Abstract:
A micro-optical-electrical-mechanical laser scanner is configured from a silicon-on-insulator substrate having a silicon substrate layer, a buried oxide layer, and a single crystal silicon device layer. A first device layer portion having a micro-mirror fabricated therefrom. A laser is connected to a second device layer portion, and a hinge connects the first device layer portion and the second device layer portion. The hinge is formed with a bimorph material, wherein the bimorph material creates built-in stresses in the hinge. The bimorph hinge moves the released micro-mirror out of the horizontal plane to a position for either directly or indirectly reflecting laser light emitted from the laser.

Description:
[0001] The U.S. Government has a paid up license in this invention and the right, in limited circumstances, to require the patent owner to license others on reasonable terms as provided for by the terms of contract number 70NANB8H4014, awarded by NIST. 
     
    
     
       BACKGROUND OF THE INVENTION  
         [0002]    Use of laser-based scanners have important applications such as bar-code scanning, retina-scanning, and xerographic printing. Integrated micro-opto-electromechanical (MOEMS) laser scanners are useful for these applications as well as others, due to their compact size and low cost. For example, in use with xerographic printing, integrated MOEMS-based laser scanners are an attractive option in constructing agile raster-optical scanning (ROS) systems for use in laser printing in order to achieve a scan resolution higher than conventional laser polygon ROS systems. With integrated MOEMS scanners it is possible not only to adjust the laser beam position in the low scan direction to correct errors such as a bow in a scan line caused by the polygon wobbling, but also to place the laser spot precisely at a sub-pixel resolution. Manufacturing integrated MOEMS based laser systems however involve complex micro-manufacturing techniques.  
           [0003]    It would, therefore be beneficial to configure an integrated MOEMS-based scanner system which is less complex to manufacture and robust in mechanical operation, while at the same time, providing a compact-size, low-cost and improved resolution.  
         SUMMARY OF THE INVENTION  
         [0004]    A micro-optical-electrical-mechanical laser scanner is configured from a silicon-on-insulator substrate having a silicon substrate layer, a buried oxide layer, and a single crystal silicon device layer. A first device layer portion has a micro-mirror fabricated therefrom. A laser is connected to a second device layer portion, and a hinge connects the first device layer portion and the second device layer portion. The hinge is formed with a bimorph material, wherein the bimorph material creates built-in stresses in the hinge. The bimorph hinge moves the released micro-mirror out of the horizontal plane to a position for either directly or indirectly reflecting laser light emitted from the laser. 
       
    
    
     BRIEF DESCRIPTION OF THE DRAWINGS  
       [0005]    [0005]FIG. 1 is a side view of a silicon-on-insulator wafer used in the present invention;  
         [0006]    [0006]FIG. 2 depicts the SOI substrate or wafer of FIG. 1 etched to have a first portion and a second portion of the single crystal silicon device layer;  
         [0007]    [0007]FIG. 3 illustrates the hinge formed with a bi-morph material according to the present invention;  
         [0008]    [0008]FIG. 4 shows a micro-mirror and edge-emitting laser attached to the first and second portions of the device layer;  
         [0009]    [0009]FIG. 5 depicts an integrated MOEMS laser scanner according to the teachings of the present invention;  
         [0010]    [0010]FIG. 6 is a top view of the laser scanner of FIG. 5;  
         [0011]    [0011]FIG. 7 depicts the angles and parameters to raise a micro-mirror to an angle of approximately 45°;  
         [0012]    [0012]FIG. 8 depicts the relationship between the mirror dimensions and the distance of the laser from the mirror;  
         [0013]    [0013]FIG. 9 depicts a SOI wafer used in a second embodiment of the present invention;  
         [0014]    [0014]FIG. 10 depicts the etching of a ribbon hinge configuration to be used as the hinge element in the present invention between a first portion and a second portion on the device layer;  
         [0015]    [0015]FIG. 11 illustrates the depositing of bi-morph material on the ribbon hinge of FIG. 10;  
         [0016]    [0016]FIG. 12 depicts the attachment of a micro-mirror and edge laser on the device layer portions;  
         [0017]    [0017]FIG. 13 shows an integrated MOEMS laser scanner according to a second embodiment;  
         [0018]    [0018]FIG. 14 depicts a first embodiment of a multi-mirror scanning system implementing concepts of the present invention;  
         [0019]    [0019]FIG. 15 sets forth a second embodiment of a multi-mirror scanning configuration using the concepts of the present invention. 
     
    
     DETAILED DESCRIPTION OF PREFERRED EMBODIMENTS  
       [0020]    Turning to FIG. 1, illustrated is a silicon-on-insulator (SOI) substrate wafer  10  which is processed in accordance with a first embodiment of the present invention. Wafer  10  includes a silicon substrate  12 , a buried oxide layer  14 , and a single crystal silicon device layer  16 . The following discussion describes processing steps used to manufacture an integrated MOEMS layer scanner assembly according to the present application. It is to be appreciated, however, that a number of different lithographic processes may be used in the present invention.  
         [0021]    As shown in FIG. 2, an initial step patterns and etches device layer  16  such that a first device layer portion  18  and a second device layer portion  20  are formed by the removal of device layer material thereby forming trench  22 . The material of device layer  16  at trench  22  is removed until reaching buried oxide layer  14 . In another embodiment trench  22  may be extended down to silicon substrate  12 .  
         [0022]    In FIG. 3, a hinge component  24  is created by having a hinge body  26  formed within trench  24 , with finger portions  28  and  30  located on respective first device layer portion  18  and second device layer portion  20 . Depositing hinge component  24  in this manner, connects or integrates the first device layer portion  18  and second device layer portion  20  via hinge body  26 . As also shown in FIG. 3, a bimorph material  32  is deposited on top of hinge body  26 . The bimorph material  32  may consist of a single layer or multiple layers utilizing a combination of compressive and tensile stresses resulting in a stress gradient across hinge  24 . The bimorph material can in one embodiment be deposited through the use of a lift-off technique.  
         [0023]    The single bimorph layer may be a metal layer such as sputtered Mo—Cr with compressive and tensile stress gradient, and the multiple layers may be composed of compressively stressed poly-Si on the bottom and tensile-strained metal on the top. For example, hinge body  26  may be constructed of the compressively stressed poly-Si. Hinge  24  is of sufficient mechanical strength to maintain the connection between the first device layer portion  18  and second device layer portion  20  when movement of at least one of the device layer portions  18 , 20  cause torque forces to be exerted on the hinge. It is also to be appreciated that hinge  24  may be made entirely of bimorph material  32 , including hinge body  26 .  
         [0024]    While bimorph material  32  generates compressive and tensile stresses which act to pull up on the first device layer portion  18  and second device layer portion  20 , since these device layer portions are attached to the buried oxide layer  14 , the portions are maintained in a planer position.  
         [0025]    Turning to FIG. 4, additional manufacturing steps deposit a micro-mirror  34  on the first device layer portion  18  by known lithographic techniques. Next, a laser chip or assembly  36 , such as an edge emitting laser, is connected to an upper surface of the second device layer portion  20 , by flip-chip technology using solder balls  38  and  40 . It is to be appreciated, however, that other connection techniques are also possible. The connection technique used should permit micro-positioning of the laser chip.  
         [0026]    Turning to FIG. 5, depicted is integrated MOEMS laser scanner  40 , where micro-mirror  34 , carried on first device layer portion  18 , and a portion of the hinge component  24  have been released from the buried oxide layer  14 . Particularly, in this embodiment the buried oxide layer  14  under the first device layer  18  and a portion of hinge  24  have been removed through known etching processes such that the tension forces in hinge  24  cause movement of first device layer portion  18  to be moved out of the device layer plane. The tensile stresses, result in a stress gradient which causes mirror  34  to be raised to an angle of  450  relative to the surface of device layer  16 .  
         [0027]    By this configuration, when laser beam  42  is emitted from edge-emitting laser chip  36 , the laser beam is reflected normal to the substrate surface. The surface normal emission allows for easy packaging of the system in a TO can package. This assembly, incorporating the bimorph effect, is useful in making MOEMS-based optical switches, and micro-mechanical spring contacts. The flip-chip attachment positioning process allows for precise placement of laser  36  on device layer  16  relative to mirror  34 .  
         [0028]    It is to be appreciated that while micro-mirror  34  is shown as a separate device from the upper surface of first device layer portion  18 , micro-mirror  34  may in fact be the polished upper surface of the first device layer portion  18 .  
         [0029]    Turning to FIG. 6, illustrated is a top view of the integrated MOEMS laser scanner  40  of FIG. 5. It is noted by viewing FIGS. 5 and 6 that micro-mirror  34  may be designed as a passive structure such that when it is released from buried oxide layer  14 , the predetermined tension within hinge  24  determines the angle at which the mirror is positioned and maintained. Alternatively, when the bimorph material is of a metallic substance, micro-mirror  34  can be scanned electrostatically by use of a power source arrangement  44 , such as a dc power source, which provides a bias voltage across a portion of hinge  24  and SOI substrate  10 . By controlling the bias voltage, it is possible to control the angle position of micro-mirror  34  from its in-plane position (0°) up to the 45° out-of-plane. Also, by fabricating power source  44  and high-quality and low-noise electronic circuitry  46  for driving the micro-mirror and laser, on remaining sections of silicon device layer  16 , full integration of optoelectronic and micro-electromechanical devices is realized.  
         [0030]    The resonant frequency of the micro-mirror depends on the stiffness of the hinge and the weight of the mirror. The resonant frequency of the mirror is therefore configurable and can be designed to be in the tens of kHz.  
         [0031]    As shown in FIG. 7, in order to raise scanning micro-mirror  34  to an angle of 45° relative to the substrate surface, the angle between bimorph hinge  24  and SOI substrate  10  should be approximately 22.5°. The lift or curling height of the hinge (b), can be expressed as:  
         b ˜ L 2 Δσ/2hY′,  
         [0032]    where L is hinge length, Δσ is the stress difference of the bimorph material, h is the hinge layer thickness, and Y′ is the average elastic modulus of the bimorph material.  
         [0033]    When L is chosen to be 200 μm long, the resulting lift height is 82 μm. If the bimorph layer thickness is 1 μm, then the stress difference in the bimorph material should be 2.4 GPa, to curl the layer at 22.5°. This stress difference can be realized by use of sputtered Mo—Cr.  
         [0034]    As shown by the above equation, increasing the length of the bimorph layer reduces the stress difference required to curl the bending part at 22.5°. However, the height of the micro-mirror increases relative to the substrate surface, which makes it more difficult to align the center of the micro-mirror to the laser beam horizontally due to the limitations of the laser chip thickness. In one embodiment, for example, the thickness of the laser assembly or die is about 120 μm. Assuming that a solder bump height is about 40 μm, the active region of the laser is then 160 μm above the substrate surface.  
         [0035]    As shown in FIG. 8, the edge-emitting laser end facet  50  is aligned to the starting line  52  of the curled hinge  24 . Assuming that the divergence angles of the laser are 35° vertically at full width half maximum (FWHM) and 8% horizontally at FWHM, the minimum error dimension of the hinge should be 200 μm long and 150 μm wide in order to fully contain the laser beam.  
         [0036]    As previously noted, a mirror scan can be realized electrostatically by a voltage biased across the bimorph material and the SOI substrate  10 . For application as an agile raster optical scanning (ROS) system, the required scan angle is on the order of a few degrees. Therefore the present system is useful to this concept. It is noted that the pre-scan angle of the mirror can be adjusted by the d.c. bias voltage.  
         [0037]    As also previously mentioned, the micro-mirror can be fabricated in the device layer of the silicon-on-insulator substrate so that the mirror is made out of single crystal silicon, which permits fabrication of high-quality, optically flat and polished surfaces.  
         [0038]    The mirror is released in a first embodiment by etching away the buried oxide layer (SiO 2 )  14  located underneath the first device layer portion and part of the hinge. However, in a second embodiment, the mirror may be released by etching away the silicon substrate  12  and the buried oxide layer  14  by opening a window from the back of substrate  12 . The second mirror release embodiment acts to reduce the release time necessary for allowing movement of the mirror.  
         [0039]    A second embodiment of the present invention may be achieved using an SOI wafer such as described in connection with FIG. 1. In a first step as shown in FIG. 9, patterning and etching processing forms a mirror  60  from device layer  16 . Next, with attention to FIG. 10, etch processing has been used to configure a ribbon hinge structure  62 . Processing of ribbon hinge structure  22  defines a first device layer portion  64 , which carries mirror  60 , and a second device layer portion  66 . Both portions are integrated to the ribbon hinge  62 . The thinning of ribbon  62  is sufficient to maintain mechanical stability while providing a flexible mechanism for movement of micro-mirror  60 .  
         [0040]    Thus, ribbon hinge  62  is formed from the device layer  16  which has been thinned down to allow increased mechanical flexibility. This design produces a high-quality mechanical structure having sufficient strength for its intended purpose. In this embodiment, the ribbon hinge or structure  64  may be approximately 500 nm thick, approximately 50 μm wide and approximately 140 μm in length.  
         [0041]    More particularly, ribbon hinge  62  may be formed using a two-mask process. The area to be thinned is first lithographically exposed and surrounding areas protected, before a time wet etch reduces the thickness of the exposed silicon area to approximately 500 nm or other appropriate depth. Then a subsequent lithographic step is used to pattern the hinge. Therefore the main difference between the ribbon hinge and first and second device layer portions  64 , 66  is the geometry of the patterning, and the physical thickness of the areas.  
         [0042]    As can be seen in FIG. 10, ribbon hinge  62  is fully integrated to the first and second device layer portions  64 , 66 . This difference in device layer thickness defines a trench area  68  used advantageously to introduce stress tension allowing for movement of mirror  60  once it is released from buried oxide layer  14 .  
         [0043]    [0043]FIG. 11 illustrates this concept more clearly by depicting bimorph material  70  having been deposited within trench area  68 . The bimorph material  70  is deposited directly on top of ribbon hinge  62 . As in the previous embodiment, the bimorph material can be either a single metal layer such as sputtered Mo—Cr having compressive and tensile stress gradients or multiple layers composed of compressively stressed poly-Si on the bottom and tensile strained metal on the top. After depositing the bimorph material  70 , an etching process such as a wet-etch solution or other known procedure is used to remove the buried oxide layer  14  from beneath mirror  60 , and partially under ribbon hinge  62 . In an alternative embodiment, the mirror and portion of the ribbon hinge may be released by etching away the silicon substrate layer  12  and the buried oxide layer  14  underneath the first device layer  64  and portion of ribbon hinge  62  by opening a window  76  from the back of substrate  12 .  
         [0044]    Once released, as shown in FIG. 12, the mirror rises to a height determined in accordance with parameters discussed in connection with the first embodiment. After the mirror is released, and as shown in FIG. 13, a laser chip or assembly  78  is integrated onto the second device layer portion  66  by a flip-chip bonding technique through the use of solder balls  80  and  82 , or by some other known attachment technique.  
         [0045]    It is to be noted that the processes illustrated in the first embodiment and the second embodiment follow somewhat different steps. For example, in the first embodiment, the laser is attached prior to release of the mirror. This is intended to show that alternative configurations for construction of scanning devices disclosed herein are possible. It is therefore to be understood that the exact sequence of construction for both embodiments may be adjusted from what is shown in these embodiments, and these embodiments are set forth only as exemplary process techniques and not to limit the concepts of the invention to these techniques.  
         [0046]    Turning to FIG. 14, set forth is an alternative design for an integrated MOEMS laser scanner  90 . The etching techniques and lithographic processes for constructing this device would be within the understanding of one in the art, and would employ similar known manufacturing techniques, such as shown in connection with the first two embodiments.  
         [0047]    The present embodiment also uses a silicon-on-insulator (SOI) wafer substrate  92  having a silicon substrate layer  94 , a buried oxide layer  96  and a device layer  98 . In addition, a further carrying substrate  100  which also may be of silicon, metal or other appropriate material. Carrying substrate  100  can be bonded to the SOI substrate  92  by anodic bonding or metallurgic bonding techniques. In an alternative embodiment to FIG. 14, instead of using additional substrate  100 , silicon substrate  12  may be etched partially through, as opposed to the full etched as in FIG. 14. In this embodiment the carrying substrate  100  would not be required.  
         [0048]    In the architecture shown in FIG. 14, a first mirror  102  is attached to a hinge  104  which in turn is partially anchored to a device layer portion  106 . Buried oxide layer  94  and silicon substrate  92  have been removed such that mirror  102 , which faces in a downward position, angles away from its initial in-plane position by a predetermined angle. A second mirror  108  is also connected via a hinge  110  to a device layer portion  112 . Second mirror  108  is designed to face upward upon its release from the buried oxide layer  96 . The angle of the mirrors is determined by parameters such as the degree of stresses in a bimorph material either incorporated into the spring  110  or deposited thereon such as in the previous embodiments. Hinges  104 ,  110  may be designed as described in the previous embodiments.  
         [0049]    A vertical cavity surface-emitting layer (VCSEL)  114  is bonded to carrying substrate  100  by use of flip-chip bonding or other connection techniques. In operation, laser beam  116  emitted from VCSEL  114  impinges upon mirror  102  which directs the laser beam to mirror  108 . Mirror  102  may be a fixed passive mirror wherein once in a set position it is maintained in that position and mirror  108  may have the capability of being scanned. This capability is achieved by voltage source  118  which generates a bias voltage across the hinge  110  and substrate  90 . By application of varying voltages (for example, by a controller  119 ), movement of hinge  110  is controllable within the range from an in-plane position to a maximum out-plane position determined by the stresses of the bimorph material.  
         [0050]    It is also possible to provide a biasing voltage to mirror  102  to allow scanning or movement of this mirror. An advantage of using a VCSEL is its low beam divergence and circular beam profile.  
         [0051]    Turning to FIG. 15, illustrated is an alternative laser scanner  120  design in which in addition to lift-up mirrors  102  and  108  of FIG. 14 also provided is an in-plane torsion hinge mirror  122 , used for beam scanning. The torsion hinge mirror  122  is driven magnetically by a current coil  124  on the mirror  122  generating a magnetic field which interacts with an external magnetic field (not shown). The metal or current coil  122  is deposited on the surface of the torsion hinge mirror  122  to generate an onboard magnetic field which interacts with the external magnetic field (with the field direction parallel to the mirror). In an alternative embodiment, the torsion hinge mirror is activated electrostatically with double electrode plates  126  located underneath the mirror deposited on the laser carrying substrate  100 . The electrode plates  126  are deposited by electroplating to make the plate thickness up to hundreds of micrometers so that a smaller gap between the mirror and the electrodes are realized.  
         [0052]    It is noted that each of the embodiments are capable of having electronics integrated thereon such as disclosed in connection with FIGS. 5, 6 and  14 .  
         [0053]    While the present invention is described with respect to preferred embodiments, it would apparent to one skilled in the art to practice the present invention in other configurations and designs. Such alternate embodiments would not cause departure from the spirit and scope of the present invention.