# Patent

## Title
Glass composition exclusively consisting of oxides which already at low temperatures form volatile fluorides by reaction with fluorine and its use

## Abstract

The glass is advantageous for microstructuring, especially reactive ion etching with fluorine and fluorine compounds, and has a glass composition based on oxide content and expressed in mol % of: SiO2, 40-70; GeO2, 0-30; B2O3, 5-20; P2O5, 5-20; WO3, 0-10; As2O3, 0-10; Yb2O3, 0-5; and Lu2O3, 0-5. Microstructure components, such as micro arrays, Fresnel lenses, micro wafers, or micro lens wafers, made by a method including reactive ion etching from the glass are also part of the present invention.

## Background
CROSS-REFERENCE
The invention described and claimed herein below is also described and claimed in German Patent Application 10 2005 034 785.1, which was filed on Jul. 21, 2005 in Germany. The aforesaid German Patent Application provides the basis for a claim of priority of invention for the invention claimed in the appended claims under 35 U.S.C. 119 (a) to (d).
BACKGROUND OF THE INVENTION
The present invention relates to a novel glass composition which exclusively comprises oxides which at low temperatures form volatile fluorides and its use in micro structuring methods.
Today, within the scope of the permanently increasing miniaturisation, the development of micro optics is an intensively examined field of development. A potential technology for the structuring of intermediate products is reactive ion etching (RIE). In this case, in bodies of silicon dioxide, such as for example wafers, the desired micro structures are generated in a plasma discharge reactor through a masking technique.
In the case of micro structuring of SiO2, volatile silicon fluoride which does not condense on the article due to the state of aggregation is formed with the use of for example CF4 or another fluorine-containing gas. SiO2 is a glass having many positive properties and may further be obtained in different geometries. Thus, SiO2 is a suitable material for this method. But currently, SiO2 is the only material which is available in bulk form for this micro structuring method. As a single component, it cannot fulfil the entirety of many demands. One significant disadvantage is e.g. that SiO2 melts only at very high temperatures (Ts=1.723° C.) and thus, the production generates high costs. Certain geometries can only be realized by costly methods of cold reprocessing. Furthermore, the low coefficient of thermal expansion of SiO2 glass which is 0.5 ppm/K is disadvantageous, when it should be linked with other materials, e.g. semiconductors, for example in the so-called “wafer level assembly”, wherein wafers of glass and of semiconductor materials should be linked and then processed together.
Finally, the low refractive index of SiO2 glass is disadvantageous, when lenses with high numerical aperture should be produced.
In this case, glasses would be preferable which have expansion coefficients in the range of the values of semiconductor materials, namely ca. 2 to 5 ppm/K, which have suitable refractive indices and which further can be produced in different required geometries.
There are a series of commercially available glasses which fulfil the demands regarding geometry, expansion coefficient and refractive index, but they all have the disadvantage that by the use of reactive ion etching which is also called RIE they form solid fluorides which after their formation immediately condense on the body to be structured. This applies to all known bulk glasses—with exception of SiO2—, since most elements of the periodic table form solid fluorides at room temperature. For example borosilicate glasses, such as for example Duran®, are available as flat glasses and can be linked well with Si, because of their expansion coefficient of 3.3 ppm/K, but in this case there is a disadvantage which lies in the fact that with the use of the RIE method the generated micro structures have low quality, since the oxides of Al, Na and K form solid fluorides during the reaction with F. There are investigations to overcome this disadvantage by a combined etching by means of the RIE method and sputtering (E. Metwalli and C. P. Pantano, Reactive ion etching of glasses: Composition dependence, Nucl. lnstr. Meth. Phys. Res. B 207 (2003) 21-27) which however is costly and undesired and in addition, nearly no micro structures with optical quality can be produced with this. Furthermore, the achievable etching rates decrease to a value which is higher than the half of the value of SiO2, thus the economical desirability of the method is remarkably lower.
Analogously, another report in the literature (Journal of Non-Crystalline Solids 342, (2004), 110-115) shows that during the reactive ion etching very complex processes take place and have to be managed, when it should be tried to microstructure alkali- or alkaline earth-containing glasses or glass ceramics by means of RIE.
From the state of the art (see J. Electrochem. Soc., Vol. 138, No. 9, pages 2836-2838, September 1991), glass systems are known which contain SiO2, GeO2, B2O3 and P2O5. They could be used in the micro linking technique in the form of reflow processes, namely for the demand of glasses which have a reflow temperature which is remarkably lower than that of SiO2. However, these glasses contain at least 71% by mole of SiO2 and are featured by glass transition temperatures (Tg) of higher than 800° C. Although the processing temperatures of these glasses are not mentioned in the literature, it can certainly be expected that all the glasses have processing temperatures which are clearly higher than 1.400° C. and thus cannot be melted in big conventional melting aggregates.
SUMMARY OF THE INVENTION
Accordingly, there is a need to provide a glass system which behaves advantageously during the micro structuring, in particular during a method for reactive ion etching. In this case, the glass should have a constitution such that during the reaction with fluorine at low temperatures exclusively volatile fluorides are generated. In the present invention, with the term “low temperature” is meant that the fluorides formed from the oxides, such as for example SiF4 or BF3, are volatile at a temperature of 25° C. Further, the glasses should fulfil additional requirements. It is important that the glasses can be melted in conventional melting aggregates, such as tanks or crucibles; thus, the melting temperature should be in a range of 1.600 or 1.700° C. and therewith it should be far below the melting temperature of SiO2 (ca. 2.500° C.). In addition, the glasses should be producible in different required geometries and should have expansion coefficients which are compatible with semiconductor materials, if possible. Further, a refractive index which is as high as possible and an Abbe number which is different from that of SiO2 (namely of 68) are desired.
This object is solved by the glasses according to the present invention which exclusively comprise oxides of B, Si, P, Ge, As, W, Yb and Lu, preferably only oxides of B, Si, P, Ge, As and W and most preferably only of B, Si, P and Ge.
The glasses according to the present invention consist of the following components (data in % by mole):
















SiO2
40-70 



GeO2
0-30



B2O3
5-20



P2O5
5-20



As2O3
0-10



WO3
0-10



Yb2O3
0-5 



Lu2O3
0-5 










Preferable embodiments consist of the following four components (data in % by mole):
















SiO2
50-65



GeO2
 3-30



B2O3
10-18



P2O5
10-18










The formulation “consisting of” should allow that normal impurities, such as remainders of fining agents or impurities of the raw materials, may be contained in the composition.
Higher contents of SiO2 are not desired, since the glasses become too viscous and cannot be melted in conventional aggregates any more. The glasses according to the present invention contain 40 to 70, preferably 50 to 70, further preferably 60 to 70% by mole of SiO2. Embodiments with contents of 40 to 65% by mole, preferably 50 to 65% by mole and further preferably of 60 to 65% by mole are also possible.
Both, B2O3 and P2O5 are components which lower the viscosity of the glasses, wherein it has also to be considered that both also lower the chemical stability of the glasses. This effect of lowering the chemical stability can be alleviated when both oxides are present in the glass in approximately the same molar portions which is a preferred embodiment of the invention. Portions of 5% by mole each for both oxides are necessary to achieve a sufficient lowering of the viscosity of the SiO2 glass, but on the other hand, portions of 20% by mole each should not be exceeded, since otherwise the chemical stability is lowered so much that processing and purification methods are not possible any longer. B2O3 is present in amounts of 5 to 20, preferably of 10 to 20 and further preferably of 15% by mole. P2O5 is present in the glass in amounts of 5 to 20, preferably of 10 to 20 and further preferably of 15% by mole.
Also GeO2 is a component which lowers the viscosity of the glass, however in view of the costs, this one will be used preferably by a person skilled in the art in amounts which are as low as possible. The component may be present in the glass in amounts of 0 to 30, of 3 to 30, of 7 to 30% by mole. The component may also be present in the glass in amounts of 0 to 20% by mole, 3 to 20% by mole and of 7 to 20% by mole. Ranges of the amounts of GeO2 of 0 to 10, 3 to 10 and 7 to % by mole are also possible.
As2O3 may be used as a fining agent, but preferably it should be omitted, because it is known that this substance is toxic.
WO3 is known in optical glasses as glass component. But according to preferred embodiments, it is not contained in the glass, since the glasses may undesirably become coloured by the change of the oxidation state.
Yb2O3 and Lu2O3 may be used in smaller portions, in particular, when the glasses should fulfil special optical functions. The amounts of these oxides can be 0 to 5% by mole, 1 to 5% by mole or 3 to 5% by mole, wherein the upper limit of 5% by mole may also be 4% by mole for each of the above given ranges.
Advantageously, the glasses according to the present invention can be melted in conventional melting aggregates. This is characterized by the so-called processing temperature VA, at which the glasses have a viscosity of 104 dPas. According to the present invention, values of 1.000° C. to 1.400° C. can be achieved here, whereas the processing temperature of SiO2 is approximately 2.350° C.
The processing temperatures (VA) of the glasses according to the present invention are in a range of 1.000 to 1.400° C., preferably of 1.050 to 1.350° C., most preferably at 1.100 to 1.300° C.
A further very important parameter for the processability of a glass is the glass transition temperature Tg. It characterizes the change of the viscoelastic over-cooled melt into the elastic and thus solid glass. Within glass families, VA and Tg strongly correlate with each other. In the present glass family, the requirement of a processing temperature of VA of lower than or equal to 1.400° C. approximately corresponds to a requirement of a glass transition temperature of Tg of lower than or equal to 700° C.
The expansion coefficients of the glasses according to the present invention are in a range of 3 to 6 ppm/K, preferably of 4 to 5.5 ppm/K, most preferably at 4.3 to 5.3 ppm/K.
The refractive indices of the glasses according to the present invention are in a range of 1.48 to 1.55, preferably of 1.495 to 1.525.
The Abbe number of the glasses according to the present invention is preferably in the range of 58 to 66. It is known that glasses having Abbe numbers of ca. 61 and PgF values (this value characterises the dispersion of the refractive index in the visible spectral region) of ca. 0.53 have an anomalous optical state. Therefore at the same time, they can be used well as glasses in normal imaging optics.
The glasses according to the present invention may be used in a superior manner in production methods in which micro structures are formed, in particular in such methods in which the technique of reactive ion etching is used. Glasses according to the present invention have a higher RIE etching rate than SiO2, namely the etching rate was 2-respectively 3-fold higher, wherein as the plasma gas CF4 respectively SF6 were used.
Since micro structuring techniques are generally aimed at small glass amounts, the technological advantages of the glasses according to the present invention which are readily meltable and stable and which therefore can be processed by many forming methods become the focus of attention and completely compensate the costs of the rather expensive starting component germanium oxide.


EXAMPLE 1
According to the following method, the following glasses were produced: The glasses were melted in Quarzal crucibles with a melting volume for 1⁄2 litres in a gas oven at temperatures of 1.550 to 1.700° C. and subsequently cast into Pt crucibles. In the Pt crucibles, it was fined at the same or slightly higher temperatures for 1 to 2 hours and subsequently it was stirred at the same or slightly lower temperatures for ca. 1⁄2 hour. In the case of viscous glasses, the crucibles were placed into a high temperature oven at ca. 1.700° C. for further 4 to 8 hours for dropping. Subsequently, the glasses were cast into metal moulds and placed into an oven which was pre-heated to a temperature of 600 to 730° C., allowed to stay therein for 1⁄2 hour and subsequently cooled slowly.
B2O3 and P2O5 are readily volatile components; also GeO2 evaporates more readily than SiO2. In the following examples, the synthesis values of the compositions are given in % by mole. After melting, the starting compositions will have changed to compositions which contain more SiO2.



















Glass
Glass
Glass
Glass
Glass
Glass
Glass
Glass


Component
1
2
3
4
5
6
7
8























SiO2
40
50
60
60
50
70
60
60


GeO2
30
20
10
20
30
0
0
7


B2O3
15
15
15
10
10
15
15
15


P2O5
15
15
15
10
10
15
15
15


WO3
0
0
0
0
0
0
10
0


As2O3
0
0
0
0
0
0
0
3









In the following table, properties of the glasses are summarized. Here, Alpha is the expansion coefficient in ppm/K, SR is the acid stability, measured according to the standard ISO 8424 for optical glasses, and n is the refractive index.






















Refractive
Abbe



Va (° C.)
Tg (° C.)
Alpha
SR
index (n)
number






















Glass 1
1024
592
5.49
4
1.536
59.6


Glass 2
1130
626
4.98
4
1.518
62.6


Glass 3
1203
661
4.62
3
1.506
65.3


Glass 4
1331
640
4.49
3
1.507
62.2


Glass 5
1239
599
4.96
4
1.524
58.8


Glass 6
nm*
702
4.04
2
nm*
nm*


Glass 7
nm*
657
4.03
nm*
nm*
nm*


Glass 8
1162
641
4.65
3
1.511
63.2





nm* means: not measured.






In particular, the glasses with high processing temperature can be produced in crucibles with a volume for 1⁄2 litres only with moderate homogeneity. Therefore, the given property values may have a higher standard deviation as is common otherwise. In particular, this applies to the optical constants refractive index and Abbe number.
The values for the glasses show that the glasses according to the present invention fulfil the desired properties of a low processing temperature and/or glass transition temperature and thus facilitate the production in conventional melting aggregates. The requirements regarding the other properties such as expansion coefficient, refractive index and Abbe number are satisfactory. In particular, the expansion coefficients of the glasses according to the present invention are much closer to Si than the expansion coefficient of SiO2. Further, the refractive indices and the Abbe numbers of the glasses according to the present invention are clearly different from those of SiO2 so that they can be used advantageously in imaging optics in a complementary way to SiO2.

## Claims

1. A glass for micro structure components, said glass consisting of (in % by mole):
















SiO2
40-70 



GeO2
0-30



B2O3
5-20



P2O5
5-20



WO3
0-10



As2O3
0-10



Yb2O3
0-5 



Lu2O3
 0-5.

2. The glass according to claim 1, consisting of (in % by mole):
















SiO2
50-65



GeO2
 5-25



B2O3
10-18



P2O5
10-18



WO3
0-5



As2O3
0-5



Yb2O3
0



Lu2O3
 0.

3. The glass according to claim 1, wherein tungsten oxide and arsenic oxide are not contained.

4. The glass according to claim 1, consisting of (in % by mole):
















SiO2
57-63



GeO2
 5-12



B2O3
12-17



P2O5
 12-17.

5. A method for the production of a glass according to claim 1, comprising the following steps:
melting of a homogenous glass in a conventional tank with refractory bricks or in a Pt or Pt/Rh crucible
forming of a casting or a rolled, pulled or floated flat glass
cold finishing of the glass raw forms to wafers.

6. Micro structure components comprising a glass according to claim 1, characterized in that the micro structures are prepared by the RIE method and the micro structure components are micro arrays, Fresnel lenses, micro wafers or micro lens wafers.

7. A method of making a micro structure component, said method comprising the steps of:
a) providing a glass body with a glass composition consisting, in % by mole, of 40-70, SiO2; 0-30, GeO2; 5-20, B2O3; 5-20, P2O5; 0-10, WO3; 0-10, As2O3; 0-5, Yb2O3; 0-5, Lu2O3; and
b) performing a reactive ion etching of the glass body to obtain a micro structure glass body.

8. The method according to claim 7, wherein the reactive ion etching is performed with a plasma gas comprising CF4 or SF6.

9. The method according to claim 7, wherein the reactive ion etching of the glass body is performed so that the micro structure glass body is a microarray, a Fresnel lens, a micro wafer, or a micro lens wafer.