Process for manufacture of micro electromechanical devices having high electrical isolation
First Claim
1. A method for fabricating a micro electromechanical (MEM) component on a substrate comprising the steps of:
- Providing a first substrate;
Providing a second substrate;
Bonding said first substrate to said second substrate to form a composite structure with an adhesive polymer layer between said substrates;
Etching a portion of said first substrate to define a MEM component; and
Selectively etching a portion of said adhesive bond to release said MEM component, said MEM component supported by said first substrate and said first substrate, other than said MEM component, remains coupled to said second substrate by a remaining portion of said adhesive polymer layer.
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Accused Products
Abstract
The present invention relates to a fabrication process relating to a fabrication process for manufacture of micro-electromechanical (MEM) devices such as cantilever supported beams. This fabrication process requires only two lithographic masking steps and offers moveable electromechanical devices with high electrical isolation. A preferred embodiment of the process uses electrically insulating glass substrate as the carrier substrate and single crystal silicon as the MEM component material. The process further includes deposition of an optional layer of insulating material such as silicon dioxide on top of a layer of doped silicon grown on a silicon substrate. The silicon dioxide is epoxy bonded to the glass substrate to create a silicon--silicon dioxide-epoxy-glass structure. The silicon is patterned using anisotropic plasma dry etching techniques. A second patterning then follows to pattern the silicon dioxide layer and an oxygen plasma etch is performed to undercut the epoxy film and to release the silicon MEM component. This two-mask process provides single crystal silicon MEMs with electrically isolated MEM component. Retaining silicon dioxide insulating material in selected areas mechanically supports the MEM component.
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Citations
38 Claims
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1. A method for fabricating a micro electromechanical (MEM) component on a substrate comprising the steps of:
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Providing a first substrate; Providing a second substrate; Bonding said first substrate to said second substrate to form a composite structure with an adhesive polymer layer between said substrates; Etching a portion of said first substrate to define a MEM component; and Selectively etching a portion of said adhesive bond to release said MEM component, said MEM component supported by said first substrate and said first substrate, other than said MEM component, remains coupled to said second substrate by a remaining portion of said adhesive polymer layer. - View Dependent Claims (2, 3)
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4. A method for fabricating a micro electromechanical (MEM) component on a substrate comprising the steps of:
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Providing a first substrate; Providing a first layer of material on said first substrate; Providing a second substrate; Forming a composite structure having a single bead of adhesive polymer between said first layer of material and said second substrate; Etching said first substrate to expose said first layer of material; Etching said first layer of material to define a MEM component in said first layer of material; and Etching a portion of said adhesive to release said MEM component, so that said MEM component is supported by said first layer of material and said first layer of material, other than said MEM component, remains coupled to said second substrate by a remaining portion of said adhesive polymer layer. - View Dependent Claims (5, 6, 7, 8, 9, 10, 11, 12)
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13. A method for fabricating a micro electromechanical component on a substrate comprising the steps of:
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Providing a silicon substrate; Depositing a layer of semiconductor material on said silicon substrate; Providing a highly insulating substrate; Bonding said highly insulating substrate to said semiconductor material to form a composite structure with an adhesive polymer layer; Etching said silicon substrate to expose said semiconductor material; Etching said semiconductor material to define a micro electromechanical component; and Performing an isotropic etch to selectively undercut the adhesive polymer layer and to release the suspended portions of said micro electromechanical component, said micro electromechanical component supported by said semiconductor material and said semiconductor material, other than said micro electromechanical component, is coupled to said highly insulating substrate by a remaining portion of said adhesive polymer layer. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28)
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29. A method for fabricating a micro electromechanical component on a substrate comprising the steps of:
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Providing a silicon-on-insulator (SOI) substrate having a buried layer of insulating material; Providing a highly insulating substrate; Bonding said highly insulating substrate to said SOI substrate with a layer of adhesive polymer to form a composite structure; Etching said SOI substrate to expose at least a portion of said buried layer insulating material; Etching said buried layer insulating material to define a micro electromechanical component; and Selectively etching said adhesive polymer layer under said micro electromechanical component so said micro electromechanical component is supported by said SOI substrate and said SOI substrate, other than said micro electromechanical component, remains bonded to said highly insulating substrate by a remaining portion of said adhesive polymer layer. - View Dependent Claims (30, 31, 32, 33, 34, 35, 36, 37, 38)
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Specification