Microsystem Technologies 10 (2004) 699–705 Ó Springer-Verlag 2004 DOI 10.1007/s00542-004-0396-1 Microfabrication of an electromagnetic power relay using SU-8 based UV-LIGA technology J. D. Williams, W. Wang 699 The fast developing technology of microelectromechanical systems (MEMS) has opened up new opportunities for developing new types of micro-relays [Peterson, 1978; Sakata, 1989]. Like the revolution started by the miniaturization of electronic circuits, the miniaturization of mechanical systems will definitely have a huge impact on various industries. The principal technology for fabricating micro-mechanical elements has been the siliconbased technology, which is relatively mature due to years of microelectronics R & D. Most of the commercially available micro-mechanical components and systems are made of silicon. Compared with the solid-state switches, electromechanical micro-relays have the same advantages as normal mechanical relays: lower on-resistance, higher off-resistance, higher dielectric strength, lower power consump1 tion, and lower cost. Furthermore, by using MEMS Introduction technology, the size, cost, and switching time of mechanRelays are widely used in various industries for a wide variety of applications. Traditional mechanical relays are ical relays are greatly improved, and they can also be combined with other electronic components. These large, slow, noisy devices, but are still widely used in advantages are even greater with multi-contact relays, such various machines and processes for control purposes. as matrix switches. Solid-state switches, which have much longer life times, There have been several different prototypes of microfaster response, and smaller sizes when compared with relays reported, most of which were electrostatically conventional mechanical relays, have been available in actuated. Gretillat [Gretillat et al., 1995] reported an elecdifferent forms for many years. However, solid-state trostatic polysilicon micro-relay integrated with MOSswitches have low off-resistance and high on-resistance, which result in high power consumption, and poor elec- FETs. Drake et al. (1995) reported an electrostatically trical isolation (typically no better than )30 dB). Design actuated micro-relay for use in automatic test equipment trade-offs for reducing the ‘‘on-resistance’’ of solid-state (ATE). Guckel et al. (1996) reported an electromagnetic microactuator with inductive sensing capability. It uses a relays tend to increase output capacitance, which introLIGA-fabricated (German acronym for lithography, elecduces additional problems in applications requiring the trodeposition and plastic molding) magnetic core wrapped switching of high frequency signals. with a mechanically wrapped coil. The electromagnetic actuator has a planar design and relatively larger size (in the millimeter range). Other groups have also reported Received: 8 August 2003/Accepted: 6 November 2003 work on electromagnetic driven micro-relays. In 1994, Hosaka et al. (1994) reported some fundamental work on J. D. Williams, W. Wang (&) electromagnetically actuated micro-relays. In their reDepartment of Mechanical Engineering, search, a miniature (inch-size) electromagnetic relay was Louisiana State University, constructed using a microfabricated spring and a large Baton Rouge, LA 70803, USA external coil assembled together. e-mail: [email protected] Rogge et al. (1995) the first LIGA fabrication process for The research work reported in this paper was made possible by micro-relays. In their study, an integrated magnetic core support from National Science Foundation under grant ECSwrapped with a microfabricated planar coil is made with #0104327; Louisiana Board of Regents, National Aeronautics and the LIGA process. Many planer electromagnetic coils have Space Administration, and the Louisiana Space Consortium also been developed for electromagnetic actuation from under agreement NASA/LEQSF (2001–2005)-LaSPACE, and silicon-based technologies (Chaing et al., 1993; Yao, 1995; NASA/LaSPACE under grant NTG5–40115. The authors would also like to thank the Center for Advanced Microstructures and Ribbas et al., 2000; Jiang et al. 2000;) These devices use Devices of LSU for the use of the cleanroom facility. solenoids that yield unconfined magnetic fields perpenAbstract Most of the MEMS relays reported in the field now are based on silicon fabrication and cannot be used for power applications. In this paper, we report a research effort to microfabricate an electromagnetic relay for power applications using a multilayer UV-LIGA process. A mechanically wrapped coil was used and very simple design for the magnetic circuit was adopted to increase the design flexibility and performances. The broad material selection and the capability of making high aspect ratio microstructures of the UV-LIGA make the technology best suited for fabricating microelectromechanical relays for power applications. The prototype relay has a truly threedimensional structure and very suitable for large power capacity applications. 700 dicular to the plane of the wafer. These electromagnets can then be placed in close proximity, above or below a microactuator to induce a mechanical motion. Typical coils produced by this technology are comprised of very thin wires that cannot carry high currents. They typically have less than 20 turns yielding a low magnetic flux. Recently, Kim and Allen (1998) produced a multilayer UV LIGA fabricated electromagnetic solenoid (Park and Allen, 1999). The solenoid was made using multiple resist patterning and electrodeposition steps to create a copper coil around a permalloy material. Other similar devices have been developed (Chen et al., 2001; Siedemann, 2003). using the same fabrication techniques. They all use thick UV resist processing to produce a coil pattern that is electroplated to produce a solenoid parallel to the surface of the wafer. This process requires long distances to wrap a high number of turns and provides no magnetic confinement. The practical utilization of electromagnetic actuators in MEMS systems is still very limited. The most common actuation principle is still the electrostatic one. This is mainly due to the difficulties in fabrication of micro-sized electromagnetic actuators. Another reason is that the electromagnetic actuation would typically require a sizable current and therefore contribute to power consumption and heat generation. control devices and isolation wiring are required to handle these voltages, resulting in a higher overall cost. Advantages in using UV-LIGA to fabricate power microrelays To achieve higher power capacity, a micro-relay based on MEMS technology should have following characteristics: (1) Materials of high electric conductivity, for example, metals or alloys such as copper should be used as electrodes; (2) relative thick wire pattern to carry larger current, other than thin films as in silicon based surface fabrication technology; (3) high aspect-ratio structures should be used in the design of the electromagnetic actuator to boast the electromagnetic force and the maximum moving range, therefore permit a smaller driving voltage; (4) and finally, to compete with the solid state devices, the MEMS relays should also have a simple design so that the final product can be commercially competitive. Flexibility in materials selection and the capability of making high aspect ratio microstructures with the LIGA process make it the best technology for microfabricating high power micro-relays and relay arrays. Compared with the more conventional MEMS processes based on silicon technology, the LIGA process has some unique advantages: (1) it allows the fabrication of high aspect ratio microstructures with structural heights up to hundreds or one thousand micrometers; (2) different materials such as plastics, metals, alloys, ceramics, or a combination of these materials can be used with the ‘‘LIGA’’ process. Advantages of electromagnetic actuation This second advantage makes it very suitable for The practical utilization of electromagnetic actuators in MEMS systems is still very limited. This is partially due to Microfabrication of the power micro relay. For example: beryllium-copper can be used for making a micro-spring, the difficulties in fabrication of micro-sized electromagnetic actuators with silicon-based MEMS technology, and thick metal structures can be used as electrodes to carry partially because of some misconceptions about electro- larger current, good electrically conducting materials such as beryllium-copper and gold can be electroplated magnetic actuation. Busch-Vishniac (1992) provided a as electrodes for better contacting condition and reduce detailed discussion and strong arguments for electrospark corrosion. magnetic micro-actuators by direct comparison of a magnetic and an electrostatic microfabricated actuator. It was concluded that the case for magnetic actuation is 2 compelling at most of the scales of interest. Designs for the electromagnetic power micro-relay If the efficiencies of electrostatic and electromagnetic Figure 1.(e) shows a schematic design of the design for actuators are compared, the smaller the actuator the more electromagnetic micro-relay, and Figs. 1. (a), (b), (c) and (d) advantageous the electrostatic type, with the transition show the operation principle of the relay. The relay is point around 1 mm [Hosaka et al., 1994]. From a practical comprised of the following components: a microfabricated point of view, this size, which is two to four orders of spring, two electrodes – one for the input and the other for magnitude smaller than conventional relays, is sufficiently output, an electromagnetic actuator, and the magnetic core small because, even if it were further reduced, total system for coil and magnetic flux circuit. The magnetic core (the size would not change much since the peripheral circuit circular post in the center) and magnetic flux circuit will be would be the dominant feature. used as one of the electrodes, and the spring, which is Two key factors in selecting an actuation mechanism electrically isolated from the remaining part of the relay, will are reliability and cost. First, since closing and opening of be used as the other electrode. An electromagnetic coil, the mechanical contacts are dust-making processes, the which is not shown in Fig. 1(e), is inserted on the central actuator for the micro-relays must be unaffected by parpost in the diagram. This arrangement helps to reduce the ticulate. Electromagnetic actuators are superior to elecnumber of components and simplifying the overall design. trostatic actuators in this aspect, since the latter are The design presented here is a truly three-dimensional deaffected by contaminant adhesion. Secondly, when consign, unlike previous prototypes reported in the literature. sidering the overall cost of micro-relays, both the relays A typical operation sequence for the device can be and the peripheral circuit costs must be taken into acshown schematically in the Fig. 1(a), (b), (c) and (d): count. Electromagnetic actuators can be controlled with low-cost electronics, but electrostatic actuators typically (1) If there is no control current supplied to the coil, the need high voltage (>30 v) to operate. Specially designed spring remains in the neutral position and the relay is operation of the micro relay 701 Fig. 1. Schematic diagrams for the design and operation of the micro-relay netic circuit is designed in such a way so that the magnetic flux is well confined. The flat spring in the design is mounted on separate supporting structures to have it electrically isolated from the magnetic core and flux circuit. This arrangement is necessary because both the magnetic core and the spring are used as electrodes and the signal wires will be connected to them for design simplicity. Another design option is to use the flux circuit as the supporting structure and directly bond the spring to it. In that case, an insulating layer will be required between them. To lower the Most previous micro-relay designs have attempted to micontact resistance between the electrodes, a thin film of crofabricate coils, therefore have significantly increased gold may also be deposited on the electrode surfaces. the complexity of the fabrication process. The LIGA technology, and silicon-based MEMS technology alike, Electromagnetic and dynamic analysis of the micro-relay should only be used for the work best suited for it. A Since detailed modeling and analysis of the prototype hybrid approach may be taken for fabrication of the electromagnetic micro-relay is not the purpose of this electromagnetic components of the micro-relay. Using the presentation, only a brief of discussion of the related UV-LIGA process for fabrication of a magnetic core and mathematical model will be provided here. The main magnetic flux circuit has overwhelming advantages over purpose of this discussion is to provide a realistic assesssilicon-based MEMS technology because of the unique ment of the performance and a guide for the basic design advantages of LIGA in making microstructures with high of the relay. For the purposes of brevity, specific details are aspect ratios and the flexibility in materials selection. not presented. However, making micro-coils with either silicon-based A lumped-parameter approach can be adopted to derive a MEMS technology or the LIGA process is not a job that simplified, closed form mathematical model for the case of a can be easily and efficiently done. Insulated copper wires permalloy spring (no permanent magnet required). The with diameters as small as 25 lm are commercially availmagnetic flux density in the air gap between the magnetic able and coils can be custom-ordered. A micro-sized core and the spring is assumed to be uniform. Then the electromagnetic actuator with the magnetic core, flux cirsystem in Fig. 1 may be modeled as a mass-spring-damper cuit, and springs made with the UV-LIGA process, system, where the equivalent spring constant of the flat assembled with a mechanically-wrapped coil would have spring is K, the damping effect is b and the equivalent mass is much lower overall cost than a monolithic microfabricated M. The equivalent resistance of the coil is R. system. Under the stated assumptions, the flux linkage k can be A mechanically wrapped micro-coil was used in the derived as electromagnetic actuator. A permalloy magnetic core and magnetic flux circuit was fabricated with UV-LIGA prol0 AN 2 i k ¼ : ð1Þ cess. The micro-coil was then inserted vertically onto the gþx magnetic core. The spring was made using the LIGA The instantaneous electromagnetic force working on the process with either copper alloy, or permalloy. If the permalloy flat spring Fe can be expressed as: spring is made of permalloy, then a closed circuit for magnetic flux can be made and a permanent magnet for 1 L0 i2 e ð2Þ self-latching may not be necessary. Both approaches will F ¼ 2 ; 2 gð1 þ x=gÞ be evaluated and their performance compared. The magoff (electrodes do not make contact) as shown in Fig. 1(a). (2) If a current is supplied to the coil, the electromagnetic force generated by the electromagnet pulls the spring downward until contact is made between the two electrodes (the spring and the magnetic core). (3) If the control current is turned off, the elastic force restores the flat spring to the horizontal position, contact is broken and the relay is off. where L0=self-inductance from the gap flux when the center of the flat spring touches the magnetic core: N ¼ number of turns on the coil, l0 ¼ permeability of the air gap, A ¼ cross-sectional area of the air gap, x ¼ displacement of the center of the flat spring, g ¼ displacement of the outer rim of the flat spring. Then the electrical and mechanical dynamic equations describing the system are: 702 3 The multi-layer UV-LIGA process From the design of the relay, it can be seen that the electrical wire patterns, the magnetic core, and the supporting pads for the suspension spring are all at different heights. The thickness of the wire patterns and the suspension spring set the limit for the power capacity. Therefore several layers of metal/alloy structures at different thickness need to be fabricated. A multi-layer UV-LIGA process L0 dt L0 i dx was developed. The detailed fabrication process is pre þ Ri ¼ v ; ð3Þ 1 þ x=g dt gð1 þ x=gÞ2 dt sented in Table 1. Figures 2 through 10 show shows a group of photographs of the prototype electromagnetic and relay at different process stages. d2 x dx To reduce the probability of electrostatic breakdown, e M 2 þ b þ Kx ¼ F ; ð4Þ alumina was used as the substrate for this process. UV dt d lithography processing of SU-8 on alumina substrates has From these two equations, expressions for both the elecpreviously demonstrated aspect ratios over 40:1 [17]. trical and mechanical time constants can be derived: Fabrication of thick metal layers on a porous ceramic substrate proved difficult. To prevent under-etching of the l0 AN 2 se ¼ : ð5Þ metal layer, a liftoff process was used. AZ 4580 was used to Rgð1 þ x0 =gÞ create the pattern for the plating base, and a 1 lm thick and copper layer was deposited into the pattern by physical vapor deposition. The resist was then removed to reveal 2M : ð6Þ the pattern shown in Fig. 2. Copper leads extend from the sm ¼ b pattern to larger electrical contacts used for electrodeThe damped natural frequency of the mechanical system is position. A subsequent layer of SU-8 between 50 and sffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffiffi 250 lm thick was then patterned over the plating base to 2ffi reveal the initial layer of the relay. Nickel was uniformly K b xnd ¼ : ð7Þ electrodeposited into the pattern, as shown in Fig. 3, using M 2M a modified nickel sulfamate bath. Chemical mechanical The system parameters can be set based on an analysis of polishing was perfomed if needed to provide a uniform the performance using the model. nickel layer thickenss. The substrate was then cleaned The mass M in Eq. (4) can be estimated using the using a strong base and plasma ashed prior coating a 2nd conventional method of one third of the weight of the spring. Given the geometric design and the material of the spring, it can be easily calculated. The spring constant k Table 1. Fabrication Procedures can be estimated by treating the flat spring as cascaded Step#1 Copper electroplating base patterned on 4’’ alumina cantilever beams. Assume small deflection, the total substrate using a liftoff process. The result is deflection of the spring at its center of can be roughly shown in Fig. 2. estimated using the fundamental relations in macro scale Step#2 Nickel electroplated into patterned SU-8 layer to and linear superposition method. Each section of the produce relay base capable of carrying large cantilever beam is treated as a beam in bending and torcurrents. The result is shown in Fig. 3. Step#3 Substrate is coated with 50 lm of SU-8 and exposed sion. to reveal interconnect patterns shown in Fig. 4. The prototype design for a relay with a current Spin-coat another layer of 1000–1500 lm of SU-8 capacity of 100 mA was modeled and simulated to and Step#4 resist. Expose, and develop to form the negative the results are provided here to offer some general ideas pattern of the bottom part of the relay. Figs. 5 and about the possible design parameters and the relay 6 shows a photograph of the exposed photo pattern performances. Assume copper is used as the main obtained. material for its good electrical and mechanical proper- Step#5 Nickel is then electroplated selectively into the pattern to produce the magnetic cup, core post and ties. Assume each piece of flat springs are designed to electrical leads for the relay. Figs. 7 and 8 show the have four cascaded beams with a width of c ¼ 50 lm photographs of the bottom parts of the relay that and a thickness of h ¼ 15 lm, and length a ¼ 150 lm, has been electroplated. the length b ¼ 450 lm. Another spring design called for Step#6 Solenoid was wrapped using 50 lm diameter copper a curved beam spring configuration. Beam width and wire and inserted onto the relay base. Figure 9 thickness remained the same, however the geometry and shows a micro-coil wrapped mechanically. therefore the spring constant change. Also assume the Step#7 Magnetic spring made of electroplated NiFe was made on a second substrate. diameter of the magnetic core is 200 lm, the height of Plunger is then released from its substrate and the magnetic core is 1000 lm, and a 20 lm air gap exist Step#8 bonded on top of the base to yield a device. between the relay base and the spring-mass. A control Figure 10 shows a photograph of the relay that has current of 10 mA is to be supplied to a coil of 30 turns been assembled. to drive the relay. 703 Fig. 4. 50 lm thick SU-8 intermediate insulation layer on nickel Fig. 2. Patterned copper plating base SU-8 layer. The Intermediate SU-8 layer was then coated and patterned to reveal only the nickel areas that were to be plated to the top of the relay base. Figure 4 shows a photograph of the patterned intermediate layer. The white rings around the pattern are areas of debonded SU-8 due to the poor adhesive properties of nickel and SU-8 resist. The debonded areas shown did not however, did not lead to underplating and did not affect the final product. After development, the substrate was dried, cleaned in O2 plasma and coated with the final SU-8 layer. The third resist layer was required a spin coat between 1000 and 1500 lm thick. Two spin coats were required to obtain layers thicker than 1300 lm in height [17]. The pattern presented in Fig. 5 is 1200 lm tall with a core cylinder wall that is 75 lm thick. The insulation layer between the magnetic cup and the solenoid is 50 lm wide, yielding an aspect ratio of 24:1. Cured SU-8 has been well known to be extremely difficult to strip. At the same time, it also has very good mechanical properties. It has quite high dielectric constant and is very good electric insulator. In our design, effort has been made to avoid the unnecessary stripping procedures of cured SU-8. While the geometric constraints permitted, the cured SU-8 is always kept as part of the permanent structure for the relay. For example, the magnetic core also serves as the conductor pad for the current to be switched on, the cured SU-8 was used to serve as the insulator between the coil to be inserted later and at the same time, it serves as the electroplating mold for fabricate the magnetic core. The relay base cross section spliced and imaged in Fig. 6 shows a 1350 lm tall relay base with a maximum aspect ratio of 27:1. It can be seen that the micro-patterns for both the cylindrical magnetic flux path (to hold the coil) and the magnetic core were designed in such as way that the exposed SU-8 resist do not need to be stripped and are kept as part of the overall structure after electroplating process is completed. The 50 lm SU-8 intermediate insulation layer patterned around the base of the relay’s core post is reveled in Fig. 6. The flat pad with a circular tip in the lower left corner of the SEM image is the first electroplated nickel layer. This pattern was used to plate one of the four nickel cylinders surrounding the magnetic cup that were used to support the Ni-Fe spring mass. Figs. 7 and 8 are images of a plated relay base after the cylinders were polished down to a height of 1000 lm. The insulation layer prevented plating inside the magnetic up and allowed for easy insertion of a wrapped solenoid for electromagnetic actuation. After plating, a flash of copper or gold was plated onto the nickel patterns to enhance the bonding process. Fig. 5. Relay base after patterning the 3rd SU-8 layer. The thick Fig. 3. 200 lm of nickel uniformly plated into the first SU-8 layer layer is 1200 lm tall on top of 200 lm of electrodeposited nickel and a 2nd 50 lm layer of SU-8 patterned over the copper 704 Fig. 8. SEM image showing electroplated nickel structures in relay base. A solenoid is inserted into the cup and leads passed through the slots on either side Fig. 6. SEM image of relay base cross section. Both the initial nickel base and the insulation layer are revealed under 1350 lm The spring mass was then bonded to the top of the thick SU-8 layer completed relay base. The bonding process can either be Figure 9 is a photograph of a 30 turns solenoid wrapped using 46 gauge insulated copper wire. A stickpin was placed next to the coil to demonstrate size. After wrapping, the solenoid was bound using adhesive and placed into the magnetic cup on the relay base. The wire leads of the coil were placed into the patterned slots on either side of the magnetic cup. They were then soldered to square nickel post shown in Fig. 7. This allows for easy interconnects between the relay and an external driving source. Placement of the solenoid represents the completion of the relay base. It can then be used to create local magnetic fields for electromagnetic actuation of any magnetic material. The power relay design required the actuation of a thin magnetic spring mass. To make the spring mass, a flat NiFe spring was also successfully fabricated using a single layer resist on a silicon substrate and then under-etching a thick plating base or stripping an exposed negative resist base. Currently, Fe content in the Ni-Fe alloy plated has been tested with XES to contain approximately 20% wt Fe. Fig. 7. Photograph of the relay base done by soldering or glued using silver paste. Figure 10 shows a photograph of the relay that has been assembled. The prototype relay is currently being tested in our lab for response time and current capacity. Different spring geometries are being evaluated to produce a relay with the optimum desired response. Results will be presented in a future work. Conclusion Most micro-sized switches (micro-relays) currently on the market or reported in the literature are solid-state devices made using semiconductor technology, with silicon the predominant material. Such devices typically have low current capacity, low off-resistance, significant on-resistance, significant power consumption, and low dielectric strength. In recent years, the fast-evolving technology of (MEMS) has opened up new opportunities for microfabricating microelectromechanical switches. However, most of the MEMS relays based on silicon fabrication cannot be used for power applications. In this paper, the microfabrication of a prototype electromagnetic actuated power relay was presented. The device was fabricated using UV-LIGA technology using Fig. 9. Micro-coil is wound around pin Fig. 10. Photograph of the assembled prototype electromagnetic relay multiple layers of SU-8 and electroplated metal. A mechanically wrapped solenoid insert was used to provide the driving mechanism for the actuator. The solenoid can be wrapped up to 4 layers thick and as tall as 1500 mm. 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