MEMS DEVICE AND INTERPOSER AND METHOD FOR INTEGRATING MEMS DEVICE AND INTERPOSER
First Claim
1. A method for manufacturing a Microelectromechanical Systems (MEMS) assembly, said method comprising:
- obtaining an SOI wafer, which comprises;
(i) a handle layer,(ii) a dielectric layer on said handle layer, and(iii) a device layer on said dielectric layer;
etching said device layer of said SOI wafer to at least partially define said MEMS device;
obtaining an interposer wafer;
bonding said SOI wafer to said interposer wafer in a way such that said device layer of said SOI wafer faces said interposer wafer;
removing said handle layer of said SOI wafer; and
removing said dielectric layer of the SOI wafer.
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Abstract
A method for producing Microelectromechanical Systems (MEMS) and related devices using Silicon-On-Insulator (SOI) wafer includes providing an SOI wafer, performing a mesa etch to at least partially define the MEMS device, bonding the SOI wafer to an interposer by direct boding, removing the handle layer of the SOI wafer, removing the oxide layer of the SOI wafer, and further etching the device layer of the SOI wafer to define the MEMS device. A structure manufactured according to the above described processes includes an interposer comprising an SOI wafer and a MEMS device mounted on the interposer. The MEMS device comprises posts extending from a silicon plate. The MEMS device is directly mounted to the interposer by bonding the posts of the MEMS device to the device layer of the interposer.
28 Citations
46 Claims
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1. A method for manufacturing a Microelectromechanical Systems (MEMS) assembly, said method comprising:
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obtaining an SOI wafer, which comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; etching said device layer of said SOI wafer to at least partially define said MEMS device; obtaining an interposer wafer; bonding said SOI wafer to said interposer wafer in a way such that said device layer of said SOI wafer faces said interposer wafer; removing said handle layer of said SOI wafer; and removing said dielectric layer of the SOI wafer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 41)
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22. A method for manufacturing a Microelectromechanical Systems (MEMS) assembly, said method comprising:
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obtaining an SOI wafer, which comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; etching said device layer of said SOI wafer to partially define said MEMS device; obtaining an interposer wafer; bonding said SOI wafer to said interposer wafer in a way such that said device layer of said SOI wafer faces said interposer wafer; removing said handle layer of said SOI wafer; removing said dielectric layer of the SOI wafer; and etching said device layer of said SOI wafer to further define said MEMS device. - View Dependent Claims (23, 42)
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24. A method of manufacturing a Microelectromechanical Systems (MEMS) assembly, said method comprising:
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obtaining a first SOI wafer, wherein said first SOI wafer comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; etching said device layer and said dielectric layer to define separate areas on said first SOI wafer; obtaining a second SOI wafer, which comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; etching said device layer of said second SOI wafer to at least partially define said MEMS device; bonding said device layer of said second SOI wafer to said device layer of said first SOI wafer; removing said handle layer of said second SOI wafer; and removing said dielectric layer of said second SOI wafer. - View Dependent Claims (25, 26, 43)
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27. A Microelectromechanical Systems (MEMS) apparatus comprising:
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an interposer wafer comprising an SOI wafer, wherein said SOI wafer comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; a MEMS device comprising posts extending from a silicon plate, wherein said MEMS device is directly mounted to said interposer by bonding said posts of said MEMS device to said device layer of said interposer. - View Dependent Claims (28, 29, 30, 31, 32, 33, 34)
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35. A method for etching an element in a structure, said structure including (i) a substrate, (ii) at least one device disposed on said substrate, and (iii) said element attached to said substrate and disposed over said device, said method comprising:
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depositing and patterning resist on said element, such that at least one selected area of said element is covered by said resist, wherein said at least one selected area is above said at least one device; and etching said element, whereby said at least one selected area covered by said resist is protected by said resist from being etched, whereby said at least one device under said area is protected from being etched.
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36. A method of manufacturing a Microelectromechanical Systems (MEMS) assembly, said method comprising:
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obtaining a first SOI wafer, wherein said first SOI wafer comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; performing a mesa etch on said device layer to define at least one structural post; obtaining a second SOI wafer, which comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; bonding said device layer of said second SOI wafer to said at least one structural post of said first SOI wafer; removing said handle layer of said second SOI wafer; and removing said dielectric layer of said second SOI wafer. - View Dependent Claims (37, 38, 44)
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39. A method for manufacturing Microelectromechanical Systems (MEMS) devices, said method comprising:
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obtaining an SOI wafer, which comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; etching said device layer of said SOI wafer to define an array of sets of structural posts, wherein each set of structural post includes at least one structure post; obtaining an interposer wafer; bonding said SOI wafer to said interposer wafer in a way such that said device layer of said SOI wafer faces said interposer wafer; removing said handle layer of said SOI wafer; removing said dielectric layer of the SOI wafer; etching said device layer of said SOI wafer to define an array of said MEMS devices; and separating the result structure into individual MEMS devices. - View Dependent Claims (45)
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40. A method of manufacturing Microelectromechanical Systems (MEMS) devices, said method comprising:
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obtaining a first SOI wafer, wherein said first SOI wafer comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; performing a mesa etch on said device layer to define an array of sets of structural posts, wherein each set of structural post includes at least one structural post; obtaining a second SOI wafer, which comprises; (i) a handle layer, (ii) a dielectric layer on said handle layer, and (iii) a device layer on said dielectric layer; bonding said device layer of said second SOI wafer to said at least one structural post of said first SOI wafer; removing said handle layer of said second SOI wafer; removing said dielectric layer of said second SOI wafer; etching said device layer of said second SOI wafer to define an array of said MEMS devices; and separating the result structure into individual MEMS devices. - View Dependent Claims (46)
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Specification