Method of manufacturing MEMS devices providing air gap control
First Claim
1. A method of making at least two types of microelectromechanical systems (MEMS) devices, the at least two types of MEMS devices having different release states after removal of sacrificial material, the method comprising:
- providing a substrate;
forming a first electrically conductive layer over at least a portion of the substrate;
forming a first sacrificial layer over at least a portion of the first conductive layer;
forming a plurality of electrically conductive moveable elements over the first sacrificial layer; and
forming a plurality of flexure controllers over the substrate configured so as to operably support the electrically conductive moveable elements after the sacrificial layer is removed, wherein at least a portion of at least one flexure controller of the plurality of flexure controllers is overlying and operably supporting at least one movable element of the plurality of electrically conductive movable elements;
the first sacrificial layer being removable to thereby release the MEMS devices and form a plurality of cavities of different depths between the first electrically conductive layer and the movable elements.
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Accused Products
Abstract
Methods and apparatus are provided for controlling a depth of a cavity between two layers of a light modulating device. A method of making a light modulating device includes providing a substrate, forming a sacrificial layer over at least a portion of the substrate, forming a reflective layer over at least a portion of the sacrificial layer, and forming one or more flexure controllers over the substrate, the flexure controllers configured so as to operably support the reflective layer and to form cavities, upon removal of the sacrificial layer, of a depth measurably different than the thickness of the sacrificial layer, wherein the depth is measured perpendicular to the substrate.
479 Citations
19 Claims
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1. A method of making at least two types of microelectromechanical systems (MEMS) devices, the at least two types of MEMS devices having different release states after removal of sacrificial material, the method comprising:
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providing a substrate; forming a first electrically conductive layer over at least a portion of the substrate; forming a first sacrificial layer over at least a portion of the first conductive layer; forming a plurality of electrically conductive moveable elements over the first sacrificial layer; and forming a plurality of flexure controllers over the substrate configured so as to operably support the electrically conductive moveable elements after the sacrificial layer is removed, wherein at least a portion of at least one flexure controller of the plurality of flexure controllers is overlying and operably supporting at least one movable element of the plurality of electrically conductive movable elements; the first sacrificial layer being removable to thereby release the MEMS devices and form a plurality of cavities of different depths between the first electrically conductive layer and the movable elements. - View Dependent Claims (2, 3, 4, 5, 6, 7, 8, 9, 10, 11, 12)
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13. A method of making at least two types of interferometric modulators, the at least two types of interferometric modulators having different cavity depths after removal of a sacrificial material, the method comprising:
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providing a substrate; forming an optical stack over at least a portion of the substrate; forming a sacrificial material over at least a portion of the optical stack, wherein the sacrificial material is removable to thereby form a plurality of cavities; forming an electrically conductive layer over portions of the sacrificial material; and forming at least two types of flexure controllers over the substrate, the flexure controllers configured so as to operably support the electrically conductive layer, wherein the at least two types of flexure controllers comprise different sized components, the different sized components configured to form the plurality of cavities of different depths under the portions of the electrically conductive layer after removal of the sacrificial layer, wherein at least a portion of at least one of the flexure controllers is overlying and operably supporting at least a portion of the electrically conductive layer. - View Dependent Claims (14)
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15. A method of controlling a depth of a cavity between two layers of a device comprising one or more film layers, the method comprising:
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providing a substrate; forming a sacrificial layer over at least a portion of the substrate; forming a first layer over at least a portion of the sacrificial layer; and forming one or more flexure controllers over the substrate, the one or more flexure controllers having one or more wing portions extending substantially parallel to the substrate and the first layer, the flexure controllers configured so as to operably support the first layer and to form a cavity between the substrate and the first layer, wherein the wing portions are dimensioned such that, after removal of the sacrificial layer, the cavity has a depth of about 30 percent greater or more than the depth of the sacrificial layer, wherein depth is measured perpendicular to the substrate, wherein at least a portion of at least one of the flexure controllers is overlying and operably supporting at least a portion of the first layer. - View Dependent Claims (16, 17, 18)
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19. A method of controlling a depth of a cavity between two layers of a device comprising one or more film layers, the method comprising:
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providing a substrate; forming a sacrificial layer over at least a portion of the substrate, the sacrificial layer being removable by etching; forming a film layer over at least a portion of the sacrificial layer; and forming one or more flexure controllers over the substrate, the one or more flexure controllers having one or more wings extending substantially parallel to the substrate, the flexure controllers configured so as to operably support the film layer and wherein the wings are dimensioned so as to displace the film layer towards the substrate, after removal of the sacrificial layer, wherein at least a portion of at least one of the flexure controllers is overlying and operably supporting at least a portion of the film layer.
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Specification