This application claims the benefit of German Application No. 102018201997.5, filed on Feb. 8, 2018, which application is hereby incorporated herein by reference.
Exemplary embodiments relate to an emitter structure comprising a membrane arrangement comprising at least two membranes, and to a corresponding production method. Further exemplary embodiments relate to a non-dispersive infrared sensor system and to a photoacoustic spectroscopy system comprising a corresponding emitter structure.
Detecting environmental parameters such as noise, sounds, temperatures or gases, for example, is becoming more and more important in the case of mobile terminals, domestic automation systems or sensors for the automotive sector. Gas sensors, in particular, are playing an ever more important part here in order to detect for example harmful gas concentrations on account of air contamination or malfunctions of installations. In accordance with the general development trend, gas detectors of this type ought to be able to be produced expediently and to be distinguished by permanent availability and high precision.
NDIR sensor systems (non-dispersive infrared sensor systems) constitute a spectroscopic device for gas detection. This spectroscopic device typically comprises a source of infrared radiation, a tube (curvette) containing the gas to be analyzed, radiation being transmitted through said tube, and also an infrared detector (and possibly a wavelength filter). The concentration of the gas sought is determined electro optically on the basis of the absorption of a specific wavelength in the infrared spectrum. One of the components having the highest influence on the measurement quality is the infrared radiation source. For the latter it is possible to use infrared lasers, infrared LEDs or thermal MEMS infrared sources, for example.
Exemplary embodiments of the present invention provide an emitter structure comprising a substrate having a membrane arrangement. The membrane arrangement comprises at least one first membrane, a first heating path and a second heating path. The two heating paths are arranged in (mutually) different substrate planes, wherein the first and second heating path are positioned with respect to one another (e.g. on the membrane if one membrane is assumed, or a respective membrane if a plurality of membranes are assumed) such that a projection (perpendicular to the substrate) of the first heating path and a (parallel) projection of the second heating path onto a common plane are imaged at least partly next to one another in the common plane. To put it another way that means that the two heating paths are thus positioned such that they do not or substantially do not overlap. This has the advantage that the emitter structure constitutes a heating structure in the sense of a temperature source in which a (to the greatest possible extent) homogenous temperature emission profile (e.g. for emitting infrared radiation) is generated over the emission surface (e.g. the topmost membrane).
There are two variants for realizing the arrangement of the two heating paths at different substrate planes. In accordance with one exemplary embodiment, the membrane arrangement comprises the first membrane, with a first heating path on a first main surface of the first membrane (e.g. on a top side) and the second heating path on a second main surface configured opposite the first main surface (i.e. e.g. the underside). In this case, it is advantageous if the membrane is thick enough to give rise to a spacing apart of the two heating paths.
In accordance with a second exemplary embodiment, the membrane arrangement can comprise a first and a second membrane, each of which then accommodates one of the two heating paths. In this case, accommodates means that the heating structure (heating path) are applied on the top side or the underside or are integrated directly into said membrane (integrated in the sense of embedded).
In accordance with exemplary embodiments, the emitter structure can be used as infrared source in an NDIR (non-dispersive infrared sensor) system or in a photoacoustic spectroscopy system for gas detection. Consequently, the exemplary embodiments provide a non-dispersive infrared sensor system comprising an infrared sensor element and a corresponding emitter structure, and also a photoacoustic spectroscopy system comprising an infrared sensor and an emitter structure. On account of the homogenous temperature distribution, a very accurately controllable and homogenous emission of the infrared radiation is effected, such that the measuring systems produced by means of the emitter structure explained above yield very accurate results. Since such MEMS emitter structures are also able to be produced cost effectively, the systems described combine the advantages of cost effective production and very good metrological properties.
Exemplary embodiments are not restricted to emitter structures comprising two membranes and two heating paths, such that an emitter structure having the above arrangement and also a third membrane in the membrane arrangement is provided in accordance with further exemplary embodiments. The third membrane likewise comprises a third heating path. The third heating path is arranged such that a projection of the third heating path onto the common plane lies next to the projection of the second heating path and/or next to the projection of the first heating path. The homogenous emission characteristic can be optimized further by means of the third or each further membrane layer having a heating element. Furthermore, it should be noted at this juncture that the heating paths are generally connected in parallel, such that the overall arrangement of the heating elements enables low resistance operation, that is to say is advantageous with regard to the power demand.
In accordance with exemplary embodiments, the projection of the first heating path relative to the projection of the second heating path can be spaced apart from one another at least in a region along the first and the second heating path. Moreover, the projection of the first heating path and the projection of the second heating path can also adjoin and overlap one another at least in a region along the first and the second heating path. If meander shaped heating paths are assumed, for example, the meander structures always run parallel to one another in the projection, such that no overlap arises. However, if ring shaped structures are assumed, then an overlap of the projection areas of the two heating paths can arise at least by virtue of the connection region of the inner ring. In accordance with exemplary embodiments, the first and/or the second heating path have/has—depending on the desired purpose of use—a meander shape and a ring shape or else an area shape. In accordance with further exemplary embodiments, each heating path is constituted by a metallization applied on the membrane, a doping or some other resistance element.
As already mentioned above, in accordance with exemplary embodiments, an emission region that emits the infrared radiation is formed by a membrane, in particular the first membrane. When looking at this emission region, the arrangement explained above makes it possible that, in accordance with exemplary embodiments, a projection area of the first heating path together with a projection area of the second heating path forms a larger projection area than each projection area by itself. By way of example, the projection area can be 1.3 or 1.5 or even 2.0 times the magnitude of one of the projection areas alone. Preferably, the common projection area forms exactly the sum of the projection area of the two heating paths. In accordance with further exemplary embodiments, the membrane arrangement can comprise an additional membrane designed for the emission. Said additional membrane is configured to distribute a thermal energy induced by the first and/or the second heating path over a lateral area of the further membrane and/or accordingly to emit the infrared radiation. This affords the advantage of further optimizing the emission characteristic.
In accordance with exemplary embodiments, the substrate comprises an opening, such as e.g. an opening produced by means of the Bosch method, or a trench (deep trench), in which the membranes are arranged. In the case of a trench, the membranes together with the trench form a cavity. The opening or cavity has the advantage that these regions do not serve as a heat sink and the response time and overall the heating capacity are thus improved. In accordance with exemplary embodiments, the membranes are spaced apart from one another, such that an interspace is formed between the membranes. In accordance with further exemplary embodiments, said interspace can be filled with a gas or fluid, for example. This filling has the purpose or advantage that the membranes are thermally coupled to one another in order to produce the desired temperature profile or temperature pattern on the first membrane (topmost or bottommost membrane). In order, in accordance with exemplary embodiments, to allow the enclosed gas to escape upon its expansion on account of the heating, the first and/or the second membrane can comprise a ventilation opening. Alternatively, the ventilation opening can also be provided in the substrate. These ventilation openings have the advantage of the membrane not being mechanically loaded on account of thermal expansion and change in volume owing to the heating of the enclosed gas.
In accordance with a further exemplary embodiment, the emitter structure comprises an integrated ASIC configured to drive the first and the second heating path. In this case, by way of example, a DC or AC excitation can be induced by the ASIC, wherein, by way of example, an AC excitation in the radio frequency range (e.g. 100 megahertz) enables an optimization of the temperature profile. In accordance with exemplary embodiments, the heating elements of the individual membranes can also be driven separately from one another in order to vary the temperature profile or generally to vary the temperature. In accordance with one advantageous variant, the temperature of the neighboring membrane can be determined by means of the pattern from the heating path in order thus to carry out the control in a more targeted manner.
A further exemplary embodiment provides a method for producing an emitter structure comprising the central step of forming a membrane arrangement in a substrate comprising shaping a first membrane with a first heating path and shaping a second membrane with a second heating path, such that the first and the second membrane are arranged with respect to one another in such a way that a projection of the first heating path and a projection of the second heating path onto a common plane lie at least partly next to one another. In accordance with a further exemplary embodiment, the method can also be extended by the previous step of introducing a trench or an opening, wherein the step of forming the membrane arrangement is then carried out such that the first and/or the second membrane are/is arranged in the opening or the trench. As already indicated above, the method has the advantage that an emitter structure which offers advantageous measurement properties by comparison with other emitter structures produced by means of MEMS technologies can be produced in a cost effective manner by means of this method.
Developments are defined in the dependent claims. Exemplary embodiments are explained with reference to the accompanying drawings, in which:
Before exemplary embodiments are explained in detail below with reference to the accompanying drawings, it should be pointed out that identically acting elements and structures are provided with identical reference signs, such that the description thereof is applicable to one another or mutually interchangeable.
Each of the membranes 12 and 14 comprises a heating element in the form of a heating path 12a and 14a, respectively. The first heating path 12a associated with the first membrane 12 extends along an arbitrary shape, such as e.g. the U-shape illustrated here or along a meander shape on or in the associated first membrane 12. Analogously thereto, the second heating path 14a likewise extends along the surface of the associated membrane 14 with an arbitrary shape. Both heating paths 12a and 14a are shaped from a lateral standpoint such that they are arranged in a non-overlapping fashion, which is explained below with reference to the projection of the two heating paths 12a and 14a onto a common plane GE.
The projection of the heating path 12a is identified by means of the reference sign 12a*, while the projection 14a is identified by the reference 14a*. The projection is effected perpendicular to the membranes 12 and 14 or perpendicular to the substrate (not illustrated) accommodating the membrane arrangement 12+14 of the emitter structure 10. As a result, the projection plane GE thus lies substantially parallel to a main surface of the substrate or to the membranes 12 and 14. As can be discerned, the projection areas 14a* and 12a* extend substantially next to one another or, in this exemplary embodiment, completely next to one another. This arrangement next to one another in the projection onto the common plane GE results because the heating elements 12a and 14 are arranged in a manner significantly offset with respect to one another in order to achieve a temperature distribution that is as homogenous as possible at the topmost membrane upon activation of said heating elements, as will also be explained below.
It should be pointed out at this juncture that, in accordance with exemplary embodiments, it suffices for the projections 14a* and 12a* to extend next to one another regionally, such that individual small overlaps or intersection points of the projections 12a* and 14a* would be conceivable, wherein this overlap can originate for example from contacting lines. Even if in this exemplary embodiment the illustration was such that there is a distance between the projections 14a* and 12a*, it would, of course, also be possible for said projections to directly adjoin one another or even partly overlap one another.
Now that the emitter structure 10 has been explained with regard to its structure, the functioning will be discussed below.
Each of the heating paths 12a and 14a is conductive (e.g. metallized or doped) and emits a dedicated temperature profile upon excitation with a voltage (DC or AC), said temperature profile in principle following the shape of the conductors 12a and 14a. By virtue of the fact that, rather than one plane, a plurality of planes with individual heating paths 12a and 14a are provided and said heating paths also lie in a manner spatially offset with respect to one another, at the emission surface of the emitter structure 10, e.g. at the surface of the membrane 12, upon emission in the direction IR, a homogenous temperature distribution is achieved as a result of superimposition of the individual temperature distributions. With elements of this type it is possible to achieve a temperature emission (directly at the element) in the range of from room temperatures (starting from 20° C.) up to 600° C.
For the purpose of preferred driving in accordance with exemplary embodiments: the emitter structure 10 or the resulting layer stack 12+14 comprising the heating paths 12a and 14a forms an arrangement of resistance and impedance elements, wherein the elements of the different layers are preferably connected in parallel, which enables low resistance driving with a correspondingly low total power. The heating elements can be configured as resistive elements, for example, such that a temperature increase is brought about by a DC or an AC excitation. Alternatively, a design as an impedance element would also be possible, such that an AC excitation (e.g. in the megahertz range) brings about a temperature emission by means of the impedance element.
Even if, in exemplary embodiments above, it was assumed that the membrane arrangement comprises the membranes 12 and 14, in accordance with further exemplary embodiments the same concept can also be realized with one membrane, e.g. one thick membrane, in the case of which a respective heating structure (heating path 12a and 14a) is provided on the top side and on the underside. This approach of the single membrane as membrane arrangement having different heating structures in different topologies is advantageous on account of the simple producability. Furthermore, it should be noted that, in accordance with further exemplary embodiments, said single membrane or each membrane can also comprise heating structures in the membrane itself, in order to form e.g. a third heating path.
A further exemplary embodiment is illustrated in
As already indicated above, the membranes 12′, 14′ and 16′ are preferably composed of polysilicon since this material has a high emissivity. As already explained above, the heating elements 12a′, 14a′ and 16a′ can be shaped as doped regions in the membranes 12′, 14′ and 16′ or else comprise other electrical elements having heating properties, i.e. thus having a high power loss in the structure. That is to say therefore in other words that a resistance, of whatever kind, is generally used.
In accordance with exemplary embodiments, the membranes 12′, 14′ and 16′ can have ventilation openings, identified here with the reference signs 12v′, 14v′ and 16v′ (cf.
Referring to
It is evident in the projection illustration, in particular, that both heating elements 12a″ and 14a″ are interleaved in one another in a ring shape fashion, although the electrical contactings (cf. 12k″ and 14k″) are arranged in a manner overlapping one another, with the result that a region of contact or overlap region thus arises.
In accordance with exemplary embodiments, this contacting region can also be arranged in a manner offset with respect to one another in order to avoid hot spots here on account of the supply of energy. In the case of such arrangements, the contacting region 12k″ would then be arranged at a different position, e.g. in the manner distributed over the circumference of the membrane 12″/14″, compared with the contacting region 14k″.
With regard to the dimensioning, it should be pointed out by way of example that it is assumed here that each membrane has a thickness in the 100 nm range, while the height of the cavity extends over a range of hundreds of μm. The two membranes are spaced apart a few μm from one another, said membranes having a diameter of a few 100 μm. Each conductor track has approximately a width of a few 10 μm. All these indications should be understood as value ranges, such that the membrane thus has a diameter of 100 to 3000 μm, and the cavity can have a depth of 100 to 1000 μm. Likewise, the thickness of each membrane can vary in the range of 100 nm to 2000 nm, wherein the distance would then also vary with the order of magnitude of 1 μm to 5 μm. The chosen diameters of the conductor tracks of the heating elements depend essentially on the desired impedance and can vary between 5 and 300 μm.
Referring to
Referring to
It should be noted at this juncture that even if, in exemplary embodiments above, it was always assumed that the heating track is embodied as a track, planar elements such as heating plates, for example, can also be provided.
In accordance with a further exemplary embodiment, an additional emission membrane can additionally be provided on the emission side, i.e. on the membrane 12 for example in the case of the emitter structure 10 from
Even if, in exemplary embodiments above, it was always assumed that emission takes place via the membrane 12, nevertheless it is also possible for the temperature emission to take place via the lower membrane.
Referring to the dimensioning of the membranes and the choice of filling for the interspaces, it should be noted that these can be used to adapt the properties of the element (thermal capacity and reaction time). If a fluid or a solid is present e.g. in the interspace, the optical reaction time is reduced since the thermal capacity is also reduced.
Further exemplary embodiments relate to a sensor system (PAS Sensor System or an NDIR Sensor System) comprising an emitter structure as explained above. An additional exemplary embodiment relates to a production method essentially comprising the steps of arranging the membranes with the heating elements in such a way that the heating elements do not overlap, i.e. are preferably arranged next to one another. Conventional MEMS production technologies such as are used e.g. for microphone production can be used in this production method.
In accordance with a further exemplary embodiment, the structure can be connected to an ASIC or generally to a controller that can be used to activate and deactivate or regulate the individual elements. By adapting the power per heating element, it is possible to adapt the thermal profile and thus also the optical emission characteristic/emission pattern. In this case, it is conceivable, for example, for the different heating elements to be driven differently in different planes or else for a temperature sensor on one plane to be taken as a basis for monitoring the temperature of the heater of the other plane in order thus to carry out a control.
Although some aspects have been described in association with a device, it goes without saying that these aspects also constitute a description of the corresponding method, and so a block or a component of a device should also be understood as a corresponding method step or as a feature of a method step. Analogously thereto, aspects described in association with or as a method step also constitute a description of a corresponding block or detail or feature of a corresponding device. Some or all of the method steps can be performed by a hardware apparatus (or using a hardware apparatus), such as, for example, a microprocessor, a programmable computer or an electronic circuit. In some exemplary embodiments, some or a plurality of the most important method steps can be performed by such an apparatus.
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