Method for fabricating improved mirror arrays for physical separation
First Claim
1. A method for fabricating an array of mirrors disposed on a die from a substrate, the method comprising:
- placing a substrate comprising a plurality of die thereon on a stage, each of the die comprising a plurality of to be movable mirror devices in an array configuration, each die comprising a peripheral region defining a street that surrounds the array configuration;
forming a plurality of tabs that join one die to another die in the street of the substrate, each of the tabs also being separated from each other in a sequential manner by a recessed region between at least two of the tabs, wherein the street is defined by the tabs and the recessed region defined therebetween in a sequential manner; and
directing a beam of high intensity electromagnetic radiation at the street between the one die and the other die to ablate each of the tabs that joins the one die to the other die to separate the one die from the other die to free the die comprising the mirror array from the other dice on the substrate.
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Accused Products
Abstract
A method for fabricating an array of mirrors disposed on a die from a substrate. The method includes placing a substrate comprising a plurality of die thereon on a stage. Each of the die comprises a plurality of movable mirror devices in an array configuration. Each die comprises a peripheral region defining a street that surrounds the array configuration. The method forms a plurality of tabs that join one die to another die in the street of the substrate. Each of the tabs also is separated from each other in a sequential manner by a recessed region between at least two of the tabs. The street defined by the tabs and the recessed region defined therebetween in a sequential manner.
51 Citations
20 Claims
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1. A method for fabricating an array of mirrors disposed on a die from a substrate, the method comprising:
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placing a substrate comprising a plurality of die thereon on a stage, each of the die comprising a plurality of to be movable mirror devices in an array configuration, each die comprising a peripheral region defining a street that surrounds the array configuration;
forming a plurality of tabs that join one die to another die in the street of the substrate, each of the tabs also being separated from each other in a sequential manner by a recessed region between at least two of the tabs, wherein the street is defined by the tabs and the recessed region defined therebetween in a sequential manner; and
directing a beam of high intensity electromagnetic radiation at the street between the one die and the other die to ablate each of the tabs that joins the one die to the other die to separate the one die from the other die to free the die comprising the mirror array from the other dice on the substrate. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A method of fabricating an array of mirrors disposed on a die from a substrate, the method comprising:
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placing a substrate comprising a plurality of die thereon on a stage, each of the die comprising a plurality of to be movable mirror devices in an array configuration, each die comprising a peripheral region defining at least one street that defines a border between one die from another die, the street having at least one tab that joins the one die to another die, the tab having a thickness of at least 100 microns, the thickness including an upper region that extends to a lower region;
etching the street to reduce a thickness of the street using a deep reactive ion etching process from an inductively coupled plasma source to produce a region having a depth to width ratio of at least five and greater, while forming a coating on vertical edges of the etched street region to prevent substantial etching in a later direction. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19)
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20. A method for forming an array of movable mirror devices, the method comprising:
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placing a substrate comprising a plurality of die thereon on a stage, each of the die comprising a plurality of to be movable mirror devices, each of the to be movable mirror devices having a cavity region defined around each of the mirror devices, in an array configuration, each die comprising a peripheral region defining at least one street that defines a border between one die from another die, the street having at least one tab that joins the one die to another die, the tab having a thickness of at least 100 microns, the thickness including an upper region that extends to a lower region;
simultaneously etching the cavity region and the street to reduce a thickness of the street using a deep reactive ion etching process from an inductively coupled plasma source to produce a region having a depth to width ratio of at least five and greater, while forming each of the movable mirror devices.
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Specification