Abstract:
PROBLEM TO BE SOLVED: To provide systems and methods for processing sacrificial layers in fabricating a microelectromechanical systems (MEMS) device.SOLUTION: In one embodiment, a method includes steps for: applying a patterned layer of an aerogel material to a substrate to form an aerogel sacrificial layer; applying at least one non-sacrificial silicon layer over the aerogel sacrificial layer where the non-sacrificial silicon layer is coupled to the substrate through one or more gaps formed in the patterned layer of the aerogel material; and removing the aerogel sacrificial layer by exposing the aerogel sacrificial layer to a removal liquid.
Abstract:
The present invention is directed to a structure comprised of alternating layers of metal and sacrificial material built up using standard CMOS processing techniques, a process for building such a structure, a process for fabricating devices from such a structure, and the devices fabricated from such a structure. In one embodiment, a first metal layer is carried by a substrate. A first sacrificial layer is carried by the first metal layer. A second metal layer is carried by the sacrificial layer. The second metal layer has a portion forming a micro-machined metal mesh. When the portion of the first sacrificial layer in the area of the micro-machined metal mesh is removed, the micro-machined metal mesh is released and suspended above the first metal layer a height determined by the thickness of the first sacrificial layer. The structure may be varied by providing a base layer of sacrificial material between the surface of the substrate and the first metal layer. In that manner, a portion of the first metal layer may form a micro-machined mesh which is released when a portion of the base sacrificial layer in the area of the micro-machined mesh is removed. Additionally, a second layer of sacrificial material and a third metal layer may be provided. A micro-machined mesh may be formed in a portion of the third metal layer. The structure of the present invention may be used to construct variable capacitors, switches and, when certain of the meshes are sealed, microspeakers and microphones.