Single crystal, dual wafer, tunneling sensor or switch with silicon on insulator substrate and a method of making same
First Claim
1. A method of making a MEM switch or tunneling sensor comprising the steps of:
- (a) defining a cantilevered beam structure and a mating structure on an etch stop formed on first substrate or wafer;
(b) forming at least one contact structure and a mating structure on a second substrate or wafer, the mating structure on the second substrate or wafer being of a complementary shape to the mating structure on the first substrate or wafer;
(c) positioning the mating structure of the first substrate into a confronting relationship with the mating structure of the second substrate or wafer;
(d) bonding a layer associated with said mating structure on the first substrate or wafer with a layer associated with the mating structure on the second substrate or wafer;
(e) removing at least a portion of the first substrate or wafer and the etch stop to release the cantilevered beam structure.
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Abstract
A method of making a micro electro-mechanical switch or tunneling sensor. A cantilevered beam structure and a mating structure are defined on an etch stop layer on a first substrate or wafer; and at least one contact structure and a mating structure are defined on a second substrate or wafer, the mating structure on the second substrate or wafer being of a complementary shape to the mating structure on the first substrate or wafer. A bonding layer, preferably a eutectic bonding layer, is provided on at least one of the mating structures. The mating structure of the first substrate is moved into a confronting relationship with the mating structure of the second substrate or wafer. Pressure is applied between the two substrates so as to cause a bond to occur between the two mating structures at the bonding or eutectic layer. Then the first substrate or wafer and the etch stop layer are removed to free the cantilevered beam structure for movement relative to the second substrate or wafer.
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Citations
56 Claims
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1. A method of making a MEM switch or tunneling sensor comprising the steps of:
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(a) defining a cantilevered beam structure and a mating structure on an etch stop formed on first substrate or wafer;
(b) forming at least one contact structure and a mating structure on a second substrate or wafer, the mating structure on the second substrate or wafer being of a complementary shape to the mating structure on the first substrate or wafer;
(c) positioning the mating structure of the first substrate into a confronting relationship with the mating structure of the second substrate or wafer;
(d) bonding a layer associated with said mating structure on the first substrate or wafer with a layer associated with the mating structure on the second substrate or wafer;
(e) removing at least a portion of the first substrate or wafer and the etch stop to release the cantilevered beam structure. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30, 31, 32)
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33. A MEM switch or tunneling sensor assembly for making a MEM switch or tunneling sensor therefrom, the assembly comprising:
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(a) a beam structure and a mating structure defined on an etch stop formed on a first substrate or wafer;
(b) at least one contact structure and a mating structure defined on a second substrate or wafer, the mating structure on the second substrate or wafer being of a complementary shape to the mating structure on the first substrate or wafer; and
(c) a pressure/heat sensitive bonding layer disposed on at least one of said mating structures for bonding the mating structure defined on the first substrate or wafer to mating structure on the second substrate in response to the application of pressure/heat therebetween. - View Dependent Claims (34, 35, 36, 37, 38, 39, 40, 41, 42, 43, 44, 45, 46, 47, 48, 49, 50, 51, 52, 53, 54, 55, 56)
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Specification