Fringing capacitance and tolerance of DRIE effect on the performance of bulk silicon comb-drive actuator

A bulk silicon comb-drive actuator with low driving voltage and large displacement is presented in this paper. The bulk silicon comb-drive actuator is fabricated by a simple bulk micromachining process based on the low temperature Au–Au bonding technology. A cascade folded beam is designed to improve the displacement of comb-drive actuator at low driving voltages. The instability of the whole system decreases by utilizing unequal wide comb fingers design. The fringing capacitance and the fabrication tolerances together with their effects on the performances of the comb-drive actuators are also discussed. The measurement results show that the capacitance change rate and the displacement change rate of the comb-drive actuator are 1.5 fF/V² and 0.125 μm/V², respectively. The displacement of the actuator can reach 28.5 μm at 15 V driving voltages. The experimental results of the comb-drive actuator are in good agreement with the modified theoretical predictions.

     

Tolerance analysis for comb-drive actuator using DRIE fabrication

Deep reactive ion etching (DRIE) process is specially invented for bulk micromachining fabrication with the objective of realizing high aspect ratio microstructures. However, various tolerances, such as slanted etched profile, uneven deep beams and undercut, cannot be avoided during the fabrication process. In this paper, the origins of various fabrication tolerances together with its effects on the performances of lateral comb-drive actuator, in terms of electrostatic force, mechanical stiffness, stability and displacement, are discussed. It shows that comb finger with positive slope generates larger electrostatic force. The mechanical stiffness along lateral direction increases when the folded beam slants negatively. The displacement is 4.832 times larger if the comb finger and folded beam are tapered to +1° and −1°, respectively. The uneven deep fingers generate an abrupt force and displacement when the motion distance reaches the initial overlap length. The undercut reduces both the driving force and the mechanical stiffness of the lateral comb-drive actuator. The fabricated comb-drive actuator, with comb finger of +1° profile and 0.025 μm undercut, and folded beam of −1° slope and 0.075 μm undercut, is measured and compared with the models where both show consistent results. These analytical results can be used to compensate the fabrication tolerances at design stage and allow the actuators to provide more predictable performance.     

Angular vertical comb actuators assembled on-chip using in-plane electrothermal actuators and latching mechanisms

We have designed, fabricated and tested self-aligned angular vertical comb-drive (AVC) actuators by on-chip assembly using in-plane electrothermal actuators and latching mechanisms. The on-chip assembly process is carried out by engaging latching mechanism connected to the torsion bars through the off-centered thinned down silicon beams. When the latching mechanism is fully engaged, the assembled AVC actuator forms permanent initial tilt angle by the retraction force of electrothermal actuators. The AVC actuators and latching mechanisms are fabricated on a silicon-on-insulator (SOI) wafer using three photomasks and three times of deep etch steps. The maximum optical scan angle of 30.7° is achieved at 4.56 kHz under the sinusoidal driving voltage of 0–80 V applied to the AVC actuator. After the reliability test performed by operating the actuator for 1.6 × 10⁸ cycles at its resonance, the measured optical scan angle variation and resonant frequency change were within 1.1% and 8 Hz, respectively, and the robustness of the latched mechanism was ensured.     

Fabrication of high aspect ratio comb-drive actuator using deep X-ray lithography at Indus-2

We report microfabrication of high aspect ratio comb-drive using deep X-ray lithography at Indus-2 synchrotron radiation source. Analysis shows that the comb-drive actuator of aspect ratio 32 will produce nearly 2.5 μm displacement when 100 V DC is applied. The displacement increases as the gap between the comb finger decreases. For fabrication of comb-drive, polyimide–gold X-ray mask using UV lithography is made for the first time in India. To pattern on an 800 μm thick X-ray photoresist (PMMA) exposures are performed using our deep X-ray lithography beamline (BL-07) at Indus-2. Metallization on the selective regions of the developed X-ray photoresist with comb-drive pattern was carried out by RF sputtering. Following this the comb-drive actuator of PMMA was fabricated by one-step X-ray lithography. The comb-drive can also be used as a sensor, energy harvester, resonator and filter.     

Design, fabrication, and operation of submicron gap comb-drivemicroactuators

Making submicron interelectrode gaps is the key to reducing the driving voltage of a micro comb-drive electrostatic actuator. Two new fabrication technologies, oxidation machining and a post-release positioning method, are proposed to realize submicron gaps. Two types of actuator (a resonant type and a nonresonant type) with submicron gaps were successfully fabricated and their operational characteristics were tested experimentally. The drive voltage was found to be lower than that of existing actuators. The stability of comb-drive actuators is discussed     

Multiple aspect-ratio structural integration in single crystal silicon (MASIS) for fabrication of transmissive MOEMS modulators

A novel fabrication process, named MASIS (multiple aspect ratio structural integration in single-crystal-silicon), is introduced for the implementation of single-crystal-silicon microstructures characterized by distinct aspect ratios to be fabricated in the same device layer. The MASIS process was especially designed for fabrication of transmissive MOEMS (Micro-Opto-Electro-Mechanical-Systems) modulators incorporating large field areas, and driven by long-stroke comb-drive actuators combined with folded suspensions. The comb-drive actuators were designed to achieve large amplitude of vibration and high natural frequencies, which allow large aperture areas at high operational frequency. The MASIS process consists of selective thinning of the device thickness in the shutter area, reducing payload mass, while preserving higher thickness of the suspension springs and comb-drive transducer fingers, thereby increasing the natural frequency of the device and reducing actuation voltages. A modulator was successfully fabricated, demonstrating maximum displacement of 50 μm at 1 kHz in resonance using an actuation voltage of 15 Vpp in air. The MOEMS modulator was adapted as integral part of a solid-state photodetection system to overcome the low-frequency noise.     

Design of large deflection electrostatic actuators

Electrostatic, comb-drive actuators have been designed for applications requiring displacements of up to 150 /spl mu/m in less than 1 ms. A nonlinear model of the actuator relates the resonant frequency and the maximum stable deflection to the actuator dimensions. A suite of experiments that were carried out on deep reactive ion etched (DRIE), single-crystal silicon, comb-drive actuators confirm the validity of the model. Four actuator design improvements were implemented. First, a folded-flexure suspension consisting of two folded beams rather than four and a U-shaped shuttle allowed the actuator area to be cut in half without degrading its performance. Second, the comb teeth were designed with linearly increasing lengths to reduce side instability by a factor of two. Third, the folded-flexure suspensions were fabricated in an initially bent configuration, improving the suspension stiffness ratio and reducing side instability by an additional factor of 30. Finally, additional actuation range was achieved using a launch and capture actuation scheme in which the actuator was allowed to swing backward after full forward deflection; the shuttle was captured and held using the backs of the comb banks as high-force, parallel-plate actuators.     

Electrostatic comb-drive actuators made of polyimide for actuating micromotion convert mechanisms

 For conventional micromachines, in particular, micromotion convert mechanisms, the output points of the mechanism can move horizontally when input points move in the same direction. Therefore, we have proposed a three-dimensional motion convert mechanism whose output points can move vertically when the input points move in the horizontal direction. This 2-degree-of-freedom (DOF) mechanism consists of electrostatic comb-drive actuators and a basic mechanism with large-deflective elastic hinges. In this study, the characteristics of comb-drive actuators are analyzed. The electrostatic comb-drive actuator which is made up of polyimide is fabricated by CVD, RIE, Wet etching, etc., technologies. The relationship between the input (voltage) and the output (displacement) of the drive has been analyzed both theoretically and experimentally. Received: 26 December 1998 / Accepted: 4 January 1999     

A micro gearing system based on a ratchet mechanism and electrostatic actuation

This paper presents the design and fabrication of a silicon micro gearing system (MGS) that utilizes electrostatic comb-drive actuators to rotate a gear ring through a ratchet mechanism. The rotational comb-drive actuator is engaged with the gear ring through a spring system and ratchet teeth at one end, reciprocally rotates around an elastic point at the other end based on the electrostatic force. Rotational motion and torque from the driving gear ring are transmitted smoothly to driven gears through involute-shaped gear teeth. Smart design of anti-gap structures helps to overcome the unavoidable gap problem occurred in deep reactive ion etching (deep-RIE) process of silicon. The MGS has been fabricated and tested successfully by using SOI (silicon-on-insulator) wafer and one mask only. The angular velocity of the gear ring is proportional to the driving frequency up to 40 Hz.     

Effect of electrode size and silicon residue on piezoelectric thin-film membrane actuators

Piezoelectric micro-electromechanical systems (MEMS) often adopt a membrane structure to facilitate sensing or actuation. Design parameters, such as membrane size, thickness of the piezoelectric thin film, and electrode types, have been studied to maximize actuation, sensitivity, or coupling coefficient. This paper is to demonstrate numerically and experimentally that the size of silicon residue and its relative size to the top electrode are two critical yet unrecognized parameters in maximizing the actuation displacement of PZT thin-film membrane actuators. To study effects of the silicon residue, we have developed a finite element model using ANSYS. The model consists of five components: a square passive silicon membrane, a silicon substrate, a PZT thin film, a square top electrode, and a silicon residue region. In particular, the silicon residue has a circular inner diameter and a square outer perimeter with a trapezoidal cross section. Predictions of the finite element model lead to several major results. First, when the silicon residue is present, there exists an optimal size of the top electrode maximizing the actuator displacement. Second, the optimal electrode size is roughly 50–60% of the inner diameters of the silicon residue. The displacement of the membrane actuator declines significantly as the electrode overlaps with the silicon residue. Third, the maximal actuator displacement decreases as the inner diameter of the silicon residue decreases. Aside from the finite element analysis, a mechanics-of-material model is also developed to predict the electrode size that maximizes the actuator displacement. To verify the simulation results, eight PZT thin-film membrane actuators with progressive electrode sizes are fabricated. These actuators all have a square membrane of 800 μm × 800 μm with the inner diameter of the silicon residue controlled between 500 and 750 μm. A laser Doppler vibrometer is used to measure the actuator displacements. The experimental measurements confirm that there exists an optimal size of the top electrode maximizing the actuator displacement.     

Development of copper based miniature electrostatic actuator using WEDM with low actuation voltage

Fabricating electrostatic micro actuator, such as comb-drive actuator, is one of the demanding areas of the MEMS technology because of the promising applications in modern engineering, such as, micro-switches, attenuators, filters, micro-lenses, optical waveguide couplers, modulation, interferometer, dynamic focus mirror, and chopper. For the fabrication, most of the cases silicon monocrystalline wafers are used through complex process. To etch the silicon substrates, researchers often use deep reactive-ion etching or anisotropic wet etching procedure which are time consuming and unsuitable for batch fabrication process. Again, resent research shows that comb-drive actuators need comparatively high voltage for actuation. In solving these problems, the study presents a copper based electrostatic micro actuator with low actuation voltage. Using wire electrical discharge machine (WEDM), the actuator is fabricated where a light weight flexible spring model is introduced. Capacitor design model is applied to present a voltage controlling electronic circuit using Arduino micro controller unit. The experimental result shows that the actuator is able to produce 1.38 mN force for 15 V DC. The experiment also proves that coper based actuator design using WEDM technology is much easier for batch processing and could provide the advantages in rapid prototyping.     

An experimental and numerical investigation into the effects of the PZT actuator shape in polymethylmethacrylate (PMMA) peristaltic micropumps

Utilizing a solvent-assisted bonding process, two diffuser-type polymethylmethacrylate (PMMA) peristaltic micropumps are fabricated with a linear array of circular microchambers with a depth and diameter of 15 m and 7 mm, respectively, actuated using either square or circular PZT actuators. Experimental trials are performed to characterize the performance of the two micropumps under driving frequencies ranging from 80 to 150 Vpp and actuation frequencies in the range of 10 Hz to 1 kHz. The results reveal that the micropump with square PZT actuators generates a maximum pumping rate and back pressure of 217 l/min and 9.2 kPa, respectively, while the micropump with circular actuators generates a maximum flow rate of 131 l/min and a back pressure of 2.7 kPa. ANSYS finite element simulations demonstrate two events. First, given an equivalent surface area, the circular actuators undergo a greater displacement than the square actuators under given actuation conditions. In other words, the circular actuator design is more efficient to represent a higher ratio of the displacement to the actuation area (d/A). However, the circular actuators with the surface area of 38.47 mm² are smaller than the square actuators (49 mm²). In addition, it is inferred that the relatively poorer performance of the circular actuators is due in part to thermal damage of the PZT patches during their removal from the bulk PZT chip using a laser cutting device in the pump fabrication process. Secondly, when the shape of the effective working area for the actuation is rectangular which is usual in a MEMS design, the rectangular actuator with length of 7 mm has significantly higher displacement (0.71 m) than that of the circular actuator with diameter of 7 mm (0.396 m). Consequently, a rectangular actuator design presents a more practical solution for higher performance of micro-actuators.     

A design method of comb-drive actuators for linear tuning characteristics in mechanically tunable optical filters

A new method is proposed in design of comb-drive actuators for specific voltage-displacement characteristics with finger gaps as the design parameters. The design method proposed by the author previously is further refined by adopting a more accurate model which considers fringe electric fields. The proposed method is applied to design comb-drive actuators with an aim to achieve linear tuning characteristics in mechanically tunable optical add-drop filters with microring resonators. To make an assessment of the accuracy of the proposed design method, three-dimensional electrostatic numerical analysis is conducted to obtain capacitances of the designed comb-drive actuators as functions of the moving finger displacement. Obtained capacitances are used to find the tuning characteristics (resonant wavelength vs. voltage) of the filter, in combination with the results from the author’s other work where a relationship between the resonant wavelength and the displacement of an index modulator was studied. It is found that by employing the actuators designed by the proposed method, the maximum deviation from linearity (MDL) can be reduced by 17.2 % points (from 25.7 % of the conventional design to 8.5 % of the new design). MDL is further reduced to 4.4 % by making a few modifications in the design.

     

Fabrication of an S-shaped microactuator

We have developed a new fabrication process for electrostatic actuators having an S-shaped film element, which we previously invented for such applications as gas valves. The developed process allows batch fabrication of the actuator whose S-shaped structure height, which is equal to the amount of vertical film displacement, is of the order of a few hundred micrometers. The microactuators are fabricated by stacking three wafers. The middle wafer contains the sputtered Ni film strip which is buckled into an S-shape during the stacking process. The length of film necessary for the S-bend profile has a folded structure which is stretched after stacking. The size of the fabricated chip was 5 mm×5 mm, and the vertical film displacement was 220 μm. The actuator was operated by electrostatic force when the applied voltage was more than 70 V     

Continuously tunable terahertz metamaterial employing a thermal actuator

In order to increase the flexibility of the resonance frequency, a widely and continuously tunable terahertz metamaterial structure that employs a thermal actuator for tuning the resonance frequency of a two-cut split-ring resonator is proposed in this paper. The tunable metamaterial device model is designed and simulated based on the MetalMUMPs process. The use of V-shaped thermal actuators enables continuous tuning of the resonance frequency over a large range from 1.374 to 1.574 THz. The transmission curves have a sharp dip in every resonance frequency, which indicates an excellent performance of strong resonance. The geometrical parameters of the V-shaped thermal actuator are optimized by COMSOL Multiphysics 4.2 in order to obtain enough displacement under minimum driven current. The relationship between driven current and slabs’ displacement is also characterized. The reliability of the metamaterial structure array actuated by the thermal actuator is also calculated and discussed.     

A Model for Electrostatic Actuation in Conducting Liquids

This paper presents a generalized model that describes the behavior of micromachined electrostatic actuators in conducting liquids and provides a guideline for designing electrostatic actuators to operate in aqueous electrolytes such as biological media. The model predicts static actuator displacement as a function of device parameters and applied frequency and potential for the typical case of negligible double-layer impedance and dynamic response. Model results are compared to the experimentally measured displacement of electrostatic comb-drive and parallel-plate actuators and exhibit good qualitative agreement with experimental observations. The model is applied to show that the pull-in instability of a parallel-plate actuator is frequency dependent near the critical frequency for actuation and can be eliminated for any actuator design by tuning the applied frequency. In addition, the model is applied to establish a frequency-dependent theoretical upper bound on the voltage that can be applied across passivated electrodes without electrolysis.     

Trapezoidal-shaped electrostatic comb-drive actuator with large displacement and high driving force density

This paper presents a design of a comb finger shape and calculation of a trapezoidal-shaped electrostatic comb-drive actuator (TECA) in order to aim a higher electrostatic force density and larger displacement in comparison with the typical rectangular-shaped electrostatic comb-drive actuator (RECA). Relation between a beam’s stiffness and a driving voltage has been examined to predict a pull-in effect occurring in TECA. Micro fabrication and characterization of TECA and RECA systems are performed by using a standard SOI-MEMS technology. Theoretical and experimental results confirm the strong points of TECA’s structure (similar to the dimensions of RECA) such as a larger number of movable comb finger arrayed at the same length and larger displacement. At driving voltages of 47.9 and 50 (V), the calculation and measurement displacement of TECA are approximately 2.2 and 1.78 times larger than that of RECA, respectively.

     

MEMS Electrostatic Actuation in Conducting Biological Media

We present design and experimental implementation of electrostatic comb-drive actuators in solutions of high conductivity relevant for biological cells. The actuators are operated in the frequency range 1-10 MHz in ionic and biological cell culture media, with ionic strengths up to 150 mmol/L. Typical displacement is 3.5 mum at an applied peak-to-peak signal of 5 V. Two different actuation schemes are presented and tested for performance at high frequency. A differential drive design is demonstrated to overcome the attenuation due to losses in parasitic impedances. The frequency dependence of the electrostatic force has been characterized in media of different ionic strengths. Circuit models for the electric double layer phenomena are used to understand and predict the actuator behavior. The actuator is integrated into a planar force sensing system to measure the stiffness of cells cultured on suspended structures.     

Frequency-dependent electrostatic actuation in microfluidic MEMS

Electrostatic actuators exhibit fast response times and are easily integrated into microsystems because they can be fabricated with standard IC micromachining processes and materials. Although electrostatic actuators have been used extensively in "dry" MEMS, they have received less attention in microfluidic systems probably because of challenges such as electrolysis, anodization, and electrode polarization. Here we demonstrate that ac drive signals can be used to prevent electrode polarization, and thus enable electrostatic actuation in many liquids, at potentials low enough to avoid electrochemistry. We measure the frequency response of an interdigitated silicon comb-drive actuator in liquids spanning a decade of dielectric permittivities and four decades of conductivity, and present a simple theory that predicts the characteristic actuation frequency. The analysis demonstrates the importance of the native oxide on silicon actuator response, and suggests that the actuation frequency can be shifted by controlling the thickness of the oxide. For native silicon devices, actuation is predicted at frequencies less than 10 MHz, in electrolytes of ionic strength up to 100 mmol/L, and thus electrostatic actuation may be feasible in many bioMEMS and other microfluidic applications.     

A rotary comb-actuated microgripper with a large displacement range

This paper reports a novel design for electrostatic microgrippers. The new structure utilizes rotary comb actuators to solve the pull-in problem of microgrippers during large displacement manipulation and therefore avoids the widely used conversion systems which necessitate a high driving voltage. The gripper is fabricated using a SOI process with a 60 μm structural layer. Test results show the gripper obtained a displacement of 94 μm with an applied voltage of 100 V. An animal hair is gripped to demonstrate the applicability of the gripper for micro object manipulations.