Process for integrating dielectric optical coatings into micro-electromechanical devices
First Claim
1. A process for fabricating a membrane with an optical coating, the process comprising:
- forming a membrane layer;
depositing a high reflectivity (HR) coating on the membrane layer;
patterning the HR coating with a dry etch process to reside at least over a portion of an optical port region of the membrane layer;
patterning the membrane layer to form the membrane; and
removing at least part of a sacrificial layer to release the membrane.
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Accused Products
Abstract
A process for fabricating an optical membrane from polycrystalline silicon comprises first forming a sacrificial layer on a handle wafer. Concavities are etched into the sacrificial layer. Polycrystalline silicon membrane layer is then formed on the sacrificial layer. The polycrystalline membrane layer is subsequently polished to achieve the predetermined membrane thickness and surface smoothness, annealed, and then patterned. Finally, the sacrificial layer is removed to release the membrane. The concavities in the sacrificial layer yield convexities in the polysilicon layer to prevent stiction adhesion to the handle wafer. During processing, a mask used to pattern the membrane layer functions to protect an highly reflecting (HR) coating for the membrane.
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Citations
35 Claims
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1. A process for fabricating a membrane with an optical coating, the process comprising:
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forming a membrane layer;
depositing a high reflectivity (HR) coating on the membrane layer;
patterning the HR coating with a dry etch process to reside at least over a portion of an optical port region of the membrane layer;
patterning the membrane layer to form the membrane; and
removing at least part of a sacrificial layer to release the membrane. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14)
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15. A process for fabricating a membrane with an optical coating, the process comprising:
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forming a membrane layer;
depositing a high reflectivity (HR) coating on the membrane layer;
patterning the HR coating with reactive ion etching to reside at least over a portion of an optical port region of the membrane layer;
patterning the membrane layer to form the membrane; and
removing at least part of a sacrificial layer to release the membrane. - View Dependent Claims (16, 17, 18, 19)
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20. A process for fabricating a membrane with an optical coating, the process comprising:
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forming a membrane layer;
depositing a high reflectivity (HR) coating on the membrane layer;
patterning the HR coating with reactive ion milling to reside at least over portion of an optical port region of the membrane layer;
patterning the membrane layer to form the membrane; and
removing at least part of a sacrificial layer to release the membrane. - View Dependent Claims (21, 22, 23, 24)
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25. A process for fabricating a membrane with an optical coating, the process comprising:
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forming a membrane layer;
depositing a high reflectivity (HR) coating on the membrane layer;
patterning the HR coating to reside at least over a portion of an optical port region of the membrane layer wherein the HR has 4 or more dielectric layers;
patterning the membrane layer to form the membrane; and
removing at least part of a sacrificial layer to release the membrane. - View Dependent Claims (26, 27, 28, 29)
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30. A process for fabricating a membrane with an optical coating, the process comprising:
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forming a membrane layer;
depositing a high reflectivity (HR) coating on the membrane layer;
patterning the HR coating to reside at least over a portion of an optical port region of the membrane layer wherein the HR coating has 8 or more dielectric layers;
patterning the membrane layer to form the membrane; and
removing at least part of a sacrificial layer to release the membrane. - View Dependent Claims (31, 32, 33, 34)
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35. A process for fabricating a membrane with an optical coating, the process comprising:
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forming a membrane layer;
depositing a high reflectivity (HR) coating on the membrane layer;
patterning the HR coating to reside at least over a portion of an optical port region of the membrane layer wherein the HR coating has 16 or more dielectric layers;
patterning the membrane layer to form the membrane; and
removing at least part of a sacrificial layer to release the membrane.
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Specification