qfimf «3 ' ‘ N ‘1‘ 5' r \ ”an {Uh}; “4 :3 m». _ v on}: a x" .m- V «4"» “5.37. . ‘ .dvl , A VI pg; “1 .5 1" (/‘KL/ 5'/ 5 W} [id-J9 59‘ [)ate 0-7 639 This is to certify that the thesis entitled Design of an Implantable Micro-Scale Pressure Sensor for Managing Glaucoma presented by Gregory Alan Goodall has been accepted towards fulfillment of the requirements for M . S . degree in MechLnical Engineering Major professor July 30, 19% MS U is an Affirmative Action/Equal Opportunity Institution UBTRARY Michigan State University PLACE IN RETURN Box to remove this checkout from your record. To AVOID FINES return on or before date due. MAY BE RECALLED with earlier due date if requested. DATE DUE DATE DUE DATE DUE 6’01 cJCIFlC/DatoDuepGS-pJS DESIGN OF AN IMPLANTABLE MICRO-SCALE PRESSURE SENSOR FOR MANAGING GLAUCOMA By Gregory Alan Goodall A THESIS Submitted to Michigan State University in partial fulfillment of the requirements for the degree of MASTER OF SCIENCE DEPARTMENT OF MECHANICAL ENGINEERING 2002 ‘ k a {31121 1‘1 3.6 ABSTRACT DESIGN OF AN IMPLANTABLE MICRO-SCALE PRESSURE SENSOR FOR MANAGING GLAUCOMA By Gregory Alan Goodall Presented in this thesis is the design of a MEMS wireless pressure sensor that will implanted in the eye of Glaucoma patients to monitor intraocular pressure (IOP) on a continuous basis. It is hoped that the device will enable doctors to treat their patients better by having a more complete patient history of IOP. The device, made of silicon and glass, will feature an on-chip inductor and a parallel plate pressure-variable capacitor. The inductor is formed from a planar coil of gold, while the capacitor is comprised of a non-movable gold electrode housed inside the sensor and a thin flexible diaphragm exposed to the pressure exerted by the eye fluid. The sensor is a simple R-L-C resonant circuit. Pressure exerted on the diaphragm by the aqueous humor results in a micron-scale deflection of the diaphragm causing a change in the capacitance of sensor. The change in capacitance will in turn change the resonant frequency of the sensor. The planar inductor coil allows for wireless telemetry to a data acquisition and processing (DAP) unit by means of inductive coupling. Measuring the electrical characteristics of the DAP provides a measure of the resonant frequency of the sensor and thus a direct measure of the capacitance and the pressure in the eye. This work of thesis consists of the design of a micro-scale sensor and concept verification by the testing of macro-scale prototypes. Results from testing the models models reflected the expected theoretical patterns for the frequency responses. This thesis is dedicated to my parents and all those that I care about. Without all of you, I never could have made it this far or enjoyed it so much. iii .4 , Cha Cha l TABLE OF CONTENTS LIST OF TABLES ....................................................................... LIST OF FIGURES ...................................................................... KEY TO SYMBOLS ................................................................... Chapter 1 Introduction ............................................................... 1.1 Thesis Statement .................................................. 1.2 Background and Significance ................................... 1.3 Implant Options ................................................... 1.4 Operating Range .................................................. Chapter 2 Theoretical Background and Circuit Analysis .................... 2.1 Conceptual Overview ............................................. 2.2 Circuit Analysis ................................................... Chapter 3 Design Parameters and Conceptual Sensor Layout .............. 3.1 Design Parameters ................................................ 3.2 Conceptual Sensor Structure .................................... Chapter 4 Capacitor Plate and Diaphragm Design ............................ 4.1 Design Variables .................................................. 4.2 Analysis to Determine the Capacitance Range ................ 4.3 Initial Capacitance Value ........................................ 4.4 Analysis of Diaphragm Deflection .............................. 4.5 The Capacitance-Pressure Relationship ......................... iv vii ix xiv 18 19 20 23 24 25 26 28 36 4.6 Effects of Residual Stress on the Diaphragm's Dynamics And Sensitivity ................................................ 4.7 Final Capacitor Design ........................................... Chapter 5 Inductor Design .......................................................... 5.1 Design Variables .................................................. 5.2 Planar Inductors ................................................... 5.3 Design Considerations on Determining the Inductance Value .............................................. 5.4 Computational Analysis for Design of a Planar Inductor. . .. Chapter 6 Consideration of Resistance and Quality Factor in Inductor Design ...................................................... 6.1 Resistance and Quality Factor of the Inductor ................ 6.2 Summary of the Inductor Design ............................... Chapter 7 Summary of Micro-Scale Prototype Design ........................ 7.1 Design Dimensions ............................................... Chapter 8 Sensor Fabrication ...................................................... 8.1 Fabrication Overview ............................................. 8.2 Fabrication of the Glass Wafer ................................. 8.3 Fabrication of the Silicon Wafer ................................ 8.4 Electrostatic Boding of Wafers .................................. Chapter 9 Prototype Testing Results ............................................. 9.1 Prototype Overview .............................................. 9.2 Testing Procedure ................................................ 9.3 Expected Results .................................................. 43 49 51 52 52 53 57 65 71 72 73 77 78 78 81 86 87 88 9O 91 ra.‘ I‘- (ha Chat App Bibli Chapter 10 Important Considerations .............................................. 9.4 Fabrication of the PC Boards .................................... 9.5 Results From Testing First Generation Prototypes ........... 9.6 Results From Testing Second Generation Prototypes ........ 10.1 Introduction ........................................................ 10.2 Volume of Air Enclosed in the Capacitive Cavity ............ 10.3 Drift ................................................................. Chapter 11 Conclusions ............................................................... Appendix Bibliography 11.] Summary .......................................................... vi 92 92 94 103 104 104 105 107 108 110 121 Chm Cha; Char Chap Appf‘r LIST OF TABLES Chapter 3 Design Parameters and Conceptual Sensor Layout Table 3.1 List of Key Sensor Design Parameters ................................ 20 Chapter 4 Capacitor Plate and Diaphragm Design Table 4.1 Properties of Thin Film Silicon Used in Analysis ................... 30 Table 4.2 Size of Resonant Frequency Range Over a Range of Deflection of 0-0.5 microns For Various Initial Capacitance Values ...... 43 Table 4.3 Summary of Capacitor Design ......................................... 49 Table 4.4 Summary of Final Diaphragm Design ................................ 50 Chapter 6 Consideration of Resistance and Quality Factor in Inductor Design Table 6.1 Summary of Inductor Design .......................................... 71 Chapter 9 Prototype Testing Results Table 9.1 Approximate Inductance Values for Prototypes for a Capacitance of 1.52 pF ............................................. 96 Table 9.2 Theoretical Approximate Resonant Frequencies for a Capacitance of 1.74 pF ............................................. 97 Table 9.3 Summary of Prototype Testing Results ............................... 97 Table 9.4 Comparison of Theoretical Resonant Frequencies to Measured Values .................................................. 102 Appendix Table A.1 Frequency Response Data for First Generation Prototype ......... 113 Table A2 Frequency Response Data for Device 11 with Capacitance C=1.52 pF ............................................................ 114 vii Table A3 Frequency Response Data for Device 11 with Capacitance C=1.74 pF ............................................................ 115 Table A.4 Frequency Response Data for Device 6 with Capacitance C=1.52 pF ............................................................ 116 Table A5 Frequency Response Data for Device 6 with Capacitance C=1.74 pF ............................................................ 117 Table A6 Frequency Response Data for Device 9 with Capacitance C=1.52 pF ............................................................ 118 Table A.7 Frequency Response Data for Device 9 with Capacitance C=1.74 pF ............................................................ 119 viii Cha Cha Chat Chat LIST OF FIGURES Page Chapter 1 Introduction Figure 1.1 Options for Implant Location in the Eye .............................. 6 Chapter 2 Theoretical Background and Circuit Analysis Figure 2.1 Concept Representation ................................................. 8 Figure 2.2 Equivalent Circuit ........................................................ 9 Figure 2.3 Impedances of Individual Elements .................................... 13 Figure 2.4 Equivalent Circuit Including Impedance from Mutual Inductance ............................................................. 15 Figure 2.5 Illustration of the Voltage Dip Demonstrated on a Theoretical Voltage Profile Across the Load Resistor. . .. 16 Chapter 3 Design Parameters and Conceptual Sensor Layout Figure 3.1 Isometric View of Sensor ................................................ 20 Figure 3.2 Isometric View of Glass Wafer Layout ............................... 21 Figure 3.3 Differential Pressure Sensor Concept ................................. 22 Chapter 4 Capacitor Plate and Diaphragm Design Figure 4.1 Variables for Design of a Capacitor ................................... 24 Figure 4.2 Resonant Frequency as a Function of Capacitance for Various Inductance Values .................................... 26 Figure 4.3 Required Capacitor Plate Side Length as a Function of Initial Gap Height to Achieve C0=2.0 pF ..................... 27 Figure 4.4 Diaphragm Shapes and Variables ...................................... 28 Figure 4.5 Required Side Length and Diameter of Stress Free Diaphragms For Each Case of Maximum Deflection at 60 mmHg ........... 31 ix Figure 4.6 Basic Size Comparison for Square and Round Diaphragms ...... Figure 4.7 Deflection as a Function of Pressure for Stress Free Diaphragm (Square or Round) for Various Maximum Deflections At 60 mmHg ........................................................... Figure 4.8 Illustration Showing Support Structure on Square Diaphragm Figure 4.9 Illustration of Round Diaphragm Formation ......................... Figure 4.10 Capacitance as a Function of Pressure for Various Initial Gap Heights Using an Initial Capacitance Co = 2pF ............ Figure 4.11 Resonant Frequency as a Function of Capacitance for Various Initial Gap Heights and Maximum Deflections Using an Inductance of 800 nH ................................................ Figure 4.12 Resonant Frequency as a Function of Pressure for Various Initial Gap Heights and Maximum Deflections Using an Inductance of 800 nH ................................................ Figure 4.13 Capacitor Plate Size versus Initial Gap Height as a Function of Initial Capacitance ................................................... Figure 4.14 Effects of Residual Stress on Diaphragm Deflection ................ Figure 4.15 Effects of 40 MPa of Residual Stress on a Diaphragm Designed to Deflect 0.5 microns at 60 mmHg ................................ Figure 4.16 Effects of Residual Stress on the Deflection of a Diaphragm ...... Figure 4.17 Sensitivity as a Function of Deflection for Various Cases of Maximum Deflection at 60 mmHg of a Square Diaphragm with Initial Gap =1.5 andAssumed Residual Stress of 40 MPa Figure 4.18 Required Side Lengths as a Function of Thickness for Stressed (40 MPa) and Stress Free Diaphragms .................. Figure 4.19 Sensitivity as a Function of Deflection for Various Initial Gaps of a 4 micron thick Square Diaphragm with an Assumed Residual Stress of 40 MPa .......................................... 32 33 35 35 37 39 41 42 44 45 46 47 48 49 Iliaml iii... :A: . . -. Cha Figure 4.20 Illustration of Final Capacitor Plate Design ........................... 50 Figure 4.21 Illustration of Final Diaphragm Design ............................... 50 Chapter 5 Inductor Design Figure 5.1 Planar Spiral Inductor Layout with n=3 Turns ...................... 52 Figure 5.2 Resonant Frequency as a Function of Capacitance for Various Values of Inductance ................................................ 54 Figure 5.3 Basic Trends of Circuit Excitation as a Function of Frequency Towards Changes in Inductance .................................... 55 Figure 5.4 Inductance as a Function of the Number of Turns for Comparing the Precision of Equations (5.2-5.4) For Various Line Spacings Using a Constant Line Width of 6 microns ........... 59 Figure 5.5 Inductance as a Function of the Number of Turns for Various Turn Spacings ......................................................... 61 Figure 5.6 Outside Diameter of the Inductor Coil as a Function of the Number of Turns for Various Turn Spacing Using a Line Width w=6 microns ............................................ 62 Figure 5.7 Inductance as a Function of the Number of Turns for Various Line Widths for a Line Spacing s=4 .............................. 63 Chapter 6 Consideration of Resistance and Quality Factor in Inductor Design Figure 6.1 Series Resistance and Skin Depth as a Function of Frequency for Case Where w = 6 microns, tw = 7 microns, 26 windings..... 66 Figure 6.2 Resistance and Q Factor as a Function of Frequency Using tw =7 microns, w = 6 microns, and 26 Windings ....... 67 Figure 6.3 Resistance of Inductor as a Function of Frequency for Various Line Thicknesses Using Line Width w = 6 microns, and 26 Windings ...................................................... 68 xi Chap Chapt Figure 6.4 Resistance as a Function of Frequency for Various Line Widths Using Line Thickness tw = 9 microns, Spacing s = 6 microns, and 26 Windings .................................... 70 Figure 6.5 Q Factor as a Function of Frequency for Various Line Widths Using Line Thickness tw = 9 microns, Spacing s = 6 microns, and 26 Windings .................................... 70 Chapter 7 Summary of Micro-Scale Prototype Design Figure 7.1 External Dimensions of Sensor ........................................ 73 Figure 7.2 Dimensions of Diaphragm Structure Created from Silicon Wafer .......................................................... 74 Figure 7.3 Dimension of Internal Structures and Glass Wafer .................. 75 Figure 7.4 Capacitor Layout ......................................................... 75 Figure 7.5 Inductor Layout .......................................................... 76 Chapter 8 Sensor Fabrication Figure 8.1 Glass Substrate with the PR Mask to Define the Coil Recess ...... 79 Figure 8.2 Glass Substrate with Coil Recess ...................................... 79 Figure 8.3 Glass Wafer with PR Mask for Electroplating Gold ............... 80 Figure 8.4 Completed Glass Wafer ................................................. 80 Figure 8.5 Orientation of a (100) Silicon Wafer .................................. 81 Figure 8.6 Silicon Wafer with Si3N4 Mask to Define Capacitive Cavity ...... 82 Figure 8.7 Silicon Wafer After Capacitive Cavity Has Been Defined ......... 83 Figure 8.8 Silicon Wafer After Boron Doping .................................... 84 Figure 8.9 Silicon Wafer with PR Mask to Define the Diaphragm ............ 85 Figure 8.10 Completed Silicon Wafer ............................................... 85 xii Figure 8.11 Set Up For Electrostatic Bonding Process ............................ 86 Chapter 9 Prototype Testing Results Figure 9.1 First Generation of Prototypes .......................................... 88 Figure 9.2 Second Generation of Prototypes ...................................... 89 Figure 9.3 Experimental Setup ...................................................... 90 Figure 9.4 Expected Results From Prototypes .................................... 91 Figure 9.5 Sensor Voltage and Voltage Across the Load Resistor for First Generation Prototypes Model # 9 ........................... 93 Figure 9.6 Sensor Voltage and Voltage Across the Load Resistor as a Function of Frequency for Second Generation Prototypes. 95 Figure 9.7 Sensor Voltage as a Function of Frequency After Increasing the Capacitance ....................................................... 98 Figure 9.8 Comparison of Sensor Voltages For Two Cases of Capacitance. 99 Figure 9.9 Comparison of Voltage Across Load Resistor For Two Cases of Capacitance ................................................ 100 Appendix Figure A.1 Mask For First Generation Prototypes 110 Figure A.2 First Mask For Second Generation Prototypes 111 Figure A.3 Second Mask For Second Generation Prototypes 112 xiii L! L\ M Co CFS K1 K2 I«GMD LMON LMW KEY TO SYNIBOLS Capacitor Plate Area (umz) Capacitance (Farads) Initial Capacitance (Farads) Capacitance at Full-Scale Deflection (Farads) Young’s Modulus (N/um) Resonant Frequency (Hz) Amplitude of an AC Sinusoidal Current (Amps) Phasor Current Geometry Dependent Coefficient for Modified Wheeler’s Equation equal to 2.34 Geometry Dependent Coefficient for Modified Wheeler’s Equation equal to 2.75 Inductance (Henries) Inductance Determined from the Current Sheet Method (Henries) Inductance Determined from the Empirical Expression (Henries) Inductance Determined from the Modified Wheeler Equation (Henries) Mutual Inductance (Henries) Pressure Difference (N/ttm) Quality Factor Resistance (Ohms) xiv Rs Series Resistance (Ohms) S Sensitivity (mZ/N) V Amplitude of an AC Sinusoidal Voltage (Volts) V Phasor Voltage X Reactance (Ohms) Z Impedance (Ohms) a Half of the Side Length of a Square Diaphragm (um) c1 Geometry Dependent Coefficient for Current Sheet Method equal to 1.27 c; Geometry Dependent Coefficient for Current Sheet Method equal to 2.07 C3 Geometry Dependent Coefficient for Current Sheet Method equal to 0.18 c4 Geometry Dependent Coefficient for Current Sheet Method equal to 0.13 d Gap Height Between Capacitor Plates (pm) dm Inner Diameter of Planar Inductor (um) dour Outer Diameter of Planar Inductor (um) h Thickness of a Diaphragm (um) 1 Total length of the Inductor Coil (m) m Side Length of a Capacitor Plate (um) 11 Number of Turns in a Planar Inductor r Radius of a Round Diaphragm (um) s Spacing Between Inductor Coils (um) XV . '1’? a2 0‘3 as Time (s) Line Thickness of the Inductor Wire (um) Side Length of Capacitor Plate (um) Deflection at the Center of a Diaphragm (um) Geometry Dependent Coefficient for Empirical Expression Equation equal to 1.62e-3 Geometry Dependent Coefficient for Empirical Expression Equation equal to —1.21 Geometry Dependent Coefficient for Empirical Expression Equation equal to —0. 147 Geometry Dependent Coefficient for Empirical Expression Equation equal to 2.4 Geometry Dependent Coefficient for Empirical Expression Equation equal to 1.78 Geometry Dependent Coefficient for Empirical Expression Equation equal to 0.030 Skin Depth (um) Dielectric Constant of the Material Between the Electrodes Dielectric Constant of a Vacuum equal to 8.85 X 106 (pF/ttm) Phase Angle of the Current (degrees) Fill Ratio of an Inductor Permeability equal to 1.26e-6 for Gold Poison’s Ratio Phase Angle of the Voltage (degrees) xvi "all Permeability of Gold equal to 2.21e-8 (ohm-m) Conductivity of Gold equal to 4.55e7 (ohm’l m") Residual Stress in a Diaphragm (N/ttm) Angular Frequency (rad/s) Resonant Frequency (rad/s) xvii Chapter 1 Introduction - .......i 1.1 C017] PUT? teier. the i.‘ com:— 11mm 3511.}; .Thfi It 1.1 Thesis Statement This thesis describes the design phase for an implantable, biomedical pressure sensor to be fabricated utilizing Microelectrical Mechanical Systems (MEMS) technologies. The sensor is one of three components in a pressure measuring system that will be used to monitor intraocular pressure (IOP) on a continuous basis. The second component in the system is a data acquisition and processing (DAP) unit, while the third component is a central database that will be utilized for record keeping purposes. The pressure sensor will be implanted in the eye and will provide wireless measurements of IOP. The device is small enough that the patient’s vision and the function of the eye will not be affected. The data acquisition unit serves multiple purposes. The device generates a signal that is transmitted to the sensor through wireless telemetry, as well as acquires, processes, and temporarily stores the data that returns from the implanted sensor. The information can then be uploaded to the central database so a complete time record of IOP measurements can be maintained. The work in this thesis is the first of multiple phases to complete the IOP monitoring system. The second phase of development will be the fabrication of the actual device based on the design information obtained from the prototype device designed in this thesis. Future steps in the process include the design of the DAP unit, design of the data base unit, component integration, implantation in to cats and primates, and finally implantation in to humans. The IOP sensor system design will employ the following general design criteria: 1) Fully implantable, wireless, and passive (without batteries) sensor designed and built using MEMS technology 2) Precision pressure measurement 3) Continuous or scheduled measurement of IOP 4) Variable data acquisition rate 5) Alarm to alert patient of unsafe pressure levels 6) Remote control of transmitter/receiver unit 7) Portable transmitter/receiver unit with rechargeable batteries 8) Data storage for record keeping A cure for glaucoma is the ultimate advance, but accurate, remote monitoring of IOP has the potential to be as important to successful management of glaucoma in patients as the heart monitor is to heart patients. Saving people’s vision is the ultimate goal. 1.2 Background and Significance Glaucoma is one of the most menacing diseases of the eye that exists today. Patients may suffer significant eye damage, including blindness, without experiencing a noticeable amount of pain or discomfort. Glaucoma is the second leading cause of blindness in the United States and is the leading cause of blindness among African Americans [1]. There are several types of glaucoma; the most common of which is called primary open-angle glaucoma (POAG). POAG affects more than 3 million people with an additional 3-6 million Americans considered to be susceptible because they have one or more of the risk factors associated with the disease [1]. Glaucoma is a progressive disease that is characterized by a specific pattern of damage to the optic nerve [1]. Development of the disease can be attributed to many risk factors, including but not limited to high IOP, a family history of glaucoma, myopia, bio in: ~| }. blood pressure, and diabetes. Age also is a critical factor [2]. The incidence of glaucoma increases approximately 10-fold between 50 and 70 years of age, ranging from about 0.2% of the population between the ages of 50 and 54 to 2.0% of the population aged 70- 74. Also, primates with experimentally induced elevations of intraocular pressure show structural [3-6] and functional [7-10] changes that are characteristic of humans with POAG, so implantation in to primates for testing will precede implantation in to humans. While it is important to note that elevated IOP is neither synonymous with glaucoma nor a guaranteed predictor of disease, it remains the most important risk factor related to the disease [1]. IOP can be associated with much of the development and progression of glaucoma damage that occurs through time. Patients with unilateral elevation of intraocular pressure that is secondary to other eye disorders often develop glaucoma. In the normal eye, intraocular pressure is maintained at ~16 millimeters of Mercury (mmHg) by a balance in the production and drainage of aqueous humor from the anterior chamber of the eye. This clear, blood-derived fluid flows from the ciliary body through the pupil to the Schlemm’s canal. The aqueous humor is then discharged through the venous system into the vascular sclera by passing through the trabecular meshwork, a sponge-like structure located in the anterior angle of the eye [11]. If the balance of the rate of production of aqueous humor and the rate of discharge is changed, the IOP is affected. A patient’s IOP experiences cyclical change on a daily basis. Fluctuations in IOP around the average value occur due to every day activity and changes in environment. IOP can show many different patterns of changes throughout a day that include impulses, .. some.“ -iv r. t '.‘ I “bar. d‘f ~ls \ piss-\h" IOP Y- 1C] In Anti. prolonged periods of high pressure, or periods of sub-normal pressure without the patient’s knowledge [12]. Measuring and monitoring of IOP is crucial for the diagnosis, treatment, management, and research of the disease. At the present time, the most common method for measuring a patient’s IOP is a procedure called tonometry [11]. While this method is considered to be very accurate for measuring IOP, there are several drawbacks. Only a single reading for the particular instant in time that the test is performed is possible. Also, a visit to a physician’s office is generally required, thus individual measurements may be separated by long periods of time. Permanent damage to many parts of the eye. including the optic nerve and retina, can result within hours of the onset if the pressures are high enough [1]. It is critical that IOP levels be monitored on a continuous basis so that pressure relieving drugs can be administered immediately after the onset of high pressures to minimize the risk of permanent damage. This monitoring system would provide benefits in both clinical and research applications. Clinically, the primary targets for such a device would be patients with severe cases of glaucoma. From a research standpoint, there are many questions that are unanswered about the true effects of IOP. Doctors still do not know what the largest concern is; the peak pressure over 24 hours, the difference between the high and low pressure measurements for a day, the cumulative IOP over a period of time, or an average IOP level [1]. It is quite possible that one or all of these factors plays a significant role in the progression of glaucoma. In this regard, such a device could lead to an extensive gain in knowledge of glaucoma and better methods of treatment. locai 1.1. dew. 1.4 0 [1. (b 1.3 Implant Options There are two options for the location of the sensor implant. The device will be located either in the vitreal chamber or the anterior chamber of the eye, shown in Figure 1.1. The implant will be attached to the wall of the eye or attached to a tether so that the device can easily be located if there is a need for it to be removed. Sensor . . chera Option 1 ° 1)V1treal chamber implant \ ‘. ‘x - —— \‘ \ ~--... gs l 1 $2 Optic Nerve \ 97/ Fi re 1.1 O tions for Im lant Location in the E e I Cornea (Macula ' Vrlreous humor ' 0 2) Anterior chamber implant Sensor Option 2 1.4 Operating Range Normal levels of IOP are considered to be around 16 mmHg. Pressures over 22 mmHg are considered to be moderately high while pressures greater than 45-50 mmHg can be extremely dangerous [1]. The pressure sensor has been designed to measure pressures in the range 0 to 60 mmHg. It should be noted that all parameters were designed with the intent of manufacturing a device that can accurately produce full-scale measurements up to 60 mmHg. However, additional safety factors were included so that the device would remain functional even if the IOP should exceed the 60 mmHg limit of the design. Chapter 2 Theoretical Background and Circuit Analysis .1- w'11nrrr I 594‘ 2.1 I, 2.1 Conceptual Overview The IOP monitoring system consists of three separate components; 1) a wireless, remote pressure sensor that is implanted inside the eye of the patient (secondary circuit), 2) a data acquisition and processing (DAP) unit located external to the body (primary circuit), and 3) a central data storage system that maintains a time record of the patient’s IOP measurements. The primary and secondary circuits communicate by means of inductive coupling (Figure 2.1). The primary circuit generates and transmits a time-wise periodic signal to the secondary circuit, or sensor. The excitation of the sensor feeds back to the primary circuit and changes the characteristics of the primary circuit. Measuring the frequency response to the periodic signal of the primary circuit provides information about the electronics, specifically the capacitance, of the sensor circuit, which is directly related to the pressure that is being exerted on the sensor. Inductive Telemetry Between Sensor \ ’3 » ' , _ and External . Central Data . Device " Database Acqursitron and And Processing Data Storage (DAP) Unit Unit (Primary Circuit) Figure 2.1 Concept Representation Implanted Sensor (Secondary Circuit) 11%:w34. qu “a“ A.» CIR. $5?» “0.. p. Ik.. I€\..l w! A schematic of the equivalent R-L—C circuit is shown in Figure 2.2. The primary circuit will have a current (i) and consists of a sinusoidal AC voltage source (V), an inductor (L), and a resistor (R). This resistor is referred to as the load resistor. The secondary circuit will be an energy-conserving transducer that utilizes a pressure sensitive, variable capacitor (C5), and an inductor (L5). Any practical inductor must be wound with a wire that has some resistance, so it is impossible to have an inductor without some finite resistance. The resistance in the coil can be considered as a separate resistor R5 in series with the inductor L3 [13]. Data Acquisition and Processing Device Sensor External to body Implanted in eye A A V ' Figure 2.2 Eguivalent Circuit 2.2 Circuit Analysis Assume that the voltage generated by the source is a forcing function of the form v(t) = V cos (wt) (2.1) For the circuit analysis, Euler’s equation will be used. Euler’s equation for complex numbers can be written as a“ = cos (out) + j sin (wt) (2.2) where we define Re [ei‘m] = cos (wt) (2.3) Im [em] = sin (wt) (2.4) From equation (2.3), equation (2.1) can be rewritten as v(t) = Re [v ei‘m] (2.5) or more specifically v(t) = Re [V cos (wt) + j V sin (0)0] (2.6) Equation (2.6) states that the original assumption for v(t) in equation (2.1) can be written as the sum of two functions; one real and one imaginary. The real part of the equation (2.6) is the initial assumed form for v(t) from equation (2.1) with a non—existent imaginary part. However, the complex notation in (2.5) is convenient for the circuit analysis, so it will be used noting that the imaginary component is non-existent in the solution. If the voltage v(t) in a circuit can be represented as a cosine function, then, in order to satisfy Kirchov’s Current and Voltage Laws (KCL and KVL respectively), the current i(t) must also be represented as a cosine function of the same frequency. As a consequence of linearity of the KVL and KCL equations, the principle of superposition holds, and the current can be derived from the expression for voltage as i(t) = I cos (cot + o) = Re [I ei‘m’] (2.7) 10 PIA AL it mum \ .hd C n . .. 1MP . l .1 -. it L .\ Jew . H“ II n i l, mu SILT undo-1J1 .idiyladflirmii. A Every steady state voltage or current in the circuit will have the same form and same frequency a) as a result of KVL. Another suitable expression for the voltage is as a complex number with magnitude and phase information v(t) = Re [vzo em] = Re [V20° ei‘m] (2.8) where O is the phase angle of the voltage equal to 0° for a pure cosine wave. Similarly, an expression can be developed for i(t). i(t) = Re [12¢ 9“] (2.9) Noting that the real part of the voltage expression is desired, the notation can be dropped for simplification. Also, the complex numbers (V40° and 11¢) represent the voltage in terms of magnitude and phase. This complex representation is referred to as a phasor and is denoted by bold letters. Rewriting our voltage and current expressions with phasor notation provides V = VAO° and I = 14¢. After substituting the phasor notation in the complex number notation of (2.8) and (2.9), the following expressions are left. v(t) = V cm" (2-10) i(t) = 1 cm (2.11) The differential equation for the primary circuit determined from KVL is thus mm + LES—to- = v(t) (2.12) Substituting equations (2.10-2.11) in to equation (2.12) gives Rrej‘”l + Lfileja’I = Vej‘“t (2.13) Note that e"m is common to every term in equation (2.13), so it can be eliminated after the differentiation, leaving just the phasors. The following equation is left R1 + ijI=V (2.14) 11 W111i; 3/ Fr Lae- t} es~ Impedance is defined as the ratio of the phasor voltage to the phasor current. From (2.14), the impedance of the primary circuit in reference to the voltage source is Z=lI/—=R+ij (2.15) In rectangular form, the impedance can be written in a general form as a complex number with real (resistive) and imaginary (reactive) components. 2(a)) = R(u)) + j X((o) (2.16) For the case of the primary circuit, the impedance from (2.15) must fit the general from in (2.16), so R(0)) must be equal to R and X(0)) must be (0L. Thus it can easily be seen that the total impedance of the circuit has a component proportional to the sum of the impedances of each of the individual elements present in the circuit. Each individual element has an associated impedance. Resistive impedance is simply the real resistance in a circuit, while inductive and capacitive impedances are both dependent on the reactance. Since inductors and capacitors respond to current, these elements are called reactive, and the opposition to current by these elements is then called reactance. Inductive reactance (XL) is defined as XL = 00L (2.17) Capacitive reactance (Xc) is given by 1 XC 3"; (2.18) When the primary and secondary circuits are in close proximity to each other, the flux in the inductor of the primary circuit couples with the inductor in the secondary circuit, and a flux is thus induced in the secondary circuit [13]. When this happens a mutual inductance (M) occurs between the circuits. 12 \ .k k.- l-Le'xa 1 ".0 .6512? I This mutual inductance serves as the pseudo driving voltage and a current is induced in the secondary circuit. From (2.15) we recall that the impedance is the ratio of the phasor voltage and current, and the total impedance is equal to the sum of the impedances of the individual elements of the circuit. An expression for the total impedance of the secondary circuit (ZS) driven by the mutual inductance can be derived. Zs(w) = Rs(w) + jXLS ((0) + jXCS ((0) (2.19) After substitution for XL and Xc in to (2.19) we get . j Z ((1)) =R ((0)+_]0)L —— (2.20) S S S at: S Notice that the resistance in (2.20) is a function of 0.). As will be seen in Chapter 6, Rs has frequency dependence because of the skin effect. This is not important to the circuit analysis that follows, but the notation will be maintained for the purpose of accuracy. The total impedance of the primary and secondary circuits based on the preceding circuit analysis is shown in Figure 2.3. External Sensor Z(w)=R-+jml. ZSUDfi=R5(m)+-flan-jhocs A A f 7 Figure 2.3 lmflances of Individual Elements 13 .,\ .. . armed—2.: “he Based on equation (2.20), the total impedance of the secondary circuit is a function of frequency. The capacitive and inductive impedances will cancel out at a particular frequency so the impedance at that frequency will be purely resistive. This frequency is called the resonant frequency and corresponds to the maximum excitation of the secondary circuit. For the inductive impedance and capacitive impedance to cancel, we must have . j aid _ 2021 J S wCS ( ) Algebraically reorganizing leads to 1 of: 1 ::m== Q23 LSCS ’ ,iLSCS measured in units of radians per second. However, it is often more convenient to use the following form 1 : 2n,/LSCS where Fr is the resonant frequency measured in hertz. E- (223) As a result of the inductive and capacitive impedances canceling at the resonant frequency, the total impedance is due to the resistance only. At resonance, a local minimum in the secondary circuit’s impedance occurs. This local minimum in the impedance corresponds to a maximum degree of excitation for the secondary circuit. The mutual inductance between the circuits results in an additional impedance of the primary circuit (XM). The result is that the total impedance of the primary circuit is related to the total impedance of the secondary circuit. The equivalent circuit is shown in Figure 2.4. 14 measurement Z((o) = R +ij+ij(w) Figure 2.4 Egulvalent Circuit Including lrngdance from Mutual Inductance The impedance due to the mutual inductance seen in Figure 2.4 is given by [13] v x M (w) = = (2.24) After substituting in the impedance of the secondary circuit, the expression for reactance due to the mutual inductance becomes 2 XM (60) = (CUM) . (2.25) Rs(a))+ja)LS 7‘; s XM((o) is inversely proportional to the impedance of the secondary circuit (ZS). As stated previously, the impedance of the secondary circuit is at a local minimum at the resonant frequency since the inductive and capacitive reactance cancel. As a result, XM((0) will have a local maximum which is dependant on Rs((o) only. Equation (2.15) imposes the constraint that the total voltage drop through the circuit must be equal to the voltage of the source or Z=¥=R+ij+jXM (2.26) 15 COT ll. £113 {of i -11 I'III" "'.‘<\— After algebraically reorganizing, (2.26) becomes [ - 2 Z=¥=R+jw L+ “M (2.27) 1 R (w)+jat -. S S Jafs d The magnitude of each cycle of the forcing function is constant. Since the combined impedance due to the inductor and the mutual inductance (jcoL + jXM) shows a local maximum at the resonant frequency, the voltage drop due to these elements is also at a maximum. To satisfy the governing equation (2.27) and the constraint of the voltage to have a constant magnitude, the magnitude of the voltage drop across the load resistor will dip (as seen in Figure 2.5) and show a local minimum since the voltage drop across the other elements is maximized. 3095- 7 Voltage Dip i 1CD 1(5 110 115 120 15 13) 1:5 140 145 13) Regatta/(Mt) Figure 2.5 Illustration of the Voltage Dip Demonstrated on a Theoretical Voltage Profile Across the Load Resistor 16 asst—H Sweeping a periodic signal through a particular frequency range and measuring the voltage across the load resistor will lead to determining the resonant frequency by finding the frequency at which the minimum occurs. While the exact measure of the dip is not significant in identifying the resonant frequency, a sharply defined dip with a large magnitude is desired so that the local minimum can be easily identified with a small margin of error. Several factors influence how sharply the voltage will dip and how large the following voltage rise will be. The effect of the resistance of the secondary circuit is to increase the frequency range that is required for the peak to occur after the voltage dip. As the resistance increases, the voltage dip will occur prior to the resonant frequency, and the rise will occur after the resonant frequency. With a resistance of 50 Ohms in the secondary circuit, for example, the frequency range will be about 5 MHz, with the dip occurring about 2 MHz prior to the resonant frequency and the peak of the rise occurring about 3 MHz after the resonant frequency. However, there is an inflection point between the voltage dip and the peak of the rise where the phase is equal to zero. This is the true location of the resonant frequency. The measurement unit could include the ability to determine phase of the signal even though phase analysis could not be performed during testing of the prototypes (Chapter 9) due to lack of equipment availability. Once the resonant frequency has been determined, equation (2.23) can be used to determine the capacitance. Since the inductance is a known, fixed value, the only variable in the equation is capacitance. The capacitance, in turn, is dependant on pressure only. Once the appropriate relationship between capacitance and pressure has been determined, the resonant frequency provides a direct measure of pressure. 17 Chapter 3 Design Parameters and Conceptual Sensor Layout 18 3.] "amnesia. .i 5-8.1.1. 4 . . l. 4 “ILL 07.; (1‘7. 1.11.3 prt ". C0:: pm ‘1 3.1 Design Parameters The design of the pressure sensor required optimization of the many linked parameters. The analysis and decision making process became complex as trade-offs in one area had to be made to improve another aspect of the design. First, the pressure sensor will be implanted in the human eye so overall size of the device is the most critical issue. The ophthalmologists associated with this project have constrained the largest dimension to not exceed about 3 millimeters. Anything larger than this could result in interference with normal vision or complicate the implantation process. Since the overall size of the pressure sensor must be less than 3 mm, this constraint is the most important parameter and will take precedence over all of the other factors in the design. Once it has been insured that the size constraint has been satisfied, maximizing the sensitivity of the device is the primary concern. It is imperative that the sensor must be made of biocompatible materials. Most MEMS sensors utilize silicon and glass, which are biocompatible. Silicon is utilized because so much is known about it, and fabrication processes used to manufacture silicon devices are much more developed than for other materials [14]. Glass is readily available and is very compatible with many fabrication processes. For these reasons, silicon and glass were chosen as the materials for all of the external structures. The design also involves optimization of the physical dimensions for each of the components. The list of important parameters that were considered and optimized is provided in Table 3.1. 19 III ‘njb’...’ 11.1. .3... .. el Table 3.1 List of Key Sensor Desig Parameters apacitance Capacitor Plate Side Length ductance Capacitor Plate Separation Frequency Range Capacitance Range Diaphragm Shape Inductor Shape Diaphragm Side Length Number of Windings Diaphragm Deflection Inductor “Wire” Thickness Diaphragm Thickness Wire Height Effects of Intrinsic Stress Gap Between Windings on Diaphragm Dynamics Quality Factor and Resistance 3.2 Conceptual Sensor Structure The base of the pressure sensor is a rigid structure, and the top surface is a flexible diaphragm (see Figure 3.1). The sensor substrate and the diaphragm are electrostatically bonded together. Thin, Flexible Diaphragm Diaphragm Support Si Wafer Glass Substrate Figure 3.1 Isometric View of Sensor 20 The substrate, or bottom wafer, will be made of glass (Pyrex). This wafer will house the electrical components of the sensor. These components include a planar spiral inductor and a conductive electrode that are deposited on to the glass substrate. The basic layout is illustrated in Figure 3.2. Gold Glass Capacitor Substrate Plate Gold Inductor Coils Figgre 3.2 Isometric View of Glass Wafer Layout The top wafer will be made of (100) silicon. This wafer will be micro-machined and heavily doped with Boron to form a thin pM silicon diaphragm. The heavy doping makes the material conductive so the diaphragm can be used as a variable capacitor along with the electrode that is housed on the glass wafer. The pressure exerted on the sensor due to the fluid in the eye will produce micron scale deflections of the diaphragm. The capacitance is a function of the electrode plate area and the gap height between the plates. The movement of the diaphragm will result in a change in capacitance due to the change in the gap height, resulting in a variance of the resonant frequency of the sensor. The 21 device is sealed with atmospheric pressure inside the capacitive chamber (a defined gap between the two wafers). The sensor system provides measurements relative to the pressure inside the cavity (Figure 3.3). ,- ,—" ’0 ‘- 5' — — a " Diaphragm P++ Silicon Membrane 4! .e N r-v ' \ Fixed Cap Plate / Inductor Coils Support Substrate(G]ass) Figt_1re 3.3 Differential Pressure Sensor M The inductor will be a planar spiral that will be made of gold electroplated on the glass substrate. A square spiral was chosen because of the ease of the layout and the symmetry. In general, planar inductors have a relatively low quality factor, or ability to absorb or emit energy, compared to other common forms of inductors, but the inductance value is well defined over a wide range and is tolerant to process variations [15]. This is important because MEMS processes typically have a relatively high degree of variability due to the micron-scale features that are present [14]. The quality factor is discussed in detail in Chapter 6. 22 Chapter 4 Capacitor Plate and Diaphragm Design 23 uni-.312: . is... .2 4.1 Design Variables The variable capacitor consists of two parallel conductive plates (see Figure 4.1). One of the plates in the sensor is a glass wafer with a thin layer of gold electroplated on to it. The second plate is made from the p” silicon diaphragm. A square capacitor plate was chosen so that the sensor would be symmetrical. Symmetry of the sensor will ensure that the electric field around the sensor will be symmetric as well. This way, orientation of the sensor inside the eye will not affect the quality of the inductive coupling between the circuits. figure 4.1 Va_riables for Desigp of a Capacitor The capacitance between 2 parallel plates is given by 880A C = d (4.1) Since the capacitor plate is square, A is equal to (m x m = m2). 24 A sensitivity study will be performed to determine the optimum capacitance range and corresponding resonant frequency range of the sensor, which will, in turn, dictate the physical dimensions of the capacitor plate. Again, the goal is to optimize the sensitivity of the device to pressure. 4.2 Analysis to Determine the Capacitance Range The full-scale deflection of the diaphragm and the maximum change in capacitance from the initial value is designed to occur at a pressure of 60 mmHg. The magnitude of the deflection is the key result that will be used to prescribe all of the other parameters. The design of the sensor was an iterative process. The first step in the design process was to estimate the initial capacitance of the device. It is desired to have as large a range for the resonant frequency as possible so that a small change in pressure produces a relatively large change in the resonant frequency. Equation (2.22) shows the dependence of the resonant frequency on the inductance and capacitance values. 1 21rd LC Equation (2.23) is used in Figure 4.2 to calculate the resonant frequency as a Fr = (2.23) function of capacitance for various inductance values. The inductances that were chosen are on the order of hundreds of nano-Henries due to the constraints imposed by fabrication. 25 :ii 140« I“. >. 120 a 2 g 100 ~ E 80 . IL ‘5 60 4 E c 40 C O a: 20 . . 0 0.005 0.01 0.015 0.02 0.025 0.03 Capacitance (nF) + L=600 nH + L=700 nH + L=800 nH -)(— L=1200 nH + L=2000nH Figure 4.2 Resonant Frequency as a Function of Capacitance for Various Inductance Values It can be seen in Figure 4.2 that the change in frequency due to a change in capacitance greatly increases as the capacitance decreases. This basic trend is true regardless of the inductor value that is used in the calculation. As shown by the steep slop of the plots in this region, the sensitivity of the resonant frequency range to capacitance change is highest when the capacitance is on the order of 1 to 3 pF. 4.3 Initial Capacitance Value To begin the design process, an initial capacitance of 2.0 pF was chosen for the first iteration. Six gap heights were considered so sensitivity to gap height could be revealed, and an optimum gap height could be determined. The gap heights used in the analysis are 1.5 um, 1.6 um, 1.7 um, 1.8 mm, 1.9 um, and 2.0 urn. The next step was to determine the side length of the capacitor plate that is required to achieve the desired capacitance for several different initial gap heights. Figure 4.3 shows the required side length of a square capacitor plate as a function of the initial gap height to achieve an initial capacitance Co = 2 pF from equation (4.1). It can 26 q .3 it“! 5... c.1313. I ’- p be seen that the side length of the capacitor plate increases from 582 microns to 672 for an initial gap height increase of only 0.5 microns. The capacitor plate size that is required to achieve a particular capacitance is very sensitive to small changes in the gap height. Capacitor Plate Side Length (um) 1.5 1.6 1.7 1.8 1.9 2 Initial Gap Height (um) Fig 4.3 Required Capacitor Plate Side Length as a Function of Initial Gap Height to Achieve Co=2.0 pF Figure 4.3 shows two valuable pieces of information. First, by reducing the gap height one can reduce the required side length of the capacitor plate. Second, the actual capacitance of the device is highly dependant on the accuracy of the value of the capacitive gap. For example, if an initial gap height of 1.5 microns is desired for a capacitance of Co = 2.0 pF (i.e. the electrode has a side length of 582 microns) and the actual gap height is 1.9 microns, the actual capacitance will be C0 = 1.57 pF. Thus, the actual initial capacitance Co will be 21% smaller than the expected value. This problem can easily be accounted for during calibration of the device, but it is still an issue during manufacture. 27 4.4 Analysis of Diaphragm Deflection The next step in the process was to determine the relationship between the capacitance and the pressure. The deflection of the diaphragm due to the application of an external pressure is dependant on the diaphragm’s shape. There are two shapes of diaphragrns that are commonly used in MEMS devices; square and round (see Figure 4.4). Of course, it is possible to use rectangular shaped diaphragms. However, for the rectangular shape non-uniform stress distributions develop due to the lack of symmetry of the structure, thus decreasing the sensitivity of the sensor so a rectangular shape was never considered. Length = 2a Diameter = 2r Length: 2a Thickness = h i Support Rim Figpre 4.4 Diaphram Shaw and Variables 28 The relationship between pressure difference, diaphragm dimensions, material properties and deflection for a stress free square diaphragm is given by [16] 24 h3 4 w w 3 P=——E—P— 4.20—9+1.58—C— (4.2) l-V a h and the relationship for a stress free round diaphragm is given by [14] 3 E E 16wc+(7-v)wC p: l—v2 r4 311 3h3 (4.3) It should be noted that the diaphragm is supported at the edges as seen in Figure 4.4 so the maximum deflection occurs at the center of the diaphragm. The maximum stress due to bending occurs at the edges. A major part of the design to address is the selection of the material of the diaphragm. In MEMS applications, the films are generally on the order of a few microns thick, and thus they may not have the same material properties as the bulk material [17]. Silicon is not an isotropic material so both the stress and strain are second rank tensors with a stiffness matrix consisting of 81 coefficients [17]. However, due to symmetry along several cryptographic planes of the silicon molecule, the stiffness matrix of silicon only has three independent coefficients. As a result, an isotropic average must be used in the determination of Young’s modulus. There are many published values for Young’s modulus, Poison’s ratio, and the density of thin film silicon. For the purposes of this analysis, the following values were used. 29 Table 4.1 Promrties of Thin Film Silicon Used in Analysis |17 | Young's Modulus 160 GPa Poison's Ratio 0.05 Density 2300 ngmAS Typical theoretical models for pressure sensors utilize small-deflection plate theory and neglect built in stress (called intrinsic or residual) in the diaphragm that result from the fabrication processes [16]. Analysis will begin with a model, which assumes the diaphragm to be stress free, and then the effects of built in stresses due to fabrication will be introduced. There are two reasons for choosing an initial gap height significantly larger than the maximum deflection of a particular design. First, it is possible for a patient to experience IOP higher than the upper limit of 60 mmHg that the device is designed for. For this reason, it is important that the plates do not touch as such a condition could jeopardize the device’s functionality. The larger gap height accounts for a safety factor against a short circuit in the sensor. Second, the fabrication of the device (see Chapter 8) requires an etching step to define the gap between the capacitor plates. Current silicon fabrication processes can control silicon etching to within about 1 micron so there is a window of error associated with the fabrication [14]. To account for this, a larger gap will be used as a safety factor to account for variations due to the fabrication processes. For the thin plate model to be accurate, the deflection must be relatively small compared to the thickness of the diaphragm. The analysis is conducted over a range of maximum deflection magnitudes from 0.3 microns to 0.5 microns. 30 The next step was to determine the side length (square diaphragm) or diameter (round diaphragm) of the diaphragms so that a comparison of the relative size for each of the theoretical designs can be made. Figure 4.5 presents a comparison of the required side length/diameter as a function of thickness to achieve each of the three deflections at a pressure of 60 mmHg. Equations (4.2) and (4.3) were used to generate Figures 4.5a and 4.5b respectively 700 m. ....._.... 1.. a) Square Diaphragm geso ~ / .§ 600 — » ~ ~ ~ ‘8' 550 g . V . I ,. _ ‘6) / 5 500 //" ‘ _I o 450 -+ 2 ‘0 400 . . E 3 0 0.3 micron deflection _ 5 H o e §300 0.4 micron deflectlon 1: . . 0.5 micron deflection 01 01 O O 1 .b 01 C 1 0.3 micron deflection 0.4 micron deflection (D h 01 C O o ‘1 l Required Diameter (microns) 0.5 micron deflection (.0 O O { 3 3.5 4 4.5 5 5.5 6 6.5 7 Diaphragm Thickness (microns) l" 01 Figure 4.5 Required Side Length and Diameter of Stress Free Diaphram For Each Case of Maximum Deflection at 60 mmHg 31 The side length/diameter of the diaphragm that is required to achieve a specific magnitude of deflection greatly increases with an increase in thickness. This intuitively makes sense since the diaphragm’s resistance to bending, or stiffness, increases with thickness. The stiffness is reduced by increasing the side length so the desired magnitude of deflection can be achieved. The diameter of a round diaphragm of a particular thickness is about 6.3% larger than the side length of a square diaphragm of the same thickness for each of the three designs (Figure 4.6). When taking in to account that the diagonal of the square diaphragm is about 30% larger than the diameter of a round diaphragm, the total amount of space occupied by either shape on a wafer is similar. There is not a clear advantage of choosing one shape over another from a size perspective. Diameter = 2r Length = 2a 2rz l .063 (2a) Fi re 4.6 Basic Size Com arison for S uare and Round Dia hra ms 32 For both the square and round diaphragms, an increase in the maximum deflection at 60 mmHg increases the required side length/diameter of the diaphragm for a particular thickness. Again, this intuitively makes sense. If it is desired to achieve a larger deflection at the maximum pressure of 60 mmHg, the diaphragm’s stiffness must be reduced by increasing the side length/diameter of the diaphragm. It should be noted that the first term in (4.2) and (4.3) dominates at small wC/h so the relationship between pressure difference and deflection becomes almost linear as seen in Figure 4.7. Since the deflection is very small, equation (4.2) can be written as 4 w3 4 P = E 2 3,-1— 4.20&+1.58—39 a E 2 EXP-203$] (4.4) l— V a h h 1— v a h and equation (4.3) becomes 4 3 4 16 7 - V w P=—E——L WC+( )C 5 E h—5.331C— (4.5) l—V2 r4 311 3h3 l—v2 r4 h 0'5 0.5 micron deflection design 0.45 0.4 0.4 micron deflection design ‘3‘ E 0'35 0.3 micron deflection design 2 0.3 E. c 0.25 3 0 2 g 01.5 8 e .0 .—L 0.05 0 1 0 20 30 40 50 60 Pressure (mmHg) Figure 4.7 Deflection as a Function of Pressure for Stress Free Diaphragm (Sguare or Round) for Various Maximum Deflections at 60 mmHg 33 The plots in Figure 4.7 are for both a square and a round diaphragm. Since the side length/radius in equations (4.2) and (4.3) respectively are designed for the same pressure and deflection ranges, the constants in front of the deflection terms are already included in the aside length/radius calculations. Figure 4.7 shows the maximum that the diaphragm will deflect as a function of pressure if the side length/diameter have been designed for each case of deflection at 60 mmHg. A square diaphragm can easily and accurately be fabricated because of the anisotropic nature of the silicon crystal structure. The (100) and (111) crystallographic planes in the silicon lattice intersect at right angles on the surface of a (100) silicon wafer. Since there are multiple (111) planes in a silicon crystal, the intersection pattern makes it easy to etch square and rectangular features [14]. This way, the capacitive cavity and diaphragm can be defined by etching both the top and the bottom of the silicon wafer. The support structure used to suspend the diaphragm above the glass wafer is a part of the silicon wafer. An illustration showing the diaphragm can be seen in Figure 4.8. The details of the square diaphragm fabrication are explained more thoroughly in Chapter 8. While the crystalline structure is very conducive to etching in straight lines, it makes precisely etching circular patterns in to silicon impossible. Instead etching away small areas of a silicon wafer to define the support structure along with the diaphragm like described previously, the round diaphragm must be defined by other methods. The area of a round diaphragm must be defined by doping a portion of the silicon making it conductive, and all of the non-dOped material is dissolved away. Since the support structure cannot be conductive because it would interfere with the on-chip electronics, it cannot be fabricated as part of a round diaphragm for this application (Figure 4.9). 34 Bottom View Side View Diaphragm i \ Support Structure / And Bonding Surface 4.8 Illustration Showin Su rt S cture on S uare Dia hra 4 Doped Rgion ,. , .2 a Diaphragm Top View 4.9 Illustration of Round Diapm Formation 35 adage . We'd-131E v.7” . For most applications, creating a support structure on the substrate does not pose a problem. However, the inductor is housed on the glass wafer below the diaphragm, and since the electronics are housed on the substrate, it would be difficult to deposit an additional fihn on the substrate and pattern it properly so that the support structure could be constructed without compromising the quality of the electronics. As a result, it was decided to utilize a square diaphragm instead of a round structure. 4.5 The Capacitance-Pressure Relationship The capacitance as a function of pressure difference for various initial gaps and maximum deflections is seen in Figure 4.10. The plots are generated by combining the results from the deflection-capacitance relationship in (4.1) with the pressure-deflection relationship in (4.2) while assuming an initial capacitance of 2.0 pF. 36 9:... mini... r I [‘3 or a) 0.3 micron deflection V A 2.4 ,xfx/r IL ,x . 9; ”x )(_..X/././l’. a 2 s .w : fer” ‘ g )6)“ g 2.2 - fl; """ O. .2 8 2.1 a 2 2.8 L b) 0.4 micron deflection 1 I" o: Capacitance (pF) N A Capacitance (pF) 0 10 20 30 40 50 60 Pressure (mmHg) + initial Gap = 2um + Initial Gap = 1.9 um + initial Gap =1.8 um mew Initial Gap = 1.7 um —4— Initial Gap = 1.6 um —e— initial Gap = 1.5 um Figure 4.10 Capacitance as a Function of Pressure for Various Initial Gap Heights Using an Initial Capacitance Co = 2pF 37 Figure 4.10 reveals several important trends. First, the capacitance is more sensitive to pressure difference as the initial gap height becomes smaller. This is seen by the larger capacitance change over the full-scale pressure differential range shown by the capacitor with a 1.5 micron gap than for the capacitor with a 2.0 micron gap. For the 0.5 micron maximum deflection case, the capacitance value changes 1.0 pF over the 0-60 mmHg scale when the initial gap is 1.5 microns, while the capacitance change when the gap is 2.0 microns is 33% less at 0.67 pF. The difference in the capacitance range between a 1.5 micron gap and a 2.0 micron gap for the 0.4 micron maximum deflection is 31% and 28% for the 0.3 micron maximum deflection design. Using a smaller initial gap and a larger total deflection for 60 mmHg increases the sensitivity of the capacitance to pressure. It is important next to understand how resonant frequency changes as a result of the capacitance change. The relationship between capacitance and the resonant frequency can be seen in Figures 4.11 assuming a constant inductance of 800 nH, an initial capacitance of 2.0 pF, and using the capacitance ranges from Figure 4.10 for each of the three cases of deflection. 38 314.3” Unifiih IA -. . a) 0.3 micron deflection ' b) 0.4 micron deflection —LA—L—t—bA—L—L-L—L—A—L—L—t-A—L—L—A—l—A—L—L—L—L—L-L—L—L COCO-AAdiiNNNNNOOOO-‘A-‘A-‘NNNNN Nkmmow#mmON-bmmN-kmmON-meON-kwm c) 0.5 micron deflection l L l i 1 i l l l l 1 1 i . 1 .J—L-L—L—L—L—L—L—L-L—t—L—L—L 0000 44-5-4410 NNNN mem om-tsaamo N-kmm I . I I 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 2.9 3 Capacitance (pF) +lnitial Gap = 2 um --a-- Initial Gap = 1.9 um --*-—- Initial Gap = 1.8 um ~-2~e- Initial Gap = 1.7 um —-1— Initial Gap = 1.6 um —e—initial Gap = 1.5 um Resonant Frequency (MHz) Resonant Frequency (MHz) Resonant Frequency (MHz) Figure 4.11 Resonant Frequency as a Function of Capacitance for Various Initial Gap Heights and Maximum Deflections Using an Igluctance of 800 n_H 39 H. “11.1.90. 1....ij . >/ Figure 4.11 shows that the resonant frequency range increases as the capacitance range increases. This agrees with the information shown in Figure 4.2. The capacitance range increases with the maximum deflection. The trends in the figure indicate that a larger deflection will result in a larger resonant frequency range. All of the analysis presented previously in this chapter leads to the decision to use a maximum deflection of 0.5 microns and a capacitance gap of 1.5 microns. As a check, the relationship between the resonant frequency and the pressure is plotted for each of the three deflection cases from Figure 4.11. Figure 4.12 shows the resonant frequency as a function of pressure difference for various initial gap heights and maximum deflections using an inductance of 800 nH. It can be observed that the largest change in resonant frequency for an incremental change in pressure occurs when the maximum deflection is 0.5 microns and the initial gap is 1.5 microns. 40 126 124 — —- 120 118i 115 - 114 . Resonant Frequency (MHz) 122 4 A A. ,- a) 0.3 micron deflection I 777177 112 125 122 119 116 113 110 Resonant Frequency (MHz) 107 126 —l d .5 1 110 4 106 ‘ Resonant Frequency (MHz) \\ \“_ 122«~ ~ ~ \N; 102 0 10 +Initial Gap = 2 um ,. |nitia| Gap = 1.7 um I 20 30 Pressure (mmHg) +Initial Gap = 1.9 um ——1—initial Gap = 1.6 um 40 50 +Initial Gap = 1.8 um —e—-lnitial Gap = 1.5 urn Figure 4.12 Resonant Frequency as a Function of Pressure for Various Initial Gap Heigpts and Maximum Deflections Using an Inductance of 800 nH 41 The final parameter to be addressed is the initial capacitance value. Figure 4.13 provides the required capacitor plate side length required as a function of initial gap height for various values of initial capacitance. Decreasing the size of the capacitor plate allows for the diaphragm size to decrease allowing for a smaller final device, which is highly desirable. O) \l O ~c0=2.0p1= ~ A - 6501 C0=1.9pF .2 2- I , _,_,-_ 630 - (30:13 PF 2 4 , C0=l.7 pF ' 5 K 610 - , O 590 ~ 570 a 550 " Required Capacitor Plate Side Length (um) 530 ~ 1.5 1.6 1.7 1.8 1.9 2 Initial Gap Height (um) Figure 4.13 Capacitor Plate Size versus Initial Gap Height as a Function of Initial Capacitance Table 4.2 shows that the total resonant frequency range increases when the initial capacitance value decreases. The resonant frequency range is 8.5% larger for an initial capacitance of 1.7 pF than for an initial capacitance of 2.0 pF. Observations from Figure 4.13 and Table 4.2 support using an initial capacitance of 1.7 pF. 42 Table 4.2 Size of Resonant Frequency Range Over a Range of Deflection of 0-0.5 microns For Various Initial Capacitance Values Frequency Range Capacitance (pF) (MHz) 1 .7 25.04 1 .8 24.34 1 .9 23.69 2 23.09 Based on the previous analysis, the capacitor will have an initial gap height of 1.5 microns with an initial capacitance of 1.7 pF. From Figure 4.13, a side length of 537 microns is required to achieve this capacitance. The full-scale deflection of the device will be 0.5 microns at 60 mmHg resulting in a capacitance of 2.55 pF. 4.6 Effects of Residual Stress on the Diaphragm’s Dynamies and Sensitivity Almost all thin films have a certain amount of residual stress built in [14]. Residual stress significantly influences the load-deflection behavior of diaphragms. The diaphragm will be made of silicon that is heavily doped with Boron. Introducing the Boron impurities in to the silicon wafer introduces considerable residual tension in the diaphragm [18]. It is typical for the residual stress in p++ silicon to be around 40 MPa [19]. Residual tension results in a resistance to bending in a diaphragm. The additional pressure needed to deflect the diaphragm is calculated by equation (4.6) [20]. PS : [EC—h] (4.6) 2 a The principle of superposition allows for this term to be added to the original expression given in equation (4.2). 4 w3 4 2 P: E h [4.20%+1.58 C+ 05“ WC] (4.7) l—v2 a4 h3 E 113 43 0’. 9.101.153 P”. /. The presence of a residual tensile stress increases the stiffness in a diaphragm so it will not displace as much for a given pressure load as will a stress free diaphragm. A plot using dimensionless units of displacement and position across the length of the diaphragm is shown in Figure 4.14 [14]. As a result of the increased stiffness, a diaphragm designed for a particular deflection at 60 mmHg will deflect less than expected if there were no residual stress. -O.2 2 I 7 i i 1 ° " " ‘ 1 1 1 "‘ 0'2 ~ ‘ ‘ os=ZSOMPa . 0.41 r ‘ . .' ' £05 "‘ “N 100 " L - 0.8 . 25 10 1— 1 ‘. "“_ 03:0 | l L 0 20 40 60 so 100 Position Fi re 4.14 Effects of Residual Stress on Dia hra Deflection 14 Figure 4.15 contains the deflection pattern of a diaphragm designed to deflect 0.5 microns at 60 mmHg. The plot shows the expected deflection of the stress free diaphragm as predicted by equation (4.2) and the deflections that will result when 40 MPa of stress is present in the- diaphragm from equation (4.7). The relationship between the deflection and pressure difference will be the same for a stress free diaphragm of any thickness as long as the side length is designed accordingly. The line representing the general stress free state in Figure 4.15 is independent of thickness. However, the deflection that will result from introducing residual stress into the diaphragm depends greatly on the thickness. A thick diaphragm is less affected by the presence of residual stress than a thinner diaphragm. A 7 micron thick diaphragm designed with an appropriate side length for a stress free state by equation (4.2) will deflect 36% less than expected if the actual stress is 40 MPa. The stress has a more significant effect on a 2.5 micron thick diaphragm. The deflection is reduced by 50% compared to the stress free deflection. 0'5 T General Stress Free State 0'45 I 7 micron diaphragm thickness 0.4 . 4 4 micron diaphragm thickness 0.35 ~ 2.5 micron diaphragm thickness 7 , fl . .0 CO 1 1 .0 N or Deflection (microns) .0 N p .2 01 0.1 »- ~ ~ , ~ 0.05 -. 0 10 20 30 40 50 60 Pressure (mmI-lg) Figure 4.15 Effects of 40 MPa of Residual Stress on a Diaphragm Desiged to Deflect 0.5 microns at 60 Mg The reduction in deflection that occurs when introducing residual stress compared to the stress free state will result in a smaller capacitance range than would be expected since the gap height is related to the deflection. In turn, a smaller resonant frequency range will be covered over the full-scale pressure range. As a result, the sensor system will not operate according to theory. 45 Closely associated with the deflection is the overall sensitivity of the device to pressure variation. The sensitivity S of a variable gap capacitive pressure sensor is given by [14] _ 2 4 1 V 337—(m2/N) (4.8) h d S = 0.0746 The silicon diaphragm will be in tension due to the Boron impurities that were introduced in to the silicon to form the p++ silicon. Figure 4.16 shows that the sensitivity of a diaphragm’s deflection to pressure decreases as the tensile stress is introduced. 100 cznrta DEFLECTION to (councssaou) reassure sensmvnv (coueacssmn) "casual: ssnsrrwrrv . (751151011) czurca DEFLECTION J NORMALIZED PRESSURE SENSITIVITY AND DIAPi-RAGM CENTER DEFLECTION 0.1 (reason) 0.0: j v v v v v r u 1 I r T v Y r 1 r I 1 ‘l’ I v 11111 0.1 I 10 100 DIMENSIONLESS STRESS, (1-u’)a,a’/£h’ Figure 4.16 Effects of Residual Stress on the Deflection of a Diaphram |14| Equation (4.8) shows that the sensitivity is a function of the size of the diaphragm, the material properties, and the capacitive gap. As a result, the sensitivity of the device changes as the diaphragm is deflected. Figure 4.17 shows the sensitivity of the device to pressure as a function of deflection for various maximum deflections at 60 mmHg. It is apparent that a device designed for a large deflection (0.5 microns) is 97% more sensitive than the device 46 designed for a small deflection (0.3 microns). This again supports the decision to design for a 0.5 micron deflection. 6.7000E-03 5.7000E-03 - ' * ' , D 7.: 47000503 ‘ 0.5 micron deflection in a: 9999 E , g a.- E .. Q.:L: : 3 . E 3.7000E-03 fi 04 . (1 fl ti ' . rmcron e ec on E \‘ .3 M r: «3 270005-03 - ~~ 1.7000E-03 0.3 micron deflection 7.0000E-04 0 0.1 0.2 0.3 0.4 0.5 Deflection (microns) Figure 4.17 Sensitivity as a Function of Deflection for Various Cases of Maximum Deflection at 60 mmHg of a Square Diaphragm with Initial Gap =1.5 and Assumed Residual Stress of 40 ME; So that the desired full-scale deflection and a high sensitivity can be achieved, the side length of the diaphragm must be increased to compensate for the residual stress. Figure 4.18 provides a comparison of the new required side length that accounts for 40 MP3 of residual stress to the former side length from the stress free model. 47 850 750* 650 ~ 550 — 450 ~ Required Side Length 2a (microns) 2.5 3 3.5 4 4.5 5 5.5 6 6.5 7 Thickness (microns) +0.3 Design w/ Stress +0.4 Design w/ Stress +0.5 Design w/ Stress —~%-- 0.3 Design w/o Stress -B-— 0.4 Design w/o Stress +0.5 Design w/o Stress Figure 4.18 Required Side Lengths as a Function of Thickness for Stressed (40 MPa) and Stress Free Diaphw The electrode and diaphragm must have roughly the same area. It was decided to use a side length of 537 microns for the capacitor plate in Section 4.5 with a maximum deflection of 0.5 microns at 60 mmHg. The diaphragm must have a side length equal to or slightly greater than 537 microns. From Figure 4.18, the thickness of the diaphragm must be 4 microns, and the side length will be 551 microns. The final observation is the effect of the capacitive gap on the sensitivity. Figure 4.19 shows the sensitivity as a function of the deflection for various initial gaps. It can be observed that the sensitivity can be increased by 50% by decreasing the initial capacitive gap from 2 microns to 1.5 microns. 48 5.7000503 520005034 4 4.7000503. . . _ - _- _ . W, 4.2000E-03 5 3.7000E-03 ., " ' Sensitivity (mmHgA-1) 3.2000E-03 V I . I - , - -. ,1 2.7000E-03 i . ~ 0 0.1 0.2 0.3 0.4 0.5 Deflection (microns) +2.0 micron Cap gap +1.9 micron Cap gap +1.8 micron Cap gap -e<-~ 1.7 micron Cap gap --1—1.6 micron Cap gap —e— 1 .5 micron Cap gap Figure 4.19 Sensitivity as a Function of Deflection for Various Initial Gaps of a 4 micron thick Square Diaphragm with an Assumed Residual Stress of 40 0123 4.7 Final Capacitor Design Table 4.3 Summagy of Capacitor Desigp Shape Square Plate Side Length 537 microns Initial Separation 1.5 microns initial Capacitance 1.7 pF Separation at Full Scale Deflection 1.0 microns Final Capacitance 2.551F 49 c0=1.7 pF CFS=2.55 pF / Diaphragm 1.5 micron Initial Gap 1.0 micron Gap at Full Deflection 537 microns Fixed C apacitor Plate Figpre 4.20 Illustration of Final Capacitor Plate Desig Table 4.4 Summagy of Final Diaphram Desigp Shape Square Diaphragm Thickness 4 microns Side Length 551 microns Full-Scale Deflection 0.5 microns 54.7 ° 551 microns \ | «.x' a. 4 microns l F igpre 4.21 Illustration of Final Diaphram Design 50 Chapter 5 Inductor Design 51 5.1 Design Variables The design of the inductor consists of determining the line thickness, number of turns, turn spacing, width, inside and outside diameter while maximizing the quality factor (Q) and minimizing parasitic resistance within the overall device design. 5.2 Planar Inductors Planar inductors of any shape are characterized by the number of turns (11), the spacing between turns (s), the line width of the conductive material (w), inner and outer diameters (due and dom- respectively in Figure 5.1), and the fill ratio defined as Tl = (dour- diN) / (dour+ dm) [15]- Ifigpre 5.1 Planar Spiral Inductor Layout with n=3 Turns |15| 52 In the specific case of this pressure sensor, the capacitor plate will be in the center, and the inductor will spiral away from the capacitor plate. The turn spacing and the size of the capacitor plate determine the inner diameter (Figure 5.1). The inner diameter will be equal to the size of the capacitor plate plus two times the turn spacing. The thickness of the wire (tw) imparts only a very small effect on the inductance, so it can be neglected in the inductance calculations [15]. However, any practical inductor must be wound with wire that has a finite resistance, so the coil will have resistance associated with it due to the length of wire. From the RLC circuit point of view, the resistance can be considered to be a separate resistor in series with the inductor [13]. The line thickness is very important when determining the resistance of the inductor. This part of the analysis is contained in the following chapter. 5.3 Design Considerations on Determining the Inductance Value The design of the inductor was an iterative process similar to the process used to determine the optimum capacitance in the previous chapter. The first step of the design was to make an estimate for the inductance. Again, the most important design parameter that is dependant on the inductance is the desired resonant frequency range. Equation (2.22) describes the dependence of the resonant frequency on the inductance and capacitance values. 1 21rd LC Figure 5.2 shows the resonant frequency range as a function of the capacitance for Fr: (2.23) six values of inductance based on the design considerations in Chapter 4. 53 Resonant Frequency (MHz) 0.0017 0.0019 0.0021 0.0023 0.0025 Capapcitance (nF) -O— L=600 nH + L=700 nH + L=800 nH -X-— L=1200 nH + L=2000nH Figure 5.2 Resonant Frequency as a Function of Capacitance for Various Values of Inductance The total range of the resonant frequency for a particular capacitance change is important to observe in Figure 5.2. Lowering the inductance value increases the total range of the resonant frequency for a particular capacitance range. For example, for a capacitance range of 0.0017 to 0.00255 nF, the range of resonant frequencies with an inductance of 2000 nanohenries (nH) is about 16 Megahertz (MHz) while the range with an inductance of 600 nH is about 29 MHz. Thus, a smaller inductance is beneficial in improving the sensitivity of the resonant frequency to a capacitance change based on the observation that the size of the frequency range becomes larger as the inductor value decreases. However, computational simulations indicate that larger inductors increase the magnitude of the responses for both the primary and secondary circuits. As the inductance value becomes larger, the voltage across the sensor’s capacitor at resonance 54 [1.1-4 4 ’1’0I 1.4., .0) increases. Also, the magnitude of the voltage dip across the load resistor increases with higher inductor values. This observation is important because the frequency at which the voltage dip occurs is used as the measurement to determine the pressure in the eye. It is desired to maximize the magnitude of the dip so that the resonant frequency will be easily identified. The general trends of the frequency responses as measured across the load resistor and the sensor capacitor is shown in Figure 5.3. h '2 02 a! ' 5 u 5 3 As inductance increases } a: 1: 0.15;; 8... 3%01 §e g 0 0.05: a ’3 > 0 53 2 “’0 g% 1.5 5.8 <0 1 . . , _ O“ i 1‘ mn- } i to O > 01 , , T 90919293949596979899100 Frequency(MI-Iz) Figure 5.3 Basic Trends of Circuit Excitation as a Function of Fregpency Towards Changes in Inductance Figure 5.2 shows that a smaller inductance value improves the sensitivity of the resonant frequency to changes in capacitance. However, a large inductance is needed to increase the magnitude of the frequency responses. A balance between both sensitivity 55 'I‘. I- \~v and accuracy must be made to optimize the sensor’s overall performance. The balance will be established by considering limitations on fabrication capabilities and a comparative look at the relative importance of the inductor value on the sensitivity and the magnitude of the frequency responses. Information from discussions with several MEMS fabrication facilities indicates that it is difficult to obtain inductances larger than about 1200 1111 on MEMS devices. The inductance value that can be obtained is limited by the size constraints imposed because the device will be implanted in the eye. Planar inductors grow quite quickly in radius, so the size of the device is significantly affected by attempts to increase the inductance. Therefore, an inductance of 1200 nH will be considered to be the upper limit that can be obtained for this particular device. Based on Figure 5.2, the resonant frequency range for an inductance value of 1200 nH is about 20% smaller than the range for an inductance of 800 nH. Additionally, the resonant frequency range with an inductance of 800 1111 is still 13% smaller than with an inductance of 600 nH. The magnitude of the voltage dip increases by roughly 33% by increasing the inductor value from 600 nH to 800 nH, and another 33% by increasing the inductance from 800 ml] to 1200 nH. The magnitude of the voltage dip increases for higher resonant frequencies. Decreasing the inductance value results in the shifting of the frequency range to higher frequencies (Figure 5.2). By lowering the inductance value, the resonant frequency will occur at higher frequencies, and the magnitude of the voltage dip will be larger. 56 An inductance of 600 nH will result in a small voltage dip across the load resistor (~ 7 mV). A 7 mV voltage dip will be very difficult to observe. It was decided to use a larger inductance to increase the magnitude of the voltage dip for the purpose of improving the accuracy despite the decrease in sensitivity of the resonant frequency to capacitance. However, the magnitude of the voltage dip increases with resonant frequency. Thus, the range of resonant frequency becomes larger and occurs at higher frequencies for a smaller value of inductance. For this reason, it would be undesirable to chose the maximum inductance of 1200 nH. Also, the size of the device increases with increases in inductance so an moderate value of 800 nH was chosen to balance between the sensitivity and the accuracy of the device. 5.4 Computational Analysis for Design of a Planar Inductor Mohan provides three different design equations for calculating the inductance of a square spiral [15]. The first method is a simple modification of Wheeler’s formula and is given as n2[dou*r +dIN] 2 (5.1) LMW = Klpo 1+ K21] Mohan’s second equation is based on the current sheet method. This method considers each of the sides of the spiral as symmetrical current sheets of equivalent current densities. The expression for inductance is given by 2 an d c c LGMD = 2V0 1 [ln[—;-]+c3p+c4p2] (5.2) 57 159V! ... .E. a g... .P. H/ The final equation used by Mohan to evaluate the inductance is the empirical expression LMON = [SdOUTOll aszVGU3na4su5 (5.3) All of the calculations in this chapter are performed with the intent of designing a sensor with an inductance of about 800 nH. However, it is desired to have a symmetric device so that orientation of the device inside the eye does not compromise the quality of the wireless telemetry. The 800 nH inductance was not held as a strict limit so that a symmetric device could be designed. The following calculations were performed for each full turn of wire. Fractions of turns were not allowed. The analysis was performed using all three equations. Consider first an inductor that has a line width of 6 microns. The inductance can be found as a function of the number of turns of wire for each of the three equations for various line widths, as seen in Figure 5.4. 58 900 ~ , . a) Spacmg = 10 rmcrons 750 - O) O O 450 . 300 Inductance (nH) 150 - ‘ b) Spacing = 6 microns \l 0'! O 1 Inductance (nH) .p U! o c) Spacing = 4 microns Inductance (nH) . a g e a a g O 2 4 6 8101214161820222426 Turns(#) -x— 15015.1 —e—EJ\I5.2 +EN5.3 Figure 5.4 Inductance as a Function of the Number of Turns for Comparing the Precision of Equations (5.2-5.4) For Various Line Spacings Using a Constant Line Width of 6 microns 59 .34. . _. pl . In. IE Iv.) An inductance 800 nH can be achieved with 25-26 turns of wire based on Figure 5.4. It was decided to use 26 turns initially because it was shown in Section 5.3 that a higher inductance would result in increased magnitude of the frequency response of the primary and secondary circuits. The three equations produce very similar results. The difference between the largest and smallest values at 26 turns is 3.2% of the smallest value in Figure 5.4a. The difference at 26 turns in Figure 5.4b is 5.7 % of the smallest value, and the difference in Figure 5.4c is 2.7%. Inductor tolerance is usually on the order of several percent [15], and the errors associated with all three methods when compared to field solver simulations performed by Mohan are on the order of 1-3%. Previously published results studied by Mohan typically show errors on the order of 20% so the expressions in (5.1)- (5.3) are the most accurate expressions for inductance that could be identified [15]. All three expressions for the inductance approximation are equally valid for the purposes of this model so there is no need to continue the analytical modeling using all three expressions. Equation (5.3) will be used in the subsequent calculations because the equation is the result of a curve fit of over 19,000 known inductors [15] so it is proven to be quite accurate. Figure 5.5 shows that the inductance is affected by the turn spacing (about 10% difference between a spacing of 4 microns and 10 microns). If a spacing of 10 microns and a line width of 6 microns are used, the number of turns can be reduced to 25. However, the 25 turns of coil will have an outer diameter of 1337 microns, where the outer diameter of 26 turns with 4 microns between each is 1057 microns; a 26.4% 60 difference. Even though the number of turns required will be greater for the smaller spacing, the outer diameter will be less, so the overall size of the sensor will be reduced. These trends can be observed in Figures 5.6 and 5.7. 1 000 900 . 800 ~ 700 - 600 * 500 _ 400 . Inductance (nH) 300 4 ~ 200 - 0 5 1 0 15 20 25 Turns (#) +s=4 -G—s=6 +s=10 Figure 5.5 Inductance as a Function of the Number of Turns for Various Turn Spacings 61 .3 A , o 1400 > '5 1300— ‘3 g 1200 , .. :371100 . = ' O E ' 3 2 < §§1ooo~ .. , ., ‘ gé 900~ , c z z .2 c = a 800 s = '3 700 ' ‘ a _ . w- ' 5’ g 600 ,4!" 02468101214161820222426 Turns(#) +sz4 +S=6 +s:10 Figure 5.6 Outside Diameter of the Inductor Coil as a Function of the Number of Turns for Various Turn Spacings Using a Line Width w=6 microns To ensure that the overall size of the sensor is minimized, it is desired to keep the spacing between turns as small as possible. Also, this improves the interwinding magnetic coupling [15]. However, the line spacing cannot be infinitesimally small because a finite distance between lines is required so that the gold will form distinct coils and not just a single connected mass. It is difficult to create features that are quite tall compared to the width, especially when the features are very close to each other as with the inductor coils. The reason for this is that it is difficult to deposit a material deep in to a relatively thin recess [14]. For this reason, a spacing of 4 microns will be assumed as the limit so that analysis can be continued. The last variable related to the inductance and size of the spiral is the line width. As with the turn spacing, a larger line width will result in a larger outer diameter. The 62 main issue is then to determine what effect the line width has on the total inductance of the spiral. Equation (5.3) is used to generate a plot of the inductance as a function of the number of turns for various line widths, and the results can be seen in Figure 5 .7. Inductance (nH) 0 2 4 6 8 10 12 14 16 18 20 22 24 26 Turns(#) +w=6 —e—w=8 +w=15 Figure 5.7 Inductance as a Function of the Number of Turns for Various Line Widths for a Line Spacing s=4 Small changes in the line width produce only a very small difference in the total inductance (4.2% difference between largest and smallest at 26 turns). A larger line width will result in making the inductor larger for the same number of turns, and the difference in inductance is minimal so minimizing the line width is desirable. It has been shown that the inductance of a planar coil is very robust against small changes in both line width and turn spacing. To minimize the total size of the sensor, the line width and spacing should be kept at a minimum. However, the analysis of the inductor design is not complete. The resistance of the coil needs to be considered to optimize the sensor’s performance. This analysis will be completed in the next chapter. 63 Chapter 6 Consideration of the Resistance And Quality Factor in the Inductor Design 6.1 Resistance and Quality Factor of the Inductor A planar inductor will have a resistance associated with it due to the resistivity of the coil material [13]. This resistance is in series with the inductor, and thus it will be referred to as the series resistance. The resistance in a planar coil is not constant due to a frequency dependence referred to as the skin effect. The skin effect is the tendency of alternating current to flow near the surface of a wire at high frequencies thus making the effective area of the wire smaller than the actual cross-sectional area [21]. The skin effect is caused by the self- inductance of the conductor, which causes an increase in the inductive reactance at high frequencies. The skin depth is the depth at which the current density has dropped to l/e (~37%) and can be calculated by [22] 2 muoc (6.1) The series resistance of the wire (measured in Ohms) then has frequency dependence due to the skin depth, dimensions of the wire, and the resistivity [22] RS = ‘01 (6.2) wall-W") where l, w, and tw are measured in meters. The series resistance and skin depth for the theoretical frequency range resulting from using an inductance of 800 nH and capacitance range of 1.7 pF to 2.55 pF (as calculated in Chapter 4) is shown in Figure 6.1. The actual resonant frequency range of the device will not be known until the final inductance value is determined at the end of the chapter. A line thickness of 7 microns was chosen as a starting value. 65 63 7.1 '1”, 62.51 , $5,; -_ 7 A 62« ”g." - II a" “r 6.9 m E. 61.55 ,c”~ as. o .c" 3 V 617 5"" ’7 6.8 9 8 1: g 60.5 -« 6.7 :5: .2 ,6" 3 O 60 5 1 65’ 5' £3 g g 59.5 3 b 5’ 8 59— ,3." 58.5 a" 58 . . 6.3 111 116 121 126 131 136 Frequency (M Hz) Figure 6.1 Series Resistance and Skin Depth as a Function of Frequency For Case Where w = 6 microns, tw = 7 microns, 26 windings The major measure of an inductor’s performance is the quality factor, Q. The quality factor is the ratio of the reactance to the resistance of an inductor and provides a measure of how well the inductor emits/absorbs energy. It is desired to maximize the Q factor for optimum effectiveness of the wireless telemetry. Q = — (6.3) A plot of the Q factor along with the series resistance of the circuit as a function of frequency is shown in Figure 6.2. 66 62 '3 61.5 « 5 ‘ o 9 61 g‘ g 60 5 § 5; ; S. 3 60 g a; 59.5 «. 59 . 58.5 56 4 111 116 121 126 131 136 Frequency (M Hz) Figure 6.2 Resistance and Q Factor as a Function of Frequency Using tw =7 microns, w = 6 microns, and 26 Windings llt is apparent that the Q factor and the resistance increase directly with the frequency. This is counterintuitive based on equation (6.3), but it is important to recall that the resistance grows slowly as a function of frequency. As a result, the frequency term in equation (6.3) dominates, so Q actually grows despite the increased resistance due to the skin effect. Figure 6.3 shows that the resistance due to the inductor is a strong function of the line thickness. The effective cross-sectional area of the wire from equation (6.2) is thus A = w5\/(1—e_tW/6) (6.4) 67 Resletance (Ohms) Figure 6.3 Resistance of Inductor as a Function of Frequency for Various Line T_hicknessw Using Line Width w = 6 microns, and 26 Windiyg becomes larger, so the series resistance, equation (6.2), will be lower for a particular frequency. A six micron wide wire with a line thickness of seven microns has 6.5% more resistance than if the line thickness were nine microns. Also, as the resistance becomes lower at a particular frequency due to increasing the line thickness, the Q factor will increase as revealed by equation (6.3). The actual line thickness will show some variability between manufacturing runs. The 64 1 7 micron Line Thickness 63 8 micron Line Thickness 62‘ 9 micron Line Thickness 61‘ 60 ~ 59* 582 57 56* 551 111 As the line thickness becomes larger, the effective cross-sectional area of the wire The goal for the fabrication process should be to maximize the line thickness. 116 121 126 Frequency (M Hz) 68 131 136 resolution in feature size in typical MEMS devices is generally about 1 micron [14]. Exact precision when depositing the gold on to the glass wafer to make the coils is not possible, so a certain amount of variability will occur on the order of about i: 1 micron depending on the capabilities of the fabrication facility. Also, the spacing between windings is desired to be as small as possible to keep the size of the device at a minimum. Since the spacing is so small between the wire windings, it is difficult to make structures that are larger than about 10 microns thick [14]. The following analysis assumes that a 9 micron line thickness is achieved. This value is chosen because it is near the upper limit and allows for some variability in the fabrication process before the upper limit is reached. The effects of changing the line width on the resistance and Q factor can be seen in Figures 6.4 and 6.5. As the line width becomes larger, the effective cross-sectional area of the wire becomes larger, which lowers the series resistance. A nine micron tall wire with a line width of 6 microns has 23.1% more resistance than if the line width were eight microns. More importantly, the Q increases by 23.0% by increasing the line width by two microns from six to eight microns. A larger line width should then be utilized to maximize the Q of the sensor. A sacrifice in size must be made so that the sensor’s performance can be improved. It is common for planar inductors to be fabricated with a ratio of w:s of 2:1 [23] so this ratio will be used for this device giving a line width of eight microns. 69 6 micron line width 8 micron line width Resistance (Ohms) t 4:. A 01 01 g 01 01 ca 0: 00 o to a: on o A N A O l 111 116 121 126 131 136 Frequency (MHz) Figure 6.4 Resistance as a Function of Frequency for Various Line Widths Using Line Thickness tw = 9 microns, Spacing s = 6 microns, and 26 Windipgg 15.5 14.5 *- 135 _, 8 micron line width . p A - ---'- -0 c' ‘- »-- - o - n o 2 5 - - ’ d v I —‘ ' - a- ’ v . - ’ v - a'- -- 7 micron line width 11.5 a 0 Factor (dimensionless) 10. 5 - 6 micron hne wrdth 9.5 1 . 111 116 121 126 131 136 Frequency (MHz) Figure 6.5 Q Factor as a Function of Frequency for Various Line Widths Using Line Thickness tw = 9 microns, Spacing s = 6 microns, and 26 Windings 70 6.2 Summary of Inductor Design Combining the results from the Chapters 5 and 6 with the capacitance range from Chapter 4, the device will have the following characteristics Table 6.1 Summary of Inductor Desim Spiral Shape Square Turns 26 Inductance 800.2 nH Line Thickness 9 microns Line Width 8 microns Turn Spacing 4 microns Inner Diameter 545 microns Outer Diameter 1161 microns Resonant Frequency At 0 mmHg 136.46 MHz Resonant Frequency At 60 mmHL 111.42 MHz 71 Chapter 7 Summary of Micro-Scale Prototype Design 72 7.1 Design Dimensions The dimensions of the prototype device are shown in Figures 7.1-7.5. Thin, Square Flexible SI membrane (551 microns) 2000 microns 525-1000 2000 rmcrons microns *Depends on availability of Ultra-thin Si wafers Figure 7.1 External Dimensions of Sensor The device will be a box with width and length of 2000 microns. The height of the device will depend on the availability of ultra thin silicon wafers. The glass wafers to be used for the substrate are typically available with a standard thickness of 500 microns. The ultra thin silicon wafers are only 25-30 microns thick, but are not commonly available. If they are not available, a standard silicon wafer is 500 microns thick. The total thickness of the device is anywhere from about 525 to 1000 microns depending on the materials available. The diaphragm will have a thickness of 4 microns as determined in Chapter 4 (see Figure 7.2 for dimension locations). The bottom of the silicon wafer will be etched so that a 3.5 micron deep recess is created to define the capacitive gap. The 3.5 micron depth includes 2.0 microns to account for the electrode height above the surface of the 73 glass wafer and 1.5 microns to account for the initial capacitive gap between the non- deflected diaphragm and the electrode. The side length of the recess is 1200 microns to ensure that the inductor coil will not touch the diaphragm. A 400 micron wide support structure surrounds the recess on the bottom of the wafer to be used as the bonding surface between the silicon wafer and the glass substrate. The top of the silicon wafer will be etched to form a 551 micron by 551 micron diaphragm. All of the etches will result in a side wall at an angle of 54.7° with the horizontal due to the crystalline structure of silicon [14]. Depends on W afer Thickness L l l 8 2—500 1‘ '1‘ l '1 microns* 400 3.5 1200 Depends on microns microns microns Availability of Ultra-Thin Si Wafers Figpre 7 .2 Dimensions of Diaphragm Structure Created from Silicon Wafer The capacitor plate will be square with a side length 537 microns (see Figures 7.3 and 7.4). The gold will be etched so that the total thickness is 2.0 microns. This is so that the gap between the plate and the non-deflected diaphragm will be 1.5 microns. The initial capacitance will be Co=1.70 pF and the capacitance at full-scale deflection will be CFS=2.55 pF. 74 2000 microns 2000 microns 500 microns Inductor Coils (26 Turns) 5 37 microns Fi re 7.3 Dimension of Intern Structures and lass Wafer C0=1.7 pF Cr-s=2-55 pF / Diaphragm 1.0 micron Gap at Full Deflection . microns Fixed Capacitor Plate Fi re 7.4 Ca acitor La out 75 The inductor will consist of 26 turns of gold wire. The wire will be electroplated on to the glass substrate. The physical dimensions are shown in Figure 7.5. The inside diameter of the coil (dm) will be 545 microns with a 4 micron gap (3) between each turn. The wire will have a line width (w) of 8 microns and line height (tw) of 9 microns. As a result of these dimensions, the outer diameter (dour) is 1161 microns, and the final inductance of the device is then 800.2 nH. Due to the inductance value and capacitance range of the device, the size of the resonant frequency range of the device will be 25.04 MHz with a resonant frequency of 136.46 MHz corresponding to 0 mmHg pressure difference across the diaphragm, and 111.43 MHz corresponding to 60 mmHg. (1001:1161 Figpre 7.5 Inductor Layout 76 Chapter 8 Sensor Fabrication 77 8.1 Fabrication Overview A possible fabrication “recipe” for the sensor is presented in the following sections. The illustrations presented in the text show the cross-section of a single device so that each step can be clearly understood and visualized. However, in the actual fabrication of the devices, many individual devices will be made from a single wafer, and the entire wafer will be fabricated at once. Hundreds of devices will be completed simultaneously. 8.2 Fabrication of the Glass Wafer First, the wafers are carefully cleaned so that the surface finish is of high quality. It is important that imperfections on the substrate are smaller than 500 Angstroms so that the final bonding procedure can be successful [14]. Next, a layer of photoresist (PR) is spun and baked on the wafer. A lithography process is then required to define the coil recess. During the lithography, a mask is used to define the patterns for the features on the substrate (see Figure 8.1). The wafer and mask are then exposed to a UV source. The PR is developed and a pattern is left on the glass wafer that is used as a mask for etching. This entire process, including spinning the PR, will be referred to as the lithography process for the remainder of this description. 78 , it’ll lur.ln..filrr.- / f N I . . / Photoresist V Figpre 8.1 Glass Substrate with the PR Mask Q Defing the Coil Recess After a recess of about 10 microns is etched into the glass substrate, the PR is removed and the structure seen in Figure 8.2 remains. Figu_re 8.2 Glass Substrate with C01] Recess Next, a lithography process is required to define the capacitor plate, the electrical contacts that will be used to connect the upper and lower wafers, and the inductor coils. Multiple depositions of PR may be required so a thick layer can be obtained since the structures to be defined are thin and tall. 79 Fi 8.3 Glass Wafer th P Mask for Electro Gold A thin seed layer (Ti/Au) is deposited on the substrate. This seed layer allows thicker layers of gold to be deposited that will become the capacitor plate and the inductor coils. The gold is deposited by electroplating. The electroplating is continued until the inductor coils are at a thickness of 7 to 9 microns tall. An additional etch step may be desired to make the capacitor plate thinner. After the PR has been removed, the glass wafer is complete. The completed glass wafer with all of the on chip electronics can be seen in Figure 8.4. Contact to Upper Wafer Cap. Plate Coils Figpre 8.4 Completed Glass Wafer 80 fit. . ..nll.ltld1.l.'...lnAtuI-u’ 8.3 Fabrication of the Silicon Wafer The second wafer to be processed is a (100) silicon wafer (see Figure 8.5). The (100) wafer is a thin, circular disk of silicon that has a (100) crystallographic plane as its top surface. A “flat” is located on the edge of the disk that corresponds to the (110) plane. This means that the <100> direction is normal to the top surface and the <110> direction is normal to the flat. <100> Figpre 8.5 Orientation of £11100) Silicon Wafer If possible, ultra-thin silicon wafers will be used so that the device size can be minimized. The thickness of these ultra-thin wafers is 25 to 30 microns. To complete the fabrication, both sides of the silicon wafer must be processed. A thin layer of Si3N4 is deposited on the silicon substrate. The nitride will be used as the mask to etch the capacitive cavity. The nitride can be deposited in a number of ways, but Low-Pressure Chemical Vapor Deposition (LPCVD) is quite common. In LPCVD, the substrate is heated to a temperature typically greater than 300°C in a low-pressure chamber, and a gas is introduced in the chamber. The reaction used to create silicon nitride is SIH4+N2+NH3=SI3H4+N2+H2 (8.1) 81 The reaction takes place as gas species hit the substrate. The deposited films from LPCVD are usually of quite high quality and uniformity, which is a major advantage over several other deposition processes [14]. A lithography process is then performed to etch the nitride so the capacitive cavity will be defined. The silicon wafer and mask are shown in Figure 8.6. Fi re 8.6 Silicon Wafer with Si 4 Mask to Define Ca acitive Cavi This cavity is etched to a depth of 3.5 microns seen in Figure 8.7. This accounts for the 2 micron thick capacitor plate and the 1.5 microns capacitive gap. The silicon will etch at an angle of 54.7° because of the crystallographic structure of the silicon atom. The (100) and (111) planes intersect at an angle of 54.7° within the crystal lattice. KOH is used as the etchant for this procedure. KOH has a selectivity ratio of 400:1 for (100) over the (111) planes [14]. This means that 400 microns in the <100> direction will etch for every 1 micron that is etched in the <111> direction. The nitride mask is then etched away. 82 Figpre 8.7 Silicon Wafer After Camdtive Cavity Has Been Defined A lithography process is performed to define the diaphragm area and electrical contacts. The photoresist is used as a mask for a diffusion step. A process called Ion Implantation is used to introduce Boron to the surface of the membrane. A high-energy beam of Boron ions is directed at the silicon wafer and Boron is literally forced in to the surface of the silicon. The substrate is then annealed in an oven at a temperature in the range of 600-900 °C. This annealing step allows the Boron ions to diffuse further in to the silicon to a depth of 4 microns to define the diaphragm thickness. The diffusion depth is a function of the intensity of the energy beam, temperature, and time. This creates a region of pH silicon seen in Figure 8.8. 83 Silicon Figpre 8.8 Silicon Wafer Aftep Boron Doping The Boron diffusion serves two purposes. First, a concentration dependant etch- stop is formed in the silicon wafer. PH silicon will not etch in common etchants such as KOH and Ethylene Diamine Pyrocatechol (EDP) as long as the concentration is high enough. Boron must have a concentration greater than 1020 cm'3 or 5 X 1019 cm‘3 to be an etch stop in KOH or EDP respectively. Concentration dependant etch stops allow for very accurate etching so the diaphragm thickness can be controlled to within about 0.1 microns [14]. This is particularly important for controlling the dynamic response of the diaphragm to pressure as explained in Chapter 4. The second purpose of the diffusion step is that p++ silicon is a conductive material where non-doped silicon in not conductive. This makes it possible for the diaphragm to be an electrode in the variable capacitor. A lithography process is then performed on the top of the wafer to define the diaphragm window, and etching is performed. 84 2W , Etch Mask Figpre 8.9 Silimn Wfier with PR Mask to Define thg mapm Again, the silicon will etch at an angle of 54.7° because of the crystallographic structure of the silicon atom. The etching will continue until the boundary of the pH silicon has been reached. The shape of the silicon wafer can be seen in Figure 8.10 after the completion of the etch step removal of the mask. Silicon Silicon Figpg 8.10 Completed Silicon Wafer 85 8.4 Electrostatic Bonding of Wafers The two wafers are brought together by an electrostatic bond. The set up can be seen in Figure 8.11. The top of the glass wafer is brought in to contact with the bottom of the silicon wafer and sandwiched between two electrodes. The positive electrode is in contact with the silicon while the negative electrode is in contact with the glass. The sandwich is raised to a temperature of about 400°C and a DC voltage of about 1000 Volts is applied. The voltage causes mobile sodium ions to pull toward the negative electrode, which leaves oxygen at the interface between the two wafers. The electrostatic voltage also pulls the two wafers very close. The oxygen ions in the glass bond to the Si atoms at the surface and a very strong SiOz bond is created. The bond is stronger than either the Si-Si bond or the glass. However, this process is very sensitive to contaminants or surface roughness. This is the reason that the wafers are carefully cleaned before hand. The bonding is to be performed in a nitrogen ambient so that a pocket of nitrogen is enclosed inside the sensor. Vs Top Electrode _ = Glass In WES/x“ f’j’ Silicon s1+202-= Sio2 Fi re 8.11 Set U For Electrostatic Bondin Process 86 Chapter 9 Prototype Testing Results 87 9.1 Prototype Overview As proof of concept, macro-sized prototypes of the sensor were constructed. The prototype of the primary circuit consists of an unshielded inductor (600 nH) connected in series with a 47 Ohm resistor. The inductor and resistor were attached to a BNC connector so that the device could be used with a function generator. Two sets of prototypes were developed. The first generation of sensors consisted of an inductor formed from a printed circuit board (see Figure A.1 of Appendix for mask) attached to a variable capacitor. As will be seen from the results, these crude models illusu-ated that the desired effect was taking place, however, the accuracy and clarity of the results were questionable. A photograph of these prototypes can be seen in Figure 9.1. . ‘4 Load Resistor . s Figure 9.1 First Genera on of Prototypes L-R Model Primary Circuit, Inductor Famed From PC Board, Completed Secondagy Circuit with Inductor, Capacitor and BNC Connector 88 The second generation prototypes more accurately model the sensor structure. They consist of an inductor and capacitor plate formed from a single printed circuit board to resemble the layout of the glass substrate (Figure A2 in the Appendix). Connected in series to this board is another PC board with a single capacitor plate made to resemble the diaphragm (Figure A3 in the Appendix). Rubber spacers between the two boards provided the capacitive gap. These prototypes are of significantly better quality and the results are much more clear than from the first prototypes. Figure 9.2 shows a photograph of the second generation prototypes. ' Inductor Coils ‘ Rubber Spacer Figure 9.2 Second Generation of Prototypes L-top PC Board Representing the Glass Substrate with Capacitor Plate and Inductor Coil, L-bottom PC Board Representing Diaphragm, R-Completed Secondag Circuit 89 f1. - 4.... .1... it... a, 9.2 Testing Procedure To test the prototypes, the primary circuit was connected to a function generator. The frequency of a sinusoidal signal was swept through a frequency range of 10 to 100 MHz. The primary circuit was placed at rest perpendicular to the sensor circuit so that the inductive coupling between the circuits could be maximized. The point of contact was recorded so to eliminate variability between uials. Even though the inductor is in contact with the sensor, there is a 1.5 mm distance between the inductors due to the 1.5 mm thickness of the PC board. A low capacitance probe (1.3 pF) was connected across the capacitor of the secondary circuit. The voltage across the capacitor was measured for various frequencies across the range and plotted. Then the procedure was repeated with the probe connected across the load resistor of the primary circuit. The voltage profiles were then compared to observe similarities and trends. The point of contact between the circuits and the connections to the equipment are shown in Figure 9.3. To Function Generator To Oscilloscope '+._ Point of Contact Between Prim. and Sec. Circuits Figpre 9.3 Experimental Setup 90 9.3 Expected Results Recall that the sensor is at a maximum degree of excitation at resonance so the voltage measured through the secondary circuit should peak at the resonant frequency. Also, the voltage across the load resistor should dip at resonance. The expected trends are shown in Figure 9.4. Note that the indicated frequency range in Figure 9.4 is not characteristic of the models and is used simply for illustrative purposes. Also, ideally, the phase of the voltage across the load resistor would be measured to find the exact resonant frequency of the sensor. Recall from Chapter 2 that the voltage dip occurs prior to the resonant frequency and the peak of the voltage rise occurs after the resonant frequency. The only accurate way to determine the actual resonant frequency is to determine where the phase of the signal equals zero. The frequency where there was a phase of zero would be the resonant frequency, but the equipment was not available perform the phase analysis. 0.2 1.1 .5. 0.18 q, 0 9 '3 0.16 - m o o g 0.14 0.7 g 3 :9? 0.12 5 g '3 0.1 § 0 Z, a: 5, 0.08 o g, 0.06 g :5 0.04 V 0.02 o . -0.1 90 92 94 96 98 100 Frequency (M Hz) Figpre 9.4 Expggted Results From Prototyms 91 The magnitude of each of the signals depends on several factors including the relative proximity of the primary and secondary circuits, the coupling coefficient, and inductor size. The magnitude of the response is not important at this stage of the analysis. The important information that is desired is to verify that the sensor is displaying the basic concept, and that the resonant frequency can be measured on an external device. 9.4 Fabrication of the PC Boards PC Boards were prepared by using a masked, copper clad PC Board with a photosensitive coating and exposing it to a UV source. The masks for each board can be found in the Appendix (Figures A.1-A.3). Once the boards had been exposed to the UV source for about ten minutes, the image was developed using a standard PC Board Developing Solution. The boards were then immersed in a Ferric Chloride Solution for about an hour to etch the copper away of the board and leave the desired pattern from each mask on the boards. The photosensitive chemical was then removed from the boards with PC Board Stripping Solution. The boards were then ready to be cut and assembled. 9.5 Results of Testing First Generation Prototypes Results from testing the first generation prototypes (see Figure 9.5) showed that the concept was occurring, but the resonant frequency was not as clearly defined as was hoped. The voltage in the sensor has a definite peak at 74 MHz and the voltage across the load resistor shows the expected pattern as seen in the computational simulations. However, the results obtained from the models were not nearly as well defined as the simulation results. The voltage dip occurred at about 4 MHz prior to the resonant 92 frequency and the peak of the voltage rise occurs about 6 MHz after the resonant frequency. A major area of concern is the relative location of the resonant frequency compared to the voltage dip and corresponding voltage rise. The magnitude of the frequency range for the dip and rise to occur is a function of the circuit resistance. More circuit resistance translates into a wider frequency range between the dip and the peak. In a perfect resonant circuit, the resistance would be infinitesimally small so the voltage dip and rise would occur exactly at the resonant frequency. The voltage dip and the rise occur over a much broader range than in the simulations as a result of the resistance. The frequency range between when the voltage dips and the rise peaks is about 0.4 MHz in the simulation, where it takes 10 MHz in the model. The circuit has a relatively high resistance so the dip occurs slightly prior to the resonant frequency, and the rise reaches a peak after the resonant frequency. While the results seen from these prototypes are not surprising considering the size of the components, the concept was not shown with a high degree of certainty. 350 . 900 330 J «- 850 9 310 « , < . w 800 O E 290 « '~ ‘ . 31 if g: 270 ‘ ' “ 75° 3.3 a 250 . «- 700 6 5 > ,1 o 3 230 « -~ 650 g 8 0 210 ~ I' C 600 ° (3 190 . a 170 « *“ 55° 150 . 500 50 60 7o 80 90 100 Frequency (MHz) Figure 9.5 Sensor Voltage and Voltage Across the Load Resistor for First Generation Prototypes Model # 9 93 It appears that the concept works; however, it would be impossible to determine the resonant frequency accurately enough to produce a pressure measurement. A new set of models was developed to obtain a more precise simulation. 9.6 Results From Testing Second Generation Prototypes It is believed that the capacitor created a high resistance in the first prototype circuit that deteriorated the quality of the results. To reduce the resistance, the second set of prototypes was made to more closely resemble the sensor structure and uses only printed circuit boards. The voltage values seen in the following plots are the average peak-to peak voltages of six periods of the signal. The error bar associated with the sensor voltage is roughly i 1.5 mV and roughly :t 3.5 mV for the voltage across the load resistor. Two 2 mm rubber spacers were placed between the capacitor plates to produce the initial gap. 94 5...»? >03: roan 38.32 <0..er >03: reed meet»... 032- ..25 33.22 » 4 a) Device 11 H 7 b) Device 6 \ l a ll mm mwmmeeomm 9'5 ems-x; .oeeem Ki... .11. _ m m m m m 9.5 ouo=o> .oeeom I4l..l it m a a a mama a m a m w as.” m m -m m c) Device 9 5.8 w m .8. 9E. omu=o> 328m 0 13) 120 WW“) 1 10 Figure 9.6 Sensor Voltage and Voltage Across the Load 1CD regime); for Second Generation Prototym Resistor as a Function of F 95 The second set of prototypes performed significantly better than the first set. The sensor voltage displays a clear peak at a particular resonant frequency unique to each device, and the voltage dip provides a rough indication of the resonant frequency. The voltage dip corresponds exactly to the peak of the sensor voltage for Devices 11 and 6. However, the voltage dip actually occurs 2 MHz after the peak of the sensor voltage for Device 9. Even though the performance of Device 9 does not exactly replicate the performance of the other two models, the concept is clearly demonstrated, and the sharpness of the peaks is significantly better than with the first prototypes. Due to equipment limitations, it was impossible to accurately measure the capacitance and inductance of the models. However, approximations for each quantity could be made from the dimensions of the capacitor plates and the resonant frequencies that appear in the Figure 9.6. Each of the capacitor plates is roughly 1.0 cm2. The spacing between the capacitor plates was 4 mm. An estimate for the capacitance can be found from equation (4.1). Additionally, there is 1.3 pF of capacitance due to the probe. The approximate total capacitance is 1.52 pF. Based on this capacitance and the resonant frequencies for each device in Figure 9.6, the inductance can be approximated by equation (2.22). The approximate inductances for each device are found in Table 9.1. Table 9.] Approximate Inductance Values for Prototypes for a Capacitance of 1.52 pF Device 11 1101.5 nH Device 6 1138.2 nH Device 9 1119.6 nH 96 As the number of spacers between the capacitor plates is decreased from two to one, the capacitance doubles, and the resonant frequency of the circuit decreases. The capacitance gap is 2 mm resulting in an approximate capacitance (including the 1.3 pF of probe capacitance) of 1.74 pF. Based on this capacitance and the approximate inductances in Table 9.1, the theoretical resonant frequency can be determined as seen in Table 9.2. Table 9.2 Theoretical Approximate Resonant Frequencies for a Capacitance of 1.74 2F Device 11 114.96 MHz Device 6 113.09 MHz i Device 9 114.03 MHz ‘ As the capacitance increases, the resonant frequency shifts to the left of the frequency scale. The measured frequency responses of the sensor and primary circuit can be seen in Figure 9.7. A comparison of the results for the two cases of capacitance can be seen in Figures 9.8 and 9.9. Table 9.3 Summary of Prototjm Tesg' g Results Peak of Sensor Voltage Voltage Dip Device 11 Case 1 123 MHz 123 MHz Case 2 109 MHz 109 MHz Device 6 Case 1 121 MHz 121 MHz Case2 113 MHz 110 MHz Device 9 Case 1 122 MHz 124 MHz Case 2 105 MHz 106 MHz 97 <28? >03.- E 3.2%.! .35 <0; >03: roan 38.82 .35 700 5 5 5 5 5 5 5 0 2 2 2 2 2 2 2 0 7 6 5 4 3 2 1 8 Il:-...__IIL .. +7 fi + F fl . “Ii _ 1 n. 1 6 e C C C c 1 o l V W a b 0 0 0 0 0 O 0 0 0 0 0 5 4 3 2 1 9.5 83.3 323m 600 500 A v 0 o 0 o o o 5 4 3 9.5 035:; concom - 300 liltlhtlllllni ‘ \. ‘1‘. \ol‘titcllll‘ll 200 <0..qu >268 roan 38.30135 0 O 0 O 0 0 0 0 0 O 0 0 O 0 0 0 2 1 7 6 5 4 3 2 _ F F . 4 i a _ a 9 e C .1 W \I C t > .1 a 0 O 0 O 0 0 O 0 0 O 0 O 0 0 1 5 4 3 2 1 9.5 33:5 30:3 150 140 30 120 110 100 90 Frequency (M Hz) re 9.7 Sensor Volta e as a Function of Fre uen After Increasin Ca acitance Fi 98 (J... I- 4. 1 n}... (I. .6 Its).- _ . . Sensor Voltage (mV) Sensor Voltage (mV) Sensor Voltage (mV) 550 a) Device 11 500 450 -« 400 350 a 300 250 200 4 150 Increasing Capacitance {z} 13 ",1. ‘; 800 b) Device 6 ' ‘ "F ‘ 500JI c) Device 9 ' 5% 90 100 110 120 130 140 150 Frequency (MHz) Figpre 9.8 Comparison of Sensor Voltages For Two Cases of Capacitance 99 Voltage Across Load Resistor (mV) Voltage Across Load Resistor (mV) Voltage Across Load Resistor (mV) 900 800 700 600 500 400 300 200 100 i a) Device 11 Increasing Capacitance 900 800 700 600 500 400 300 200 100 700 650 600 550 500 450 400 350 300 250 200 b) Device 6 c) Device 9 f ’ " .i y 90 100 110 120 30 140 150 Frequency (Mi-I2) Figure 9.9 Comparison of Voltage Across Load Resistor For Two Cases of Capacitance 100 There are several important trends to notice from Figures 9.7-9.9. First, Device 11 remained consistent in its performance. The voltage dip across the load resistor and the sensor’s peak voltage occurred at the same frequency for both cases of capacitance. Device 6 was less consistent. For the first case of capacitance, the voltage dip and the peak of the sensor voltage occurred at the same frequency. After increasing the capacitance, the dip occurs 3 MHz prior to the peak of the sensor voltage. However, this device required repair between trials to fix a loose wire that is a likely cause of the inconsistency. Device 9 did not perform according to theory for the first trial. The voltage dip occurred 2 MHz after the peak of the sensor voltage. However, the device was fairly consistent because the voltage dip occurred 1 MHz after the resonant frequency for the second case of capacitance as well. Since measurements were taken at intervals of 1 MHz, it is likely that the 1 MHz difference in the results is due to the resolution of the measurements. It should be noted as well that the magnitude of the responses is similar between the devices, but not identical. Also, the magnitude of the response for a particular device is not maintained once the capacitance has changed. After multiple trials, it has been determined that the differences in magnitude between different devices and even the same device for different capacitances is due to the coupling. The point of contact between the primary circuit and the secondary circuit for each trial and held consistent for a particular. However, due to the small size of the devices being tested, there was an immeasurably small difference in the location of the contact point between trials. This resulted in slight differences in the magnitude of the responses. 101 Table 9.4 Comparison of Theoretical Resonant Frauencies to Measured Values Theoretical Measured Device 11 114.96 MHz 109 MHz Device 6 113.09 MHz 113 MHz Device 9 114.03 MHz 105 MHz Notice that the resonant frequencies calculated by theory do not correspond exactly with the measured frequencies. This is not a necessarily a surprise since the capacitance and inductance are very sensitive to the dimensions of the on-chip components. The printed circuit boards were fabricated at one time using multiple masks on the same substrate. Small changes in the masks from sample to sample could easily result in a difference in capacitance or inductance of the devices. This is most likely the case since the resonant frequency of each device was not the same for the initial test used to provide Figure 9.6. Also, there will be an amount of inductance and capacitance in each sensor due to the connection wires and solder that are used to assemble the models. The important trend to notice is that the measured resonant frequency is measured to be equal to or less than the theoretical value. The additional inductance and capacitance that are present would result in the resonant frequency of the device being lower than predicted. The results support the hypothesis. Despite the obvious difference in size, the macro-models clearly demonstrate the basic concept for the sensor. The quality of the prototypes pales in comparison to the quality level that can be achieved for MEMS devices. The difference in the results between the first and second set of prototypes show that the quality of the results that can be obtained is directly related to the quality of the device. The MEMS pressure sensors will be a drastic improvement on the macro-sized models. 102 Ft" Chapter 10 Important Considerations 103 10.1 Introduction Once the device has been completed, there are several issues that need to be considered about the performance of the device over its lifetime. These issues include quantifying the actual volume of gas enclosed in the capacitive cavity, determining the temperature dependence of the device, development of an off-set in the readings, and drift. These issues are all important to consider and understand before the device is implemented into humans because it is not desirable to remove the sensor after implantation to verify calibration. 10.2 Volume of Air Enclosed in the Capacitive Cavity The first issue to be considered is to quantify the actual pressure inside the sensor. This pressure is used as a reference and the sensor measures only the differential pressure. Theoretically, since the device will be sealed in ambient conditions, the pressure in the cavity should be equal to 1 ATM. Initially, air was chosen as the gas to be present in the device. However, during the electrostatic bond a quantity of the oxygen would be consumed to form Si02 bonds on the surface of the diaphragm. This will result in lowering the pressure enclosed in the cavity. There is a sufficient amount of silicon atoms at the surface of the capacitive cavity to react with all of the oxygen present so it stands to reason that the pressure enclosed inside the cavity would actually be reduced by 0.2 ATM [24]. The actual volume enclosed in the cavity would only be about 0.8 ATM (608 mmHg) as opposed to the theoretical pressure of 1 ATM (760 mmHg). Bonding the wafers in a nitrogen ambient instead of air eliminates the reaction. Another common solution is to seal the device in vacuum so that there is no gas inside 104 the device. The device then becomes an absolute pressure sensor instead of a differential sensor. However, the size of the diaphragm becomes too large, and the size constraints on the device do not allow the luxury of manufacturing an absolute sensor. Another factor to consider is the temperature dependence of the sensor. Since the sensor is sealed in air instead of vacuum the sensor becomes dependant on temperature due to the expansion of the gas trapped inside the cavity [24]. Fortunately, the temperature in the eye is maintained nearly constant by the body so the temperature will not fluctuate more than a few degrees. However, the electrostatic bond that seals the device occurs at a temperature of about 400°C. The gas will compress slightly as the temperature is reduced and the pressure inside the cavity will be lower than 1 ATM [22]. Testing will provide the actual pressure inside the cavity. It is possible to seal the device at an elevated pressure, so possibly device could be sealed initially with greater than 1 ATM of pressure so that the final pressure after cooling is 1 ATM. 10.3 Drift Another parameter important to sensor performance is drift. Drift is the tendency of a device to show different patterns of operation than expected due to changes in material properties. The calibration of the device will shift slightly so the output of the device will not exactly correspond to the input in the predicted manner. Drift is very difficult to predict as it is often caused by changes in material properties due to repeated movement of the sensor’s components such as the diaphragm [14]. IOP fluctuations between 20 and 60 mmHg for one patient will result in a different rate of degradation of the diaphragm than another patient showing fluctuations between 20 and 25 mmHg. 105 These issues are not obstacles that will limit the device’s ability to accurately measure IOP, but they are issues that need to be considered and accounted for during manufacturing, testing, and further development stages. 106 1"" " Chapter 11 Conclusions 107 11.1 Summary This thesis has outlined the design of an implantable, biomedical pressure sensor to be fabricated by standard Microelectrical Mechanical Systems (MEMS) technologies. The objective of this invention is to design and develop a micro-sensor intraocular pressure measuring system that can be implanted in the patient’s eye for the purpose of glaucoma treatment/management. Future research will be performed to complete the remaining components of the measurement system. The previous chapters presented the steps and decision process required to achieve a final design of the sensor. The design was an iterative process since there is no single correct solution to the problem. The goal was to implement many gradual changes to an initial, tentative design to achieve a very accurate and precise device. At times, finite limits had to be placed on parameters based on common sense and judgment, as an equation is not available to specifically predict the capabilities of a fabrication facility. There is room for many small adjustments in the design to improve performance such as changing the feature size of a structure by a few microns. The capabilities of a fabrication facility will dictate the exact feature size and process precision that is available, but the design in this thesis is a viable solution to the problem. It is hoped that this device will allow physicians to better care for their patients, provide new insight in Glaucoma, save patients vision, and ultimately aid in the development of a cure for glaucoma and many other pressure related problems of the body. 108 "1L 6: ‘ Appendix 109 Figure Ai Mask For- First Generation Prototpytlfi 110 @i—QQ tr .l l I: 11--.!» 01.4 Figure A3 Second Mask For Second Generation Prototypes 112 Table A.l Frequency Resmnse Data for First Generation Protom Freq Sensor V mv Freq “Resistor V 1 5 1 35 0.1 35 1 5 2 20 140 0.14 20 1.76 25 1 65 0.1 65 25 1 .5 30 1 85 0.1 85 30 1 .42 35 235 0.235 35 1 .41 40 325 0.325 40 1 .45 43 400 0.4 43 1 .43 45 330 0.33 45 1 .37 50 300 0.3 50 1 .15 55 330 0.33 55 0.94 60 360 0.36 60 0.78 65 360 0.36 62 0.765 66 370 0.37 63 0.76 67 370 0.37 64 0.74 68 380 0.38 65 0.725 69 385 0.385 66 0.695 70 370 0.37 67 0.7 71 370 0.37 68 0.71 72 320 0.32 69 0.72 73 330 0.33 70 0.715 74 330 0.33 71 0.705 75 320 0.32 72 0.705 80 280 0.28 73 0.73 85 220 0.22 74 0.735 90 200 0.2 75 0.74 95 1 80 0.1 8 80 0.77 100 170 0.17 85 0.73 90 0.7 95 0.66 1 00 0.605 113 0.0.0 o 0>< 0...? 50; 05.0 5V0 or; 50.0 0%... 05.0 00.? 5...0 00.5 00... 00.5 50... 00.0 00.0 00... 00.5 05.0 556 006 00.0 00.0 50.5 00.? 50... 00.0 05.0 00.0 00.0 00.0 00.0 00.0 00.0 00.0 50.0 00.0 05... 00.0 50; 00.0 00.0 00.0 0v... 00.0 00... 00.0 00.0 00.0 55... 00.0 00.0 0 .meou ..Otm . 0v.0 00.0 00.0 50.0 0V0 50.0 00.0 50.0 00.0 00.? 50.0 00.5 00.0 05.5 50.5 00.0 00.0 00.0 05.5 00. 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F5¢ 0.000 050 ¢.000 ¢.00¢ 0.50¢ 5.050 5.000 F.¢00 F.000 ¢.0F0 0.00F 0.0F F 00. F0 F> 00F 0¢F 00F 00F 0FF 0FF 00F 00F 50F 00F 00F ¢0F 00F 00F FOF 00F 00 00 00 00 00 05 00: ..Omcww h ¢5AHU 00:00.00 00 5.3 0 00309 ..8 S09 0000 00“ 0:0: 00.0 5.< 0300. 119 Bibliography 120 10. 11. BIBLIOGRAPHY . New York Glaucoma Research Institute. www.glaucoma.net/nvgri/questions. W.M Hart, Jr. “The epidemiology of primary open-angle glaucoma and ocular hypertension”, in R. Ritch, M.B. Shields, T. Krupin (eds): The Glaucomas. St. Louis, CV. Mosby Co., 1989, pp 789-795. H.A. Quigley. “Pathophysiology of the optic nerve in glaucoma”. In: J .A. McAllister, R.P. Wilson, eds. Glaucoma. London: Butterworths; 1986:30-53. J .C. Morrison, C.G. Moore, L.M.H. Deppmeier, B.G. Gold, C.K. Meshul, E.C. Johnson. “A rat model of chronic pressure-induced optic nerve damage”. Exp. Eye Res. 1997; 64:85-96. E. Garcia-Valenzuela, S. Shareef, J. Walsh, S.C. 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