The present invention relates to acoustic wave devices.
Acoustic wave devices have been widely used as filters for cellular phones. Japanese Unexamined Patent Application Publication No. 2004-260194 discloses a surface acoustic wave (SAW) device as an example of an acoustic wave device. In this SAW device, an interdigital transducer (IDT) electrode is provided on a piezoelectric substrate. The IDT electrode includes Al and a metal that forms an intermetallic compound with Al.
When using an alloy material for the IDT electrode in the acoustic wave device as described in Japanese Unexamined Patent Application Publication No. 2004-260194, heat resistance and electric power handling capability are sometimes not improved sufficiently.
Example embodiments of the present invention provide acoustic wave devices each being capable of improving heat resistance and electric power handling capability of an IDT electrode.
In an acoustic wave device according to an example embodiment of the present invention, a piezoelectric substrate and an IDT electrode provided on the piezoelectric substrate are provided, in which the IDT electrode includes a layer including an electrode material including a base element A and an additive B, where A is a metal element being a base element and B is an element being an additive, a state of a compound represented by AxBy is included in a region where a concentration of the additive B is about 50 at % or less in a binary phase diagram of the base element A and the additive B, where x and y are any positive numbers, in the binary phase diagram, Ta<Tc and Tb−Ta<300° C., where Ta is a melting point of the base element A, Tb is a melting point of the additive B, and Tc is a melting point of the compound AxBy, in the electrode material, the compound AxBy segregates in the base element A, and in the electrode material, a grain size of the base element A and a grain size of the compound AxBy are about 10 nm or more and about 100 nm or less.
In another acoustic wave device according to an example embodiment of the present invention, a piezoelectric substrate and an IDT electrode provided on the piezoelectric substrate are provided, in which the IDT electrode includes a layer including an electrode material including a base element A and an additive B, where A is a metal element being a base element and B is an element being an additive, the electrode material includes a compound represented by AxBy, where x and y are any positive numbers, the base element A is Al, the additive B is at least one of Ba, Ca, Ce, La, Sb, Sr, Yb, or Pr, and in the electrode material, a grain size of the base element A and a grain size of the compound AxBy are about 10 nm or more and about 100 nm or less.
In still another example embodiment of an acoustic wave device according to the present invention, a piezoelectric substrate and an IDT electrode provided on the piezoelectric substrate are provided, in which the IDT electrode includes a layer including an electrode material including a base element A and an additive B, where A is a metal element being a base element and B is an element being an additive, a state of a compound represented by AxBy is included in a region where a concentration of the additive B is about 50 at % or less in a binary phase diagram of the base element A and the additive B, where x and y are any positive numbers, in the binary phase diagram, Ta<Tc, where Ta is a melting point of the base element A, Tb is a melting point of the additive B, and Tc is a melting point of the compound AxBy, a temperature at 1 Pa vapor pressure of the base element A is higher than a temperature at 1 Pa vapor pressure of the additive B, where a temperature at 1 Pa vapor pressure is a temperature at which a vapor pressure of the base element A or the additive B becomes 1 Pa, in the electrode material, the compound AxBy segregates in the base element A, and in the electrode material, a grain size of the base element A and a grain size of the compound AxBy are about 10 nm or more and about 100 nm or less.
In yet another example embodiment of an acoustic wave device according to the present invention, a piezoelectric substrate and an IDT electrode provided on the piezoelectric substrate are provided, in which the IDT electrode includes a layer made of an electrode material including a base element A and an additive B, where A is a metal element being a base element and B is an element being an additive, the electrode material includes a compound represented by AxBy, where x and y are any positive numbers, the base element A is Al, the additive B is at least one of Ba, Ca, Sb, Sr, Sm, or Dy, and in the electrode material, a grain size of the base element A and a grain size of the compound AxBy are about 10 nm or more and about 100 nm or less.
With the acoustic wave devices according to example embodiments of the present invention, the heat resistance and the electric power handling capability of the IDT electrode can be improved.
The above and other elements, features, steps, characteristics and advantages of the present invention will become more apparent from the following detailed description of the example embodiments with reference to the attached drawings.
Hereinafter, the present invention will be clarified by describing specific example embodiments of the present invention with reference to the drawings.
It should be noted that the example embodiments described in this specification are merely examples, and partial replacement or combination of configurations is possible between different example embodiments.
As illustrated in
An IDT electrode 3 is provided on the piezoelectric substrate 2. Acoustic waves are excited by applying an AC voltage to the IDT electrode 3. A pair of reflectors 4A and 4B are provided on both sides of the IDT electrode 3 on the piezoelectric substrate 2 in an acoustic wave propagation direction. Thus, the acoustic wave device 1 in the present example embodiment is a surface acoustic wave resonator. Note that the acoustic wave device in the present invention is not limited to the acoustic wave resonator, and may be, for example, a filter device or a multiplexer including multiple acoustic wave resonators.
As illustrated in
In the present example embodiment, the IDT electrode 3, the reflector 4A, and the reflector 4B each include a single-layer metal film. However, the IDT electrode 3, the reflector 4A, and the reflector 4B may be each composed of a laminate.
In the present example embodiment, an electrode material of the IDT electrode 3 preferably has all of configurations in 1) to 5) below. 1) The electrode material includes a base element A and an additive B, where A is a metal element that is a base element, and B is an element that is an additive. In this specification, the base element refers to an element that accounts for more than about 50 at % in the electrode material. 2) In a binary phase diagram of the base element A and the additive B, a state of a compound represented by AxBy is included in a region where a concentration of the additive B is about 50 at % or less, where x and y are any positive numbers. 3) In the binary phase diagram, Ta<Tc and Tb−Ta<300° C., where Ta is a melting point of the base element A, Tb is a melting point of the additive B, and Tc is a melting point of the compound AxBy. 4) The compound AxBy segregates in the base element A. 5) A grain size of the base element A and a grain size of the compound AxBy are about 10 nm or more and about 100 nm or less. Thus, heat resistance and electric power handling capability of the IDT electrode 3 can be improved. This will be described in detail below.
In the present example embodiment, specifically, the base element A in the electrode material of the IDT electrode 3 is Al. The additive B is Ce. A binary phase diagram of the base element Al and the additive Ce is shown in
It is understood that a state in region C surrounded by an alternate long and short dash line in
A melting point Ta of the base element Al shown in
As in 4) above, in the electrode material of the IDT electrode 3, the compound Al11Ce3 segregates in the base element Al. As in 5) above, in the electrode material, a grain size of the base element Al and a grain size of the compound Al11Ce3 are about 10 nm or more and about 100 nm or less.
The states of the base element A and the compound AxBy in the electrode material of the IDT electrode 3 can be observed using, for example, a transmission electron microscope (TEM). The grain size can also be confirmed by calculating the crystallite size from X-ray diffraction (XRD) using the Scherrer equation.
In the present example embodiment, the heat resistance and the electric power handling capability of the IDT electrode 3 can be improved. This is related to the Hall-Petch relation and the inverse Hall-Petch relation. As shown in
In the electrode material of the IDT electrode 3 of the acoustic wave device 1, the grain size of the base element Al and the grain size of the compound Al11Ce3 are about 10 nm or more and about 100 nm or less, for example. Thus, the mechanical strength of the IDT electrode 3 is high based on the Hall-Petch relation and the inverse Hall-Petch relation. In addition, in the electrode material of the IDT electrode 3, the melting point Tc of the compound Al11Ce3 is higher than the melting point Ta of the base element Al. Thus, even when high power is applied to the IDT electrode 3 and the IDT electrode 3 becomes a high temperature, the inside of the electrode material is stabilized. Therefore, even when the IDT electrode 3 is at a high temperature, grain sizes of the base element Al and the compound Al11Ce3 can be kept within the above range, so the IDT electrode 3 is less likely to be damaged. Thus, the heat resistance and the electric power handling capability of the IDT electrode 3 can be improved.
An example of a method for manufacturing the acoustic wave device 1 in the present example embodiment will be described below.
As illustrated in
Subsequently, the resist pattern 7 is peeled off. Thus, as illustrated in
As described above, the compound Al11Ce3 is formed by the appropriate heat treatment.
In the alloy film before the heat treatment, Al and Ce are mixed and laminated. The alloy film is in a supersaturated solid solution state. To be more specific, the base element Al and the additive Ce are solid-solved in a supersaturated state. This is because Al and Ce, which are the deposition materials, are rapidly cooled during deposition of the alloy film.
Subsequent heat treatment separates the alloy in the supersaturated solid solution state into grains of the base element Al and grains of the compound Al11Ce3. Thus, in the obtained electrode material, the compound Al11Ce3 segregates in the base element Al. Such a behavior in which the compound segregates in the base element due to the heat treatment from the supersaturated solid solution state occurs only in limited combinations of elements, such as Al and Ce.
In addition, the appropriate heat treatment as exemplified above reduces or prevents coarsening of the grains of the base element Al and the grains of the compound Al11Ce3 in the electrode material of the IDT electrode 3. On the other hand, when a pure metal is used as the electrode material, it is difficult to reduce or prevent coarsening of grains. For example, when a metal film made of a pure metal is deposited and then heat-treated, the grains of the metal film are likely to be coarsened.
In contrast, as described above, the coarsening of the grains of the base element and the grains of the compound can be reduced or prevented by segregating the compound in the base element through the appropriate heat treatment from the state where the alloy film is a supersaturated solid solution. Thus, as in the present example embodiment, the grain size of the base element Al and the grain size of the compound Al11Ce3 can be about 10 nm or more and about 100 nm or less, for example.
Further, by satisfying Tb−Ta<300° C., coarsening of the grains of the base element Al and the grains of the compound Al11Ce3 can be reduced or prevented more reliably. This is thought to be because the melting point Tb of the additive Ce is low, which reduces energy of the entire deposition material and reduces or prevents coarsening of the grains of the deposition material during deposition.
The method for manufacturing the acoustic wave device 1 using a lift-off method has been described above. However, the above manufacturing method is merely an example, and the lift-off method is not necessarily used when forming the IDT electrode 3. For example, after an alloy film is deposited on the piezoelectric substrate 2, a resist pattern may be formed on the alloy film, followed by etching. The deposition of the alloy film is not limited to the alloy vapor deposition and, for example, binary vapor deposition of Al and Ce may be performed, or a sputtering method may be used. Al and Ce may be simultaneously deposited as deposition materials.
In the present example embodiment, an example is illustrated in which the base element A is Al and the additive B is Ce. Note that the base element A and the additive B are not limited to the above. However, the base element A is preferably Al. On the other hand, the additive B is preferably at least one of Ba, Ca, Ce, La, Sb, Sr, Yb, or Pr. Table 1 shows the melting point Tb, the difference in melting points Tb−Ta, the composition formula of the compound AxBy, and the melting point Tc of the compound AxBy when Al is used as the base element A and the above elements are used as the additive B.
When any of the above elements other than Ce is used as the additive B, the heat resistance and the electric power handling capability of the IDT electrode can be improved as in the present example embodiment.
In
A dielectric film may be provided on the piezoelectric substrate 2 so as to cover the IDT electrode 3. In this case, the IDT electrode 3 is less likely to be damaged. For example, silicon oxide, silicon nitride, or silicon oxynitride, or the like, can be used for the dielectric film. When silicon oxide is used for the dielectric film, frequency-temperature characteristics of the acoustic wave device 1 can be improved.
The present example embodiment is different from the first example embodiment in that an IDT electrode 13 is formed of a laminate. Except for the above point, the acoustic wave device in the present example embodiment has the same configuration as the acoustic wave device 1 in the first example embodiment.
The IDT electrode 13 includes a first layer 14 and a second layer 15. To be specific, the first layer 14 is provided on a piezoelectric substrate 2. The second layer 15 is provided on the first layer 14. The first layer 14 is a layer with the same electrode material as in the first example embodiment. The second layer 15 is a low resistance layer. Electrical resistance of the second layer 15 is lower than electrical resistance of the first layer 14.
As described above, the first layer 14 in the present example embodiment is made of the same electrode material as the IDT electrode 3 in the first example embodiment. Thus, heat resistance and electric power handling capability of the IDT electrode 13 can be improved. Further, since the second layer 15 is provided as a low resistance layer, the electrical resistance of the IDT electrode 13 can be lowered.
Note that the number of layers of the IDT electrode 13 may be three or more. Also in this case, the first layer 14 is preferably located closer to the piezoelectric substrate 2 than is the second layer 15. Thus, the heat resistance and the electric power handling capability of the IDT electrode 13 can be improved more reliably.
In the following, a third example embodiment of the invention is presented. The third example embodiment is different from the first example embodiment only in a material of the IDT electrode. Therefore, the drawings and reference numerals used in the description of the first example embodiment will be used in the description of the third example embodiment.
In the third example embodiment described with reference to
The third example embodiment has the configurations in 1), 2), 4), and 5) above in the first example embodiment. That is, as follows. 1) The electrode material includes the base element A and the additive B. 2) In a binary phase diagram of the base element A and the additive B, a state of a compound represented by AxBy is included in a region where a concentration of the additive B is about 50 at % or less. 4) The compound AxBy segregates in the base element A. 5) A grain size of the base element A and a grain size of the compound AxBy are about 10 nm or more and about 100 nm or less, for example.
In addition, the third example embodiment has a configuration in 6) below instead of the configuration in 3) above. 6) A melting point Ta of the base element A is lower than a melting point Tc of the compound AxBy. That is, Ta<Tc. On the other hand, the melting point Ta of the base element A and the melting point Tb of the additive do not have to satisfy the relation Tb−Ta<300° C.
Further, the third example embodiment has a configuration in 7) below. 7) A temperature at 1 Pa vapor pressure of the base element A is higher than a temperature at 1 Pa vapor pressure of the additive B, where a temperature at 1 Pa vapor pressure is a temperature at which vapor pressure of the base element A or the additive B becomes 1 Pa.
Table 2 shows the temperature at 1 Pa vapor pressure, the composition formula of the compound AxBy, and the melting point Tc of the compound AxBy, for the combination of the base element A and the additive B in the third example embodiment. When the base element A is Al, the melting point Ta is about 660° C.
Also in the third example embodiment, heat resistance and electric power handling capability of the IDT electrode 3 can be improved as in the first example embodiment.
Note that the acoustic wave device in the third example embodiment can be obtained, for example, by the manufacturing method illustrated in
Also when the combination of the base element A and the additive B is the combination shown in Table 2, the compound AxBy segregates in the base element A by heat-treating the alloy film 8 illustrated with reference to
Also in the second example embodiment illustrated in
While example embodiments of the present invention have been described above, it is to be understood that variations and modifications will be apparent to those skilled in the art without departing from the scope and spirit of the present invention. The scope of the present invention, therefore, is to be determined solely by the following claims.
Number | Date | Country | Kind |
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2022-053802 | Mar 2022 | JP | national |
This application claims the benefit of priority to Japanese Patent Application No. 2022-053802 filed on Mar. 29, 2022 and is a Continuation application of PCT Application No. PCT/JP2023/006762 filed on Feb. 24, 2023. The entire contents of each application are hereby incorporated herein by reference.
Number | Date | Country | |
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Parent | PCT/JP2023/006762 | Feb 2023 | WO |
Child | 18773665 | US |