SMART SENSOR TECHNOLOGIES
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1 2 SMART SENSOR TECHNOLOGIES Dr. H. K. Verma Distinguished Professor (EEE) Sharda University, Greater Noida (Formerly: Deputy Director and Professor of Instrumentation Indian Institute of Technology Roorkee) 1
2 q IC Technologies Ø Originally developed for producing microelectronic components and circuits Ø If sensor is an electrical or electronic device (e.g. a piezo-resistive strain gauge or a siliconjunction temperature sensor), then the complete sensor can be produced using IC technologies alone. q Micromachining Technologies Ø Originally developed for producing micromechanical components and systems Ø Used only for producing sensing elements in the form of a micro-mechanical structure or a micro-electro-mechanical system (MEMS). 2
3 2.1 IC Technologies & Capabilities IC Technologies Thick-film Technology Thin-film Technology Monolithic IC Technology Capabilities R, C & L Conductors Sensor elements Sensor supports Capabilities R & C Conductors Sensor elements Capabilities R & C Diodes & transistors Conductors Sensor elements 3
4 2.2 Thick-Film Technology Process : Print Dry Fire Trim Finish Materials: Substrate + Paste or Ink + Printing screen Paste : Suspended particles of selected material + Dispersed in an organic solvent + Glass frit 4
5 Thick-Film Technology Particle Materials Conductive For interconnections & small inductances Resistive For resistances and sensors Dielectric For capacitors and some sensors Other materials For some sensors and sensor supports 5
6 Thick-Film Pastes & Substrates v Low-Temperature Pastes Ø Melting Point: Less than C Ø Substrate : Plastic materials Glass fibre with epoxy Anodized aluminum v Medium-Temperature Pastes Ø Melting Point: C Ø Substrate: Low carbon steel with porcelain enamel coating v High-Temperature Pastes Ø Melting Point: C Ø Substrate : Ceramic 6
7 Thick-Film Technology Thick-Film Process Take substrate Take printing screen & paste Print as thick film on substrate Dry the printed film at C Fire on conveyer-belt furnance Screen printing Comp. width = µm Comp. thickness=10-25 µm Removes the organic solvent Metal powder sinters and glass frit melts thereby bonding the film to the substrate Next Repeat with another paste and printing screen until all films are deposited Thick-film components ready Tolerance = 10 20% Trim components Add IC chips Smart Sensor is ready By abrasion or laser vaporization Tolerance = % 7
8 Thick-Film Sensor Elements (successfully developed / manufactured) q Temperature Sensors q Pressure Sensors : Film RTD, film thermistor, film thermocouple : Film diaphragms & film capacitors Piezo-electric & piezo-resistive pastes q Light Sensors : Photo-conductive pastes q Magnetic Sensors : Magneto-resistive pastes q Humidity Sensors : Organic polymer based pastes q Gas Sensors : Metal-oxide pastes 8
9 Advantages of Thick Film Technology q Almost any material can be deposited as a thick film q Low-value resistances and high-value capacitances possible q Small inductances possible q Special features of thick-film sensors Ø Can withstand high temperatures Ø Allow large voltage / current excitation Ø Heaters can be integrated Ø Economically competitive for low-volume production 9
10 Limitations of Thick Film Technology q Active components cannot be produced q Size of thick-film components is very large as compared to thin-film components q Not suitable for medium and large scale production 10
11 2.3 Thin-Film Technology q Film thickness: 1 25 µm q Process: Deposit thin-film by vacuum evaporation or other similar technique q Patterns: By masking q No printing, drying, firing and trimming 11
12 Thin-Film Technology Substrate q High purity alumina q Low alkalinity glass q Silicon q Silicon oxide 12
13 Thin-Film Technology Deposition Techniques q Vacuum evaporation q Spin casting q Sputtering or cathodic deposition q Reactive growth q Chemical vapour deposition q Plasma deposition 13
14 Thin-Film Technology Thin-Film Materials q For conductors: Aluminium or gold q For resistors: Nichrome q For dielectrics: Silicon dioxide q For sensors (some examples): Ø Strain gauge: Nichrome, polycrystalline silicon Ø RTD: Platinum Ø Conductivity sensor: Platinum Ø Gas sensors: Zinc oxide Ø Piezoresistive pressure sensor: Nichrome, polycrystalline silicon Ø Magnetoresistive magnetic sensor: Nickel, Cobalt, Iron alloys Ø Thermo-anemometric flow sensor: Gold 14
15 Thin-Film Components q Thin-film resistors q MOS capacitors q Thin-film conductors q Thin-film sensors 14
16 Advantages of Thin-Film Technology q Almost any metal can be deposited as thin film q Miniaturization q Suitable for adding resistances, capacitances and sensors to monolithic IC q Suitable for low and medium volume production 16
17 Limitations of Thin Film Technology q Active components cannot be produced q Size of thin-film components is very large as compared to monolithic IC components q Not suitable for high-volume production 17
18 2.4 Monolithic IC Technology q Processes: Epitaxial growth Silicon-oxide layer formation Photolithographic etching Planar diffusion of dopants Metallization (vacuum evaporation of aluminium) Stitch bonding q Substrate: Wafer of silicon (less used are Ge and GaAs) q Dimensions: Sub-micrometric, nano-metric q Capability: R, C, diodes, transistors, conductors, and silicon sensors 18
19 Monolithic IC Process: Steps Step I: Epitaxial growth Step II: Isolation diffusion Step III: Base diffusion Step IV: Emitter diffusion Step V: Metallization Step VI: Packaging (optional) 19
20 Monolithic IC Process: Flowchart Substrate 150 µm thick, p type, Si wafer I Grow epitaxial layer at the top of substrate 25 µm thick, singlecrystal, n type Form SiO 2 layer at the top of epitaxial layer By heating in oxygen atmosphere at C II Remove SiO 2 layer selectively using photolithographic etching Remaining SiO 2 serves as mask Diffuse p-impurity (boron) through windows in SiO 2 mark Islands or isolated regions of n-type Si are formed A 20
21 Monolithic IC Process: Flowchart (contd ) A III Form second SiO 2 layer at the top Open second set of windows in SiO 2 layer (mask) Diffuse p-impurity through openings in mask The regions are: base of transistors, anode of diodes, resistances IV Form third SiO 2 layer at the top Open third set of windows in SiO 2 layer (mask) Diffuse n-impurity phosphorus through openings in mask B The regions are: emitter of transistors, cathode of diodes, contact regions (Contd ) 21
22 Monolithic IC Process: Flowchart (contd ) B V Form fourth SiO 2 layer at the top Open fourth set of windows in SiO 2 layer (mask) Deposit aluminium layer over entire surface (penetrates into openings) and remove unwanted portions For metallic contacts to make inter-component & external connections Using vacuum evaporation of Al followed by etching VI Scribe wafer to separate individual chips (ICs) Mount chip on ceramic wafer and attach to a suitable header Connect terminal pads on IC to Package leads by stitch bonding Using diamond-tipped tool Using Al or gold wire Packaged Chip 22
23 Advantages of Monolithic IC Technology q Both active and passive devices q Miniaturization: very high density of devices q Suitable for large, very large and ultra large scale integration q Silicon sensors made alongwith integrated circuit on same chip q High repeatability (consistency) q Very cheap if produced in high volumes 23
24 Limitations of Monolithic IC Technology q Sensors of silicon only q Resistances in medium-range only q Resistances have large temperature coefficient q Capacitors of small values only q Capacitors have some shortcomings q Too expensive for low-volume production 24
25 2.5 Micromachining Technologies Micromachining Processes Bulk micromachining Surface micromachining Wafer bonding Other processes 25
26 Bulk Micromachining q Significant amounts of material are removed by chemical etching from relatively thick substrate q Substrate is usually silicon crystal; sometimes glass, quartz, germanium or gallium arsenide is used q Substrate (wafer) is etched on single side or both sides q Etching done with masks and etchants solutions q Masking by photolithographic etching technique q Etching processes: a) Isotropic etching b) Anistropic etching 26
27 Etching Processes for Bulk Micromachining (a) Isotropic Etching Ø Etchants used have the same etching rate for all crystallographic orientations of silicon wafer (crystal) Ø Common Etchants: Sulfur hexafluoride (SF6) and Hydrogen fluoride (HF) Ø Common Structures Produced: Cantilever, semi-spherical cavity (b) Anistropic Etching Ø Etchants used have different etching rates for different crystallographic orientations of silicon wafer (crystal) Ø Common Etchants: Ethylene-diamine pyrocatechol (EDP) and potassium hydroxide (KOH) Ø Common Structure Produced: Diaphragm 27
28 Surface Micromachining q 3-dimensional structures built by stacking layers q Layers are deposited using vacuum evaporation or other process and removed using chemical etching q All etching and depositing processes are carried out on one surface only q Layers used: a) Structural layers: Retained in the final structure b) Sacrificial layers: Sacrificed during the process q Intricate structures produced by using two types of layers q Substrate is usually Si; sometimes glass is used q Silicon oxide and silicon nitride used for masking 28
29 Wafer Bonding Used for bonding two silicon wafers or two materials to produce complex structures: Ø Silicon-on-silicon bonding Ø Silicon-on-silicon dioxide bonding Ø Silicon-on-glass bonding Silicon-on-Silicon bonding Silicon-on-SiO2 bonding Silicon-on-glass bonding Adhesive bonding Anodic bonding Fusion bonding Anodic bonding Anodic bonding 29
30 Other Micromachining Processes q LIGA (Lithographie Galvonoformung Abformung) process q DRIE (Deep Reactive Ion Etching) process q Plasma etching q Micro-milling 30
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