Design and Fabrication of Wideband Air-Coupled Capacitive Micromachined Ultrasonic Transducers With Varying Width Annular-Ring and Spiral Cell Structures

Air-coupled transducers with broad bandwidth are desired for many airborne applications, such as obstacle detection, haptic feedback, and flow metering. In this article, we present a design strategy and demonstrate a fabrication process for developing improved concentric annular- and novel spiral-shaped capacitive micromachined ultrasonic transducers (CMUTs) that can generate high output pressure and provide wide bandwidth in air. We explore the ability to implement complex geometries by photolithographic definition to improve the bandwidth of air-coupled CMUTs. The ring widths in the annular design were varied so that the device can be improved in terms of bandwidth when these rings resonate in parallel. Using the same ring width parameters for the spiral-shaped design but with a smoother transition between the ring widths along the spiral, the bandwidth of the spiral-shaped device is improved. With the reduced process complexity associated with the anodic-bonding-based fabrication process, a 25-mu m vibrating silicon plate was bonded to a borosilicate glass wafer with up to 15-mu m deep cavities. The fabricated devices show an atmospheric deflection profile that is in agreement with the FEM results to verify the vacuum sealing of the devices. The devices show a 3-dB fractional bandwidth (FBW) of 12% and 15% for spiral- and annular-shaped CMUTs, respectively. We measured a 127-dB sound pressure level at the surface of the transducers. The angular response of the fabricated CMUTs was also characterized. The results demonstrated in this article show the possibility of improving the bandwidth of air-coupled devices by exploring the flexibility in the design process associated with CMUT technology.