Microelectrodes
are used
in a wide range of applications from analytical electrochemistry and
biomolecular sensing to in vivo implants. While a variety of insulating
materials have been used to define the microelectrode active area,
most are not suitable for nanoscale electrodes (<1 μm2) due to the limited robustness of these films when the film
thickness is on the order of the nanoelectrode dimension. In this
study, we investigate atomic layer deposited hafnium dioxide (ALD
HfO2) as an insulating film to coat planar platinum microelectrodes,
with the active areas being defined where the HfO2 is etched.
Thermally grown films with thicknesses between 10 and 60 nm were deposited
by 100 to 550 ALD cycles and were initially characterized by measuring
their standard electrical properties and imaging incipient texture
development. Electrochemical measurements on the structures were made,
including linear sweep voltammetry and electrochemical impedance spectroscopy,
which identified the presence of pinholes in films deposited over
the range of 100 to 350 cycles, resulting in leakage. These measurements
also suggest a lower limit to the size of microelectrodes below which
the electrochemical current detected is no longer dominated by that
through the exposed active area. A bilayer insulator comprising ALD
HfO2 coated with parylene-C was investigated to minimize
the pinhole leakage. Steady-state currents were measured for different
electrode areas, qualitatively agreeing with the theory for areas
down to ∼1 μm2. For sub-square micrometer
electrode areas, bilayer-insulated devices with parylene-C apertures
that exposed the smallest microelectrode area showed measured currents
that were consistent with extrapolations, indicating that it reduces
leakage through HfO2.