RF-MEMS switches are commonly electrostatically actuated. This way of actuation has the advantage of technological simplicity. However the actuation voltage is relatively high. Piezoelectric actuation can have significantly lower actuation voltages, depending on the used materials and geometries. Analysis shows that clamped-free beams and clamped-clamped beams can have a reasonable deflection when aluminum nitride is used as the piezoelectric material. A five mask monolithic process has been developed for the realization of piezoelectrically actuated cantilevers and RF-MEMS switches. The complexity of this process is comparable with the complexity of the process for electrostatically actuated switches. Deflections of piezoelectrically actuated cantilever beams have been measured. Due to a high stress gradient in the beams, the assumptions that have been made in the analysis are not valid anymore. Finit element simulations were needed to verify the measurement data. The simulations fit with the measurements when the following values are taken for the properties of the aluminum nitrde film: Young's modulus Ep = 320 GPa and piezoelectric coefficient d31 = -3.2 pC/N.
The ability of various deposition processes and materials to fill and planarize topographical features (trenches deeper than 10 micrometers ) is investigated in this work. Three different deposition processes are considered: LPCVD (Ge), PECVD (Ge, Si3N4, SiO2) and spin coating (BCB, resist, polyimide). Comparing LPCVD and PECVD processes show that, for the same trench width, thick PECVD layers can close off trenches from the top, while thick LPCVD layers fill the trenches completely. The use of PECVD layers is thus advantageous for sealing applications, where a low bottom step coverage is desired. LPCVD layers on the other hand are very useful for planarization purposes where a low ratio between the deposited film thickness and the planarized trench width is desired. Also the deposition of polymers by spin coating yields excellent planarization results with a simpler process and lower thermal budget compared to LPCVD processes. All polymers investigated fill the trenches totally. If these planarization layers are used as sacrificial layers, they should be etched isotropically and selectively with respect to the structural layer. Ge can be etched in oxidizing solutions (H2O2/H2O) and the sacrificial etch of Ge is selective towards Si, SiO2 and many other layers. SiO2 can be removed by wet or vapor HF, and resist, polyimide and BCB can be removed by O2 or O2/SF6 plasma. Which layer should be used depends on the trench fill requirements, the thermal budget and the further processing needed.
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