Method and forming a micromirror array device with a small pitch size
First Claim
1. A method, comprising:
- depositing first and second sacrificial layers on a substrate, and forming a hinge layer on one of the first and second sacrificial layers, and forming a mirror plate layer on the other one of the first and second sacrificial layers;
wherein the one of the first and second sacrificial layers that is disposed between the hinge layer and the mirror plate layer has a thickness of from about 0.15 to about 1.5 micron;
wherein the mirror plate layer is patterned to form an array of individual mirror plates having a gap between adjacent mirror plates of about 0.1 to about 0.5 micrometers; and
removing the first and second sacrificial layers to form movable mirror plates.
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Accused Products
Abstract
A spatial light modulator is disclosed, along with a method for making such a modulator that comprises an array of micromirror devices. The center-to-center distance and the gap between adjacent micromirror devices are determined corresponding to the light source being used so as to optimize optical efficiency and performance quality. The micromirror device comprises a hinge support formed on a substrate and a hinge that is held by the hinge support. A mirror plate is connected to the hinge via a contact, and the distance between the mirror plate and the hinge is determined according to desired maximum rotation angle of the mirror plate, the optimum gap and pitch between the adjacent micromirrors. In a method of fabricating such spatial light modulator, one sacrificial layer is deposited on a substrate followed by forming the mirror plates, and another sacrificial layer is deposited on the mirror plates followed by forming the hinge supports. The two sacrificial layers are removed via the small gap between adjacent mirror devices with spontaneous vapor phase chemical etchant.
2 Citations
34 Claims
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1. A method, comprising:
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depositing first and second sacrificial layers on a substrate, and forming a hinge layer on one of the first and second sacrificial layers, and forming a mirror plate layer on the other one of the first and second sacrificial layers; wherein the one of the first and second sacrificial layers that is disposed between the hinge layer and the mirror plate layer has a thickness of from about 0.15 to about 1.5 micron; wherein the mirror plate layer is patterned to form an array of individual mirror plates having a gap between adjacent mirror plates of about 0.1 to about 0.5 micrometers; and removing the first and second sacrificial layers to form movable mirror plates. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method, comprising:
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depositing a first sacrificial layer and a second sacrificial layer on a substrate, and forming a hinge layer on one of the first sacrificial layer and the second sacrificial layer, and forming a mirror plate layer on the other one of the first sacrificial layer and the second sacrificial layer; wherein the one of the first sacrificial layer and the second sacrificial layer that is disposed between the hinge layer and the mirror plate layer has a thickness between about 0.15 to about 1.5 micron; wherein the mirror plate layer is patterned to form individual mirror plates having a center to center distance between adjacent mirror plates of about 4.38 to about 10.16 micrometers; and removing the first and second sacrificial layers to form movable mirror plates. - View Dependent Claims (14, 15, 16, 17, 18, 19, 20, 21, 22, 23, 24)
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25. A method, comprising:
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depositing first and second sacrificial layers on a substrate, and forming a hinge layer on one of the first and second sacrificial layers, and forming a mirror plate layer on the other one of the first and second sacrificial layers; wherein the one of the first and second sacrificial layers that is disposed between the hinge layer and the mirror plate layer has a thickness of from about 0.15 to about 1.5 micron; patterning the mirror plate layer to form individual mirror plates having a center to center distance between adjacent mirror plates of about 4.38 to about 10.16 micrometers and having a gap between adjacent mirror plates of about 0.1 to about 0.5 micrometers; and removing the first and second sacrificial layers to allow the mirror plates to move. - View Dependent Claims (26, 27, 28, 29, 30, 31, 32, 33, 34)
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Specification