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Nanoo
Nanoo
Nanoo
of nanomaterials
substrate,
■ Materials
silicon, glass, ceramics, polymers, compound
semiconductors, titanium and tungsten.
Silicon
■ Silicon (Si) is among the most abundant material on earth. It almost
always exists in compounds with other elements.
■ Single crystal silicon is the most widely used substrate material for
MEMS and microsystems.
■ The popularity of silicon for such application is primarily for the
following
■ reasons:
(1) It is mechanically stable and it is feasible to be integrated into electronics
on the same substrate (b/c it is a semiconducting material).
(2) Electronics for signal transduction such as the p or n-type piezoresistive
can be readily integrated with the Si substrate-ideal for transistors.
(3) Silicon is almost an ideal structure material. It has about the same
Young’s modulus as steel (∼ 2x105 MPa), but is as light as aluminum
with a density of about 2.3 g/cm3.
Silicon
(4) It has a melting point at 1400oC, which is about twice higher than that of
aluminum. This high melting point makes silicon dimensionally stable even at
elevated temperature.
(5) Its thermal expansion coefficient is about 8 times smaller than that of steel,
and is more than 10 times smaller than that of aluminum.
(6) Silicon shows virtually no mechanical hysteresis. It is thus an ideal candidate
material for sensors and actuators.
(7) Silicon wafers are extremely flat for coatings and additional thin film layers
for either being integral structural parts, or performing precise
electromechanical functions.
(8) There is a greater flexibility in design and manufacture with silicon than
with other substrate materials. Treatments and fabrication processes for silicon
substrates are well established and documented.
Single-Crystal Silicon
■ For silicon to be used as a substrate material in integrated circuits and
MEMS, it has to be in a pure single-crystal form.
■ The most commonly used method of producing single-crystal silicon is
the Czochralski (CZ) method.
The Czochralski method for producing
single-crystal silicon
(1) Raw Si (quartzite) + coal, coke, woodchips)
are melted in the crucible.
(2) A “seed” crystal is brought to be in contact
with molten Si to form larger crystal.
(3) The “puller” slowly pulls the molten Si up
to form pure Si “boule” after the solidification.
(4) The diameters of the “bologna-like” boules
vary from 100 mm (4”) to 300 mm (12”) in
diameters.
Single-Crystal Silicon
The primary flat is used for automated positioning of the wafer during subsequent
processing steps, e.g., lithographic patterning and dicing. Other smaller flats are called
"secondary flats" and are used to identify the crystal orientation , (<111> versus <100>)
and the material (n-type versus p-type)
(Bulk) Mechanical and Thermophysical
Properties of Silicon
Silicon Compounds
■ There are 3 principal silicon compounds used in MEMS and
microsystems: Silicon dioxide (SiO2), Silicon carbide (SiC) and
silicon nitride (Si3N4) – each has distinct characteristic and unique
applications.
Silicon dioxide (SiO2)
■ It is least expensive material to offer good thermal and electrical
insulation.
■ Also used a low-cost material for “masks” in micro fabrication
processes
■ such as etching, deposition and diffusion.
■ Used as sacrificial material in “surface micromachining”.
■ Above all, it is very easy to produce:
■ - by dry heating of silicon: Si + O2 → SiO2
■ - or by oxide silicon in wet steam: Si + 2H2O → SiO2 + 2H2
Silicon Compounds
■ Silicon carbide (SiC)
■ Its very high melting point and resistance to chemical reactions
make it ideal candidate material for being masks in micro fabrication
processes. It has superior dimensional stability.
(UV)
Photoresist
■ Photo sensitive material
■ Temporarily coated on wafer surface
■ Transfer design image on it through
exposure
■ Very similar to the photo sensitive coating
on the film for camera
Photoresist
Exposed area
of photoresist
oxide
photoresist
oxide oxide
to vacuum
pump spindle
Softbake
■ Partial evaporation of
photo-resist solvents
■ Improves adhesion
■ Improves uniformity
■ Improves etch resistance
■ Improves linewidth control
■ Optimizes light absorbance
characteristics of photoresist
Alignment & Exposure
■ Alignment errors
(many different types)
■ Mask aligner
equipment
■ Double sided
alignment especially
important in
micromachines
Lithography systems-UV light
Alignment & Exposure
■ Normally requires at least two alignment mark sets on
opposite sides of wafer or stepped region.
■ Use a split-field microscope to make alignment easier:
Mask Aligner Fixture
Hard bake
■ Evaporate remaining
photoresist
■ Improve adhesion
■ Higher temperature
than soft bake
Developing the photoresist
■ Soluble areas of photoresist are
developer
dissolved by developer dispenser
chemical
■ Visible patterns appear on
wafer
windows
islands
■ Quality measures:
line resolution vacuum chuck
uniformity
spindle
particles & defects
Wafer inspection
■ Optical or SEM metrology
■ Quality issues:
particles
defects
critical dimensions
linewidth resolution
overlay accuracy
Photolithography combined with etching
and thin film deposition
Plasma etch ( dry etching with plasma) -to remove the photoresist
2 μm x 2μm x 2 2 μm x 3μm x 2 2 μm x 15μm x 2
μm μm μm
2 μm x 7μm x 2 2 μm x 10μm x 2
μm μm
Photolithography Methods
@150-200oC
Photolithography
Microfabrication Process
Etching
■ Bulk micromanufacturing technique involves creating 3-D components
by removing materials from thick substrates (silicon or other
materials) using primarily etching method.
■ Etching - dry or wet etching is the principal technique used in bulk
micromanufacturing.
■ Substrates that can be etched in bulk micromanufacturing include:
Silicon , SiC, GaAs, special polymers
■ Wet etching involves the use of chemical solvents (called etchants)
■ Dry etching uses plasma to remove materials at the desired locations
on a substrate.
Choosing a Method
■ Choosing a method
■ Desired shapes
■ Etch depth and uniformity
■ Surface roughness
■ Process compatibility
■ Safety, cost, availability,
environmental impact
Isotropic and Anisotropic
etching
■ When a material is attacked by a liquid or vapor etchant, it is removed
isotropically (uniformly in all directions) or anisotropic etching
(uniformity in vertical direction).
Anisotropy Isotropy
■ Material removal rate for wet-etching is usually faster than the rates
for many dry etching processes
■ Etching rate changed by varying temperature or the concentration of
active species.
Isotropic and Anisotropic
etching
■ Pure silicon crystals are not isotropic in their properties due to
non-uniform distribution of atoms at their interior.
■ Such anisotropic properties are represented by three distinct planes.
■ The (111) plane makes an angle of 54.74o with the (100) plane.
■ Corresponding to these (3) planes are 3 distinct directions in which
etching takes place: <100>, <110> and <111>.
■ The <100> is the easiest direction for etching, and the <111> is the
hardest direction for etching.
Wet Etch
■ Removal process that uses liquid chemicals or etchants to remove
materials from a wafer.
■ The specific patters are defined by masks on the wafer.
■ Materials that are not protected by the masks are etched away by
liquid chemicals.
■ These masks are deposited and patterned on the wafers in a prior
fabrication step using lithography.
Etching Chemistry
■ A wet etching process involves multiple chemical reactions
■ The wet etch process can be described by three basic steps.
(1) Diffusion of the liquid etchant to the structure that is to be removed.
(2) The reaction between the liquid etchant and the material being etched
away. A reduction-oxidation (redox) reaction usually occurs. This
reaction entails the oxidation of the material then dissolving the
oxidized material.
(3) Diffusion of the byproducts in the reaction from the reacted surface
■ Key ingredients in any wet etchant:
– Oxidizer
examples: H2O2, HNO3
– Acid or base to dissolve oxidized surface
examples: H2SO4, NH4OH
– Dillutent media to transport reactants and products through
examples: H2O, CH3COOH
Anisotropic wet etching
■ Liquid etchants etch crystalline materials at different rates depending
upon which crystal face is exposed to the etchant .
■ Depend on Si crystalline plane.
■ Anisotropic etching is easier to control of the etched shape of the
substrates.
Anisotropic wet etching
■ Alkaline chemicals with ph > 12 for anisotropic etching.
■ Popular anisotropic etchants are:
■ KOH ( potassium hydroxide)
■ EDP (ethylene-diamine and pyrocatecol)
■ TMAH (tetramethyl ammonium hydroxide)
■ Hydrazine
■ Most etchants are used with 1:1 by weight mixture with water.
■ Typical etching rates are:
Hydroxide Etching of
Silicon
Isotropy Wet etching
■ For isotropic wet etching, a mixture of hydrofluoric acid, nitric acid,
and acetic acid (HNA) is the most common etchant solvent for
silicon.
■ The concentrations of each etchant determines the etch rate.
■ Silicon dioxide or silicon nitride is usually used as a masking material
against HNA.
■ Silicon compounds are much stronger etching resistive materials than
silicon.
■ These materials can thus be used as masks for etching of silicon
substrates.
“Wet chemical etching is generally isotropic even though a mask is
present since the liquid etchant can penetrate underneath the mask. If
directionality is very important for high-resolution pattern transfer,
wet chemical etching is normally not used. “
Etch stop
■ Etch Stop refers to stopping the etching reaction be it isotropic or
anisotropic at a desired point.
There are two categories for etch stop –
1. Time based etch stop
Etching is stopped by removing the wafer from the etching solution at a certain time.
2. Selectivity based etch stop
■ Etching may be stopped by the following two methods, both related to
doping of the silicon substrates.
■ Controlled by doping:
■ Doped silicon dissolved faster in etchants than pure silicon
■ Al-Doped silicon-faster etch rate,
■ Heavily boron doped-Etch Stop
■ Controlled by electrochemical etch stop
Control Of Wet etching
On etching geometry:
■ Timing and agitated flow patterns can affect the geometry of etched
substrate geometry:
George M. Whitesides
(Harvard)
“Size is not the only thing that matters, function is more important” (something like this),
PDMS: poly(dimethyl-siloxane)
PDMS properties:
• Silicone elastomer with a range of viscosities
• Flexible (1 MPa Young’s modulus, typical polymer 1 GPa) and easy to
mold.
• Elastomer, conforms to surface over large areas.
• Chemically inert, optically transparent
• Low surface energy: bonds reversibly (or permanent).
• Seals to flat and clean surfaces for micro-fluidic channels
• Durable (reusable), low thermal expansion
• Biocompatible (even used for food additive)
• Environmentally safe
• Best Resolution: 2-10 nm (for hard PMDS)
Dow Corning
brand 84
PDMS surface treatment
Plasma
oxidation
contact PDMS
Irreversible seal:
surfaces formation of covalent
bonds
Biggest issue: it becomes hydrophobic quickly, very bad for micro-fluidic applications.
(liquid hard to get into the channels once it becomes hydrophobic)
PMDS is absolutely the most popular material for bio-medical lab-on-chip (microfluidic)
applications, but may not be suitable for commercial applications, which need chemically
stable surface.
PDMS surface treatment
• PDMS has a low interfacial free energy such that molecules of most
polymers won’t stick on or react with its surface.
• The interfacial free energy can be manipulated with plasma treatment.
• For nano-imprint or soft lithography mold, plasma can make PMDS surface
like SiO2, easy for mold release agent coating using silane chemistry.
PDMS
fabrication
Peel off
PDMS
Master pattern (red color) can be in: photoresist (SU-8), silicon, glass…
Silanization of master mold needed to obtain low surface energy for easy
separation. 87
Microfabrication of
Microgrooved Patterns
UV exposure
Chrome mask
Development
Photoresist
Si wafer
PDMS
polymerization
SEM image
Micro fabrication & Replica
Molding
mask Expose Cast PDMS
& Develop PDMS Drill & Seal
photoresist master
on Si wafer
inlets outlet
flow
Side View
finished 1 cm
device
The most recent lithography
methods
Printing, stamping, and molding use mechanical processes instead of photons or
electrons. These methods are normally called soft lithography
methods because they involve the use of polymers.
microcontact printing method
A chemical precursor to polydimethylfiloxane
(PDMS) is poured over and cured into the rubbery
solid PDMS stamp that reproduces the original
pattern. The stamp can then be used in various
inexpensive ways to make nanostructures.
The stamp is inked with a solution consisting of
organic molecules and then pressed into a thin film
of gold on a silicon plate.
The organic molecules form a self-assembled
monolayer on the solid surface that reproduces the
pattern with a precision of approximately 50 nm.
Advantages of lithography
Once the master template has
been made, no special equipment
is required.
Soft lithographic methods are
capable of producing nanostructures in a wide
range of materials and can
print or mold on curved as well as
planar surfaces
Alkanethiolates
CH3(CH2)nS-Au(111)
in
ethanol
Liquid-phase synthesis
Gas-phase synthesis
Vapor-phase synthesis
Liquid-Phase Synthesis
• Coprecipitation
• Sol-gel Processing
• Microemulsions
• Hydrothermal/Solvothermal Synthesis
• Microwave Synthesis
• Sonochemical Synthesis
• Template Synthesis
• Biomimetic Synthesis
Coprecipitation
Murray C.B. et al., Annu. Rev. Mater. Sci. 2000, 30, 545.
Sol-gel processing
The sol-gel process is a wet-chemical technique that uses either a chemical solution (sol
short for solution) or colloidal particles (sol for nanoscale particle) to produce an
integrated network (gel).
Metal alkoxides and metal chlorides are typical precursors. They undergo
hydrolysis and polycondensation reactions to form a colloid, a system composed of
nanoparticles dispersed in a solvent. The sol evolves then towards the formation of an
inorganic continuous network containing a liquid phase (gel).
After a drying process, the liquid phase is removed from the gel. Then, a thermal
treatment (calcination) may be performed in order to favor further polycondensation
and enhance mechanical properties.
Making Gel formation
Sol-gel process
Example: TiO2 nanoparticle-mediated mesoporous film by sol-gel
processing
Alkoxide
+H2O Stabilizer
Nanodisperse Oxide 100 nm
Sol
(Particulate or
Polymeric)
-H2O
Gel
-H2O
Xerog
el T > 400 ºC TiO2 nanoparticle-mediated
-H2O mesoporous film (Yu, J. C. et al. Chem.
-Stabilizer Mater. 2004, 16, 1523.)
Porous TiO2
Microemulsion
In a sealed vessel (bomb, autoclave, etc.), solvents can be brought to temperatures well above
their boiling points by the increase in autogenous pressures resulting from heating. Performing
a chemical reaction under such conditions is referred to as solvothermal processing or, in the
case of water as solvent, hydrothermal processing.
ZnIn2S4
TiO2
Yu, J. C. et al. J. Solid State Chem. 2005, 178, 321; Cryst. Growth Des. 2007, 7, 1444
Microwave-Assisted Synthesis
Microwaves are a form of electromagnetic energy with
frequencies in the range of 300 MHz to 300 GHz. The commonly
used frequency is 2.45G Hz.
• conductive heat
• heating by
convection currents
• Solvent/reagent
absorbs MW energy
• Vessel wall
transparent to MW
• Instant on-off
1 μm 100 nm
Mesoporous TiO2
Hydrolysis/
Condensatio UI
TI n A
))))
P
Hydrolysis/
Condensatio
Acetic acid modified n
UI UI
)))) A A
TIP
40 kHz ultrasound
Cleaning Vessel
Yu J.C. et al., Adv. Funct. Mater. 2004, 14, 1178.
Biomimetic Synthesis
Nature is a school for material science and its associated discipline such as
chemistry, biology, physics or engineering. Nature fascinates scientists and
engineers with numerous examples of exceptionally building materials. These
materials often show complex hierarchical organization from the nanometer to
the macroscopic scale.
Learning from nature and imitating the growth and assembly processes found in
nature enable new strategies for the design of nanoarchitectures. Biomimetic or
bio-inspired processes generally occur under mild conditions such as room
temperature, aqueous environment, and neutral pH, and thus are benign in
comparison to traditional chemical reactions. Biologically inspired synthesis,
hierarchical structuring, and stimuli-responsive materials chemistry may enable
nanostructured materials systems with unprecedented functions .
Protein-encapsulated CoPt
A protein of methanococcus nanoparticles by bio-inspired
jannaschii MjHsp synthesis
(Stone M. O. et al. Adv. Funct. Mater. 2005, 15, 1489.)
Gas-Phase Synthesis
Tubular reactor
Vapor-Phase Synthesis
■ Same mechanism as liquid-phase reaction
■ size affections
■ reaction and nucleation
Methods for making 0-D Nanomaterials
The metal vapor cools through collisions with the inert gas atoms,
becomes supersaturated and then nucleates homogeneously; the
particle size is usually in the range 1–100 nm and can be
controlled by varying the inert gas pressure.
Electrodeposition (ED)
is being exploited now to make
complex 3D electrical
interconnects in computer
chips. The key concept is that
electrodeposited materials
grow from the conductive
substrate outward, and the
geometry of the growth can be
controlled using an insulating
mask (so-called through mask
Electrochemically fabricated flip-chip electrodeposition).
interconnects
Challenges
■ Reproducibility
■ Scale up
AFM
Atomic Force Microscopes (AFM)
Contact mode is typically used for scanning hard samples and when a
resolution of greater than 50 nanometers is required. The cantilevers
used for contact mode may be constructed from silicon or silicon nitride.
Resonant frequencies of contact mode cantilevers are typically around
50 KHz and the force constants are below 1 N/m.
Contact mode images
For the spontaneous Raman effect, the molecule will be excited from
the ground state to a virtual energy state, and relax into a vibrational
excited state, which generates Stokes Raman scattering. If the
molecule was already in an elevated vibrational energy state, the
Raman scattering is then called anti-Stokes Raman scattering.
Virtual
State
hν0 hν0+hν
hν0 hν0 hν0−hνm m
Energy
E0+hνm
E0
IR Rayleigh Stokes Anti-Stokes
Absorption Scattering Scattering Scattering
(elastic)
Raman
(inelastic)