Methods for forming layers within a MEMS device using liftoff processes
First Claim
1. A method of fabricating a MEMS device, comprising:
- forming an electrode layer over a substrate;
forming a sacrificial layer over the electrode layer;
patterning the sacrificial layer to form at least one tapered aperture extending through the sacrificial layer;
forming a movable layer over the patterned sacrificial layer;
forming a mask layer over at least a portion of the movable layer, the mask layer comprising an aperture overlying the tapered aperture extending through the sacrificial layer;
depositing a support layer over the mask layer; and
removing the mask layer via a liftoff process, thereby forming a support structure overlying at least a portion of the movable layer and located at least partially within the tapered aperture extending through the sacrificial layer.
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Accused Products
Abstract
Certain MEMS devices include layers patterned to have tapered edges. One method for forming layers having tapered edges includes the use of an etch leading layer. Another method for forming layers having tapered edges includes the deposition of a layer in which the upper portion is etchable at a faster rate than the lower portion. Another method for forming layers having tapered edges includes the use of multiple iterative etches. Another method for forming layers having tapered edges includes the use of a liftoff mask layer having an aperture including a negative angle, such that a layer can be deposited over the liftoff mask layer and the mask layer removed, leaving a structure having tapered edges.
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Citations
15 Claims
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1. A method of fabricating a MEMS device, comprising:
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forming an electrode layer over a substrate; forming a sacrificial layer over the electrode layer; patterning the sacrificial layer to form at least one tapered aperture extending through the sacrificial layer; forming a movable layer over the patterned sacrificial layer; forming a mask layer over at least a portion of the movable layer, the mask layer comprising an aperture overlying the tapered aperture extending through the sacrificial layer; depositing a support layer over the mask layer; and removing the mask layer via a liftoff process, thereby forming a support structure overlying at least a portion of the movable layer and located at least partially within the tapered aperture extending through the sacrificial layer. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15)
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Specification