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System and method of encapsulation

  • US 7,993,950 B2
  • Filed: 11/06/2008
  • Issued: 08/09/2011
  • Est. Priority Date: 04/30/2008
  • Status: Active Grant
First Claim
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1. A method of encapsulating a device, comprising:

  • depositing one or more sacrificial layers over a substrate, the one or more sacrificial layers forming a body substantially equivalent to a shape of a first cavity to be formed, the one or more sacrificial layers additionally having one or more release tabs extending from the body;

    forming a device in the one or more sacrificial layers;

    depositing a first encapsulating layer over the one or more sacrificial layers, the first encapsulating layer in contact with the substrate;

    etching the first encapsulating layer to expose the one or more release tabs and to form a first encapsulating sidewall extending from a top of the first encapsulating layer to the substrate, the one or more release tabs extending beyond the first encapsulating sidewall;

    removing the one or more sacrificial layers to form one or more openings between the first encapsulating layer and the substrate and the first cavity between the substrate, the first encapsulating layer, and the first encapsulating sidewall; and

    depositing a second encapsulating layer over the first encapsulating layer to seal the opening, wherein the one or more sacrificial layers comprise a first sacrificial layer and a second sacrificial layer, the method further comprising;

    etching the first sacrificial layer to expose an electrode of the substrate;

    depositing a conductive layer over the first sacrificial layer and the electrode;

    depositing the second sacrificial layer over the conductive layer and the first sacrificial layer; and

    etching the second sacrificial layer.

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