The present disclosure relates to a piezoelectric film integrated device, a manufacturing method thereof, and an acoustic oscillation sensor.
Conventionally, there has been disclosed a piezoelectric element in which two piezoelectric films are stacked together via an adhesion layer. See Japanese Patent Application Publication No. 2017-130701 (Patent Reference 1), for example.
However, a high-performance piezoelectric film integrated device cannot be obtained when a plurality of piezoelectric films are arranged in superimposition in a conventional device.
An object of the present disclosure is to provide a high-performance piezoelectric film integrated device in which two or more types of piezoelectric elements each including a monocrystalline piezoelectric film are provided in superimposition, a manufacturing method thereof, and an acoustic oscillation sensor including the piezoelectric film integrated device.
A piezoelectric film integrated device according to the present disclosure includes a substrate, an electrode that is provided on the substrate, a first piezoelectric element that is provided on the electrode and includes a first monocrystalline piezoelectric film and a first electrode film superimposed on the first monocrystalline piezoelectric film, and a second piezoelectric element that is provided on the first piezoelectric element and includes a second monocrystalline piezoelectric film and a second electrode film superimposed on the second monocrystalline piezoelectric film.
According to the present disclosure, by providing two or more types of piezoelectric elements each including a monocrystalline piezoelectric film in superimposition, the performance of the piezoelectric film integrated device and the acoustic oscillation sensor can be increased.
The present disclosure will become more fully understood from the detailed description given hereinbelow and the accompanying drawings which are given by way of illustration only, and wherein:
A piezoelectric film integrated device, a manufacturing method thereof, and an acoustic oscillation sensor according to each embodiment will be described below with reference to the drawings. The following embodiments are just examples and a variety of modifications are possible within the scope of the present disclosure. In the present application, the piezoelectric film integrated device is a device in which two or more monocrystalline piezoelectric films are provided on the same substrate. Further, in the present application, the acoustic oscillation sensor is a sensor that detects status (e.g., distance, shape, movement or the like) of a detection target object by outputting an acoustic oscillatory wave and detecting reflected waves of the acoustic oscillatory wave. The acoustic oscillation sensor is referred to also as an “ultrasonic sensor”. In general, and in the present application, the acoustic oscillatory wave is made up of at least one of a sonic wave and an ultrasonic wave. Namely, the acoustic oscillatory wave includes a sonic wave, an ultrasonic wave, or both of a sonic wave and an ultrasonic wave.
The piezoelectric film integrated device 100 includes an SOI substrate 33 as a substrate and a platinum (Pt) film 34 as an electrode provided on the SOI substrate 33. As shown in
The piezoelectric film integrated device 100 includes a first piezoelectric element (25, 26) as a lower-side piezoelectric element provided on the Pt film 34 and a second piezoelectric element (15, 16) as an upper-side piezoelectric element provided on the first piezoelectric element. A Pt film 26 has a function as a common electrode for the first piezoelectric element (25, 26) and the second piezoelectric element (15, 16). However, the second piezoelectric element (15, 16) may have an electrode film other than the Pt film 26. The first piezoelectric element includes a monocrystalline AlN film as a first monocrystalline piezoelectric film and the Pt film 26 as a first electrode film superimposed on the monocrystalline AlN film 25. The second piezoelectric element includes a monocrystalline PZT film 15 as a second monocrystalline piezoelectric film and a Pt film 16 as a second electrode film superimposed on the monocrystalline PZT film 15. The AlN represents aluminum nitride. The PZT represents piezoelectric zirconate titanate (lead zirconate titanate). As the first monocrystalline piezoelectric film, instead of the monocrystalline AlN film 25, a piezoelectric film made of a different monocrystalline material such as a monocrystalline lithium tantalate (monocrystalline LiTaO3) film or a monocrystalline lithium niobate (monocrystalline LiNbO3) film may be used. As the second monocrystalline piezoelectric film, instead of the monocrystalline PZT film 15, a piezoelectric film made of a different monocrystalline material such as a monocrystalline potassium sodium niobate (monocrystalline KNN) film or a monocrystalline barium titanate (monocrystalline BaTiO3) film may be used. In the illustrated example, the first monocrystalline piezoelectric film is a piezoelectric body that detects the acoustic oscillatory wave (or its reflected waves), and is desired to be a piezoelectric body having lower specific inductive capacity and higher detection sensitivity compared to the second monocrystalline piezoelectric film. The second monocrystalline piezoelectric film is a piezoelectric body that generates the acoustic oscillatory wave, and is desired to be a piezoelectric body having a higher piezoelectric constant and capable of obtaining greater oscillation amplitude compared to the first monocrystalline piezoelectric film.
Incidentally, it is permissible even if the first piezoelectric element as the lower-side piezoelectric element includes a monocrystalline PZT film as the first monocrystalline piezoelectric film and a Pt film and the second piezoelectric element as the upper-side piezoelectric element includes a monocrystalline AlN film and a Pt film superimposed on the monocrystalline AlN film.
Further, the piezoelectric film integrated device 100 includes an insulation film 35a, a wiring film 36a formed on the insulation film 35a, an insulation film 35b, and a wiring film 36b formed on the insulation film 35b.
The SOI substrate 33 includes a Si substrate 30, a silicon dioxide (SiO2) part 31 as an insulation film, and a monocrystalline silicon (monocrystalline Si) part 32. A cavity 71 is formed by etching the Si substrate 30 in a region of the monocrystalline silicon (monocrystalline Si) part 32 under the monocrystalline PZT film 15 and the monocrystalline AlN film 25 (i.e., a region overlapping with the piezoelectric films), and the SiO2 part 31 and the monocrystalline silicon (monocrystalline Si) part 32 situated in the region where the cavity 71 is formed have a function as a vibrating plate. Further, variations in the thickness of the vibrating plate due to influence of the etching can be prevented by forming the silicon dioxide (SiO2) part 31 made of a material different from the Si substrate 30 and giving the silicon dioxide (SiO2) part 31 a function as an etching stop layer. Furthermore, as the substrate, a substrate made of a different material such as a glass substrate or an organic film substrate may also be used instead of the SOI substrate 33. In the Si substrate 30 of the SOI substrate 33, the cavity 71 that exposes the SiO2 part 31 is formed. The cavity 71 is formed in a circular shape as an opening shape corresponding to the shape of the monocrystalline PZT film 15 or the monocrystalline AlN film 25. The acoustic oscillatory wave generated by the monocrystalline PZT film 15 is outputted through the cavity 71, and the monocrystalline AlN film 25 detects reflected waves of the acoustic oscillatory wave through the cavity 71.
The monocrystalline AlN film 25 of the first piezoelectric element is an epitaxial growth film having a (0001)-surface as a crystal face parallel to a surface of the Pt film 34 and being stuck (or bonded) on the surface of the Pt film 34. The monocrystalline PZT film 15 of the second piezoelectric element is an epitaxial growth film having a (001)-surface as a crystal face parallel to the surface of the Pt film 26 and being stuck (or bonded) on the surface of the Pt film 26 of the first piezoelectric element. The thickness of the monocrystalline PZT film 15 is generally in a range of 10 nm to 10 μm, and preferably in a range of 100 nm to 5 μm. The thickness of the monocrystalline AlN film 25 is generally in a range of 10 nm to 10 μm, and preferably in a range of 100 nm to 2 μm. The Pt film 34 is formed on an upper surface of the SOI substrate 33. The surface (upper surface) of the Pt film 34 and the (0001)-surface as the crystal face of the monocrystalline AlN film 25 are joined together by intermolecular force. The surface of the Pt film 26 of the first piezoelectric element and the (001)-surface as the crystal face of the monocrystalline PZT film 15 are joined together by intermolecular force. For these joints, the use of an adhesive agent is unnecessary. For excellently joining these surfaces by intermolecular force, the surface roughness of the Pt film 34 and the Pt film 26 is desired to be less than or equal to nm. For this purpose, a process for smoothing the surfaces of the Pt film 34 and the Pt film 26 may be executed.
Further, a crystal c-axis direction of the monocrystalline PZT film 15 and a crystal c-axis direction of the monocrystalline AlN film 25 are in the parallel relationship. This feature will be described later by using
The epitaxial growth film in
“The ZrO2 film 12 is (100)-oriented” means that the (100)-surface of the ZrO2 film 12 having a cubic crystal structure is formed along the (100)-surface of the growth substrate 11, namely, is parallel to the (100)-surface of the growth substrate 11. Further, “is parallel to” also means a state in which an angle formed by the upper surface of the growth substrate 11 and the (100)-surface of the ZrO2 film 12 is less than or equal to 20°. Furthermore, the meaning of “orientation” is the same also for relationship between other films.
Table 1 shows the lattice constant of monocrystalline Si of the growth substrate 11, the lattice constant of ZrO2 of the ZrO2 film 12, the lattice constant of Pt of the Pt film 13, the lattice constant of SRO of the SRO film 14, and the lattice constant of monocrystalline PZT of the monocrystalline PZT film 15.
The lattice constant of Si is 0.543 nm, the lattice constant of ZrO2 is 0.511 nm, and inconsistency of the lattice constant of ZrO2 with the lattice constant of Si is as small as 6.1%, and thus the consistency of the lattice constant of ZrO2 with the lattice constant of Si is high. Therefore, as shown in the schematic diagram of
In cases where the ZrO2 film 12 is a zirconium dioxide film having a cubic crystal structure and (100)-oriented, the ZrO2 film 12 is oriented so that the ZrO2 film 12's <100> direction along the upper surface of the growth substrate 11 as the principal surface is parallel to the <100> direction along the upper surface of the growth substrate 11.
Incidentally, “the ZrO2 film 12's <100> direction along the upper surface of the growth substrate 11 is parallel to the <100> direction along the upper surface of the growth substrate 11” means not only that the ZrO2 film 12's <100> direction is perfectly parallel to the <100> direction along the upper surface of the growth substrate 11 but also a state in which an angle formed by the ZrO2 film 12's <100> direction and the <100> direction along the upper surface of the growth substrate 11 is less than or equal to 20°. The same goes not only for the ZrO2 film 12 but also for in-plane orientation of a film in a different layer.
Meanwhile, although the lattice constant of ZrO2 is 0.511 nm and the lattice constant of Pt is 0.392 nm as shown in Table 1, if Pt is rotated in a plane by 45°, the length of a diagonal line is 0.554 nm and the inconsistency of the length of the diagonal line with the lattice constant of ZrO2 is as small as 8.1%. Thus, the Pt film 13 can be grown epitaxially on the (100)-surface of the ZrO2 film 12.
Further, as shown in Table 1, the lattice constant of Pt is 0.392 nm, the lattice constant of SRO is 0.390-0.393 nm, and the inconsistency of the lattice constant of SRO with the lattice constant of Pt is as small as 0.5% or less. Thus, the consistency of the lattice constant of SRO with the lattice constant of Pt is high, and the SRO film 14 can be grown epitaxially on the (100)-surface of the Pt film 13 as shown in
In cases where the monocrystalline PZT film 15 has a cubic crystal structure and includes a (100)-oriented PZT film, the piezoelectric zirconate titanate (lead zirconate titanate) film is oriented so that its <100> direction along the upper surface of the growth substrate 11 is parallel to the <100> direction along the upper surface of the growth substrate 11.
On the (001)-oriented monocrystalline PZT film 15, the Pt film 16 is grown epitaxially in the (100)-orientation and thereby formed as an electrode. The electrode film on the monocrystalline PZT film 15 is the uppermost layer, and thus may also be formed by a different manufacturing method.
The epitaxial growth film in
In cases where the monocrystalline AlN film 25 is formed of a hexagonal crystal of aluminum nitride, the monocrystalline AlN film 25 can be grown epitaxially in the (0001)-orientation in the hexagonal crystal representation on the growth substrate 21. On the monocrystalline AlN film 25, the Pt film 26 having a cubic crystal structure and (100)-oriented can be further grown epitaxially.
“The ZrO2 film 22 is (111)-oriented” means that the (111)-surface of the ZrO2 film 22 having a cubic crystal structure is along the (111)-surface of the growth substrate 21, namely, is parallel to the (111)-surface of the growth substrate 21. Further, “parallel” also means a state in which an angle formed by the (111)-surface of the ZrO2 film 22 and the principal surface of the growth substrate 21 is less than or equal to 20°. The same goes for orientation between other layers.
Table 2 shows the lattice constant of Si, the lattice constant of ZrO2, the lattice constant of Pt, the lattice constant of SRO, and the lattice constant of monocrystalline AlN.
The lattice constant of Si is 0.543 nm, the lattice constant of ZrO2 is 0.511 nm, and the inconsistency of the lattice constant of ZrO2 with the lattice constant of Si is as small as 6.1%, and thus the consistency of the lattice constant of ZrO2 with the lattice constant of Si is high. Thus, the ZrO2 film 22 can be grown epitaxially on a principal surface formed by the (111)-surface of the growth substrate 21. Accordingly, the ZrO2 film 22 can be (111)-oriented in a cubic crystal structure on the (111)-surface of the growth substrate 21, and the crystallinity of the ZrO2 film 22 can be improved. The (111)-surface of the cubic crystal is shown in
In cases where the ZrO2 film 22 as an orientation film is a zirconium dioxide film having a cubic crystal structure and (111)-oriented, the ZrO2 film 22 is oriented so that the ZrO2 film 22's <111> direction along the upper surface of the growth substrate 21 as the principal surface is parallel to the <111> direction along the upper surface of the growth substrate 21.
Incidentally, “the ZrO2 film 22's <111> direction along the upper surface of the growth substrate 21 is parallel to the <111> direction along the upper surface of the growth substrate 21” means not only that the ZrO2 film 22's <111> direction is perfectly parallel to the <111> direction along the upper surface of the growth substrate 21 but also a state in which an angle formed by the ZrO2 film 22's <111> direction and the <111> direction along the upper surface of the growth substrate 21 is less than or equal to 20°. The same goes for orientation between films in different layers.
Meanwhile, although the lattice constant of ZrO2 is 0.511 nm and the lattice constant of Pt is 0.392 nm, if Pt is rotated in a plane by 45°, the length of a diagonal line is 0.554 nm and the inconsistency of the length of the diagonal line with the lattice constant of ZrO2 is as small as 8.1%, and thus the Pt film 23 can be grown epitaxially on the (111)-surface of the ZrO2 film 22.
Further, the lattice constant of Pt is 0.392 nm, the lattice constant of SRO is 0.390-0.393 nm, and the consistency of the lattice constant of SRO with the lattice constant of Pt is high. Thus, the SRO film 24 can be grown epitaxially on the (111)-surface of the Pt film 23 as shown in
In cases where the monocrystalline AlN film 25 has a hexagonal crystal structure and includes a (0001)-oriented aluminum nitride film, the monocrystalline AlN film 25 is oriented so that its <111> direction along the upper surface of the growth substrate 21 is parallel to the <111> direction of the upper surface of the growth substrate 21. The (0001)-surface of the hexagonal crystal is shown in
A method for manufacturing the piezoelectric film integrated device 100 by using the PZT epitaxial growth film (including the monocrystalline PZT film 15 and the Pt film 16) as a piezoelectric element deposited on the growth substrate 11 of monocrystalline Si whose upper surface is a (100)-surface and the AlN epitaxial growth film (including the monocrystalline AlN film and the Pt film 26) as a piezoelectric element deposited on the growth substrate 21 of monocrystalline Si whose upper surface is a (111)-surface will be described below.
First, a wiring layer is formed on the SOI substrate 33 being a device substrate (step ST101). Subsequently, as shown in
Further, the SRO film 14, the monocrystalline PZT film 15 and the Pt film 16 are grown epitaxially on the growth substrate 11 as a first growth substrate as shown in
Furthermore, the SRO film 24, the monocrystalline AlN film and the Pt film 26 are grown epitaxially on the growth substrate 21 as a second growth substrate as shown in
Subsequently, an individual piece (i.e., a piezoelectric element as the AlN epitaxial growth film) formed with the monocrystalline AlN film 25 and the Pt film 26 is held by a stamp 80 as a holding member as shown in
Subsequently, an individual piece (i.e., the second piezoelectric element in the first embodiment) formed with the monocrystalline PZT film 15 and the Pt film 16 is held by the stamp 80 as the holding member as shown in
Subsequently, as shown in
As shown in
As described above, the monocrystalline PZT film 15 and the monocrystalline AlN film 25, which are unlikely to grow epitaxially on the same SOI substrate 33 because of the difference in the lattice constant and the crystal structure, are respectively grown in monocrystalline epitaxial growth on separate growth substrates, peeled off from the growth substrates, and stuck (or bonded) on a common SOI substrate 33 in superimposition with each other, by which a high-performance piezoelectric film integrated device 100 can be manufactured.
Further, since the monocrystalline PZT film 15 has a higher piezoelectric constant compared to a polycrystalline PZT film, amplitude of the oscillation can be increased with ease.
Furthermore, since the monocrystalline AlN film 25 has lower specific inductive capacity compared to a polycrystalline AlN film, the oscillation reception sensitivity can be increased.
Moreover, conventionally, in order to form piezoelectric films of different types, a process like temporarily covering one piezoelectric film with a protective layer, forming the other piezoelectric film, and thereafter removing the protective layer used to be a complicated process, and application of heat in processing in each step used to leave residual stress distortion in the piezoelectric films and cause deterioration in the efficiency of the sensor. In the manufacturing method in the first embodiment, the sticking of the epitaxial growth films as the piezoelectric elements is employed, and thus the piezoelectric film integrated device and the acoustic oscillation sensor can be formed in a state with no residual stress distortion.
In the first embodiment, the AlN epitaxial growth film including the monocrystalline AlN film 25 and the Pt film 26 is grown on the growth substrate 21 and is stuck (or bonded) on the Pt film 34 on the SOI substrate 33, and the PZT epitaxial growth film including the monocrystalline PZT film 15 and the Pt film 16 is grown on the growth substrate 11 and is stuck (or bonded) on the AlN epitaxial growth film that has been stuck (or bonded) on the Pt film 34 on the SOI substrate 33. Alternatively, in the first embodiment, the AlN epitaxial growth film is stuck (or bonded) on the PZT epitaxial growth film that has been stuck (or bonded) on the Pt film 34 on the SOI substrate 33. In contrast, in a second embodiment, the PZT epitaxial growth film is grown on an SOI substrate 50. The upper surface of the SOI substrate 50 is formed by a (100)-surface. Therefore, the PZT epitaxial growth film can be grown epitaxially on the SOI substrate 50 by a process similar to the process in the first embodiment.
First, as shown in
Subsequently, the individual piece of the AlN epitaxial growth film (upper-side piezoelectric element) made up of the monocrystalline AlN film 25 and the Pt film 26 is held by the stamp 80 as the holding member, and the individual piece of the AlN epitaxial growth film is peeled off by etching the SRO film 24 as the sacrificial layer and is moved onto and stuck (or bonded) on the PZT epitaxial growth film on the SOI substrate 50 being the device substrate as shown in
Thereafter, the manufacture of the piezoelectric film integrated device 200 shown in
In the second embodiment, the epitaxial growth film including the monocrystalline AlN film 25 is stuck on the Pt film 34 on the SOI substrate 50 having the epitaxially grown monocrystalline PZT film 15 thereon, by which a monocrystalline and high-performances piezoelectric film integrated device can be obtained similarly to the first embodiment.
In the second embodiment, alignment accuracy of the monocrystalline PZT film 15 increases compared to the first embodiment. Therefore, in the second embodiment, the acoustic oscillatory wave output performances increases compared to the first and third embodiments.
Except for the above-described features, the second embodiment is the same as the first embodiment.
In the first embodiment, the AlN epitaxial growth film is grown on the growth substrate 21, the PZT epitaxial growth film is grown on the growth substrate 11, and the PZT epitaxial growth film is stuck (or bonded) on the AlN epitaxial growth film that has been stuck (or bonded) on the Pt film 34 on the SOI substrate 33. Alternatively, in the first embodiment, the AlN epitaxial growth film is stuck (or bonded) on the PZT epitaxial growth film that has been stuck (or bonded) on the Pt film 34 on the SOI substrate 33. In contrast, in a third embodiment, the PZT epitaxial growth film is grown on an SOI substrate 60. The upper surface of the SOI substrate 60 is formed by a (111)-surface. Therefore, the AlN epitaxial growth film can be grown epitaxially on the SOI substrate 60 by a process similar to the process in the first embodiment.
First, as shown in
Subsequently, the individual piece of the PZT epitaxial growth film (upper-side piezoelectric element) made up of the monocrystalline PZT film 15 and the Pt film 16 is held by the stamp 80 as the holding member, and the individual piece of the PZT epitaxial growth film is peeled off by etching the SRO film 14 as the sacrificial layer and is moved onto and stuck (or bonded) on the AlN epitaxial growth film on the SOI substrate 60 being the device substrate as shown in
Thereafter, the manufacture of the piezoelectric film integrated device 300 shown in
In the third embodiment, the epitaxial growth film including the monocrystalline PZT film 15 is stuck (or bonded) on the AlN epitaxial growth film including the epitaxially grown monocrystalline AlN film 25 and the Pt film 26, by which a high-performances piezoelectric film integrated device 300 can be obtained by use of a plurality of monocrystalline piezoelectric films similarly to the first embodiment.
In the third embodiment, the alignment accuracy of the monocrystalline AlN film 25 increases compared to the first embodiment. Therefore, in the third embodiment, the acoustic oscillatory wave detection sensitivity and the S/N ratio increase compared to the first and second embodiments.
Except for the above-described features, the third embodiment is the same as the first or second embodiment.
A piezoelectric film integrated device 500 according to a first modification differs from the piezoelectric film integrated device 100 according to the first embodiment in which the epitaxial growth film stuck (or bonded) on the Pt film 34 is formed with the monocrystalline AlN film 25 and the Pt film 26 and the epitaxial growth film stuck (or bonded) on the Pt film 26 is formed with the monocrystalline PZT film 15 and the Pt film 16, in that the epitaxial growth film stuck (or bonded) on the Pt film 34 on the SOI substrate 33 is formed with a Pt film 126, the monocrystalline AlN film 25 and the Pt film 26 and the epitaxial growth film stuck (or bonded) on the Pt film 26 is formed with a Pt film 116, the monocrystalline PZT film 15 and the Pt film 16. Except for these features, the piezoelectric film integrated device 500 according to the first modification is the same as the piezoelectric film integrated device 100 according to the first embodiment.
Incidentally, it is also possible to use the epitaxial growth film formed with the Pt film 116, the monocrystalline PZT film 15 and the Pt film 16 (shown in
The piezoelectric film integrated devices 100, 200 and 300 and the acoustic oscillation sensors 400 according to the embodiments are usable not only for a distance sensor but also for other types of sensors such as a fingerprint sensor and a vein (pulse wave) sensor.
Further, with a piezoelectric film integrated device in which pairs of the monocrystalline PZT film 15 and the monocrystalline AlN film 25 are arranged in a matrix, a surface shape of the detection target object can be detected.
100, 100a, 200, 300, 500: piezoelectric film integrated device, 400: acoustic oscillation sensor, 11, 21: growth substrate (monocrystalline Si substrate), 15: monocrystalline PZT film (first monocrystalline piezoelectric film), 16: Pt film (electrode film), 14, 24: SRO film (orientation film), 25: monocrystalline AlN film (second monocrystalline piezoelectric film), 26: Pt film (electrode film), 31: SiO2 part, 32: monocrystalline Si part, 33, 50, 60: SOI substrate (substrate), 34: Pt film (electrode), 71, 72: cavity, 116: Pt film, 126: Pt film.
Number | Date | Country | Kind |
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2022-055955 | Mar 2022 | JP | national |