Method of forming a compliant monopolar micro device transfer head with silicon electrode
First Claim
1. A method of forming a compliant micro device transfer head array comprising:
- etching a top silicon layer of a silicon-on-insulator stack to form an array of silicon electrodes electrically connected with a silicon interconnect, each silicon electrode including an electrode lead and a mesa structure that protrudes above the silicon interconnect;
forming a dielectric layer over the array of silicon electrodes; and
etching one or more cavities in the base substrate directly underneath the array of silicon electrodes such that each silicon electrode in the array of silicon electrodes is deflectable into the one or more cavities.
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Abstract
A compliant monopolar micro device transfer head array and method of forming a compliant monopolar micro device transfer array from an SOI substrate are described. In an embodiment, the micro device transfer head array including a base substrate and a patterned silicon layer over the base substrate. The patterned silicon layer may include a silicon interconnect and an array of silicon electrodes electrically connected with the silicon interconnect. Each silicon electrode includes a mesa structure protruding above the silicon interconnect, and each silicon electrode is deflectable into a cavity between the base substrate and the silicon electrode. A dielectric layer covers a top surface of each mesa structure.
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Citations
23 Claims
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1. A method of forming a compliant micro device transfer head array comprising:
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etching a top silicon layer of a silicon-on-insulator stack to form an array of silicon electrodes electrically connected with a silicon interconnect, each silicon electrode including an electrode lead and a mesa structure that protrudes above the silicon interconnect; forming a dielectric layer over the array of silicon electrodes; and etching one or more cavities in the base substrate directly underneath the array of silicon electrodes such that each silicon electrode in the array of silicon electrodes is deflectable into the one or more cavities. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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Specification