Method for manufacturing a mirror device by means of a plurality of sacrificial layers
First Claim
1. A method for manufacturing a mirror device comprising deflectable mirrors supported on a deflectable hinge extending vertically along approximately a perpendicular direction from a substrate wherein the method comprises:
- forming electrodes on the substrate and covering the electrodes with an insulation layer wherein the step of forming the electrodes further comprising a step of forming the electrodes having a horizontally and outwardly extended convex-shaped extension horizontally extended away from the hinge with sharp-edge upper corner with significantly reduced contacting area for contacting and stopping the deflectable mirrors of the mirror device;
forming a first and a second sacrificial layers covering over the insulation layer;
opening a vertical trench penetrating through the first sacrificial layer and the second sacrificial layer and depositing a deflectable hinge material into the vertical trench;
forming the deflectable mirror by depositing a reflective layer directly on top of the second sacrificial layer wherein the reflective layer directly contacting a top surface of the hinge material deposited in the vertical trench; and
removing the first and second sacrificial layers to expose the insulation layer covering the electrodes and the hinge material constituting the vertical hinge for supporting and deflecting the mirror to different deflection angles and stopped by the contacting points of the electrodes contact the deflectable mirrors.
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Accused Products
Abstract
A method for manufacturing a device comprising an elastic member on a substrate includes steps of: forming a sacrificial layer by forming a plurality of sacrificial sub-layers on the substrate; forming a plate member in or on the sacrificial layers connected to the substrate and substantially parallel to a top surface of the substrate; and removing the sacrificial sub-layers after forming the plate member by removing the sacrificial sub-layers in an order different from the reverse order of forming the sacrificial sub-layers.
19 Citations
43 Claims
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1. A method for manufacturing a mirror device comprising deflectable mirrors supported on a deflectable hinge extending vertically along approximately a perpendicular direction from a substrate wherein the method comprises:
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forming electrodes on the substrate and covering the electrodes with an insulation layer wherein the step of forming the electrodes further comprising a step of forming the electrodes having a horizontally and outwardly extended convex-shaped extension horizontally extended away from the hinge with sharp-edge upper corner with significantly reduced contacting area for contacting and stopping the deflectable mirrors of the mirror device; forming a first and a second sacrificial layers covering over the insulation layer; opening a vertical trench penetrating through the first sacrificial layer and the second sacrificial layer and depositing a deflectable hinge material into the vertical trench; forming the deflectable mirror by depositing a reflective layer directly on top of the second sacrificial layer wherein the reflective layer directly contacting a top surface of the hinge material deposited in the vertical trench; and removing the first and second sacrificial layers to expose the insulation layer covering the electrodes and the hinge material constituting the vertical hinge for supporting and deflecting the mirror to different deflection angles and stopped by the contacting points of the electrodes contact the deflectable mirrors. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12, 38)
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13. A method of manufacturing a device comprising a movable member supported on a deflectable hinge extending vertically along approximately a perpendicular direction from a substrate, wherein the method comprises:
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forming electrodes on the substrate and covering the electrodes with an insulation layer wherein the step of forming the electrodes further comprising a step of forming the electrodes having a horizontally and outwardly extended convex-shaped extension horizontally extended away from the hinge with sharp-edge upper corner with significantly reduced contacting area for contacting and stopping the deflectable mirrors of the mirror device; forming a first and a second sacrificial layers covering over the insulation layer; forming a first sacrificial layer covering over the insulation layer disposed on the substrate; opening a cavity in the first sacrificial layer and the insulation layer exposing a top surface of the substrate; depositing a layer of deflectable material on a vertical sidewall of the cavity opened in said first sacrificial layer wherein said layer of deflectable material having a bottom lateral portion supported on the substrate; filling the cavity with a second sacrificial layer; forming the movable member immediately on top of the first and second sacrificial layers and contacting a top surface of the layer of the deflectable material; and removing the first sacrificial layer followed by removing the second sacrificial layer for exposing the deflectable hinge supporting the movable member.
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14. A method for manufacturing a device comprising a movable member supported on a deflectable hinge extending vertically along approximately a perpendicular direction from, a substrate, wherein the method comprises:
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forming electrodes on the substrate and covering the electrodes with an insulation layer wherein the step of forming the electrodes further comprising a step of forming the electrodes having a horizontally and outwardly extended convex-shaped extension horizontally extended away from the hinge with sharp-edge upper corner with significantly reduced contacting area for contacting and stopping the deflectable mirrors of the mirror device; forming a first sacrificial layer comprising several sub-layers covering over the insulation layer; opening a vertical trench in the first sacrificial layer and through the insulation layer and filling the vertical trench with a deflectable material having a bottom surface supported on the substrate; forming a movable member directly on top of the first sacrificial layer with a bottom surface contacting a top surface of the deflectable material filled in the vertical trench; forming a second sacrificial layer over the movable member; and removing the first and second sacrificial layers for exposing the deflectable material filling in the vertical trench constituting the hinge supporting the movable member supported on the hinge. - View Dependent Claims (15, 16, 17, 18, 19, 20, 21, 22, 23, 24, 25, 26, 27, 28, 29, 30)
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31. A method of manufacturing a device includes a vertical elastic member extending from a top surface of a substrate for supporting a plate member on top of the vertical elastic member, the method comprising:
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forming electrodes on the substrate and covering the electrodes with an insulation layer wherein the step of forming the electrodes further comprising a step of forming the electrodes having a horizontally and outwardly extended convex-shaped extension horizontally extended away from the hinge with sharp-edge upper corner with significantly reduced contacting area for contacting and stopping the deflectable mirrors of the mirror device; forming a sacrificial layer covering over the insulation layer and opening a vertical trench in the sacrificial layer followed by filling the trench with an elastic material;
forming a plate member directly on top of the sacrificial layer parallel to a surface of the substrate and contacting a top surface of the elastic material filled in the vertical trench and removing the sacrificial layer for exposing the elastic material filled in the trench constituting the vertical elastic member supporting the plate member. - View Dependent Claims (32, 33, 34)
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35. A method of manufacturing a device including a vertical elastic member extending from a top surface of a substrate for supporting a movable member on top of the vertical elastic member, the method, comprising:
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forming electrodes on the substrate and covering the electrodes with an insulation layer wherein the step of forming the electrodes further comprising a step of forming the electrodes having a horizontally and outwardly extended convex-shaped extension horizontally extended away from the hinge with sharp-edge upper corner with significantly reduced contacting area for contacting and stopping the deflectable mirrors of the mirror device; forming a sacrificial layer on the substrate including a plurality of sacrificial sub-layers and opening a vertical trench in the sacrificial layer followed by filling the trench with an elastic material;
forming the movable member directly on top of the sacrificial layer and contacting a top surface of the elastic material filled in the vertical trench; andremoving, in an reverse order of forming the sub-layers, the plurality of sacrificial sub-layers after forming the movable member. - View Dependent Claims (36)
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37. A method of manufacturing a device including a vertical elastic member extending from a top surface of a substrate for supporting a movable member on top of the vertical elastic member, the method, comprising:
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forming electrodes on the substrate and covering the electrodes with an insulation layer wherein the step of forming the electrodes further comprising a step of forming the electrodes having a horizontally and outwardly extended convex-shaped extension horizontally extended away from the hinge with sharp-edge upper corner with significantly reduced contacting area for contacting and stopping the deflectable mirrors of the mirror device; forming a sacrificial layer on the substrate including a plurality of sacrificial sub-layers and opening a vertical trench in the sacrificial layer followed by filling the trench with an elastic material;
forming the movable member directly on top of the sacrificial layer and contacting a top surface of the elastic material filled in the vertical trench; andremoving the plurality of sacrificial sub-layers by first etching the sacrificial sub-layer surrounding the vertical trench filled with the elastic material or the sacrificial layer contacting the movable member at a slowest etching rates among etching rates for etching the plurality of the sacrificial sub-layers. - View Dependent Claims (39, 40, 41, 42, 43)
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Specification