Process control monitors for interferometric modulators
First Claim
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1. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
- forming a process control monitor that consists of at least three layers of material deposited during the manufacturing, wherein the at least three layers of material is less than the number of layers deposited during manufacturing of the MEMS, wherein the at least three layers of material form an etalon, wherein forming the process control monitor comprises exposing the process control monitor to the same material deposition and patterning steps as used during the manufacturing; and
detecting light reflected from the etalon with a light detector.
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Abstract
Process control monitors are disclosed that are produced using at least some of the same process steps used to manufacture a MEMS device. Analysis of the process control monitors can provide information regarding properties of the MEMS device and components or sub-components in the device. This information can be used to identify errors in processing or to optimize the MEMS device. In some embodiments, analysis of the process control monitors may utilize optical measurements.
328 Citations
20 Claims
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1. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor that consists of at least three layers of material deposited during the manufacturing, wherein the at least three layers of material is less than the number of layers deposited during manufacturing of the MEMS, wherein the at least three layers of material form an etalon, wherein forming the process control monitor comprises exposing the process control monitor to the same material deposition and patterning steps as used during the manufacturing; and detecting light reflected from the etalon with a light detector. - View Dependent Claims (6, 7, 8, 9, 11, 12)
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2. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor that consists of at least three layers of material deposited during the manufacturing, wherein the at least three layers of material is less than the number of layers deposited during manufacturing of the MEMS, wherein the at least three layers of material form an etalon, wherein forming the process control monitor comprises exposing the process control monitor to the same material deposition steps as used during the manufacturing; detecting light reflected from the etalon with a light detector; determining an index of refraction of at least one of the materials from the detected light; and outputting the index of refraction.
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3. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor that consists of at least three layers of material deposited during the manufacturing, wherein the at least three layers of material is less than the number of layers deposited during manufacturing of the MEMS, wherein the at least three layers of material form an etalon, wherein forming the process control monitor comprises exposing the process control monitor to the same patterning steps as used during the manufacturing; detecting light reflected from the etalon with a light detector; determining reflectivity of at least one of the materials from the detected light; and outputting the reflectivity.
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4. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor that consists of at least three layers of material deposited during the manufacturing, wherein the at least three layers of material is less than the number of layers deposited during manufacturing of the MEMS, wherein the at least three layers of material form an etalon, wherein forming the process control monitor comprises exposing the process control monitor to the same manufacturing steps as used during the manufacturing of the MEMS; detecting light reflected from the etalon with a light detector; determining transmittance of at least one of the materials from the detected light; and outputting the transmittance.
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5. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor that consists of at least three layers of material deposited during the manufacturing, wherein the at least three layers of material is less than the number of layers deposited during manufacturing of the MEMS, wherein the at least three layers of material form an etalon, wherein forming the process control monitor comprises exposing the process control monitor to the same material deposition steps as used during the manufacturing; detecting light reflected from the etalon with a light detector; determining the thickness of at least one of the materials from the detected light; and outputting the thickness.
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10. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor that consists of at least three layers of material deposited during the manufacturing, wherein the at least three layers of material is less than the number of layers deposited during manufacturing of the MEMS, wherein the at least three layers of material form an etalon, wherein the process control monitor is formed at the same time that the MEMS is manufactured; and detecting light reflected from the etalon with a colorimeter.
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13. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor comprising one or more layers of material deposited during the manufacturing, wherein the number of layers of material in the process control monitor is less than the number of layers deposited during manufacturing of the MEMS, wherein forming the process control monitor comprises applying an identical sequence of material deposition and patterning steps as used in the manufacturing of the MEMS; and detecting the reflectance of the process control monitor with a light detector. - View Dependent Claims (14, 18, 19, 20)
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15. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor comprising one or more layers of material deposited during the manufacturing, wherein the number of layers of material in the process control monitor is less than the number of layers deposited during manufacturing of the MEMS, wherein forming the process control monitor comprises exposing the process control monitor to the same material deposition steps as used during the manufacturing; detecting the reflectance of the process control monitor with a light detector; determining the reflectance of one of the layers in the process control monitor; and outputting the reflectance.
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16. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor comprising one or more layers of material deposited during the manufacturing, wherein the number of layers of material in the process control monitor is less than the number of layers deposited during manufacturing of the MEMS, wherein forming the process control monitor comprises exposing the process control monitor to the same manufacturing steps as used during the manufacturing of the MEMS; detecting the reflectance of the process control monitor with a light detector; determining the transmittance of one of the layers in the process control monitor; and outputting the transmittance.
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17. A method of monitoring deposition of material deposited during manufacturing of a micro-electro-mechanical system (MEMS), comprising:
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forming a process control monitor comprising one or more layers of material deposited during the manufacturing, wherein the number of layers of material in the process control monitor is less than the number of layers deposited during manufacturing of the MEMS, wherein forming the process control monitor comprises exposing the process control monitor to the same material deposition steps as used during the manufacturing; detecting the reflectance of the process control monitor with a light detector; determining the thickness of one of the layers in the process control monitor; and
outputting the thickness.
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Specification