Hostname: page-component-74656f9884-c52kr Total loading time: 0 Render date: 2026-11-07T14:45:39.961Z Has data issue: false hasContentIssue false

Microwave MEMS devices designed for process robustness and operational reliability

Published online by Cambridge University Press:  18 October 2011

Mikael Sterner*
Affiliation:
Microsystem Technology Lab, KTH – Royal Institute of Technology, Osquldas väg 10, SE-100 44 Stockholm, Sweden.
Nutapong Somjit
Affiliation:
Microsystem Technology Lab, KTH – Royal Institute of Technology, Osquldas väg 10, SE-100 44 Stockholm, Sweden.
Umer Shah
Affiliation:
Microsystem Technology Lab, KTH – Royal Institute of Technology, Osquldas väg 10, SE-100 44 Stockholm, Sweden.
Sergey Dudorov
Affiliation:
Microsystem Technology Lab, KTH – Royal Institute of Technology, Osquldas väg 10, SE-100 44 Stockholm, Sweden.
Dmitry Chicherin
Affiliation:
Department of Radio Science and Engineering, SMARAD Centre of Excellence, Aalto University, PO Box 13000, FI-00076 Aalto, Finland.
Antti Räisänen
Affiliation:
Department of Radio Science and Engineering, SMARAD Centre of Excellence, Aalto University, PO Box 13000, FI-00076 Aalto, Finland.
Joachim Oberhammer
Affiliation:
Microsystem Technology Lab, KTH – Royal Institute of Technology, Osquldas väg 10, SE-100 44 Stockholm, Sweden.
*
Corresponding author: M. Sterner Email: msterner@kth.se
Rights & Permissions [Opens in a new window]

Abstract

This paper presents an overview on novel microwave micro-electromechanical systems (MEMS) device concepts developed in our research group during the last 5 years, which are specifically designed for addressing some fundamental problems for reliable device operation and robustness to process parameter variation. In contrast to conventional solutions, the presented device concepts are targeted at eliminating their respective failure modes rather than reducing or controlling them. Novel concepts of MEMS phase shifters, tunable microwave surfaces, reconfigurable leaky-wave antennas, multi-stable switches, and tunable capacitors are presented, featuring the following innovative design elements: dielectric-less actuators to overcome dielectric charging; reversing active/passive functions in MEMS switch actuators to improve recovery from contact stiction; symmetrical anti-parallel metallization for full stress-control and temperature compensation of composite dielectric/metal layers for free-standing structures; monocrystalline silicon as structural material for superior mechanical performance; and eliminating thin metallic bridges for high–power handling. This paper summarizes the design, fabrication, and measurement of devices featuring these concepts, enhanced by new characterization data, and discusses them in the context of the conventional MEMS device design.

Information

Type
Research Papers
Copyright
Copyright © Cambridge University Press and the European Microwave Association 2011
Figure 0

Table 1. Overview of major fundamental design problems of conventional RF MEMS devices and novel design concepts addressing these issues as discussed in this paper.

Figure 1

Fig. 1. Comparison between two conventional phase shifter concepts and the presented novel dielectric-block phase shifter: (a) switched TTD network [58]; (b) DMTL phase shifter [59], and (c) novel dielectric-block phase shifter [55–57].

Figure 2

Fig. 2. (a) Scanning electron microscopy (SEM) picture of a 45°, a 30°, and a 15° stage in series; (b) 7-stage phase shifters at 75 GHz: binary–coded 5 × 45° + 30° + 15° phase shifter [55, 56].

Figure 3

Fig. 3. Performance of the binary–coded phase shifter for the W-band: (a) insertion loss and return loss for actuating 1 – 7 stages; (b) phase shift in all states. Non-linearity investigation; (c) relative phase shift of a 45° stage depending on signal power; and (d) intermodulation product and intercept point of third order [55, 56].

Figure 4

Fig. 4. Simulated peak-temperature rises of the three MEMS phase-shifter concepts, at a signal power from 0.1 to 10 W (20 –  40 dBm) at 75 GHz. [57]

Figure 5

Table 2. Comparative figure-of-merit performance summary of the two conventional phase shifters and the presented novel dielectric-block concept [37].

Figure 6

Fig. 5. Illustration of (a) MEMS tunable HIS; (b) reflective beam-steering with MEMS HIS [47].

Figure 7

Fig. 6. Concept of stress-compensation by symmetrical deposition of metal (right), as compared to conventional metalized membrane with resulting stress gradient (left) [45].

Figure 8

Fig. 7. Cross-section of a single element [47].

Figure 9

Fig. 8. SEM pictures of a fabricated HIS array with close-up views [47].

Figure 10

Fig. 9. RF characterization [47, 62].

Figure 11

Fig. 10. Surface profile of a stress-compensated membrane obtained by white-light interferometry, showing very uniform curvature distribution [45].

Figure 12

Fig. 11. Curvature of the multi-layer membranes, invariant over actuated membrane deflection [45].

Figure 13

Fig. 12. Lifecycle measurements over 100 million actuation cycles, showing virtually no degradation or plastic deformation: (a) invariance of the membrane curvature; (b) excellent repeatability of the absolute membrane deflection. In the unactuated curve, both the measurement point before and the one after the actuated measurement are shown [45].

Figure 14

Fig. 13. Final fabrication steps on the leaky-wave antenna.

Figure 15

Fig. 14. SEM images of fabricated leaky-wave antennas: (a) the whole chip with a 30-element array; (b) close-up view of the wire bonds connecting the membranes to the ground plane; and (c) close-up view of the membranes with springs and anchors.

Figure 16

Fig. 15. Illustration of the difference between 2D and 3D transmission lines. Transmission losses are lower in the 3D micromachined SOI RF MEMS transmission line due to much lower electrical field penetration in the substrate and a larger conductor volume for the signal current without skin–depth limitations [67].

Figure 17

Fig. 16. Conceptual illustration of the presented static zero-power-consumption CPW–integrated metal-contact MEMS switch.

Figure 18

Fig. 17. Actuation phases illustrating the sequence of the transition between the two mechanically stable states of the presented CPW–integrated switches [26].

Figure 19

Fig. 18. SEM pictures of fabricated microswitches: (a–c) different embodiments A, B, and C of the two-port design (SPST); (d) three-port device (SPDT); (e) SPST device with locked cantilevers; and (f) with unlocked cantilevers [26, 50].

Figure 20

Fig. 19. RF measurement results of the design variant shown in Fig. 18(c): (a) open state and (b) closed state with comparison to a straight transmission line piece and a line geometry corresponding to the switch outline [26].

Figure 21

Fig. 20. Illustration of moving sidewalls multistep tunable capacitors integrated into the ground edges of a 3D micromachined CPW transmission line [69].

Figure 22

Fig. 21. Illustration of the seven operation states of a three-step moving-sidewall tunable capacitor, with electrode distances and measured capacitance values for each state given.

Figure 23

Fig. 22. Measured return loss (S11) of fabricated devices for all actuation states as listed in Fig. 21 [69].

Figure 24

Fig. 23. SEM picture of a fabricated three-step tunable capacitor [69].

Figure 25

Fig. 24. Simulated self-actuation robustness for a three-step device, showing the combined series stiffness of the device in all states and how the capacitor gap is affected by different power levels on the signal line.