a structured silicon wafer 30 between two encasing member 20 and 21, which can be structured or not, and which can be glass or silicon, depending on the sensor function and operating principle. Figure 2 shows an exemplary top view of an inertial sensor according to the present invention. The substrate wafer 30 contains at least one silicon seismic mass 32 which acts as the sensor's primary sensing component, attached to a fixed silicon frame 31 by means of at least one flexible suspension system 33 and a rigid pedestal member 40. The suspension systems are indicated in the figures as double clamped straight beams, but they may have any arbitrary planar shape. With this configuration, an impressed mechanical signal causes the sensing components 32 to undergo limited displacement(s) with respect to the fixed silicon support wall and frame 31 thus proportionally modifying either the stress level in at least one suspension system 33 or the separation gap 50 between at least one sensing element 32 and the encasing member 20. Using a transducing principle, for instance a piezoresistive effect or capacitance changes, the sensor 10 provides an electrical output signal proportional to the impressed mechanical input. The Assembly-related strains and stress and the associated temperature-induced variations negatively affect the proportionality between the electrical output signal and the impressed mechanical input, however. The assembly-related strains and stress and the associated temperature-induced variations transmitted to the sensing component are reduced by using the principles of the invention. In the substrate wafer 30 at least one pedestal member 40 is structured by a combination of anisotropic wet and dry etching steps, as follows by way of example in the preferred fabrication process. A. Into the boron doped substrate wafer 30, the lateral geometry of at least one pedestal member 40, of at least one seismic mass 32 and of the fixed silicon frame 31 is defined by at least one implantation of donor impurities, such as phosphorous. Different doses may be used for the pedestal member, seismic masses and silicon support wall and fixed frame dependent upon. the specific sensor's application and design. At least one drive-in process is used to diffuse the donor impurities deep into the silicon wafer until the desired thickness of these structures is achieved. The shape of these structures is defined by the location of the p-n junctions, deep junctions, formed between the n-type-implanted silicon and the p-type substrate. These drive-in steps generate the rounded features illustrated throughout the cross-sectional views shown in figures 1 to 3 and 5 to 8. B. An n-type epitaxial layer is grown on top of the substrate wafer, with a thickness that depends on the sensor's specific application and design. This epitaxial layer is separated from the p-type substrate by a shallower p-n junction, said shallower junction, apart for several other purposes in the sensor's functionality, provides the entire front surface of the substrate wafer 30 with a continuous type material that will be used as an etch stop layer during a subsequent wet etching step. The epitaxial layer also gives the opportunity of structuring the pedestal member 40 and the seismic masses 32 on several levels, as well as providing the material of the suspension system 33. C. A recess 50, providing separation gap, is etched into the epitaxial layer in order to provide a separation between any movable structures, such as the seismic masses 32 and the suspension systems 33, and the top encasing member 20, thus allowing limited motion of these structures. D. An anisotropic wet etching step, in combination with an electrochemical etch-stop technique is performed from the back side of the substrate wafer. This is used to selectively remove the p-type material while the n-type material remains unetched. Depending on the crystal orientation of the silicon substrate wafer, on the etching window and its orientation with respect to the silicon crystal and on the anisotropic properties of the etching solution, the lateral walls of the fixed silicon frame 31 are pyramidal in shape. The formed structures are defined by the shape of the deep and shallow junctions, resulting in thicker regions (members) if etch stop occurs on the deep junctions and thinner regions (membranes) if etch stop occurs on the shallow junctions. E. The final shaping of at least one pedestal member 40, at least one seismic mass 32 component, at least one suspension system 33 and the fixed silicon frame 31 is achieved by dry, reactive ion or plasma etching (or combination thereof) through the said membranes. Figure 2 shows the structured substrate wafer 30 after this processing step. F. A suitable bonding technique is used to join and permanently bond the structured substrate wafer 30 with two encasing members 20 and 21, which may also be structured to form a sealed cavity 34. During this fabrication step, the top surface 41 of the pedestal member structure 40 is firmly bonded on the top encasing member 20, completing the assembly process of the sensor element 10 and all its components. If glass wafers are used for encaseonent, then an anodic bonding technique is suitable; if silicon wafers are used, then silicon-to-silicon bonding techniques are advantageously suited. If figure 2, the pedestal member structure 40 is located inside the dashed rectangle and the cross-hatched areas represent the surface of the structured substrate wafer 30 that is firmly bonded on the top encasing member 20. Apart from the above mentioned fabrication steps, several other conventional steps such as photolithography, selective growth and etch back of thermal oxides, deposition and patterning of thin metallic films can be used within a generally inexpensive mass production process flow. The preferred fabrication process described above, including the method of assembly, allows a simultaneous structuring and fabrication of all of the device elements and relies on well known and established micromachining processes. The examples described hereinafter are based only on two levels of structuring: the thicker regions defined by implantation and drive-in and the thinner regions (structured membranes) patterned in the epitaxial layer. However, in alternative fabrication processes, the members may be realised by several implantations and diffusion processes and the epitaxial layer may be replaced as well by at least one implanted and diffused layer, resulting in several levels of structuring with various thickness for the pedestals members 40, the seismic masses 32, the suspension systems 33 and the fixed silicon frame 31. In alternative fabrication processes the starting material of the substrate wafer 30 can be of n-type. In this case acceptor impurities are implanted and driven-in to form the pedestal members 40, the seismic masses 32 and the fixed silicon frame 31. Consequently, the epitaxial layer, if used, is also of a p-type silicon and the wet anisotropic etching of silicon is to be combined with an etch stop technique that allows the selective removal of the n-type material of the substrate while not etching the p-type silicon. The photovoltaic etch stop technique or the high boron doping etch stop are advantageous in this particular context. In alternative fabrication processes the starting substrate wafer 30 can be an SOI wafer of any kind, that is it consists of a single crystal silicon top layer 74 separated from the bulk silicon by a buried, very thin layer of insulating oxide 75. In this case the pedestal member structure is formed by etch stop on the buried oxide layer followed by a deep reactive etching for lateral definition. The separation gap 50 between the movable silicon structures, such as the seismic masses 32 and the suspension systems 33, and the top encasing member 20, is still employed in order to allow a limited motion of these structures. Figure 4 shows a cross sectional view of the intertial sensor 10 after the last processing step in the SOI wafer-based alternative processing. With a suitable design for etching window, wet isotropic etching of a silicon in combination with a suitable etch stop technique can be used to remove all the excess substrate material. Figure 2 shows an example device, which is a sensor and its preferred geometry according to the present invention. Figures 3a and 3b show cross-sectional views along lines A-A and B-B of figure 2. The pedestal member structure 40 has an elongate shape consisting of a longer dimension (pedestal length) and a smaller dimension (pedestal width) where the pedestal length and width are mutually a perpendicular. The pedestal structure comprises a thick portion 44 and associated bonded surface 41 or bonded top area. A thinner rim 43 (pedestal rim) and any number of transversal shallow recesses 42 (direct crossing). The thick portion 44 is formed by selective removal of the substrate material with an etch stop on said deep p-n junctions. The pedestal rim 43 is formed by selective removal of the substrate material with an etch stop on shallow p-n junctions. The direct crossings 42 are produced by shallow wet or dry etching of either the said pedestal member structure 40 or the encasing member 20, or both. One end of the pedestal member structure is attached along its width to a wall of fixed silicon frame 31 while the other end, a pedestal tip, is free as indicated in figure 3a. In order to minimise the longitudinal strains and stress(es) that may originate in the fixed frame, the suspension systems 33 that flexibly connect the seismic masses 32 to the pedestal member 40 are attached as far as possible from the edges of the wall of fixed silicon frame 31, that is close to the pedestal tip, in attachments of said hinge 45. The attachments of hinges 45 are indicated in figure 3a with dotted line, indicating the fact that they are not crossed by the sectioning line. Except for the attachment to the fixed silicon frame, the bonded top area 41 and the attachments of hinges 45, all the remaining pedestal surfaces are free and, therefore, no strains or stress can develop along them. In order to reduce further on the transmitted strain and stress, the suspension system can be attached directly to the pedestal rim 43 and as far as possible from the thick portion 44 and bonded top area 41, resulting an overall T-shaped pedestal, as indicated in figure 2. Figure 3b shows a transversal cross-section through the inertial sensor 10, showing the pedestal member structure 40 and indicating the recommended location of the attachments of hinges 45. The length of the pedestal member and the width of the pedestal rim in the regions of the attachments of hinges are preferably as large as possible, their size being limited only by the available space within the sensor die. At the same time, the bonded top area 41 should be minimised in order to reduce the stress developed due to possible material mismatch between the substrate wafer 30 and the encasing member 20. However, in order to achieve a rigid and strong bonding, the bonded top area 41 must not be reduced below certain limits that depend mainly on the chosen bonding technique. In the preferred embodiment, as indicated in figure 5, only longitudinal mechanical loads can generate strain and stress in the attachments of hinges 45 and through the suspension system 33 further on into the device component 32. However, owing to the pedestal geometry and method of assembly according to the present invention, the transmitted loads are several orders of magnitude smaller than the loads exerted on the silicon fixed frame 31. The mechanical strains and stress through the pedestal member structure 40 decrease from the wall of the silicon fixed frame 31 towards the pedestal tip and from the bonded top area 41 towards the sides and underneath free surfaces of the pedestal member. With the suspension systems attached as indicated in figures 2, 3a and 3b, the transmitted loads to the suspension systems 33 are torques which generate a negligible rotation around the attachments of hinges 45. If the suspension systems 33 are attached exactly at the pedestal tip, along the pedestal length, the transmitted load 90 is a bending momentum. The direct crossing 42 provide an advantageous way of reducing the bonded top area 41 between the pedestal member 40 and the encasing member 20, thus minimising the transmitted load 90, while preserving a required width which allows a strong and rigid bonding. In figures 6a to 6d several designs for the device are shown in transversal cross-sectional view and in analogy with the examples shown in figures 1, 2, 3a, 3b and 5. Figure 6a shows a transversal cross-sectional view through a basic example pedestal member structure 40, wherein the separation gap 50 is achieved in two distinctive steps: a primary or recess 51 is structured by etching the silicon, either wet or dry, along the pedestal rim 43, and a secondary (optional) recess 52 is structured by etching the silicon, either wet or dry above the suspension systems 33 and/or seismic masses 32. The dashed line in figure 6a represents the surface of the substrate wafer 30 if the optional recess 52 is omitted. Generally, the pedestal member structure 40 is electrically conductive, therefore electrically nonconductive layers, such as thermal oxides or regions, such as p-n junctions, must be employed whenever several electrically conductive paths are to be isolated from each other and/or from the pedestal bulk material. Figures 6b, 6c and 6d show further optional features that can be implemented along with the basic pedestal member structure, depicted in figure 6a. The present invention allows the implementation of direct electrical contacts between a patterned metal film 61 located on the encasing member 20 and a patterned metal film 62 located on the-substrate wafer 30, by pressing and squeezing them into each other during the wafer bonding step, resulting in an electrical contact (press-contact) 60. The press-contacts 60 allow the direct transfer of electric signals from conductive paths located on the encasing member 20 to conductive paths located on the substrate wafer 30, a feature of importance in the design of micromachined sensors. At least one of the two metallic films 61 and 62 employed within a press contact 60 should be a soft metal that deforms and flows easily under pressure. In addition, the total area of each of the said press-contacts 60 should preferably remain small in order to allow for lateral flow of the soft metal film and the total thickness of the two metallic films 61 and 62 employed within a press-contact should be slightly larger than the said film recess 51, but not excessively larger in order not to hinder the bonding process between the pedestal member 40 and the encasing member 20 occurring nearby. Figure 6b shows an example of press-contacts 60 in accordance with the present invention. The present invention also allows the implementation of buried conductive paths (buried crossings) transversally through the thick portion 44. The buried crossings are fabricated by a patterned implantation of a p-type impurity inside the thick portion 44 and a subsequent drive-in to the desired depth, such that a p-n junction forms between the implanted area and the underlying n-type thick portion 44, followed by the epitaxial growth which buries the p-type conductor (buried conductor) 70. Additionally, p-type impurities are implanted in at least two isolated islands and subsequently driven-in, resulting in surface conductors 71, where surface conductors 71 are driven-in long enough to contact the buried conductor 70, such that a transversal, continuous and buried electrical path between at least two press-contacts 60 is formed. Figure 6b shows an example of buried crossings in accordance with the present invention. Surface conductors 71 can be used to carry isolated electrical signals along the pedestal rim 43, where the separation gap 50 or recess rim 51 is used to prevent the bonding between the areas in which the surface conductors 71 are located and the encasing member 20 and where an-oxide layer 72 is used to passivate the p-n junctions that separate the said surface conductors 71 from the n-type material of the pedestal member 40. Metal conductors 62 can be used to carry isolated electrical signals along pedestal rim 43, where an oxide layer 72 is used to electrically isolate the metal conductors 62 from the pedestal member 40 and where the separation gap 50 of recess rim 51 is used to prevent the bonding between the metal conductor 62 and the covering wafer 20. The present invention allows the implementation above and across the thick portion 44 of direct conductive paths within the said direct crossings 42, wherein a patterned metal film 61 located on the encasing member 20 is the conductive element which is electrically isolated from the thick portion 44 by the separation gap 50 or recess rim 51. Figure 6c shows surface conductors and metal conductors either along the pedestal rim 43 or across the thick portion 44 in accordance with the present invention. The lateral walls of the thick portion 44, adjacent to the said direct crossings 42, are shown with dotted lines, indicating the fact that they are not crossed by the sectioning line. The present invention allows the implementation above and across the thick portion 44 of direct conductive paths within the said crossings 42, wherein a patterned metal film 62 located on the thick portion 44 is the conductive element which is electrically isolated from the thick portion 44 by means of an oxide layer 72 and from the encasing member 20 by the separation gap 50 or recess rim 51. The present invention allows the implementation above and across the pedestal member 40 of direct conductive paths within the direct crossings 42, wherein a patterned surface conductor 71 located within the pedestal member 40 is the conductive element which is electrically isolated from the pedestal member 40 by means of a p-n junction and has its surface passivated by an oxide layer 72. This in turn is separated from the encasing member 20 by the separation gap 50 or recess rim 51. Figure 6d shows examples of the surface conductors and metal conductors across the pedestal member 40 in accordance with the present invention. The lateral walls of the pedestal member 40, adjacent to the said direct crossings 42, are shown with dotted lines, indicating the fact that they are not crossed by the sectioning line. Side views of the said direct crossings 42, with a direct conductive path realised as patterned metal film 61 or without are shown in figures 3a and 5. In alternative fabrication processes the pedestal material can be of a p-type. Consequently, the epitaxial layer, if used, is also of a p-type silicon. In this case donor impurities are implanted and driven-in to form the said buried conductors 70 and said surface conductors 71. Figures 7a to 7d, 8a and 8d to 9 show examples of the invention realised in alternative fabrication processes. In alternative fabrication processes the separation gap 50 can be realised either totally or partially in the top encasing member 20. In alternative fabrication processes the pedestal member can have a structured thickness, achieved by using several and different implantation and drive-in steps, depending on the specific device application and design and on the attachment location of the suspension systems. Figures 7a and 7b show cross-sectional views along lines A-A and B-B of figure 2, presenting an alternative pedestal member structure 40 in an alternative fabrication process in which the separation gap 50 is totally realised in the encasing member 20. Figure 7c shows a cross-sectional view along line A-A of figure 2, presenting an alternative example of the pedestal member structure in a alternative fabrication process in which the pedestal member 40 has a structured thickness and the separation gap 50 is totally realised within the substrate wafer 30. Figure 7d shows a cross-sectional view along line A-A of figure 2, presenting an alternative example of the pedestal member structure in the alternative fabrication process in which the pedestal member 40 has a structured thickness and the separation gap 50 is totally realised in the top covering wafer 20. Figure 8a shows a cross-sectional view along line B-B of figure 2, presenting alternative examples of the pedestal member structure in the alternative fabrication process in which the separation gap 50 is partially realised in the top encasing member 20 and partially realised in the substrate wafer 30, wherein the separation gap 50 consists of the rim recess 51 realised in the top encasing member 20 and at least one optional recess realised either within the substrate wafer 30, denoted by reference designation 52, or within the encasing member 20, denoted by reference designation 53. Figure 8b presents examples of press-contacts 60 and buried crossings in the pedestal member structure of figure 8a. Figures 8c and 8d present examples of electrical conductors along the pedestal rim 43 and/or across the pedestal member 40 and the direct crossings 42, in the pedestal structure of figure 8a. The lateral walls of the pedestal member 40, adjacent to the direct crossings 42 are shown with dotted lines, indicating the fact that they are not crossed by the sectioning line. Figure 9 shows a cross-sectional view along line A-A of figure 2, presenting an alternative embodiment of the pedestal member structure in an alternative fabrication process in which the substrate wafer 30 is of an SOI type, that is it consists of a single crystal silicon top layer 74 separated from the bulk silicon by a buried, very thin layer of insulating oxide 75. The separation gap 50 is depicted as being realised totally in the encasing member 20, in comparison with the example shown in figure 4 where the separation gap 50 is realised totally within the top silicon layer 74.

Claims: A micromechanical device (1) characterised by : a pedestal member (40) formed from a semiconductor wafer (30) and connected to a support wall structured out of the same wafer; and first (20) and second (21) encasing members which are bonded to a frame member (31) which comprises the support wall: wherein least a portion of the pedestal member has a peripheral portion of reduced thickness defining a rim (43) which extends away from the pedestal member (11) and supports, in use, at least one sensing component (32) of the device; wherein the pedestal member is elongate, with a longer dimension of the pedestal member extending in a direction substantially perpendicular to that of the support wall to which the pedestal member connects; wherein the pedestal member is bonded, inward of the rim, to the first encasing member only; and wherein the pedestal member has a transverse shallow recess (42), the recess defining an area over which the pedestal is not bonded to the first encasing member. A device (10) according to claim 1, wherein the support wall is arranged such that the support wall surrounds both the pedestal member and the sensing component of the device. A device (10) according to claim 1, wherein the sensing component (32) is connected to the pedestal rim (43) by one or more planar flexible hinges (45). A device (10) according to any preceding claim, configured to an inertial sensor, such as acceleration sensor, angular rate sensor, inclination sensor, and angular acceleration sensor. A device (10) according to claim 3 or claim 4, wherein there is a gap that separates the first encasing member (20) from the sensing component (32), the planar hinge (45) and the pedestal rim (43). A device (10) according to claim 6, wherein the gap is formed by etched recesses either in the said substrate, or in the first encasing member (20), or in both. A device (10) according to any preceding claim, in which direct electrical contacts are provided between patterned metallic films located on the rim (43) of the pedestal member (40) and on the contact surface of the first encasing member (20). A device (10) according to any preceding claim, wherein electrical conductors are provided by local implantation and drive-in of impurities into the pedestal structure, characterised by the fact that the conductors are isolated from each other and from the bulk of the pedestal structure by the inherent p-n junctions. A device (10) according to any preceding claim, wherein electrical conductors are provided by deposition and patterning of metallic films into the pedestal rim (43), characterised by the fact that the conductors are isolated from each other and from the bulk of the pedestal structure by thermally grown oxides. A device (10) according to any preceding claim, wherein electrical conductors are provided by local implantation and drive-in of impurities into the pedestal structure, followed by an epitaxial growth, characterised by the fact that the conductors are buried in the pedestal structure and isolated from each other and from the bulk of the pedestal structure by the inherent p-n junctions. A device (10) according to any preceding claim, wherein electrical conductors are provided by deposition and patterning of metallic films into the first encasing member (20) characterised by the fact that the conductors are isolated from the pedestal structure by the separation gap. A method of manufacturing a micromechanical device according to any preceding claim, the method characterised by : structuring of the pedestal member (40), the support wall, the sensing component(s) (32) and planar hinge(s) (45) in a top layer atop an etch stop layer out of the substrate wafer (30), by etching the said top layer to provide the said rim and the said transverse shallow recess and wet etching the excess material of the substrate down, from the backside of the substrate wafer, to the said etch stop layer, final shaping of the pedestal member (40), the sensing component(s) (32), and the frame member (31) by etching; bonding the frame member (31) to the first encasing member (20); bonding the pedestal member, inward of the rim though outward of the recess; to the first encasing member; and bonding the frame member (31) to a second encasing member (21). A method according to claim 12, wherein the substrate wafer is single crystal semiconductor of p-type, the method further specified by: the said top layer is realised by at least one patterned implantation of donor impurities and at least one drive-in step, followed by the formation of an uppermost n-type layer, wherein the pedestal member is defined inside the implanted regions and the pedestal rim is defined outside the implanted regions; the etch step layer is in the p-n junction formed between the original substrate material of p-type and the said n-type top layer and the wet etching of the excess material of the substrate is anisotropic and performed in combination with electrochemical etch stop technique. A method according to claim 13, wherein the said formation of an uppermost n-type layer comprises the growth of an epitaxial layer. The method of claim 13, wherein the said formation of an uppermost n-type layer comprises an implantation of donor impurities performed over the entire surface of the substrate wafer followed by a drive-in step. The method of claim 13 to 15 wherein the said wet etching of the excess material of the substrate is isotropic and performed in combination with an electrochemical etch stop technique. A method according to claim 12, wherein the substrate wafer is an SOI-type wafer, wherein: the said top layer is the top semiconductor layer of the SOI wafer; the said etch stop layer is the thin buried insulating layer of the SOI wafer. A method according to any of claims 12 to 17, wherein the first encasing member (20) is formed from glass and the bonding between the micromachined substrate wafer and the first encasing member is achieved by anodic bonding. A method according to any of claims 12 to 17, wherein the first encasing member (20) is formed from silicon and the bonding between the micromachined substrate wafer (30) and the first encasing member is achieved by silicon-to-silicon direct bonding. A method according to any of claims 12 to 17, wherein the first encasing member (20) is formed from silicon and the bonding between the micromachined substrate wafer (30) and the first encasing member is achieved by using an intermediate glass film, structured or not, applied onto the surface of either the substrate wafer or the first encasing member or both. A method according to any of claims 12 to 20, wherein a separation gap is etched in the substrate wafer (30) prior to bonding with the first encasing member (20). A method according to any of claims 12 to 20, wherein a separation gap is etched in the first encasing member (20) prior to bonding with the support wall and pedestal member (40). A method according to any of claims 12 to 20, wherein a separation gap is partially etched in the substrate wafer and partially etched in the first encasing member (20) prior to their bonding with each other.

Inventors: JAKOBSEN HENRIK, KVISTEROY TERJU, LAPADATU DANIEL, JAKOBSEN, HENRIK, KVISTEROY, TERJU, LAPADATU, DANIEL
Applicants: SENSONOR ASA
Application year: 1999
Main classification: G01P15
IPC codes: G01P15, H01L21, G01C19, H01L29, G01P9, B81B3, B81B7, G01P1, G01P3