TWI669498B - 氣體感測器及其製造方法 - Google Patents
氣體感測器及其製造方法 Download PDFInfo
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- TWI669498B TWI669498B TW108102450A TW108102450A TWI669498B TW I669498 B TWI669498 B TW I669498B TW 108102450 A TW108102450 A TW 108102450A TW 108102450 A TW108102450 A TW 108102450A TW I669498 B TWI669498 B TW I669498B
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- gas sensor
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- 238000004519 manufacturing process Methods 0.000 title claims description 13
- 239000010432 diamond Substances 0.000 claims abstract description 71
- 229910003460 diamond Inorganic materials 0.000 claims abstract description 71
- 239000005300 metallic glass Substances 0.000 claims abstract description 65
- 239000000758 substrate Substances 0.000 claims abstract description 37
- 239000002086 nanomaterial Substances 0.000 claims abstract description 29
- 239000007789 gas Substances 0.000 claims description 147
- 230000004044 response Effects 0.000 claims description 45
- 239000001257 hydrogen Substances 0.000 claims description 39
- 229910052739 hydrogen Inorganic materials 0.000 claims description 39
- XLOMVQKBTHCTTD-UHFFFAOYSA-N Zinc monoxide Chemical compound [Zn]=O XLOMVQKBTHCTTD-UHFFFAOYSA-N 0.000 claims description 36
- UFHFLCQGNIYNRP-UHFFFAOYSA-N Hydrogen Chemical compound [H][H] UFHFLCQGNIYNRP-UHFFFAOYSA-N 0.000 claims description 26
- 238000000034 method Methods 0.000 claims description 24
- 239000011787 zinc oxide Substances 0.000 claims description 18
- 150000002431 hydrogen Chemical group 0.000 claims description 15
- CSCPPACGZOOCGX-UHFFFAOYSA-N Acetone Chemical compound CC(C)=O CSCPPACGZOOCGX-UHFFFAOYSA-N 0.000 claims description 14
- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 claims description 11
- 238000000151 deposition Methods 0.000 claims description 10
- 239000010949 copper Substances 0.000 claims description 8
- RYGMFSIKBFXOCR-UHFFFAOYSA-N Copper Chemical compound [Cu] RYGMFSIKBFXOCR-UHFFFAOYSA-N 0.000 claims description 6
- 229910052802 copper Inorganic materials 0.000 claims description 6
- 230000008021 deposition Effects 0.000 claims description 6
- 239000002071 nanotube Substances 0.000 claims description 6
- BQCADISMDOOEFD-UHFFFAOYSA-N Silver Chemical compound [Ag] BQCADISMDOOEFD-UHFFFAOYSA-N 0.000 claims description 3
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- 239000004332 silver Substances 0.000 claims description 3
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- 239000002184 metal Substances 0.000 description 7
- XKRFYHLGVUSROY-UHFFFAOYSA-N Argon Chemical compound [Ar] XKRFYHLGVUSROY-UHFFFAOYSA-N 0.000 description 6
- 230000007547 defect Effects 0.000 description 6
- 238000011084 recovery Methods 0.000 description 6
- 230000005855 radiation Effects 0.000 description 5
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- 230000008859 change Effects 0.000 description 4
- 229910044991 metal oxide Inorganic materials 0.000 description 4
- 150000004706 metal oxides Chemical class 0.000 description 4
- VNWKTOKETHGBQD-UHFFFAOYSA-N methane Chemical compound C VNWKTOKETHGBQD-UHFFFAOYSA-N 0.000 description 4
- XUIMIQQOPSSXEZ-UHFFFAOYSA-N Silicon Chemical compound [Si] XUIMIQQOPSSXEZ-UHFFFAOYSA-N 0.000 description 3
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- 229910052786 argon Inorganic materials 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 230000005264 electron capture Effects 0.000 description 3
- 238000001755 magnetron sputter deposition Methods 0.000 description 3
- 238000000623 plasma-assisted chemical vapour deposition Methods 0.000 description 3
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- 229910052710 silicon Inorganic materials 0.000 description 3
- 239000010703 silicon Substances 0.000 description 3
- 239000010409 thin film Substances 0.000 description 3
- 239000010936 titanium Substances 0.000 description 3
- IJGRMHOSHXDMSA-UHFFFAOYSA-N Atomic nitrogen Chemical compound N#N IJGRMHOSHXDMSA-UHFFFAOYSA-N 0.000 description 2
- 229910045601 alloy Inorganic materials 0.000 description 2
- 239000000956 alloy Substances 0.000 description 2
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- 230000003287 optical effect Effects 0.000 description 2
- 238000000103 photoluminescence spectrum Methods 0.000 description 2
- BASFCYQUMIYNBI-UHFFFAOYSA-N platinum Chemical compound [Pt] BASFCYQUMIYNBI-UHFFFAOYSA-N 0.000 description 2
- 230000006798 recombination Effects 0.000 description 2
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- 229910052719 titanium Inorganic materials 0.000 description 2
- 229910052726 zirconium Inorganic materials 0.000 description 2
- 229910018575 Al—Ti Inorganic materials 0.000 description 1
- RTAQQCXQSZGOHL-UHFFFAOYSA-N Titanium Chemical compound [Ti] RTAQQCXQSZGOHL-UHFFFAOYSA-N 0.000 description 1
- QCWXUUIWCKQGHC-UHFFFAOYSA-N Zirconium Chemical compound [Zr] QCWXUUIWCKQGHC-UHFFFAOYSA-N 0.000 description 1
- ZOIORXHNWRGPMV-UHFFFAOYSA-N acetic acid;zinc Chemical compound [Zn].CC(O)=O.CC(O)=O ZOIORXHNWRGPMV-UHFFFAOYSA-N 0.000 description 1
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 1
- 239000012300 argon atmosphere Substances 0.000 description 1
- 239000012298 atmosphere Substances 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- 230000002238 attenuated effect Effects 0.000 description 1
- UBAZGMLMVVQSCD-UHFFFAOYSA-N carbon dioxide;molecular oxygen Chemical compound O=O.O=C=O UBAZGMLMVVQSCD-UHFFFAOYSA-N 0.000 description 1
- 238000007084 catalytic combustion reaction Methods 0.000 description 1
- 239000002800 charge carrier Substances 0.000 description 1
- 239000008367 deionised water Substances 0.000 description 1
- 229910021641 deionized water Inorganic materials 0.000 description 1
- 238000003795 desorption Methods 0.000 description 1
- 239000000428 dust Substances 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 238000002474 experimental method Methods 0.000 description 1
- 230000006870 function Effects 0.000 description 1
- 238000001027 hydrothermal synthesis Methods 0.000 description 1
- 239000012535 impurity Substances 0.000 description 1
- 230000007774 longterm Effects 0.000 description 1
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- 229910052757 nitrogen Inorganic materials 0.000 description 1
- 231100000956 nontoxicity Toxicity 0.000 description 1
- 230000009965 odorless effect Effects 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 239000002957 persistent organic pollutant Substances 0.000 description 1
- 238000005424 photoluminescence Methods 0.000 description 1
- 229910052697 platinum Inorganic materials 0.000 description 1
- 239000002861 polymer material Substances 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 239000010980 sapphire Substances 0.000 description 1
- 229910052594 sapphire Inorganic materials 0.000 description 1
- 239000011265 semifinished product Substances 0.000 description 1
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N silicon dioxide Inorganic materials O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 1
- 230000003595 spectral effect Effects 0.000 description 1
- 238000004528 spin coating Methods 0.000 description 1
- 239000013077 target material Substances 0.000 description 1
- 238000012360 testing method Methods 0.000 description 1
- XOLBLPGZBRYERU-UHFFFAOYSA-N tin dioxide Chemical compound O=[Sn]=O XOLBLPGZBRYERU-UHFFFAOYSA-N 0.000 description 1
- 229910001887 tin oxide Inorganic materials 0.000 description 1
- 238000012546 transfer Methods 0.000 description 1
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Chemical compound O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 1
- 239000011701 zinc Substances 0.000 description 1
- 239000004246 zinc acetate Substances 0.000 description 1
- -1 zinc oxide Chemical class 0.000 description 1
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Abstract
一種氣體感測器,包括基材、金屬玻璃薄膜、超奈米晶鑽石層及感測結構。金屬玻璃薄膜形成於基材上;超奈米晶鑽石層局部覆蓋金屬玻璃薄膜;感測結構包括形成於超奈米晶鑽石層上之種子層及形成於種子層上之複數奈米結構。
Description
本發明係關於一種氣體感測器,尤指一種應用超奈米晶鑽石材料之氣體感測器。本發明更包括該氣體感測器之製造方法。
氣體感測器用於感測大氣中之特定氣體,例如氫氣、氧氣、二氧化碳或其他有害氣體等。由於大部分之氣體無色無味,無法直接以人體肉眼或嗅覺予以辨識,因此必須利用氣體感測器來進行感測。氣體感測器之感測原理主要藉由感測特定氣體時產生對應之電性參數變化(例如電壓、電流、電阻、電導率等),進而監測其變化程度以判斷該特定氣體之濃度。
目前氣體感測器依設計不同可區分為半導體式、觸媒燃燒式、電化學式等感測器類型。以半導體式氣體感測器為例,大多採用金屬氧化物(例如氧化鋅、氧化錫等)製成主要感測結構,藉由感測結構吸附氣體後所產生電阻值變化導出感測訊號。然而金屬氧化物所具備之高電阻率、有限之工作溫度範圍將影響氣體感測器之反應時間及靈敏度,並限制其氣體感測選擇性。
因此,如何能研究出一種能改善前述問題之氣體感測器,實為一值得研究之課題。
本發明之目的在於提供一種氣體感測器,藉由結合超奈米晶鑽石材料及金屬玻璃材料而能有效提高感測器之感測靈敏度。
為達上述目的,本發明之氣體感測器包括基材、金屬玻璃薄膜、超奈米晶鑽石層及感測結構。金屬玻璃薄膜形成於基材上;超奈米晶鑽石層局部覆蓋金屬玻璃薄膜;感測結構包括形成於超奈米晶鑽石層上之種子層及形成於種子層上之複數奈米結構。
在本發明之一實施例中,超奈米晶鑽石層於金屬玻璃薄膜上之覆蓋率為50%至90%。
在本發明之一實施例中,金屬玻璃薄膜包括銅基金屬玻璃薄膜或銀基金屬玻璃薄膜。
在本發明之一實施例中,各奈米結構為氧化鋅奈米管或氧化鋅奈米柱。
在本發明之一實施例中,氣體感測器更包括形成於感測結構上之電極層。
在本發明之一實施例中,氣體感測器可感測位於大氣溫度下之氣體。
在本發明之一實施例中,氣體感測器為氫氣感測器、氨氣感測器或丙酮感測器。
在本發明之一實施例中,當氣體為氫氣,氣體感測器可感測之氫氣濃度範圍自10ppm至500ppm,且氣體感測器之感測器響應高於34%。
在本發明之一實施例中,當氫氣濃度為100ppm,氣體感測器之感測器響應衰減於60天內小於1%。
本發明之氣體感測器製造方法包括以下步驟:提供一基材;於基材上形成金屬玻璃薄膜;於金屬玻璃薄膜上沉積超奈米晶鑽石層,其中超奈米晶鑽石層局部覆蓋金屬玻璃薄膜;以及於超奈米晶鑽石層上形成感測結構。
在本發明之一實施例中,氣體感測器製造方法更包括:於感測結構上形成電極層。
在本發明之一實施例中,超奈米晶鑽石層於金屬玻璃薄膜上之覆蓋率可藉由控制超奈米晶鑽石層之沉積時間予以調整。
200‧‧‧氣體感測器
210‧‧‧基材
220‧‧‧金屬玻璃薄膜
230‧‧‧超奈米晶鑽石層
240‧‧‧感測結構
241‧‧‧種子層
242‧‧‧奈米結構
250‧‧‧電極層
S1~S5、S41~S42‧‧‧步驟
A、B‧‧‧對照組
C‧‧‧實驗組
圖1為本發明之氣體感測器之結構示意圖。
圖2為本發明之氣體感測器製造方法之流程圖。
圖3為本發明之氣體感測器製造方法之各步驟對應結構示意圖。
圖4為分別量測本發明之氣體感測器與不同對照組之氫氣濃度與感測器響應關係之示意圖。
圖5為分別量測本發明之氣體感測器與不同對照組之光致發光光譜之示意圖
圖6為本發明之氣體感測器暴露於氫氣環境下之響應曲線之示意圖。
圖7為本發明之氣體感測器暴露於不同氣體環境下之感測器響應之示意圖。
圖8為本發明之氣體感測器一定時間內持續暴露於氫氣環境下之響應曲線之示意圖。
圖9為本發明之氣體感測器長期感測氫氣之響應曲線之示意圖。
由於各種態樣與實施例僅為例示性且非限制性,故在閱讀本說明書後,具有通常知識者在不偏離本發明之範疇下,亦可能有其他態樣與實施例。根據下述之詳細說明與申請專利範圍,將可使該等實施例之特徵及優點更加彰顯。
於本文中,用語「包括」、「具有」或其他任何類似用語意欲涵蓋非排他性之包括物。舉例而言,含有複數要件的元件或結構不僅限於本文所列出之此等要件而已,而是可以包括未明確列出但卻是該元件或結構通常固有之其他要件。
請先參考圖1為本發明之氣體感測器之結構示意圖。本發明之氣體感測器200如圖1所示,氣體感測器200包括基材210、金屬玻璃薄膜220、超奈米晶鑽石層(ultrananocrystalline diamond layer)230及感測結構240。
在本發明之一實施例中,基材210可以是矽晶片,但也可採用IIIV族半導體、玻璃、石英、藍寶石等材料製成,更可採用塑膠或其他高分子材料製成,端視需求不同來選擇基材210之材料,不以本實施例為限。
金屬玻璃薄膜220形成於基材210上,也就是說,金屬玻璃薄膜220形成於基材210之一側。金屬玻璃薄膜220係以具有非晶結構之金屬玻璃材料構成,而所述非晶結構定義為材料中原子無規則排列之結構,且金屬玻璃薄膜220具有無晶界缺陷、良好機械性能、低電子散射及低漏電流等特性。在本發明之一實施例中,金屬玻璃薄膜220包括銅基金屬玻璃薄膜或銀基金屬玻璃薄膜,但本發明不以此為限。舉例來說,銅基金屬玻璃薄膜可包括銅、鋯、鋁及鈦等元素成分,例如Cu-Zr-Al-Ti合金(Cu:47 at%、Zr:42 at%、Al:7 at%及Ti:4 at%),
但銅基金屬玻璃薄膜亦可採用其他合金成分,並不以此為限。在本發明之一實施例中,金屬玻璃薄膜220之厚度約為5-20nm,但本發明不以此為限。
超奈米晶鑽石層230形成於金屬玻璃薄膜220上,也就是說,超奈米晶鑽石層230形成於金屬玻璃薄膜220與基材210接觸之相對側,為位於金屬玻璃薄膜220之一側之薄膜層。超奈米晶鑽石層230係以超奈米晶鑽石材料構成,且超奈米晶鑽石層230僅局部覆蓋金屬玻璃薄膜220。其中超奈米晶鑽石層230包括奈米級結構缺陷,使得超奈米晶鑽石層230並不會完全覆蓋住金屬玻璃薄膜220,前述奈米級結構缺陷可以是超奈米晶鑽石層230在晶粒成長過程中由於氫氣將鑽石之sp3鍵結斷鍵所形成。舉例來說,超奈米晶鑽石層230因為是由複數極細微之晶粒所構成,每個晶粒大小約3-5nm且彼此具有不同之原子排列方向,使得相鄰二晶粒之間形成前述奈米級結構缺陷,即所謂晶界。藉由複數晶粒所形成之晶界,使得超奈米晶鑽石層230具有非常高之晶界濃度(~10%)。然而,本發明並不以此為限,舉例來說,前述奈米級結構缺陷更可包括相鄰二晶粒間之位錯或其他形式之缺陷等。在本發明之一實施例中,超奈米晶鑽石層230之厚度約為10-50nm,但本發明不以此為限。
此外,在本發明之一實施例中,超奈米晶鑽石層230於金屬玻璃薄膜220上之覆蓋率約為50%至90%,但本發明不以此為限。藉由基材210、金屬玻璃薄膜220及超奈米晶鑽石層230之結合,以作為氣體感測器200之基底,並提供感測結構240較佳之成型環境。其中,藉由金屬玻璃薄膜220及超奈米晶鑽石層230之結構配置,配合超奈米晶鑽石層230之奈米級結構缺陷,使得超奈米晶鑽石層230能提供較佳電子捕獲效果,並能提高導電率,有助於延長電荷載體壽
命並減少載體傳輸時間。據此,本發明之氣體感測器200更能有效增加氣體感測器之感測效果。
感測結構240形成於超奈米晶鑽石層230上,也就是說,感測結構240形成於超奈米晶鑽石層230與金屬玻璃薄膜220接觸之相對側。感測結構240包括種子層241及複數奈米結構242,其中種子層241形成於超奈米晶鑽石層230上,且複數奈米結構242形成於種子層241上。在本發明之一實施例中,感測結構240包括金屬氧化物,例如氧化鋅,其具有成本低廉、無毒性、穩定性高等優點,但本發明不以此為限。
複數奈米結構242於種子層241上均勻地排列,且任意相鄰二奈米結構242之間保持間距。在本發明之一實施例中,各奈米結構242可為氧化鋅奈米管或氧化鋅奈米柱。氧化鋅奈米管或氧化鋅奈米柱會因為材料本身之氧空缺(oxygen vacancy)而相較於其他材料產生較多缺陷,使得各奈米結構242能提供較佳電子捕獲能力。各奈米結構242實質上垂直設置於種子層241之表面,且各奈米結構242之一端連接種子層241。在本發明之一實施例中,各奈米結構242之直徑平均約為100nm,且各奈米結構242之高度約為2-3μm。
據此,感測結構240可藉由複數奈米結構242之設置提供大範圍之感測面積,且氣體可通過複數奈米結構242之間隙而易於被複數奈米結構242之表面吸附,進而達到感測效果。
此外,在本發明之一實施例中,氣體感測器200更包括電極層250。此電極層250形成於感測結構240上,舉例來說,電極層250會形成於各奈米結構242與種子層241彼此連接之相對端,但電極層250亦可視設計需求而改變其設置位置。此處電極層250可採用一指叉式電極,但本發明不以此為限。
以下請一併參考圖2及圖3。圖2為本發明之氣體感測器製造方法之流程圖,圖3為本發明之氣體感測器製造方法之各步驟對應結構示意圖。如圖2及圖3所示,本發明之氣體感測器製造方法主要包括步驟S1至步驟S4。以下將詳細說明該方法之各個步驟:
步驟S1:提供一基材。
首先,依據本發明之氣體感測器200之使用需求,提供適合作為基底之基材210。此處基材210可以是預先製備好具有固定尺寸規格之片狀或塊狀材料,以下基材210以矽晶片為例加以說明,但本發明不以此為限。作為基材210之矽晶片可先執行清洗及乾燥製程以去除表面灰塵或有機汙染物。
步驟S2:於基材上形成金屬玻璃薄膜。
於前述步驟S1提供基材210後,接著於基材210之一側形成金屬玻璃薄膜220。在本發明之一實施例中,金屬玻璃薄膜220可以利用金屬玻璃材料製成之靶材(例如,在本發明之一實施例中,採用Cu47Zr42Al7Ti4之合金化靶材)經由射頻磁控濺鍍(radio frequency magnetron sputtering)製程濺鍍於基材210之一側。前述射頻磁控濺鍍濺鍍製程是採用射頻磁控濺鍍系統,在保持基礎壓力約為1.0*10-6mTorr及工作壓力約為3mTorr、濺鍍距離約為10cm且存在於氬氣環境之條件下,以金屬玻璃材料製成之靶材對基材210之一側執行濺鍍。其中,氬氣是以20sccm之流速導入前述濺鍍製程環境內。此外,為了保持金屬玻璃材料於基材210上之濺鍍均勻性,於前述濺鍍製程中,基材210會以20rpm之轉速旋轉。
步驟S3:於金屬玻璃薄膜上沉積超奈米晶鑽石層,其中超奈米晶鑽石層局部覆蓋金屬玻璃薄膜。
於前述步驟S2形成金屬玻璃薄膜220後,接著於金屬玻璃薄膜220上沉積超奈米晶鑽石層230。已形成金屬玻璃薄膜220之基材210同樣可先執行另一清洗及乾燥製程以去除黏附於表面之異物或雜質。在本發明之一實施例中,超奈米晶鑽石層230可以經由微波電漿增強化學氣相沉積(microwave plasma-enhanced chemical vapor deposition,MPECVD)製程,以氫氣、甲烷及氬氣之混合氣體所組成之電漿(例如,在本發明之一實施例中,採用組成為2%氫氣、8%甲烷及90%氬氣之電漿)於金屬玻璃薄膜220之表面(即金屬玻璃薄膜220與基材10接觸之相對側)沉積形成超奈米晶鑽石薄膜,以作為超奈米晶鑽石層230。前述微波電漿增強化學氣相沉積製程是採用微波電漿增強化學氣相沉積系統,在保持壓力約為60Torr、電漿微波功率約為1200W及沉積時間約7.5min之條件下,執行超奈米晶鑽石層230之沉積。
由於超奈米晶鑽石層230僅局部覆蓋金屬玻璃薄膜220(在本發明之一實施例中,超奈米晶鑽石層230於金屬玻璃薄膜220上之覆蓋率為50%至90%),於步驟S3中,超奈米晶鑽石層230於金屬玻璃薄膜220上之覆蓋率可藉由控制超奈米晶鑽石層230之沉積時間予以調整,例如沉積時間可為5~10min,但本發明不以此為限。
步驟S4:於超奈米晶鑽石層上形成感測結構。
於前述步驟S3形成超奈米晶鑽石層230後,接著於超奈米晶鑽石層230上形成感測結構240。在本發明之一實施例中,於步驟S4中更包括步驟S41及步驟S42,以下將針對步驟S41及步驟S42進一步說明。
步驟S41:於超奈米晶鑽石層上形成種子層。
於前述步驟S3形成超奈米晶鑽石層230後,首先於超奈米晶鑽石層230上形成感測結構240之種子層241。在本發明之一實施例中,利用包含氧化鋅之種子層材料,以旋轉塗佈方式於超奈米晶鑽石層230之表面(即超奈米晶鑽石層230與金屬玻璃薄膜220接觸之相對側)形成種子層241。其中,為了提高種子層241之結晶度,可針對已形成之種子層241執行退火製程。此處退火製程是將種子層241於氮氣環境下以350℃之固定溫度下靜置一段時間,然而退火製程所需之固定溫度及時間可隨需求而調整,本發明不以此為限。
步驟S42:於種子層上形成複數奈米結構。
於前述步驟S41形成種子層241後,於種子層241之表面(即種子層241與超奈米晶鑽石層230金屬接觸之相對側)形成感測結構240之複數奈米結構242。在本發明之一實施例中,複數奈米結構22是利用水熱法,將前述已形成種子層241之氣體感測器200半成品浸入包括乙酸鋅(Zn(CH3COO2).2H2O)及六甲基四胺(C6H12N4)之等莫耳溶液之去離子水中,在約95℃之固定溫度下靜置約3小時,藉以於種子層241之表面沉積氧化鋅以形成複數奈米結構242。複數奈米結構242可為各自獨立連接種子層241之奈米柱或奈米管,且各奈米結構242相對於連接種子層241之一端為開放端。
又如圖2及圖3所示,在本實施例中,本發明之氣體感測器製造方法於步驟S4後更包括步驟S5:於感測結構上形成電極層。
於前述步驟S4形成感測結構240後,於感測結構240上形成電極層250。在本發明之一實施例中,電極層250可以利用白金靶材針對感測結構240之複數奈米結構242(即複數奈米結構242未連接種子層241之開放端)以濺鍍方式製作出指叉式電極。
以下請參考圖4為分別量測本發明之氣體感測器與不同對照組之氫氣濃度與感測器響應關係之示意圖。以下分別以本發明之氣體感測器200作為實驗組,搭配具有不同差異條件之氣體感測器作為對照組,在相同環境設定條件下分別進行氣體感測,進而比較實驗組及對照組之數據,以證明本發明之氣體感測器200之實際功效。在以下實驗中,均於正常大氣溫度條件(即室溫)下,對實驗組及各對照組之氣體感測器供應待感測氣體,以量測並記錄其相關參數並進行比對。
在實驗組及各對照組之氣體感測器之感測結構均採用氧化鋅為主要材料,且各奈米結構採用奈米柱形式之條件下,以不包括金屬玻璃薄膜及超奈米晶鑽石層之氣體感測器(即直接於基材210上形成感測結構240之氣體感測器)作為對照組A,以不包括超奈米晶鑽石層之氣體感測器(即於基材210已形成之金屬玻璃薄膜220之表面直接形成感測結構240之氣體感測器)作為對照組B,並以本發明之氣體感測器200作為實驗組C,在相同環境條件下分別將對照組A、B及實驗組C暴露於不同之氫氣濃度(單位為ppm)環境中,以量測並計算各氣體感測器之感測器響應(sensor response,單位為%),如表1所示。
前述氣體感測器之感測器響應可藉由氣體感測器之感測結構表面於感測過程中因為氣體分子之吸附或脫附而產生之電阻值變化來計算。其感測器響應之計算公式如下:S=(Rv-Rg)/Rv×100%
其中S是感測器響應,Rv是氣體感測器未吸附氣體分子時之電阻值,Rg是氣體感測器已吸附氣體分子時之電阻值。一般氣體感測器處於已吸附氣體分子之狀態下,將導致其電阻值降低。因此,若感測器響應之數值越高,表示氣體感測器之感測效果越佳。
如圖4及表1所示,在氫氣濃度從10ppm至500ppm之範圍內,無論是對照組A、B或是實驗組C,氣體感測器之感測器響應均隨著氫氣濃度增加而上升;且很明顯地,相較於對照組A、B,實驗組C無論在何種氫氣濃度下均表現出較佳之感測器響應。即使在氣體感測器暴露於氫氣濃度極低(例如10ppm)之環境下,實驗組C仍可保持高於34%之感測器響應。此外,如圖4所示,實驗組C所呈現之感測靈敏度(sensitivity,定義為氣體感測器之響應曲線之斜率)也遠超過對照組A、B所呈現之感測靈敏度。據此,本發明之氣體感測器200藉由金屬玻璃薄膜及超奈米晶鑽石層之結構組合及配置,能呈現較佳之氫氣感測效果。
請參考圖5為分別量測本發明之氣體感測器與不同對照組之光致發光光譜(photoluminescence spectra)之示意圖。此處針對前述對照組A、B及實驗組C,在相同環境設定條件下分別照射紫外光等光束以進行光致發光之強度測試。由圖5可知,無論是對照組A、B或實驗組C,其光譜結果均呈現兩次較明顯之輻射區域。其中,在光波長約為377nm時會產生第一次光輻射,其原因可
歸因於氧化鋅之帶間激子再結合(band-to-band excitonic recombination)有關之近帶邊緣輻射(near-band-edge emission,NBE);而在光波長約為500-700nm時會產生第二次光輻射,其原因可歸因於光生電荷與氧化鋅之晶體缺陷再結合所導致之深能階輻射(deep-level emission,DLE)。比較各組NBE及DLE之光致發光強度I之最大值,可發現對照組A之INBE/IDLE約為1.09,對照組B之INBE/IDLE約為0.37,而實驗組C之INBE/IDLE約為0.31;也就是說,相較於對照組A、B,實驗組C所具備之氧化鋅感測結構可形成較多缺陷。據此,本發明之氣體感測器200即藉由金屬玻璃薄膜及超奈米晶鑽石層之結構組合及配置,增加所形成之氧化鋅感測結構之缺陷數量,進而提高電子捕獲能力及導電性,改善氫氣感測之效果。
對於氣體感測器而言,響應時間(response time,單位為秒)及恢復時間(recovery time,單位為秒)也是重要參數。以下請參考圖6為本發明之氣體感測器暴露於氫氣環境下之響應曲線之示意圖。於正常大氣溫度條件下,將本發明之氣體感測器200暴露於100ppm之氫氣濃度環境中,以量測並計算感測器響應隨時間之變化。由圖6可知,在前述氫氣環境條件下,本發明之氣體感測器200所表現之響應時間Ton約為20秒,而恢復時間Toff約為35秒;而在經過前述恢復時間後,本發明之氣體感測器200已可恢復約90%之響應。
又,以下基於現有技術文獻及前述實驗數據,於表2中分別列出已知不同材料製成之氣體感測器與本發明之氣體感測器200暴露於100ppm之氫氣濃度下之感測器響應、響應時間、恢復時間及工作溫度等相關感測參數,藉以比對本發明之氣體感測器200與已知氣體感測器之差異。其中,大部分已知氣
體感測器於基材上採用氧化鋅或具有類似金屬氧化物為主要材料,利用奈米柱或奈米管等結構,並加入不同材料以構成氣體感測器。
如表2所示,除了少數氣體感測器需要在較高之特定工作溫度下運作以外,大部分氣體感測器均可應用於室溫環境下進行感測。隨著感測器材料及結構配置不同,感測器響應、響應時間及恢復時間也呈現不同變化;但很明顯地,相較於已知各類氣體感測器,本發明之氣體感測器200均可表現出較佳之感測器響應,且針對響應時間及恢復時間之表現同樣很顯著。據此,足以證明本發明之氣體感測器200藉由金屬玻璃薄膜及超奈米晶鑽石層之結構組合及配置,能呈現較佳之感測器響應及相關感測參數。
此外,對於氣體感測器而言,對氣體之選擇性(selectivity)也是另一個重要參數。以下請參考圖7為本發明之氣體感測器暴露於不同氣體環境下之感測器響應之示意圖。於正常大氣溫度條件下,將本發明之氣體感測器200分別暴露於100ppm之氫氣、氨氣及丙酮環境中,以量測並計算感測器響應。由圖7可知,本發明之氣體感測器200對氫氣、氨氣及丙酮均有不錯之感測器響應表現,使得本發明之氣體感測器200可視不同需求作為氫氣感測器、氨氣感測器或丙酮感測器。其中,本發明之氣體感測器200對氫氣之感測器響應高於氨氣或丙酮之感測器響應,顯示本發明之氣體感測器200對氫氣具有高度之選擇性。
此外,對於氣體感測器而言,針對持續暴露於氣體環境中之訊號產生能力及感測之長期穩定性也是蠻重要之參數。請參考圖8為本發明之氣體感測器一定時間內持續暴露於氫氣環境下之響應曲線之示意圖。於正常大氣溫度條件下,將本發明之氣體感測器200持續暴露於100ppm之氫氣濃度環境中超過1
小時,以量測並計算感測器響應隨時間之變化。由圖8可知,本發明之氣體感測器200隨著氫氣持續導入,其感測結構之表面會因為氫氣分子持續被吸附而導致電阻值大幅度降低後至趨於穩定狀態,使得感測器響應相對地於響應時間內大幅度升高且隨後緩慢增加。據此,本發明之氣體感測器200即使於一定時間內持續暴露於氣體環境中,也仍然保持較佳之訊號產生能力。
請參考圖9為本發明之氣體感測器長期感測氫氣之響應曲線之示意圖。於正常大氣溫度條件下,以15天為一周期將本發明之氣體感測器200暴露於100ppm之氫氣濃度環境中,並持續60天,以重複量測並計算感測器響應。由圖9可知,本發明之氣體感測器200於每次感測後均可呈現較佳之感測器響應,即使在經過60天後,本發明之氣體感測器200之感測器響應衰減小於1%,也就是說,本發明之氣體感測器200執行氫氣感測後所呈現之感測器響應與最初感測後之感測器響應表現幾乎相同。據此,本發明之氣體感測器200即使長期使用,也仍然能保持較佳之氣體感測效果。
綜上所述,本發明之氣體感測器基於金屬玻璃薄膜及超奈米晶鑽石層之結構組合及配置,藉由金屬玻璃及超奈米晶鑽石之材料特性,配合所形成之感測結構,用以提高氣體感測器之感測器響應及相關感測參數,提供更佳之氣體感測效果。此外,本發明之氣體感測器應用於氫氣、氨氣或丙酮等氣體之感測時,效果更加顯著。
以上實施方式本質上僅為輔助說明,且並不欲用以限制申請標的之實施例或該等實施例的應用或用途。此外,儘管已於前述實施方式中提出至少一例示性實施例,但應瞭解本發明仍可存在大量的變化。同樣應瞭解的是,本文所述之實施例並不欲用以透過任何方式限制所請求之申請標的之範圍、用
途或組態。相反的,前述實施方式將可提供本領域具有通常知識者一種簡便的指引以實施所述之一或多種實施例。再者,可對元件之功能與排列進行各種變化而不脫離申請專利範圍所界定的範疇,且申請專利範圍包含已知的均等物及在本專利申請案提出申請時的所有可預見均等物。
Claims (12)
- 一種氣體感測器,包括: 一基材; 一金屬玻璃薄膜,形成於該基材上; 一超奈米晶鑽石層,局部覆蓋該金屬玻璃薄膜;以及 一感測結構,包括形成於該超奈米晶鑽石層上之一種子層及形成於該種子層上之複數奈米結構。
- 如請求項1所述之氣體感測器,其中該超奈米晶鑽石層於該金屬玻璃薄膜上之覆蓋率為50%至90%。
- 如請求項1所述之氣體感測器,其中該金屬玻璃薄膜包括一銅基金屬玻璃薄膜或一銀基金屬玻璃薄膜。
- 如請求項1所述之氣體感測器,其中各該奈米結構為一氧化鋅奈米管或一氧化鋅奈米柱。
- 如請求項1所述之氣體感測器,更包括形成於該感測結構上之一電極層。
- 如請求項1所述之氣體感測器,其中該氣體感測器可感測位於大氣溫度下之一氣體。
- 如請求項6所述之氣體感測器,該氣體感測器為一氫氣感測器、一氨氣感測器或一丙酮感測器。
- 如請求項6所述之氣體感測器,其中當該氣體為氫氣,該氣體感測器可感測之一氫氣濃度範圍自10ppm至500ppm,且該氣體感測器之感測器響應高於34%。
- 如請求項8所述之氣體感測器,其中當該氫氣濃度為100ppm,該氣體感測器之感測器響應衰減於60天內小於1%。
- 一種氣體感測器製造方法,包括以下步驟: 提供一基材; 於該基材上形成一金屬玻璃薄膜; 於該金屬玻璃薄膜上沉積一超奈米晶鑽石層,其中該超奈米晶鑽石層局部覆蓋該金屬玻璃薄膜;以及 於該超奈米晶鑽石層上形成一感測結構。
- 如請求項10所述之氣體感測器製造方法,更包括:於該感測結構上形成一電極層。
- 如請求項10所述之氣體感測器製造方法,其中該超奈米晶鑽石層於該金屬玻璃薄膜上之覆蓋率可藉由控制該超奈米晶鑽石層之一沉積時間予以調整。
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