Designing, fabrication and post- fabrication characterization of half-frequency driven 16 x 16 waterborne transmit CMUT array

Abstract

Capacitive Micromachined Ultrasonic Transducers (CMUT) are micro-scaled electromechanical devices which are used to either transmit or receive pressure signals and applicable for various purposes such as ultrasonic sensor, medical imaging, accurate biometric sensing and parametric speakers. For transmitting CMUT transducer, different sizes and array configurations are used to intensify the transmission power depending on the application. The half-frequency driven waterborne transmitting CMUT array designed in this work is to be used for high resolution volumetric medical imaging purpose. This was accomplished by a design which prioritizes maximizing the power output, achieving a directive radiation pattern with low sidelobes which maximizes the beamformable region. In this work, the issues with steering of the focused beam are also resolved to achieve a focused steerable beam. This work is an advancement from the earlier designed half-frequency driven airborne transmit CMUT to improve power output, introduce the beamforming and focused transmission capabilities and be applicable for high resolution volumetric medical imaging purpose. To improve the power output, the design was made to compensate for the static depression. Compensating for static depression was achieved by designing to operate the CMUT without DC bias voltage which allows for full-gap swing and giving output signal of twice the input frequency. This property allows the cell to produce high power output with low voltage levels but also brings the advantage of operating the cell with very high voltages without collapsing. The CMUT was chosen to be operating at 7.5 MHz and be driven by Digital Phased Array System (DiPhAS) which allowed to have maximum of 256 channels which for volumetric transmission meant a maximum of 16 x 16 array. Since the radiation pattern and Rayleigh distance are both the functions of radius, frequency and the pitch, the design optimization was found while considering all the above preferences simultaneously. The cells’ radii were determined to be 80 µm, the plate thickness was 15 µm, the gap height was found to be 117 nm and the pitch was 192 µm. The array designing was carried out using the large-signal equivalent circuit model and the radiation impedance matrix phenomenon. The simulations showed that with this design, the maximized Rayleigh distance was 45.3 mm and the sidelobe of -17.4 dB. In simulations, very high pressure outputs were achievable with individual cells up to 425 kPa per cell with 150 VPP input while up to 1.5 MPa was emitted by the array plane wave transmission with only 10 VPP input and almost doubles when the transmitted beam was focused at zero degrees. Fabrication was done by the wafer boding and flip-chip bonding techniques where the whole process required only two lithography masks. After fabrication, the tests were performed to identify the yield of the transducer was 18.75% of the array then impedance analysis was done to characterize the functional cells and resonance frequency drift. The transducer was cased in a water-tight manner and the waterborne transmission were done with individual cells to characterize and compare the performance with the design simulations which were in the range of agreement achieving an average of 1625 Pa per cell. The functional cells were then used for plane wave transmission with 10 VPP and the output pressure of 397 kPa was achieved at resonance frequency. The measurement results showed that the design could further be improved by compensating the active area to improve the yield for better results and be able to use it for high resolution 3D medical imaging.