Patent ID: 9388040
Filing Date: 2016-07-12
CPC Classification: B81B,B81C,H01L

Claim Text:
1. A method of forming a stacked semiconductor device, the method comprising: providing a first substrate having a front surface; forming a plurality of metal sections over the front surface of the first substrate; forming a first dielectric layer over the front surface of the first substrate, the first dielectric layer having a cavity exposing portions of the metal sections; forming a dielectric stop layer over the first dielectric layer, an interior surface of the cavity and the exposed metal sections; filling the cavity with a sacrificial material; forming a second dielectric layer over the filled sacrificial material and portions of the dielectric stop layer; forming metal features over the second dielectric layer; forming a flexible dielectric membrane over the metal features, the flexible dielectric membrane having a plurality of openings exposing portions of the metal features; forming a metal layer having discrete portions over the flexible dielectric membrane, parts of the discrete portions contacting the exposed metal features through the openings; forming a cap dielectric layer over the metal layer and the flexible dielectric membrane; etching portions of the cap dielectric layer, the flexible dielectric membrane and the second dielectric layer, thereby forming through-holes to expose portions of the filled sacrificial material; removing the filled sacrificial material through the through-holes from the cavity, thereby forming a movable structure including the cap dielectric layer, the metal layer, the flexible dielectric membrane, the metal features and the second dielectric layer suspending over the cavity; providing a second substrate having at least one transistor; forming a multilayer interconnect over the at least one transistor and electrically coupled to the at least one transistor; forming metal element) over the multilayer interconnect; and bonding the metal elements to the metal layer of the first substrate through bonding feature).