Impact of support material deformation in MEMS bulk micromachined diaphragm pressure sensors

Abstract

Abstract In this work, experimental data and finite element analysis reveals deflection in diaphragm supporting material leading to non-linear pressure-reflection response. These results are contrary to the standard assumptions presented in literature, where modelling of deflection response in diaphragm pressure sensors is primarily carried out assuming a rigid supporting structure. An extrinsic fiber-optic Fabry–Perot pressure sensor, based on micro-electromechanical system, is developed and used to investigate optical deflection response. While the sensor is not novel, a series of experiments to validate support deflection phenomena are designed and carried out using a silicon membrane at gauge pressures from 0 to 1000 PSI in ambient temperature. The device is packaged with an industry standard stainless-steel housing typically used in plastic injection moulding. Sensor performance is compared to analytical and finite element modelling. Results suggest that the device is experiencing greater deflection than analytically predicted at pressures above 200 PSI, where a rigid support is assumed in existing literature. Based on these results, a modified analytical model is proposed to correct for this behaviour. The modified model is created through addition of a nonlinear component to an existing model, which is then fitted to the experimental data using least-square methods. Prediction of the experimental deflection results is improved from 81% error using a fixed-support analytical model to 4% error using the presented adjusted model. It is demonstrated that nonlinear effects are present and optically measurable in cases where deflection is lower than 1% of the membrane thickness. This work will aid in the implementation of high-resolution pressure sensors operating in harsh environment conditions.