Patent ID: 6655002
Filing Date: 2003-12-02
Classification: G11B,H02K,Y10T

Abstract:
A method for making a microactuator, comprising:providing first, second, and third substrates; adhering said first and second silicon wafers together; thinning said first silicon wafer to a desired substrate thickness; patterning first windows through said first silicon wafer to form a mold; forming coil and flux-conducting interconnect features in respective said first windows through said first substrate; forming first partial microactuator structures on one side of said first substrate by: patterning a first layer of photoresist on said one side of said first substrate to form a mold to contain coil portions and coil interconnection traces; molding coil material into the mold of said first layer of photoresist to form said coil portions and said coil interconnection traces; removing said first layer of photoresist; forming a first permanent dielectric layer overall; patterning said first permanent dielectric layer to form second windows to expose said flux-conducting interconnect features; forming additional flux-conducting features in said second windows of said first permanent dielectric layer to contact said exposed flux-conducting interconnect features; patterning a second photoresist layer over said first layer of dielectric to form a mold for top flux-conducting features; forming top flux-conducting features in said mold in said second photoresist layer; stripping the second photoresist layer; forming at least a portion of a gap between two nickel-iron bars; attaching said third substrate to said nickel-iron features; forming second partial microactuator structures on another side of said first substrate by repeating the steps to form the first partial microactuator for said another side of said first substrate; and removing said second and third substrates from said first substrate.