Adjustable compound microlens apparatus with MEMS controller

An adjustable compound optical microlens apparatus comprises first and second microlenses that are separated from one another along their optical axes. At least one of the microlenses is movable relative to the other. In a preferred embodiment, one microlens is stationary, the other movable. A MEMS controller electrically controls the position of the movable microlens relative to the stationary microlens, or the positions of at least two movable microlenses relative to one another. In accordance with one embodiment of our invention, an array of such microlens apparatuses is also contemplated, especially for applications such optical switches and routers. In accordance with another embodiment of our invention, the apparatus functions as an optical filter or dispersion compensator. Also described is method of compensating for variations in an optical parameter (e.g., effective focal length) of such an apparatus in an array.

BACKGROUND OF THE INVENTION

1. Field of the Invention

This invention relates to compound microlenses and, more particularly, to compound microlenses that are controlled by a micro-electromechanical structure or subsystem (MEMS).

2. Discussion of the Related Art

In the optoelectronic art optical lenses have many applications as both individual lens elements (single or compound lenses) or as arrays of such elements. Individual lens elements are used, for example, to couple an optical source (e.g., a laser) to an optical receptor. Receptors include well-known optical waveguides (e.g., optical fibers and silica waveguides), well-known photodetectors (e.g., p-i-n and avalanche photodiodes), and other optical devices. On the other hand, an array of such lenses can perform the same coupling function between an array of optical sources and an array of optical receptors. The coupling function may include one or more of the following function species: focusing, collimating and shaping.

State-of-the-art lens arrays include microlenses that are etched in a semiconductor (e.g., Si) or a dielectric (e.g., a silica-based glass) body. There are many techniques to fabricate such a microlens array. Most involve standard photolithographic processing techniques. Whenever a master is available, a microlens array can be duplicated using molding techniques. For many applications, large focal length uniformity across all lenses is desired, but is not necessarily achieved because of defects in the materials and variations in the process (e.g., in the etch profile). One approach to solving the latter problem is described by C. Bolle in copending U.S. patent application Ser. No. 10/010,570, entitledMethod for Compensating for Nonunifrom Etch Profiles. The application, which was filed on Nov. 13, 2001 and assigned to the assignee hereof, is incorporated herein by reference. Another prior art technique for making Si microlenses is described by L. Erdmann et al.,Opt. Eng., Vol. 36, No. 4, pp. 1094-1098 (1977), which is also incorporated herein by reference.

In theory at least, such individual microlenses or microlens arrays can be fabricated from other materials such as plastic. In practice, however, the choice of material often depends on the precision demanded by the particular application. For example, many optoelectronic applications discussed below require extremely high precision in the way that light beams are coupled from one device/element to another. These applications dictate the use of a material (e.g., Si) that has a mature processing technology that enables the microlenses to be shaped with corresponding precision.

A microlens array is an essential component for many types of optical subsystems, such as optical switches, routers, attenuators, filters, equalizers and dispersion compensators. In typical applications, the microlens array is used to collimate optical beams from an array of fibers or lasers and to focus them onto an array of receptors.

Conventional optical routers and switches use arrays of microlenses to collimate/focus optical beams from an array of optical input fibers to an array of optical output fibers, so that the coupling between the two arrays is efficient. The collimating and focusing functions serve to match the diameter of the optical beams to the aperture of the optical fibers.

In a MEMS structure, such conventional microlens arrays generally do not provide optimal coupling of the optical beams to the optical fibers for several reasons. First, the lens curvature varies from lens to lens due to limited manufacturing tolerances. These curvature variations lead to focal length variations, which, in turn, lead to optical beam diameter variations in the optical output fibers. Second, optical path lengths between different pairs of input and output fibers vary for different routings, which leads to variations in beam diameters at the output fibers.

BRIEF SUMMARY OF THE INVENTION

In accordance with one aspect of our invention, an adjustable compound optical microlens apparatus comprises first and second microlenses that are separated from one another along their optical axes. At least one of the microlenses is movable relative to the other. In a preferred embodiment, one microlens is stationary, the other movable. A MEMS controller electrically controls the position of the movable microlens relative to the stationary microlens, or the positions of at least two movable microlenses relative to one another.

In accordance with one embodiment of our invention, an array of such microlens apparatuses is also contemplated, especially for applications such as optical switches and routers.

In accordance with another embodiment of our invention the facing optical surfaces of the microlenses include partially transmissive metal coatings, so that the apparatus functions as an optical filter or dispersion compensator.

In accordance with another aspect of our invention, a method of compensating for variations in an optical parameter (e.g., effective focal length) of a first apparatus in an array comprises the steps of: (a) determining that the first apparatus in the array has a value of the parameter different from a predetermined standard value; and (b) applying an electrical signal to the MEMS controller of the first apparatus, thereby causing the controller to perform a mechanical action that makes the value of the parameter of the first apparatus closer to the standard value. (Illustratively, the mechanical action alters the separation and/or tilt between a pair of microlenses in the first apparatus.) In one embodiment, the standard value is stored (for example, in a computer), and in another embodiment it is determined by the value of the same parameter of a second apparatus in the array. Depending on the application, we contemplate a multiplicity of adjustments over time or a single adjustment followed by fixing all of the movable microlenses in place.

DETAILED DESCRIPTION OF THE INVENTION

General Structure

In accordance with various aspects of our invention, the following sections describe the design of MEMS-adjustable (i.e., tunable) compound microlens apparatuses (i.e., either a single apparatus that includes a compound microlens or an array of such apparatuses), as well as methods of making them, and methods of operating them in various systems. Depending on the particular embodiment, the vertical separation between the microlenses along a common optical axis, the horizontal separation of their optical axes and/or the tilt of their optical axes relative to one another can be adjusted by voltages applied via the MEMS. Control of separation and tilt, in turn, allows an optical parameter (e.g., effective focal length) of the microlens apparatus to be altered.

A single compound microlens apparatus may be used as an attenuator, equalizer, dispersion compensator, or filter (FIG.34), for example, or a multiplicity of such apparatuses may be formed as an array (FIG.36). The pitch of the array may be fixed or variable (in space;not time).

An array of compound microlens apparatuses is particularly useful in applications (e.g., fiber-optic transmission systems) where the uniformity requirement is high or where tunability is desired. The tunable microlens array is envisioned to be included in an optical subsystem (e.g., an optical switch or router) and to be controlled by a feedback voltage source, which adapts the microlens array configurations to internal variations, such as temperature changes, or external variations, such as beam profile changes.

A single apparatus10a, which includes a microlens doublet and a MEMS controller, is shown schematically in FIG.1(a). Here, we depict apparatus10aas including two coaxial microlenses12aand14a. At least one of the microlenses is movable. In the case illustrated, lens14ais movable; lens12ais stationary, and the doublet has two curved surfaces, one on the interior facing surface of each microlens. Alternatively, a similar apparatus10bis shown in FIG.1(b), which also includes a doublet formed by coaxial microlenses12b(stationary) and14b(movable). But, in this case the doublet has three curved surfaces, one on each of the interior and exterior surfaces of microlens12b, and one on the exterior surface of microlens14b. More than two microlenses (e.g., a triplet), however, and hence more than four curved surfaces, could be utilized if the attendant increase in complexity can be tolerated.

In addition, each lens may be concave or convex, and may be spherical, aspherical, or may have other shapes including anamorphic (e.g., cylindrical).

The microlenses are usually coated with anti-reflection coatings designed to have low reflectivity within a wavelength range determined by the particular system and/or application. (However, reflective coatings are used in some applications such as, for example, filters and dispersion compensators, which are discussed in later sections.)

More detailed, yet still schematic, renderings of various embodiments of single microlens apparatuses in accordance with our invention are shown inFIGS. 13,14and33.

The MEMS portion of each microlens apparatus10aand10bincludes a support structure16aand16b, resilient means20aand20b, a top electrode and a multiplicity of bottom electrodes20aand20b, as shown in FIGs.1(a) and1(b), respectively. The support structures16aand16bhave openings22aand22b(e.g., square openings) in which the movable lenses14aand14b, respectively, are suspended. The resilient means20aand20bsuspend the movable lenses14aand4bwithin the openings22aand22b, respectively. Illustratively, the resilient means are serpentine springs20aand20b, which for simplicity are depicted only in the top-views of FIGS.1(a) and1(b), respectively, and in the expanded top view of FIG.1(c). Finally, the entire movable microlenses14aand14bserve as the top electrodes, whereas the bottom electrodes18aand18bare positioned around the perimeter of the stationary microlenses12aand12b, respectively. In FIG.1(a) the electrodes18aare shown positioned in the four corners of the square opening22a; in FIG.1(b) the electrodes18bare shown positioned at the midpoints of the four sides of the square opening22b. Other arrangements of the bottom electrodes are also suitable.

Illustratively, the top electrode (movable lens) is coupled to an electrical source of ground potential, and the bottom electrodes are coupled to a source of voltage. Each bottom electrode may have the same or a different voltage applied to it. The embodiments ofFIGS. 13 and 14are designed in this fashion. In these embodiments, the vertical separation, horizontal separation and/or tilt of the microlenses in the doublet may be adjusted (i.e., tuned) by varying the voltages applied to all or any subcombination of the multiplicity of bottom electrodes. However, in order to alter the horizontal separation, the design of FIGS.1(a) and1(b) would be modified to enable lateral motion of the movable lens. A typical modified design would include additional electrodes18(not shown) around the periphery of the stationary lens and additional springs20(not shown) coupling the movable lens to the support structure.

In general, the voltages applied via the MEMS alter the capacitive coupling between the microlenses, thereby causing the microlenses to move relative to one another. For example, when voltages are applied between the multiplicity of bottom electrodes and the top electrode (movable lens) ofFIG. 1, the movable microlens14a,14bis pulled toward the stationary microlens12a,12b, respectively. The serpentine springs20a,20bthat support the movable lens12a,12b, respectively, provide a restoring force and can be designed to allow large variations in the vertical separation d between the microlenses. By increasing the length and number of repetitions of the springs, our invention attains a small spring constant and a large displacement (the amount by which the vertical separation changes).

Alternatively, the top electrode (movable lens) is coupled to a source of voltage and all the bottom electrodes are coupled to an electrical source of ground potential The embodiment ofFIG. 33is designed in this fashion. In this embodiment, the vertical separation between the two microlenses can be adjusted, but not the relative position or tilt.

Assuming both microlenses of the apparatus ofFIG. 1have the same optical axis, the effective focal length, f12, of the doublet and its derivative are given byf12=f1⁢f2f1+f2-d,(1)∂f12∂d=f122f1⁢f2,(2)
where f1and f2are the focal lengths of the two microlenses and d is their vertical separation. The focal length of each of the microlenses is fixed by the processing technique used in its fabrication. (See, the Bolle application and the Erdmann et al. paper cited supra.) For a fixed f12and d, maximum tunability, ∂f12/∂d, occurs near the singularity ofFIG. 2where
f1+f2≈d(3)
and smallest value of f1f2. Note that depending on the curvatures of the microlenses, f1and/or f2can be either positive or negative. A typical functional relationship of the effective focal length as a function of normalized separation is shown in FIG.2. Note that the variation is small outside the region of singularity where d/f2˜2.1. Changing the ratio, f1/f2, shifts the curve along the d/f2axis.
Filter

As mentioned above, a tunable compound microlens apparatus may be adapted to perform a filtering function. An illustrative filter30, a Gire-Tournois (GT) filter (or interferometer), is shown in FIG.34. The GT filter employs a doublet of the type shown in FIG.1(a). However, other doublet designs, including (but limited to) that of FIG.1(b), are also suitable. InFIG. 34, the interior surfaces of microlenses32aand32bare coated with reflective coatings33aand33b, respectively. These coatings may be metallic, may be multilayered dielectrics, or may be of other suitable design well known in the art. In any case, the two reflective coatings form a cavity resonator. By using the MEMS to change the position of the movable microlens, we can alter the length of the resonator, which in turn allows us to filter the radiation (or light) beam34spectrally or spatially. In addition, the GT filter has its own wavelength dispersion characteristic, which may be designed to compensate for the dispersion of another optical device.

Feedback Control Subsystem

In many applications a microlens apparatus, or an array of them, is subject to variable conditions (e.g., temperature, humidity, aging) that cause the apparatus or array to have variable optical parameters (e.g., wavelength, power, beam profile). Thus, as shown inFIG. 35, a divergent input optical beam42ipasses through a microlens apparatus41and exits as a collimated output optical beam42o. (For simplicity, only a single ray of the beams is shown.) If, for example, the temperature of the apparatus41changes, as a result of changes in the temperature of its ambient, then the properties (e.g., wavelength, power, beam profile) of the output beam will also change. To stabilize these optical parameters (i.e., the limit their variation to predetermined, acceptable ranges) the apparatus is provided with a feedback control subsystem, which includes a controller45, a temperature sensor43, and a photodetector44. The latter may function as a receiver-detector; e.g., in conjunction with (or as an integral part of) a receiver47used to extract information from the output beam42o, or it may function as a monitor-detector; e.g., in a feedback loop used to sense an optical parameter of the output beam42o.

Let us assume initially that the photodetector is a receiver-detector, and that the apparatus41and the sensor43are located within a chamber46(e.g., a hermetic chamber). In this case, the photodetector provides an electrical signal (containing information to be decoded) on leads44aand44bto receiver47(not to controller45on lead44c). Sensor43provides an electrical signal (proportional to temperature) on lead43ato an input of controller45. The controller, in turn, provides an electrical output signal on lead45athat provides both (1) coarse adjustment of the position of the movable microlens41a(in response to a signal that sets its desired initial position) and (2) fine tuning of the position of the movable microlens41a(in response to signals from the sensor43).

Alternatively, feedback control may be based on the wavelength, power or spatial profile of the output beam42o. In this case, photodetector44could be used as a monitor-detector to sense changes in these optical parameters and to provide an electrical signal on leads44aand44cto another input of controller45, which functions in a manner similar to that described above to control the position of movable microlens41a.

The detector44is depicted as being located inside the chamber46, but alternatively it may be located outside provided that transmission means (e.g., a window) is provided for the output beam to be incident on the photodetector.

In contrast, if the apparatus41is located in a temperature/humidity controlled environment, then the need for chamber46and possibly the temperature sensor43would be obviated, and feedback control would be predicated on sensing parameters other than temperature.

Arrays

In an important embodiment of our invention depicted schematically inFIG. 36, a multiplicity of adjustable compound microlens apparatuses51form an array50. Each apparatus51includes a compound lens and a MEMS controller of the type described above.

In a typical application, the microlens array couples optical beams from an array60of optical sources61to an array70of optical receptors71. For purposes of illustration, only two rays (of many) emanating from a typical single source61aare depicted as forming an optical beam62that is incident on microlens array50. In practice, a multiplicity of sources61would simultaneously emit a multiplicity of such beams incident on different apparatuses in the microlens array. As shown, the beam62is incident upon a typical microlens apparatus51a, which collimates the beam. The collimated beam64is incident on a typical receptor71a

The array60of sources may include an array of active devices such as lasers. Typically the active sources are semiconductor diode lasers that are directly coupled into the microlens array50. Preferably, the source array60comprises an array of vertical cavity, surface-emitting lasers known as VCSELs. Alternatively, the array60may include an array of passive devices such as optical input fibers or optical micro-mirrors that couple optical beams into the microlens array50. We use the terms passive and active in the sense that active devices convert an electrical signal to an optical one, and conversely; passive devices do not (e.g., the latter are illustratively optical waveguides or light beam redirectors).

The array70of receptors71may likewise include an array of active devices such as photodetectors or an array of passive devices such as output optical fibers, splitters, or micro-mirrors.

An optical router is an important subsystem application of such arrays. For example, in a typical router the source array60includes an array of optical fibers coupled at its input end to an array of lasers and at its output end to microlens array50. The collimated beams (e.g., 64) are directed into an array of well-known micro-mirrors, which perform a beam steering function. After being redirected by the micro-mirror array, the beams are coupled into another microlens array, which refocuses the beams onto the input end of an array of optical output fibers.

Compensation Method

As mentioned earlier, conventional microlens arrays generally do not provide optimal coupling of the optical beams to the optical fibers (or other optical receptors) for several reasons. First, the microlens curvature varies from microlens to microlens due to limited manufacturing tolerances. These curvature variations lead to focal length variation, which, in turn, lead to optical beam diameter variations in the optical output fibers. Second, optical path lengths between different pairs of input and output fibers vary for different routings, which leads to variations in beam diameters at the output fibers.

In accordance with another aspect of our invention, we provide a method of compensating for variations in an optical parameter (e.g., effective focal length) among different ones of individual microlens apparatuses in an array of the type described above. Our compensation method includes: (a) determining that a first apparatus in the array has a value of the parameter different from that of a standard value; and (b) applying an electrical signal to the MEMS controller of the first apparatus, thereby causing the controller to perform a mechanical action that makes the value of the parameter of the first apparatus closer to the standard value. In an illustrative embodiment of this aspect of our invention, the mechanical action alters the vertical separation, horizontal separation and/or tilt between a pair of microlenses in the first apparatus.

Of course, the same method may be applied to a multiplicity of apparatuses that have a value different from that of at least one other apparatus.

In addition, the standard value of the optical parameter may be a predetermined value of that parameter that is (1) extant in a particular second apparatus of the array or (2) stored in a computer, with adjustments being made to those apparatuses that do not satisfy the standard.

Depending on the application, we contemplate a multiplicity of adjustments over time (in the factory or in the field) or a single adjustment (in the factory) followed by fixing the movable lens (or lenses) in place. The latter might be utilized, for example, to optimize the focal system within an assembled router (or switch) and then to lock all of the movable microlenses into position.

Next we describe two methods of fabricating compound microlens apparatus of the type shown inFIGS. 13,14and33. In the corresponding text various materials, dimensions and operating conditions are provided by way of illustration only and, unless otherwise expressly stated, are not intended to limit the scope of the invention.

Fabrication Method I

The fabrication technique below describes the process flow for making adjustable compound microlens apparatus of the type shown inFIG. 13or14. We describe the fabrication of the active (movable) lens, the stationary lens and the MEMS, as well as the assembly of the various components. The technique describes an array of such apparatuses, which, however, can be diced or otherwise separated into individual apparatuses, if so desired.

Active Lens

In conjunction withFIGS. 3-9we describe the fabrication of the active microlens.

As shown inFIG. 3, the starting material for making the active microlens is a silicon-on-insulator (SOI) wafer80, which comprises a SiO2layer81buried between a lower Si region (or substrate)82and an upper Si region (or layer)83. SOI wafers are well known, being used, for example, in the fabrication of advanced ICs as well as MEMS. Although a bulk Si wafer can be used instead of an SOI wafer, the process is much more complex, with much narrower process margins. Wafers made of other materials (e.g., fused silica, quartz, zinc oxide or even plastic) or of other semiconductors (e.g., SiGe) can be used.

The starting step is the fabrication of an array of essentially circular (in top view) active microlenses84(FIG. 4) on the SOI wafer. In general, these microlenses are created by creating hemispherical masks85(FIG. 3) on top of the wafer, and transferring their shapes into the upper Si layer83. There are number of well-known ways to create this type of shaped mask. Commonly, the mask-making process begins by forming a multiplicity of essentially cylindrical masks (not shown; one for each active microlens) that have their cylinder axes essentially normal to the top surface of the wafer. These masks are formed in a polymer [e.g., photoresist (PR)] layer by standard photolithography. Then, the cylindrically shaped PR masks are flowed by a well-known technique that includes, for example, either baking them at an elevated temperature and/or exposing them to a solvent. Most of these approaches convert the cylindrical masks into essentially hemispherical masks84(FIG.3). Once the mask shape is transferred into the upper Si layer83, either spherical or aspherical microlenses84(FIG. 4) are obtained, depending on the etching conditions (e.g., etchant type and strength; etching time and temperature).

Alternatively, the mask material may be made of a glass that changes shape upon exposure to elevated temperatures.

The mask material85and the upper Si layer83are then etched together to form the microlenses84shown in FIG.4. The lens aperture a, and lens sag, s are designed to fit the particular application. For instance, if the microlens aperture, dictated by the application, is 0.4 mm and the required focal length is 0.4 mm, the sag s will be 20.4 μm for a spherical microlens (using a refractive index n=3.48 for Si).

In an illustrative etching process, using Cl2-based chemistry for the etchant, Si etches 1.3 times faster than a novolac-based photoresist (nPR) mask. (Novolac, also spelled novolac, is a well-known phenol formaldehyde resin.) Therefore, the targeted sag height in nPR should be 15.7 μm In an illustrative resist-flow process, the microlens sag in nPR is 1.8 times greater than the nPR thickness, as coated. (A simple calculation, based on volume conservation, shows that a cylinder with aperture (diameter) α, when transformed into a microlens, leads to a sag roughly twice as high as the initial height. However, due to some densification, the sag in the nPR is reduced roughly by 10%, yielding a value of 1.8. Based on these calculations, the target for nPR thickness before reflow is 8.7 μm;The mask shape obtained by the flow process is essentially hemispherical, as shown in FIG.3. The etching process affects the shape somewhat, but for the dimensions mentioned above, the deviations from spherical shape are minimal, and for all practical purposes the shape of the curved surface of the Si microlenses84(FIG. 4) is spherical (essentially equal etch rates of Si and PR preserve the spherical shape; however, deviations are small for the dimensions in the example above). Once the PR is consumed in its entirety, the shape of the microlenses remains unchanged even if the etching process continues. (Actually, an overetch process is preferred to insure complete PR removal from the entire wafer.) In upper Si layer83, the remaining regions83a(FIG.4), which are located between adjacent microlenses, will be used to form the serpentine springs in accordance with one embodiment of our invention. A spring thickness (height) of a few micrometers is adequate. For example, if the desired spring height is 5 μm, the initial thickness of the Si regions83ashould be slightly greater than 25.4 μm (the sum of the lens sag and the spring thickness). Uniformity and control in the etching step that forms the springs are important since these process characteristics affect the spring constants.

We now turn toFIGS. 5 & 6, which (after a few additional process steps) show exploded views of the outlined section of FIG.4. These figures illustrate how the springs for the individual microlenses are formed. (Henceforth, we describe only the fabrication of a single microlens apparatus, it being understood that the process is applicable to the fabrication of an array as well.) The mask for this part of the process is PR, a conformal hard mask (e.g., SiO2), or a combination of the two. If only a PR mask is used, it should be thick enough to cover the microlenses during the entire etching process. Simple calculation shows that if the PR flows to produce a flat profile, which is an extreme case, its thickness should be roughly 25 μm. In contrast, if only a SiO2hard mask is used, its thickness should be at least1μm (assuming a 5:1 ratio of the etch rates of Si:siO2). This type of hard mask is patterned by conventional dry-etching (e.g., plasma etching) techniques, the PR is then stripped, and the SiO2serves as the mask during the etching of the Si regions83aFinally, if a combination of a PR layer86and a hard mask87is used during the etching of Si regions83a, as shown inFIG. 5, then thinner layers of PR and hard mask SiO2can advantageously be used.

The PR is next patterned using standard photolithography to form serpentine openings86a, and a dry-etching process is used to transfer that pattern into the Si regions83a(only their cross-section is shown in FIG.5). After the PR is stripped, the structure shown inFIG. 6is obtained. The serpentine springs are designated88. This figure demonstrates why an SOI wafer is the preferred starting material; that is, the buried oxide layer81serves as an etch-stop both in the above spring-forming step and in a subsequent etching step used to form cavity89(FIG.8), as described below.

As shown inFIG. 8, the next phase of the fabrication of the apparatus involves the formation of a cavity89below the microlens84, which allows the microlens to be suspended by its serpentine springs88. As shown inFIG. 7, the first step is to cover the top surface of the microlens with a relatively thick PR layer90, which protects the top surface of the microlens and provides a flat top surface90aof the PR layer. During the etching process (e.g., plasma etching, which generates heat), the wafer is cooled by clamping it to a chuck. Helium gas is used to provide thermal contact between the wafer and the chuck. The flat surface90ais advantageous in reducing the helium leak-rate into the etching chamber. The thickness of PR layer90should be at least 50 μm in this phase of the process.

After the microlens has been protected by the PR layer90, the wafer is flipped, and an opening89is defined photolithographically, using a PR layer91, as shown in FIG.7. The patterned PR layer91should be at least 20 μm thick to facilitate etching the bottom Si layer82to a depth of about 700 μm. Typically the etchant for this step is SF6-based, and Si:PR etch rate selectivities of at least 50:1 are realized.

The uniformity of this etching step, as well as its selectivity to etching Si over SiO2, determines the thickness of the buried SiO2layer81in the SOI wafer. An etch uniformity in this step of ±5% translates into a variation of ±10% in the etch-rate across the wafer. This variation implies that in some areas of the wafer, the etching step that forms cavity89may expose the SiO2layer81(from the bottom), whereas in other areas this same etching step may leave layer81buried beneath about 70 μm of residual Si from layer82. The structure ofFIG. 7is then exposed to dry etching (e.g., plasma etching) until any residual Si is removed. For purposes of illustration, if we assume Si:SiO2etch-rate selectivities of at least 100:1 in this step, the buried SiO2layer81should be at least 0.7 μm thick. However, a slightly thicker layer (at least 1μm) is preferable to provide a margin of safety in the etching step.

After the dry etching process, the PR layers90and91are stripped, resulting in the structure shown in FIG.8. Next, a suitable etchant (e.g., an HF solution) removes the SiO2layers81and87shown in FIG.8.

Then, as shown inFIG. 9, anti-reflection coatings (ARCs)92and93are deposited on the top and bottom surfaces of the microlens84. Each ARC could be, for instance, a single layer of dielectric material (e.g., Si3N4) with thickness equal to ¼ of the operating center wavelength, or a multi-layered dielectric structure designed to provide low reflectance over a broad range of wavelengths.

Note, here, that the active microlens ofFIG. 9includes a support structure or spacer102, which will allow the active microlens to be suspended over the stationary one. The support structure102forms a cavity89into which the stationary lens protrudes, as shown in FIG.13.

Although the support structure may take on a variety of geometric shapes, one of the simplest is a square (depicted in top view in FIG.1), which readily allows a circular microlens (in top view) to be positioned therein.

Stationary Lens

In conjunction withFIGS. 10-12we describe the fabrication of the stationary lens and the electrodes associated with it.

The stationary microlens94shown inFIG. 10may be fabricated from a standard semiconductor (e.g., Si) wafer, an SOI wafer is not required. In principle, however, other materials (e.g., fused silica, quartz, optical glass, zinc oxide or even plastic) or other semiconductors (e.g., SiGe) can be used as well.

Assuming that we utilize a standard Si wafer98, the initial steps used to form the hemispherical shape of microlens94are similar to those used to shape the active microlens84, as described in conjunction withFIGS. 3 and 4. At this point, the back of the wafer98is polished (if the standard Si wafer has a rough back surface) and ARC coatings95and96are deposited on the top and bottom surfaces, respectively. Then, a sacrificial layer97(e.g., 200 nm thick SiO2) is deposited on the top ARC95. Layer97protects the underlying ARC95during an etching step to be discussed below. The structure obtained is shown in FIG.10. Alternatively, it may be advantageous to cover the bottom ARC96with a protective layer as well.

As shown inFIG. 11, in order to begin the process of forming electrodes around the periphery of the stationary microlens94, a metal layer99is first deposited on the protective layer97. After metal deposition (e.g., 0.5-μm-thick Al), a PR layer is deposited. The PR layer is patterned by standard photolithography to form a multiplicity of PR pillars100located around the periphery of the stationary microlens94. In the two dimensional view ofFIG. 11only two pillars are shown; however, in three dimensions more than two, and typically four, pillars would be used to enable, for example, four electrodes (18a,18b) to be subsequently formed, as shown in FIG.1. Corresponding electrodes are designated by numeral101inFIGS. 12-14.

Next, the patterned wafer is etched to transfer the PR pattern into the metal layer99, thereby defining the electrodes101, as shown in FIG.12. This step is also used to form conductors or wiring (not shown) to allow electrical signals to be applied the electrodes101. (Corresponding wiring is not necessary for the movable microlens because it is grounded and hence carries no current. A conductive epoxy is sufficient to couple the movable microlens to ground.) A wet or a dry etch step is then used to remove the protective layer97leaving the structure shown in FIG.12. When using Si3N4as the material of the ARCs95and96and SiO2as the material of the protective layer97, a suitable wet etchant comprises an ethylene-glycol/HF solution or an ethylene-glycol/BOE solution.

Assembly

In accordance with one embodiment of our invention, the active microlens (FIG. 9) and the stationary microlens (FIG. 12) are the assembled to form the apparatus shown in FIG.13. This assembly includes a support structure (or spacer)102, which was formed in FIG.8and now is interposed between the two lenses so as to support or suspend the active lens84coaxially over the stationary lens94. Its height is sufficient to provide between the two microlenses a gap that allows their separation and/or tilt to be adjusted electrically.

Illustratively, the support structure comprises a semiconductor material (e.g., Si or SiGe) and is affixed around the periphery of the stationary lens by an adhesive material (e.g., epoxy or polyimide).

In operation, wiring (not shown) couples a source of voltage to selected ones of the bottom electrodes101. The same voltage level may be applied to all of the electrodes101, so as to alter only the vertical separation between the two microlenses, or different voltage levels may be applied to different ones of the electrodes101, so as to alter the tilt of the active (or movable) microlens as well as the vertical separation between the two microlenses. On the other hand, inFIG. 13the active microlens84and the structure102are not electrically isolated from one another. As noted above, the active microlens and the support structure are coupled to a source of ground potential.

In the embodiment ofFIG. 13, the hemispherical surfaces of the two microlenses face in the same direction, akin to the design of FIG.1(b), but excluding the curved surface on the back of microlens12b. Alternatively, as shown inFIG. 14, the active microlens can be flipped and mounted so that the hemispherical surfaces of the two microlenses face one another, akin to the design of FIG.1(a). In this configuration, the Si support structure102(FIG. 13) may not be high enough to allow for adequate separation between the two microlenses. In this case, an alternative taller support structure103(FIG. 14) may be interposed between the two microlenses. This support structure need not be made from semiconductor material; a suitable alternative is a photolithography-definable polyimide.

Assuming the focal length for each of the active and stationary microlenses is f1=f2=0.4 mm and their vertical separation d=700 μm, equation (1) gives the effective focal length of the apparatus of eitherFIG. 13orFIG. 14as f12=1.6 mm.

Fabrication Method II

The fabrication technique below describes a process flow for making a preferred adjustable compound microlens apparatus of the type shown in FIG.33. We describe the fabrication of the active (movable) lens, the stationary lens and the MEMS, as well as the assembly of the various components. The technique describes array of such apparatuses, which, however, can be diced or otherwise separated into individual apparatuses, if so desired.

This fabrication technique, although slightly more complicated, results in a design that has significant advantages our previous designs shown inFIGS. 13 and 14. In particular, in the microlens apparatus ofFIG. 33the active lens and the walls of the support structure are isolated from one another, allowing the active lens to be powered, while the walls and the stationary lenses are held at ground potential. Simulations show that this design is much better behaved than the previous one; that is, the new design has lower operating voltage and larger operational displacement.

In addition, the incorporation of a second etch-stop layer in Method II addresses the control issue associated with the spring formation in Method I.

Active Lens

In conjunction withFIGS. 15-31we describe the fabrication of a modified active lens.

As in Method1, the starting material is an SOI wafer110having a 1-μm-thick buried SiO2layer111, as shown in the bottom portion of FIG.15. The thickness of the top Si layer112should be equal to approximately the thickness of the springs in the active microlens structure. In Method I, the thickness was about 5 μm, but since the etch-uniformity requirements of Method II are less stringent, an even thinner top Si layer112can be used. Layer112will also serve as an electrical conductor to the individual active microlenses and, therefore, should have a reasonably high doping level (e.g., in the range of about 1016-1017cm−3, which is sufficient to provide adequate electrical conduction without causing too much optical absorption).

As shown in the top portion ofFIG. 15, a second wafer115(not SOI, but bulk Si) is oxidized as well to form a SiO2layer116. [Although this step may also form an oxide layer (not shown) on the top surface of bulk wafer115, the presence of such an oxide layer is moot since ultimately the top surface will be ground and polished.] The oxidized SOI and bulk Si wafers are joined by bonding together the exposed surfaces of oxide layers113and116. The bonded oxide layers are indicated by reference numeral117in FIG.16. (Although not shown inFIG. 16, in practice the thickness of layer117would be approximately equal to the sum of the thicknesses of layers113and116.) After bonding of these layers is complete, the top surface of the bulk Si wafer115is ground and polished to yield a top Si layer115a(FIG. 16) in which the active microlenses will be formed. Therefore, layer115ashould have a thickness that is about 0.5 μm greater than the desired microlens sag. In Method I the sag is illustratively about 25.4 μm, which is also applicable to Method II. Accordingly, the total thickness of layer115ashould be about 26 μm.

The resulting structure shown inFIG. 16is known as double SOI. This type of wafer is also available from commercial sources, such as Soitec Inc., which has offices in Bernin, France and Peabody, Mass.

Next, the oxide layer114on the back of the wafer is patterned (FIG. 17) using standard photolithographic and etching techniques to form circular openings118. Each opening will eventually be aligned with an active microlens and will have a diameter slightly smaller the microlens aperture. Using the illustration of Method I, where the aperture diameter was 0.4 mm, we estimate that the diameter of the openings118should be approximately 0.38 mm.

At this point the active microlenses119(FIG. 19) are formed in Si layer115ausing hemispherically shaped PR masks120(FIG. 18) in the manner described in Method1, except that the microlenses119are aligned to the openings118on the back of the wafers.

An ARC121is then deposited on the microlenses119as shown in FIG.20. As before, a Si3N4layer with ¼ wavelength thickness can be used for the ARC. A protective Sio2layer122, approximately 200 nm thick, is deposited on the ARC121.

The next step isolates the individual lenses from one another. To do so, a patterned PR layer123, is photolithographically formed on the protective layer122. The PR layer should be thick enough to protect the microlenses during the etching process (i.e., the etching that removes Si/SiO2material exposed by the openings in PR). In a worst-case scenario, where the PR layer planarizes the wafer, as above, the PR layer should be at least 26 μm thick. (In reality, complete planarity is not achieved in most cases, and so it is possible to use a much thinner PR) Openings124in the patterned PR expose regions between adjacent microlenses These regions are etched down to Si layer115b, which leaves each microlens119isolated atop a segment117aof oxide layer117, as shown in the structure of FIG.21. Actually, this etching step removes the following layers within the exposed regions: the protective layer122, ARC121, Si layer115aand the SiO2layer117.

After the individual active microlenses have been isolated, a doped polysilicon (or amorphous Si) layer125, about 500 nm thick (the exact thickness is not critical and can vary from application to application) is then deposited over the entire wafer (FIG.22). Layer125is then etched back to form spacers126(FIGS. 23 and 24) that will ultimately provide an electrical connection to the Si layer115bbelow. In top view, the spacers form a complete annulus around the active lens.FIG. 24shows an exploded view of the individual active microlens ofFIG. 23outlined by the dotted line rectangle.

As shown inFIG. 25, the next part of the process involves photolithographic patterning and etching of Si layer115b. The patterned Si has a dual purpose: it forms the electrical routing (wiring) to each active microlens, and it serves as the serpentine spring material.

Next, a cavity128(FIG. 28) will be opened in the backside of the wafer. The cavity has two sections arranged in tandem along the optical axis of microlens119: a narrower section128a(FIG. 28; corresponding to the width of opening118shown in FIGS.24-26), and a wider section128b(FIG. 28; corresponding to the width of opening131shown in FIG.26). The cavity is formed in multiple steps that will be described in conjunction withFIGS. 26 and 27.

First, thick PR layers129and130FIG. 26) are deposited on the top and bottom of the wafer, respectively. As before, the top PR layer129should be thick enough to provide a planar surface, which allows the wafer to be placed in the chuck of an etching tool. Then, the PR layer130on the bottom of the wafer is photolithographically patterned to form an opening131, which is wide enough to encompass the microlens119and its springs127(FIG.26).

Second, as shown inFIG. 27, the opening118in oxide layer114is used to form the narrower cavity section128a; that is, illustratively about 100 μm of Si is etched from the back of the wafer (Si region110a) using an SF6-based etchant having an etch-rate selectivity of >100:1 for Si:SiO2) in conjunction with a 1-μm-thick oxide mask.

Third, the remaining exposed portions114aof the oxide layer114are etched away, and the deep etching of Si region111ais resumed until the central portion11aof buried oxide layer111is exposed (FIG.28). The deep etching step forms the wider cavity section128band translates the shape of the narrower cavity section128aupward until it abuts the central portion111aof buried oxide layer111.

After the cavity-forming process exposes the central portion111aof the buried oxide111under each microlens, that portion is etched away (FIG. 29) to avoid having multiple refection surfaces in the light path. Then, the exposed central portion112aof Si layer112is removed (e.g., using again an SF6-based etchant) to produce the structure shown in FIG.30. This step again exposes oxide, but this time the central portion117aof oxide layer117.

At this point the PR is stripped, and the microlenses are released; that is, as shown, isFIGS. 30 and 31the peripheral portions111b(under the springs127) of buried oxide layer111and the central portion117a(on the bottom of the microlens119) of oxide layer117are etched away, as shown in FIG.31. Finally, an ARC132is deposited on the bottom of the microlens119(and incidentally on other backside surfaces) with similar thickness requirements discussed earlier regarding the formation of ARC121on the topside of the microlens.FIG. 31shows the final form of the active microlens resiliently suspended from support structure133by means of springs127.

Stationary Lens

The process for making the stationary microlens134(FIG. 32) is similar to that described in Method I, but without the metal layer99(FIG. 11) used to form the electrodes101(FIGS.12-14). The microlens134is shown inFIG. 32after ARCs135and136have been deposited on its topside and backside, respectively.

Stationary microlens134of Method II is simpler to fabricate than the corresponding microlens94of Method I since the former requires only one photolithography step (as opposed to two such steps in Method I) and does not require the deposition of oxides and metal to form the electrodes.

Assembly

The active microlens119and the stationary microlens134are then assembled by mounting the support structure133on the peripheral surfaces of the stationary microlens as shown in FIG.33. Typically the support structure133is affixed to the peripheral surfaces by means of a suitable adhesive material (e.g., epoxy or polyimide).

In this design, both the stationary lens134and the walls of the support structure are coupled to a source of ground potential, whereas the active microlens119is powered (i.e., coupled to a source of voltage).

Metal pads (not shown), which facilitate making electrical connections, can be deposited on the top surface of the assembly by using standard evaporation of metal through the openings in a shadow mask. Alternatively, the pads can be formed by the following process: an additional photolithographic step after the formation of the spacers (FIG.24), evaporation of a metal layer, and a well-known lift-off technique.

It is to be understood that the above-described arrangements are merely illustrative of the many possible specific embodiments that can be devised to represent application of the principles of the invention. Numerous and varied other arrangements can be devised in accordance with these principles by those skilled in the art without departing from the spirit and scope of the invention. In particular, the active and stationary microlenses of the apparatus ofFIG. 33, as with the apparatuses ofFIGS. 13 and 14, can also be fabricated from materials such as SiGe, fused silica, quartz, zinc oxide or even plastic.