Micro-electro mechanical system (MEMS) structures with through substrate vias and methods of forming the same
First Claim
1. A method of forming a micro-electro mechanical system (MEMS) structure, the method comprising:
- providing a first substrate structure having a first layer with a first silicon surface, wherein the providing the first substrate structure includes forming the first layer having the first silicon surface consisting of silicon;
providing a second substrate having a second layer with a second silicon surface, wherein the providing the second substrate includes forming the second layer having the second silicon surface consisting of silicon;
bonding the second substrate to the first substrate structure using fusion bonding, wherein the bonding forms a fusion bonding interface between the first and second silicon surfaces, wherein the second substrate includes at least one micro-electro mechanical system (MEMS) device, and wherein there is at least one cavity surrounding at least a portion of the MEMS device; and
forming a through silicon via (TSV) in the first substrate structure and through the fusion bonding interface between the first substrate structure and the second substrate such that a conductive layer of the TSV extends through the fusion bonding interface.
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Abstract
The present disclosure includes micro-electro mechanical system (MEMS) structures and methods of forming the same. Substrates of the MEMS structures are bonded together by fusion bonding at high processing temperatures, which enables more complete removal of chemical species from the dielectric materials in the substrates prior to sealing cavities of the MEMS structures. Fusion bonding of MEMS structures reduces outgassing of chemical species and is compatible with the cavity formation process. The MEMS structures bonded by fusion bonding are mechanically stronger compared to eutectic bonding due to a higher bonding ratio. In addition, fusion bonding enables the formation of through substrate vias (TSVs) in the MEMS structures.
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Citations
20 Claims
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1. A method of forming a micro-electro mechanical system (MEMS) structure, the method comprising:
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providing a first substrate structure having a first layer with a first silicon surface, wherein the providing the first substrate structure includes forming the first layer having the first silicon surface consisting of silicon; providing a second substrate having a second layer with a second silicon surface, wherein the providing the second substrate includes forming the second layer having the second silicon surface consisting of silicon; bonding the second substrate to the first substrate structure using fusion bonding, wherein the bonding forms a fusion bonding interface between the first and second silicon surfaces, wherein the second substrate includes at least one micro-electro mechanical system (MEMS) device, and wherein there is at least one cavity surrounding at least a portion of the MEMS device; and forming a through silicon via (TSV) in the first substrate structure and through the fusion bonding interface between the first substrate structure and the second substrate such that a conductive layer of the TSV extends through the fusion bonding interface. - View Dependent Claims (2, 3, 4, 5, 6)
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7. A method of forming a micro-electro mechanical system (MEMS) structure, the method comprising:
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providing a first substrate structure having a first layer with a first silicon surface; providing a second substrate having at least one micro-electro mechanical system (MEMS) device and having disposed thereon a second layer with a second silicon surface, wherein the second layer is formed over and interfaces a top surface of the second substrate, the top surface being a semiconductor material; fusion bonding the second substrate to the first substrate structure, wherein the fusion bonding forms a bonding interface between the first and second silicon surfaces; and forming an interconnect through the first substrate structure and the bonding interface to contact the top surface of the second substrate. - View Dependent Claims (8, 9, 10, 11, 12, 13)
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14. A method of forming a micro-electro mechanical system (MEMS) structure, the method comprising:
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providing a first substrate structure, wherein a first layer with a first silicon surface is disposed on the first substrate structure; providing a second substrate, wherein a second layer with a second silicon surface is disposed on the second substrate a bottommost surface of the second layer interfacing the second substrate; fusion bonding the second substrate to the first substrate structure, wherein the fusion bonding includes;
annealing the first substrate structure and second substrate to form a bonding interface between the first and second silicon surfaces; andforming an interconnect through the first substrate structure and the bonding interface and contacting the second substrate below the second layer, wherein a bottommost surface of the interconnect is coplanar with the bottommost surface of the second layer. - View Dependent Claims (15, 16, 17, 18, 19, 20)
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Specification