MEMS structures, methods of fabricating MEMS components on separate substrates and assembly of same
First Claim
1. A method of making a MEMS device, the method comprising:
- providing a transparent electrode assembly comprising a transparent substrate and an at least partially transparent electrode formed over the transparent substrate;
providing a carrier with a reflective electrode formed thereover; and
attaching the transparent electrode assembly to the carrier after providing the carrier with the reflective electrode such that the reflective electrode faces the at least partially transparent electrode to form a cavity therebetween, wherein attaching the transparent electrode assembly comprises pressing portions of the reflective electrode against the transparent electrode assembly.
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Accused Products
Abstract
Methods of fabricating a microelectromechanical systems (MEMS) device with reduced masking and MEMS devices formed by the same are disclosed. In one embodiment, a MEMS device is fabricated by laminating a front substrate and a carrier, each of which has components preformed thereon. The front substrate is provided with stationary electrodes formed thereover. A carrier including movable electrodes formed thereover is attached to the front substrate. The carrier of some embodiments is released after transferring the movable electrodes to the front substrate. In other embodiments, the carrier stays over the front substrate, and serves as a backplate for the MEMS device. Features are formed by deposition and patterning, by embossing, or by patterning and etching. In some embodiments in which the MEMS device serves as an interferometric modulator, the front substrate is also provided with black masks to prevent or mitigate bright areas in the actuated state of the MEMS device. Static interferometric modulators can also be formed by shaping or preformation and lamination. The methods not only reduce the manufacturing costs, but also provide a higher yield. The resulting MEMS devices can trap smaller volumes between laminated substrates and are less susceptible to pressure variations and moisture leakage.
593 Citations
26 Claims
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1. A method of making a MEMS device, the method comprising:
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providing a transparent electrode assembly comprising a transparent substrate and an at least partially transparent electrode formed over the transparent substrate; providing a carrier with a reflective electrode formed thereover; and attaching the transparent electrode assembly to the carrier after providing the carrier with the reflective electrode such that the reflective electrode faces the at least partially transparent electrode to form a cavity therebetween, wherein attaching the transparent electrode assembly comprises pressing portions of the reflective electrode against the transparent electrode assembly. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10)
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11. A microelectromechanical system (MEMS) device comprising:
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a front substrate comprising a plurality of supports defining cavities on a surface of the front substrate; a second substrate opposing the front substrate; and a plurality of movable electrodes supported on top of the supports, each of the movable electrodes comprising; first portions of the movable electrodes overlying the supports, the first portions having a first thickness, wherein the first portions of the movable electrodes are interposed between, and contact both of, the second substrate and the supports of the front substrate; and second portions of the movable electrodes neighboring the first portions and extending between the first portions, the second portions not overlying the supports, the second portions having a second thickness different from the first thickness. - View Dependent Claims (12, 13, 14, 15, 16, 17, 18, 19, 20, 21)
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22. An array of microelectromechanical systems (MEMS) devices, comprising:
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a front substrate comprising a plurality of supports defining cavities on the front substrate, each of the cavities having a bottom surface; a backplate substantially opposing and overlying the front substrate, the backplate having a surface facing the cavities of the front substrate, the surface being most removed from the front substrate; and a plurality of mechanical strips interposed between the supports and the surface of the backplate, each of the mechanical strips serving as moving electrodes for multiple MEMS devices, wherein a distance between the bottom surface of one of the cavities and the most removed surface of the backplate is between about 6,500 Å and
about 20 μ
m. - View Dependent Claims (23, 24, 25, 26)
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Specification