TW202019808A - Manufacturing method of micro fluid actuator - Google Patents
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本案關於一種微流體致動器之製造方法,尤指一種使用微機電半導體製程之微流體致動器之製造方法。This case relates to a method of manufacturing a microfluidic actuator, particularly a method of manufacturing a microfluidic actuator using a micro-electromechanical semiconductor manufacturing process.
目前於各領域中無論是醫藥、電腦科技、列印、能源等工業,產品均朝精緻化及微小化方向發展,其中微幫浦、噴霧器、噴墨頭、工業列印裝置等產品所包含之流體輸送結構為其關鍵技術。At present, in all fields of medicine, computer technology, printing, energy and other industries, products are developing towards refinement and miniaturization. Among them, micro pumps, sprayers, inkjet heads, industrial printing devices and other products are included Fluid delivery structure is its key technology.
隨著科技的日新月異,流體輸送結構的應用上亦愈來愈多元化,舉凡工業應用、生醫應用、醫療保健、電子散熱等等,甚至近來熱門的穿戴式裝置皆可見它的踨影,可見傳統的流體輸送結構已漸漸有朝向裝置微小化、流量極大化的趨勢。With the rapid development of technology, the application of fluid delivery structure is becoming more and more diversified. For example, industrial applications, biomedical applications, medical care, electronic heat dissipation, etc., and even the most popular wearable devices can be seen in its shadows. The traditional fluid delivery structure has gradually tended to miniaturize the device and maximize the flow rate.
於現有技術中,雖已有利用微機電製程製出一體成型之微型化流體輸送結構,但因存在著薄膜壓電層位移量過小的缺點,現有的微型化流體輸送結構常有作動流體壓縮比不足的問題,使得傳輸流量過小,是以,如何藉創新微型化結構突破其技術瓶頸,為發展之重要內容。In the prior art, although a micro-electromechanical process has been used to produce an integrally formed miniaturized fluid transport structure, the existing miniaturized fluid transport structure often has an actuating fluid compression ratio due to the shortcoming of the displacement of the thin film piezoelectric layer is too small The problem of insufficiency makes the transmission flow too small. Therefore, how to break through its technical bottleneck with innovative miniaturized structure is an important part of development.
本案之主要目的係提供一種微流體致動器之製造方法,以標準化微機電半導體製程製造,微流體致動器使用半導體薄膜製作,用以傳輸流體。因此,將薄膜腔體的深度控制在非常淺的範圍時,仍可增加微流體致動器作動時之流體壓縮比。The main objective of this case is to provide a method for manufacturing a microfluidic actuator, which is manufactured using a standardized micro-electromechanical semiconductor manufacturing process. The microfluidic actuator is manufactured using a semiconductor thin film to transmit fluid. Therefore, when the depth of the film cavity is controlled in a very shallow range, the fluid compression ratio when the microfluidic actuator is actuated can still be increased.
本案之一廣義實施態樣為一種微流體致動器之製造方法,包含以下步驟:1.提供一基板沉積一腔體層,該基板具有一第一表面及一第二表面,係透過一氧化材料沉積於該基板之該第一表面上,以形成該腔體層;2.該腔體層沉積一振動層,係透過一氮化材料沉積於該腔體層上,以形成該振動層;3.該振動層沉積蝕刻一致動層,係先透過一第一金屬材料沉積於該振動層上,以形成一下電極層,透過一壓電材料沉積於該下電極層上,以形成一壓電致動層,以及再透過一第二金屬材料沉積於該壓電致動層上,以形成一上電極層,最後透過蝕刻定義出該致動層;4.該基板蝕刻複數個流道,係透過蝕刻定義出該基板之一出口流道及一入口流道;5.該基板沉積一遮罩層蝕刻複數個連接流道,係先透過該氧化材料沉積於該基板之該第二表面上以及該出口流道與該入口流道內,以形成該遮罩層,再透過穿孔露出該基板,而該基板經低溫深蝕刻定義出一出流連接流道、複數個第一進流連接流道及一第二進流連接流道;6.該腔體層蝕刻一儲流腔室,係在該腔體層透過蝕刻定義出該儲流腔室,該儲流腔室與該出流連接流道、該複數個第一進流連接流道及該第二進流連接流道相連通;7.提供一孔板層,並蝕刻複數個流道口,該孔板層透過蝕刻定義出一出流道口以及一入流道口;8.該孔板層滾壓乾膜及微影製出一流道層之複數個通道,該孔板層先透過一乾膜材料滾壓於該孔板層上,以形成該流道層,再於該流道層透過微影製程於該流道層中定義出與該出流道口相連通之一出流通道、與該入流道口相連通之一入流通道以及複數個柱狀結構;以及9.覆晶對位及熱壓接合該流道層,該流道層係透過覆晶對位及熱壓接合該流道層於該基板之該第二表面,使該孔板層之該出流道口與該基板之該出口流道相連通,該流道層之該入流通道對應到該基板之該入口流道,以及該孔板層之該入流道口與該基板之該入口流道相連通,以構成該微流體致動器整體結構。A broad implementation aspect of this case is a method of manufacturing a microfluidic actuator, which includes the following steps: 1. Provide a substrate to deposit a cavity layer, the substrate having a first surface and a second surface, through an oxidized material Deposited on the first surface of the substrate to form the cavity layer; 2. the cavity layer is deposited with a vibrating layer, which is deposited on the cavity layer through a nitride material to form the vibrating layer; 3. the vibration The layer-deposition etching active layer is first deposited on the vibration layer through a first metal material to form a lower electrode layer, and deposited on the lower electrode layer through a piezoelectric material to form a piezoelectric actuation layer, And then deposited on the piezoelectric actuation layer through a second metal material to form an upper electrode layer, and finally the actuation layer is defined by etching; 4. The substrate is etched with a plurality of flow channels, which are defined by etching An outlet flow channel and an inlet flow channel of the substrate; 5. The substrate deposits a mask layer to etch a plurality of connecting flow channels, which are first deposited on the second surface of the substrate and the outlet flow channel through the oxide material And the inlet flow channel to form the mask layer, and then expose the substrate through the perforation, and the substrate is etched at a low temperature to define an outflow connection flow channel, a plurality of first inflow connection flow channels, and a second Inflow connection flow channel; 6. The cavity layer is etched a storage chamber, the storage layer is defined by etching in the cavity layer, the storage chamber and the outflow connection flow channel, the plurality of An inflow connection flow channel and the second inflow connection flow channel are connected; 7. Provide an orifice layer and etch a plurality of flow channel openings, the orifice layer defines an outflow channel opening and an inflow channel opening by etching; 8. The orifice layer rolls the dry film and lithography to produce a plurality of channels of the first channel layer. The orifice layer is first rolled on the orifice layer through a dry film material to form the flow channel layer, and then The flow channel layer defines a flow channel communicating with the flow channel opening, a flow channel communicating with the flow channel opening, and a plurality of columnar structures in the flow channel layer through a lithography process; and 9. Crystal alignment and thermocompression bonding the flow channel layer, the flow channel layer is through the flip chip alignment and thermocompression bonding the flow channel layer to the second surface of the substrate, so that the orifice layer of the flow channel opening and The outlet flow channel of the substrate is connected, the inflow channel of the flow channel layer corresponds to the inlet flow channel of the substrate, and the inlet channel opening of the orifice layer communicates with the inlet flow channel of the substrate to form The overall structure of the microfluidic actuator.
體現本案特徵與優點的一些典型實施例將在後段的說明中詳細敘述。應理解的是本案能夠在不同的態樣上具有各種的變化,其皆不脫離本案的範圍,且其中的說明及圖示在本質上當作說明之用,而非用以限制本案。Some typical embodiments embodying the features and advantages of this case will be described in detail in the description in the following paragraphs. It should be understood that this case can have various changes in different forms, and it does not deviate from the scope of this case, and the descriptions and illustrations therein are essentially used for explanation, not for limiting this case.
本案之微流體致動器用於輸送流體,請參閱第1圖,於本案實施例中,微流體致動器100包含有:一基板1a、一腔體層1b、一振動層1c、一下電極層1d、一壓電致動層1e、一上電極層1f、一孔板層1h以及一流道層1i,其製造方法如下步驟說明。The microfluidic actuator in this case is used to convey fluid. Please refer to FIG. 1. In the embodiment of this case, the
請參閱第2圖及第3A圖,如步驟S1所示,提供一基板沉積一腔體層,係透過一氧化材料沉積於基板1a之第一表面11a之上以形成腔體層1b。於本案實施例中,沉積製程可為一物理氣相沉積製程(PVD)、一化學氣相沉積製程(CVD)或兩者之組合,但不以此為限。於本案實施例中,基板1a為一矽基材,氧化材料為一二氧化矽材料,但不以此為限。Please refer to FIGS. 2 and 3A. As shown in step S1, a substrate is provided to deposit a cavity layer, which is deposited on the
請參閱第2圖及第3A圖,如步驟S2所示,腔體層沉積一振動層,係透過一氮化材料沉積於腔體層1b之上以形成振動層1c。於本案實施例中,氮化材料為一氮化矽材料,但不以此為限。Please refer to FIG. 2 and FIG. 3A. As shown in step S2, the cavity layer deposits a vibration layer, which is deposited on the
請參閱第2圖及第3B圖,如步驟S3所示,振動層沉積蝕刻一致動層,係先透過一第一金屬材料沉積於振動層1c上,以形成下電極層1d,再透過一壓電材料沉積於下電極層1d上,以形成壓電致動層1e,再透過一第二金屬材料沉積於壓電致動層1e上,以形成上電極層1f,復以蝕刻下電極層1d、壓電致動層1e及上電極層1f,以定義出所需求尺寸之一致動層M。於本案實施例中,第一金屬材料為一鉑金屬材料或一鈦金屬材料,但不以此為限。於本案實施例中,第二金屬材料為一金金屬材料或一鋁金屬材料,但不以此為限。值得注意的是,於本案實施例中,蝕刻製程可為一濕式蝕刻製程、一乾式蝕刻製程或兩者之組合,但不以此為限。Please refer to FIG. 2 and FIG. 3B. As shown in step S3, the vibrating layer is deposited and etched as the moving layer, which is first deposited on the vibrating
請參閱第2圖及第3C圖,如步驟S4所示,基板蝕刻複數個流道,係透過乾式蝕刻製程於基板1a之第二表面12a蝕刻以形成一出口流道13a以及一入口流道14a,且出口流道13a以及入口流道14a具有相同之蝕刻深度,且蝕刻深度為蝕刻至第一表面11a以及第二表面12a之間而不穿透第一表面11a。Please refer to FIGS. 2 and 3C. As shown in step S4, the substrate is etched with a plurality of flow channels, which are etched on the
請參閱第2圖、及第3D圖至第3F圖,如步驟S5所示,基板沉積一遮罩層蝕刻複數個連接流道,係先透過氧化材料沉積於基板1a之第二表面12a上以及出口流道13a與入口流道14a內以形成遮罩層1g,再透過一精密穿孔製程於出口流道13a內形成一第一流通孔11g、於入口流道14a內形成複數個第二流通孔12g以及一第三流通孔13g。於本案實施例中,第一流通孔11g之孔徑大於第三流通孔13g之孔徑、第三流通孔13g之孔徑大於每一複數個第二流通孔12g之孔徑,但不以此為限。第一流通孔11g、複數個第二流通孔12g以及第三流通孔13g之穿孔深度為至與基板1a接觸為止,使得基板1a得以露出。於本案實施例中,精密穿孔製程為一準分子雷射加工製程,但不以此為限。值得注意的是,由於第一流通孔11g、複數個第二流通孔12g以及第三流通孔13g分別具有一深度,若透過微影製程來成形會有對焦不易的問題,而準分子雷射加工製程無此問題存在。Please refer to FIG. 2 and FIGS. 3D to 3F. As shown in step S5, a mask layer is deposited on the substrate to etch a plurality of connection channels, which are first deposited on the
請參閱第2圖、第3F圖及第4圖,承上所述,於本案實施例中,成形第一流通孔11g、複數個第二流通孔12g以及第三流通孔13g後,透過低溫深蝕刻製程蝕刻基板1a對應於第一流通孔11g、複數個第二流通孔12g以及第三流通孔13g的部分,藉以形成基板1a之一出流連接流道15a、複數個第一進流連接流道16a以及一第二進流連接流道17a。出流連接流道15a為沿第一流通孔11g蝕刻至與腔體層1b接觸為止所構成,複數個第一進流連接流道16a為分別沿複數個第二流通孔12g蝕刻至與腔體層1b接觸為止所構成,以及第二進流連接流道17a為沿第三流通孔13g蝕刻至與腔體層1b接觸為止所構成。於本案實施例中,低溫深蝕刻製程為一深反應性離子蝕刻(BOSCH Process),但不以此為限。Please refer to Figure 2, Figure 3F and Figure 4, as mentioned above, in the embodiment of the present invention, after forming the
請參閱第2圖、第3E圖及第6A圖,承上所述,於本案實施例中,遮罩層1g利用準分子雷射加工製程形成第一流通孔11g、複數個第二流通孔12g以及第三流通孔13g時,為了避免穿孔位置或穿孔角度的偏差,於出口流道13a及入口流道14a之側壁特予保留一緩衝距離e。此外,採用深反應性離子蝕刻製程(BOSCH Process)只對於基板1a之矽材料做蝕刻,因此利用準分子雷射加工製程在基板1a上留有一過蝕深度t,有利於基板1a能確實且容易從過蝕深度t去蝕刻形成出流連接流道15a、複數個第一進流連接流道16a以及第二進流連接流道17a。於本案實施例中,出流連接流道15a、複數個第一進流連接流道16a以及第二進流連接流道17a之最小孔徑為5~50微米(μm),並且孔徑大小視流體性質而定。接著,請參閱第3F圖及第6B圖,出流連接流道15a、每一個第一進流連接流道16a以及第二進流連接流道17a具有一穿孔深度d以及一穿孔孔徑s,所形成之連接流道之深寬比d/s可達40,在實施此加工製程中考量適當連接流道之深寬比d/s可避免加工所產生的高溫影響後端壓電材料之極性分布,造成退極化反應。Please refer to FIG. 2, FIG. 3E and FIG. 6A. As mentioned above, in the embodiment of the present invention, the
請參閱第2圖、第3G圖,如步驟S6所示,腔體層蝕刻一儲流腔室,係腔體層1b透過一濕蝕刻製程於腔體層1b內部蝕刻出一儲流腔室11b。意即,透過蝕刻液由第一流通孔11g、複數個第二流通孔12g以及第三流通孔13g流入,經由出流連接流道15a、複數個第一進流連接流道16a以及第二進流連接流道17a流至腔體層1b,進而蝕刻並釋放移除腔體層1b之部分,藉以定義出儲流腔室11b。藉此,儲流腔室11b與出流連接流道15a、複數個第一進流連接流道16a以及第二進流連接流道17a相連通。於本案實施例中,濕蝕刻製程利用氫氟酸(HF)蝕刻液蝕刻腔體層1b,但不以此為限。於本案實施例中,腔體層1b厚度為1~5微米(μm),但不以此為限。值得注意的是,透過濕時刻製程成形儲流腔室11b時,遮罩層1g亦會一併被移除。完成儲流腔室11b成形與移除遮罩層1g後,基板1a之出口流道13a與出流連接流道15a相連通、入口流道14a與複數個第一進流連接流道16a以及第二進流連接流道17a相連通。Please refer to FIG. 2 and FIG. 3G. As shown in step S6, the cavity layer etches a reservoir chamber. The
請參閱第3G圖及第6C圖,於本案實施例中,濕蝕刻製程通常為等向性蝕刻,於本案實施例中,在蝕刻儲液腔室11b時,儲液腔室11b具有一腔體深度r,其等同於腔體層1b之厚度,而濕蝕刻所產生的側蝕距離為r',因此腔體深度r與側蝕距離r'相等,即為一等向性蝕刻。又由於出流連接流道15a、每一個第一進流連接流道16a以及第二進流連接流道17a的孔徑僅介於5~50微米(μm)之間,而腔體深度r僅介於1~5微米(μm)之間,因此在蝕刻儲液腔室11b時需要一過度蝕刻,以加長蝕刻時間才能將未被蝕刻之餘料移除乾淨。於本案實施例中,以此進行濕蝕刻製程形成儲液腔室11b時,會產生一過蝕距離L,並且過蝕距離L大於側蝕距離為r',才能使儲液腔室11b範圍內的二氧化矽材料完全被移除。Please refer to FIG. 3G and FIG. 6C. In the embodiment of the present invention, the wet etching process is usually isotropic etching. In the embodiment of the present invention, when etching the
請參閱第2圖、第3H圖及第3I圖,如步驟S7所示,提供一孔板層蝕刻複數個流道口,係透過蝕刻製程於孔板層1h蝕刻出一出流道口11h以及一入流道口12h。於本案實施例中,孔板層1h之蝕刻製程可為一濕蝕刻製程、一乾蝕刻製程或二者之組合,但不以此為限。於本案實施例中,孔板層1h為一不銹鋼材料或一玻璃材料,但不以此為限。Please refer to FIG. 2, FIG. 3H and FIG. 3I, as shown in step S7, a plurality of flow channel openings are provided by etching an orifice layer, an
請參閱第2圖、第3J圖、第3K圖及第5圖,如步驟S8所示,孔板層滾壓乾膜及微影製出一流道層之複數個通道,係先透過一乾膜材料滾壓於孔板層1h之上以形成流道層1i,再透過微影製程於流道層1i形成一出流通道11i、一入流通道12i以及複數個柱狀結構13i,且構成出流通道11i與孔板層1h之出流道口11h相連通,以及構成入流通道12i與孔板層1h之入流道口12h相連通。於本案實施例中,複數個柱狀結構13i交錯排列形成於入流通道12i內(如第5圖),用以過濾流體中之雜質。於本案實施例中,乾膜材料為一感光型高分子乾膜,但不以此為限。Please refer to Figure 2, Figure 3J, Figure 3K and Figure 5, as shown in step S8, the orifice layer rolls the dry film and the lithography to produce a plurality of channels of the first-class layer, first through a dry film material Rolling on the
請回到第1圖及第2圖,如步驟S9所示,覆晶對位及熱壓接合流道層,係透過一覆晶對位製程以及一熱壓製程將流道層1i接合於基板1a之第二表面12a,形成本案之微流體致動器100。藉此,孔板層1h之出流道口11h藉由流道層1i之出流通道11i與基板1a之出口流道13a相連通;以及孔板層1h之入流道口12h藉由流道層1i之入流通道12i與基板1a之入口流道14a相連通。Please return to FIG. 1 and FIG. 2, as shown in step S9, the flip-chip alignment and hot-press bonding channel layer is to join the
值得注意的是,由於第三流通孔13g之孔徑大於每一複數個第二流通孔12g之孔徑,複數個第一進流連接流道16a係分別對應複數個第二流通孔12g的位置設置,以及第二進流連接流道17a係對應第三流通孔13g的位置設置,因此第二進流連接流道17a之孔徑大於每一複數個第一進流連接流道16a之孔徑。再者,第二進流連接流道17a設置在相對於儲液腔室11b的邊緣部分,因此第二進流連接流道17a的設置有助於儲液腔室11b的濕蝕刻製程。It is worth noting that since the diameter of the
請參閱第7A圖及第7B圖,於本案實施例中,微流體致動器100的具體作動方式,係提供具有相反相位電荷之驅動電源至上電極層1f以及下電極層1d,以驅動並控制振動層1c產生上下位移。如第7A圖所示,當施加正電壓給上電極層1f以及負電壓給下電極層1d時,壓電致動層1e帶動振動層1c朝向遠離基板1a的方向位移,藉此,外部流體由孔板層1h之入流道口12h被吸入至微流體致動器100內,而進入微流體致動器100內的流體接著依序通過流道層1i之入流通道12i、基板1a之入口流道14a以及基板1a之複數個第一進流連接流道16a與第二進流連接流道17a,最後匯集於腔體層1b之儲流腔室11b內。如第7B圖所示,接著轉換上電極層1f以及下電極層1d之電性,施加負電壓給上電極層1f以及正電壓給下電極層1d,如此振動層1c朝向靠近基板1a的方向位移,使儲流腔室11b內體積受振動層1c壓縮,致使匯集於儲流腔室11b內的流體得以依序通過基板1a之出流連接流道15a、基板1a之出口流道13a以及流道層1i之出流通道11i後自孔板層1h之出流道口11h排出於微流體致動器100外,完成流體之傳輸。Please refer to FIGS. 7A and 7B. In the embodiment of the present invention, the specific operation mode of the
值得注意的是,當微流體致動器100吸入外部流體時,部分外部流體會由孔板層1h之出流道口11h被吸入微流體致動器100內,但由於基板1a之出流連接流道15a對應到壓電致動層1c的位置並非位移量最大之區域,所以外部流體自出流道口11h被吸入的量相對較少。當微流體致動器100排出流體時,流道層1i之複數個柱狀結構13i對於回流之流體會產生阻尼效果,此外,基板1a之第二進流連接流道17a對應到壓電致動層1c位移量最小的邊緣位置。所以流體自入流道口12h被排出的量相對較少。It is worth noting that when the
再者,值得注意的是,基板1a之複數個第一進流連接流道16a流通阻力過大的問題可藉由調整電壓波形、拉長微流體致動器100吸入外部流體的作動時間而改善。Furthermore, it is worth noting that the problem of excessive flow resistance of the plurality of first
本案提供一微流體致動器之製造方法,主要以微機電半導體製程來完成的,並且藉由施加不同相位電荷之驅動電源於上電極層以及下電極層,使得振動層產生上下位移,進而達到流體傳輸。如此,微流體致動器能夠在極淺之腔室結構中克服靜電力,達到傳輸流體之實施可行性及在極微型化結構中產生極大的傳輸效率,極具產業之利用價值,爰依法提出申請。This case provides a method for manufacturing a microfluidic actuator, which is mainly completed by a micro-electromechanical semiconductor process, and by applying driving power of different phase charges to the upper electrode layer and the lower electrode layer, the vibrating layer is displaced up and down, and then reached Fluid transmission. In this way, the microfluidic actuator can overcome the electrostatic force in a very shallow chamber structure, achieve the feasibility of transmitting fluid and produce a very large transmission efficiency in a very miniaturized structure, and has great industrial use value. Application.
本案得由熟知此技術之人士任施匠思而為諸般修飾,然皆不脫如附申請專利範圍所欲保護者。This case may be modified by any person familiar with the technology, such as Shi Shisi, but none of them are as protected as the scope of the patent application.
100:微流體致動器1a:基板11a:第一表面12a:第二表面13a:出口流道14a:入口流道15a:出流連接流道16a:第一進流連接流道17a:第二進流連接流道1b:腔體層11b:儲流腔室1c:振動層1d:下電極層1e:壓電致動層1f:上電極層1g:遮罩層11g:第一流通孔12g:第二流通孔13g:第三流通孔1h:孔板層11h:出流道口12h:入流道口1i:流道層11i:出流通道12i:入流通道13i:柱狀結構e:緩衝距離t:過蝕深度d:穿孔深度s:穿孔孔徑r:腔體深度r':側蝕距離L:過蝕距離M:致動層S1~S9:微流體致動器之製造方法之步驟100:
第1圖為本案微流體致動器之剖面示意圖。 第2圖為本案微流體致動器之製造方法之流程示意圖。 第3A圖至第3K圖為本案微流體致動器之製造步驟分解示意圖。 第4圖為本案微流體致動器之俯視示意圖。 第5圖為本案微流體致動器之仰視示意圖。 第6A圖至第6C圖為本案為流體致動器之進流連接流道之蝕刻步驟分解示意圖。 第7A圖至第7B圖為本案微流體致動器之作動示意圖。Figure 1 is a schematic cross-sectional view of the microfluidic actuator of this case. Fig. 2 is a schematic flow chart of the manufacturing method of the microfluidic actuator in this case. Figures 3A to 3K are exploded schematic diagrams of the manufacturing steps of the microfluidic actuator in this case. Figure 4 is a schematic top view of the microfluidic actuator of this case. Figure 5 is a schematic diagram of a bottom view of the microfluidic actuator of the present case. FIGS. 6A to 6C are exploded schematic diagrams of the etching steps of the inflow connecting flow channel of the fluid actuator in this case. Figures 7A to 7B are schematic diagrams of the operation of the microfluidic actuator in this case.
S1~S9:微流體致動器之製造方法之步驟 S1~S9: Steps of manufacturing method of microfluidic actuator
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