Abstract:
The invention is a tunable RF MEMS switch developed with a BST dielectric at the contact interface. BST has a very high dielectric constant (&gt;300) making it very appealing for RF MEMS capacitive switches. The tunable dielectric constant of BST provides a possibility of making linearly tunable MEMS capacitive switches. The capacitive tunable RF MEMS switch with a BST dielectric is disclosed showing its characterization and properties up to 40 GHz.

Description:
PRIORITY  
       [0001]     Applicants claim priority benefit of U.S. Provisional Patent Application No. 60/663,606 filed 21 Mar. 2005. 
     
    
     FIELD OF THE INVENTION  
       [0002]     The present invention is directed to a tunable RF MEMS (Radio Frequency, MicroElectroMechanical Systems) capacitive switch. In particular, the invention is directed to a tunable RF MEMS switch developed with a variable dielectric, such as BST (Barium Strontium Titanate), at the contact interface. BST has a very high dielectric constant (&gt;300) making it very appealing for RF MEMS capacitive switches. The tunable dielectric constant of BST provides linearly tunable MEMS capacitive switches. The invention is directed to a tunable RF MEMS capacitive switch, preferably with a BST dielectric, and its characterization and properties up to 40 GHz.  
       BACKGROUND OF THE INVENTION  
       [0003]     RF MEMS switch technology has been introduced during the last 10-15 years as a prime candidate to replace the conventional GaAs FET and p-i-n diode switches in RF and microwave communication systems, mainly due to their low insertion loss, good isolation, linear characteristics and low power consumption. It has also provided the way for the development of novel revolutionary RF circuits that can be used in the next generation of broadband, wireless, and intelligent communication and radar systems. Recently, many researchers have been focusing on the development of miniaturized, low power and low cost, RF/Microwave circuits with RF MEMS switches. MEMS switches have been used in different RF circuit applications: tunable microwave filters, tunable phase shifters, tunable antennas and tunable matching networks. Microwave and millimeter-wave technology that offers wide tunability is essential for today&#39;s cost-driven commercial and military industries. In order to meet the above requirements, recently, micromachined tunable capacitors have been shown to have an adequate Q-factor when they are fabricated in either an aluminum or a polysilicon surface micromachining technology. Also, a three-plate structure with a wide tuning range has been reported.  
         [0004]     Tunable capacitors are enabling components for millimeter-wave systems. There are two approaches to make such components. One is a compositional approach that improves properties of the materials, and the other is a physical approach that controls the gap or area of the dielectric layer for variable capacitance. MEMS switches&#39; precise, micrometer-level movements are ideal drives for the physical approach. A MEMS-based switching diaphragm can be used as a variable capacitor. The tunability of this component is very impressive because an ultra-low loss, 2 μm air gap is used for the dielectric layer. However, the range of this variable capacitance is limited when the top member collapses onto the bottom plate.  
       SUMMARY OF THE INVENTION  
       [0005]     Emerging BST thin film technology is being investigated for enhancing RF-MEMS capacitive switches due to BST&#39;s comparatively high dielectric constant (ε r&gt; 300). In the present invention, a capacitive RF tunable MEMS switch with a variable dielectric material, such as BST, as the dielectric layer is provided. It provides continuous (analog) tunability of the capacitor after the MEMS switch has been pulled down (closed), due to voltage-controlled properties of the BST dielectric material. The switch can be used to develop very compact digital capacitor banks with enhanced analog tuning for a variety of reconfigurable networks (e.g. filters, tuners). A special MEMS design with a separate actuation electrode provides tunability of the switch and prevents the breakdown problem of the BST.  
         [0006]     This invention provides a clamped-free (cantilever-type) coplanar waveguide (CPW) switch. A demonstration device made as described hereinafter has a contact area of 100 μm×200μm. These switches were fabricated on sapphire substrates using a five-mask process. 
     
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0007]     Figures  1   a  and  1   b  show an RF tunable cantilever capacitive switch using BST thin film with a separate actuation electrode in both switch-up ( Figure 1   a ) and switch-down ( Figure 1   b ) states.  
         [0008]      FIGS. 2   a ,  2   b ,  2   c ,  2   d  and  2   e  illustrate steps of fabricating the switch of  FIGS. 1   a  and  1   b.    
         [0009]      FIG. 3  shows an SEM of a fabricated cantilever type CPW switch on sapphire (left side) with a 200 nm BST layer (bottom right) and 1.2 μm thick Au foil (top right).  
         [0010]      FIG. 4  shows an SEM close-up view of a deposited BST thin film that forms the dielectric layer of the capacitive switch.  
         [0011]      FIG. 5  shows the capacitance-voltage (C-V) characteristic of a MEMS capacitive switch with a BST dielectric layer at the down (closed) state.  
         [0012]      FIG. 6   a  shows the measured S-parameters of the MEMS switch with BST dielectric layer in the down-state (closed) position.  
         [0013]      FIG. 6   b  shows the measured S-parameters of the MEMS switch with BST dielectric layer in the up-state (open) position.  
         [0014]      FIG. 7  shows a comparison between BST and SiN switches, i.e., switches having these materials as the capacitor dielectric. 
     
    
     DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS  
       [0015]     The present invention may be understood more readily by reference to the following detailed description of preferred embodiments of the invention and the figures.  
         [0016]      Figure 1   a  and  1   b  show the designed CPW cantilever capacitive switch  10  in both up ( FIG. 1   a ) and down ( Figure 1   b ) switch states.  
         [0017]     The switch  10  is formed on a substrate  12  of insulating material, such as sapphire or silicon. Improved BST can be formed on a substrate that has a lattice structure appropriate for growth thereon of epitaxial or near-epitaxial BST. Conductive material, such as platinum, on the upper surface of the substrate  12 , forms circuitry traces  14   a ,  14   b , and  14   c . In this switch  10 , the capacitive circuitry is between traces  14   a  and  14   c , and trace  14   b  is connected to an isolated electrical circuit by which an electrostatic field may be created.  
         [0018]     Fabricated on trace  14   a  is a cantilever member  16 , including an upright section  18  and a flexible foil arm  20  that is capable of being flexed between the “up” or “open” position of  FIG. 1   a  and the “down” or “closed” position of  FIG. 1   b . The cantilever member  16  is preferably formed as a unitary structure from a metal, such as gold or of multiple layers of metal. The foil arm must be bendable to the closed position and resume its unbent open position through multiple openings and closings.  
         [0019]     A layer  22  of insulating material is formed on trace  14   b . This  22  layer is intended to prevent electrical contact between the foil arm  20  and electrostatic charge trace  14   b , yet be of a material and of appropriate thickness to transmit the electrostatic field of trace  14   b  to the foil arm  20 .  
         [0020]     The capacitor dielectric layer  24  is formed on trace  14   c , and when the switch  10  is in the down or closed position of  FIG. 1   b , a capacitor is formed that includes conductive foil arm  20 , dielectric material layer  24 , and conductive circuitry trace  14   c.    
         [0021]     In a very much-preferred aspect of the present invention, the dielectric material of layer  24  is tunable by applying an electrical potential across the material. The preferred dielectric material for this layer is barium strontium titanate, Ba x Sr 1−x TiO 3  where x is between 0.1 and 0.9, preferably between 0.4 and 0.6. Other ferroelectrics or materials, such as bismuth zinc niobate, and artificial dielectrics can also be used. For non-tunable MEMS capacitive switches, non-tunable material, such as silicon nitride (SiN) may be used as the dielectric material layer  24 .  
         [0022]     The switch  10  is designed for a very low capacitance between the top membrane and the bottom signal line in the up state. Once voltage is applied through the actuation electrode, the top membrane is deflected due to electrostatic forces and as it touches the bottom electrode, a larger metal-insulator-metal capacitor is formed. The down-state capacitance of the design is highly enhanced by the use of high dielectric constant BST material.  
         [0023]     It is preferred that the low frequency control voltage that actuates switching between the up and down (open and closed) states be isolated from the RF circuitry. This may be accomplished by one or more high resistance resistors, i.e. 10,000 ohms and upward. The resistor(s) are preferably integrated high value thin film resistors. Shown connected to circuitry trace  14   b  is a resistor  27 . Shown connected to circuitry trace  14   c  is a resistor  29 . Examples of thin film resistors and their formation are found in U.S. Pat. Nos. 6,210,592, 6,208,234, 6,500,350 and 6,329,899.  
         [0000]     Deposition and Properties of BST Thin Film  
         [0024]     Ferroelectric material is a category of material with reorientable spontaneous polarization, a sub-category of pyroelectric materials. Because of their high dielectric constant, the electric field dependence and the temperature dependence of their dielectric constant, and high breakdown voltage, ferroelectric materials have a wide range of applications such as IR detection, high-density capacitors, DRAMs, non-volatile ferroelectric memory, and high frequency microwave devices. Ba x Sr 1−x TiO 3  (BST) has been the subject of extensive investigation for these applications.  
         [0025]     Ba 0.45 Sr 0.55 TiO 3  films were prepared by using the combustion chemical vapor deposition (CCVD), such as described in WO 02/07966 published 31 Jan. 2002. In the liquid solution CCVD process, precursors, which are the metal-bearing chemicals used to coat an object, are dissolved in a solution, which typically is a combustible fuel. This solution is atomized to form microscopic droplets by means of an atomizer; one such atomizer is the Nanomiser® device by nGimat Co., Atlanta, Ga. These droplets are then carried by an oxygen-containing stream to the flame where they are combusted. A substrate (the material being coated) is coated by simply drawing it in front of the flame. The heat from the flame provides the energy required to vaporize the droplets and for the precursors to react and vapor deposit (condense) on the substrates. One of the strengths of the CCVD process is the variety of complex materials and substrates that can be utilized.  
         [0000]     Fabrication of the Switches  
         [0026]     Fabrication of the device is described with reference to  FIGS. 2   a - 2   e . Due to the high growth temperature (900° C.) of BST, platinum electrodes are used as the bottom electrodes ( 14   a ,  14   b ,  14   c ) in the BST thin film deposition. Because Pt is very hard to pattern using wet etching, a lift off process is first used to pattern Ti/Pt (200Å/1000Å) on the sapphire (aluminum oxide) substrate  12  before the BST deposition. The BST layer is then deposited, patterned and etched in a diluted HF solution with an etching rate of 500Å per minute to form the dielectric layer  24  on circuitry trace  14   c , thereby forming the structure illustrated in  FIG. 2   a.    
         [0027]     A 2000Å Silicon Nitride layer is then deposited by PECVD (plasma enhanced chemical vapor deposition) and patterned using RIE (reactive ion etching) for the actuation electrode comprising circuitry trace  14   b  overlaid with SiN 22, giving the structure shown in  FIG. 2   b.    
         [0028]     A 2μm thick photoresist (Shipley S-1813 Microposit®) “sacrificial” layer  50  is then spin coated and patterned to define the air-gap. This patterned structure is shown in  FIG. 2   c.    
         [0029]     A Ti/Au/Ti (200Å/3000Å/200Å) seed layer  52  is then plasma vapor evaporated to form the structure shown in  FIG. 2   d.    
         [0030]     This seed layer  52  is then patterned and electroplated to form the cantilever member  16 , this structure being shown in  FIG. 2   e.    
         [0031]     Finally, after removing the sacrificial photoresist layer with resist stripper, the stripper and rinse fluids are removed by a drying process and then the metal is released to form the switch as previously described in reference to  FIGS. 1   a  and  1   b.    
         [0032]     It is to be understood that the process is used to produce a plurality of MEMS CPW switches simultaneously, and these can be integrated into a wide range of devices.  
         [0033]     A Scanning Electron Microscope (SEM) picture of the fabricated cantilever type CPW switch structure with a 1.2μm thick gold membrane, a 2μm air-gap and a contact area of 100×200 μm ((0.02 mm 2 ) is shown in  FIG. 3 . The BST layer is illustrated in  FIG. 4 .  
         [0000]     Performance Results  
         [0034]      FIG. 5  shows the C-V characteristic and the tunability of the BST MEMS switches at the down state using a Keithley 590 CV station. The capacitance changes from 130 pF to 71.2 pF when the applied voltage ranges from 1 to 5 volts. The tunable range is 182%. The measured Q-factor is 260. A different capacitance range can be achieved with a different area. S-parameter measurements of the cantilever switch were taken using an Agilent 8510 network analyzer. A TRL (thru-reflect-line) calibration was performed to de-embed the coplanar line and transition losses. Measured results of switch at both up and down state positions are shown in  FIG. 6 . The pull-down voltage was measured to be 45 to 50 volts. The insertion loss in the up state is −0.3dB at 20GHz and −0.4dB at 40GHz, while the isolation is −25dB at 20GHz. An equivalent LCR circuit was used to fit the measured data. The fitted up state capacitance is 10fF, the series inductance and the series resistance of the switch are 5pH and 0.5O, respectively.  
         [0035]     In the down state position, the insertion loss is −0.6dB up to 40GHz with a little bit of fluctuation between 26.6GHz and 28.2GHz, while more than 20dB return loss is achieved from DC up to 26GHz. The fitted down state capacitance and series inductance are 120 pF and 5pH, the series resistance is 0.3 O. The insertion loss is slightly higher when compared with other MEMS switches, because the signal lines of the switch are only 1000Å thick. A much lower loss can be achieved by increasing the thickness of the Pt layer.  
         [0036]     To further understand the BST MEMS switches performance, switches of the same physical structure and size with silicon nitride as the dielectric layer were fabricated and measured.  FIG. 7  shows the down state return loss of both BST and Si 3 N 4  MEMS switches. From the comparison we can see that BST switches have higher return loss than that of the Si 3 N 4  switches. This is because the BST switch capacitance is much higher due to the higher dielectric constant.  
         [0037]     In this invention, tunable MEMS capacitive switches with emerging variable dielectric, e.g., BST, thin film technology is realized. An excellent insertion loss of −0.6dB was obtained in a frequency range from 0.5GHz to 40 GHz, while the return loss is less than −20dB up to 26 GHz. Tunability of the BST switches was also achieved for the first time. Measured results show that the capacitance of the BST MEMS switch can change 182% when the applied voltage ranges from 1 to 5 volts. The proposed RF MEMS switch can be used for the development of compact, low loss tunable digital capacitor banks for reconfigurable microwave circuits. The hybrid scheme of tunability (digital and analog) is expected to provide more design flexibility for compact reconfigurable RF front ends. There are a wide range of MEMS designs and processing methods that can be used to form the desired switches. Most of these designs have contact areas of 0.1 mm 2  or less, preferably 0.001 mm 2  or less.  
         [0038]     The MEMS capacitive switches of the present invention are useful in a variety of electronic applications. The switches can be used within devices such as delay lines, tunable filters or phase shifters to switch in additional capacitance ranges or to modify function better and different frequencies or bandwidths.  
         [0039]     Multiple switches can enable further functional changes in a device.  
         [0040]     The switches may serve multiple purposes in an electronic circuit, e.g., as both a time delay line and a tunable filter.  
         [0041]     Because the MEMS switch may be used in a variable capacitance device, it can be used simply as a high return loss switch on the same wafer with no additional processing steps. After completion of a wafer containing multiple MEMS switches, the multiple switches may be incorporated into the variable dielectric integrated device. Or multiple switches may be diced out of the same wafer to be used in a plurality of separate devices.