Abstract:
A thin film apparatus having a plurality of thin film cells is disclosed. Each thin film cell includes a crystalline layer and a surrounding layer. The crystalline layer has a shape of polygon. The surrounding layer is partially located on the crystalline layer. The crystalline layer is surrounded by the surrounding layer.

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    This non-provisional application claims priority under 35 U.S.C. §119(a) on Patent Application No(s). 102108322 filed in Taiwan, R.O.C. on Mar. 8, 2013, the entire contents of which are hereby incorporated by reference. 
       TECHNICAL FIELD 
       [0002]    The disclosure relates to a thin film apparatus, and more particularly to a thin film apparatus which has a stronger structural strength and a stable and firm structure that is not deformed. 
       BACKGROUND 
       [0003]    For the semiconductor fabrication of semiconductor devices, metal layers and oxide layers are very commonly used. Most metal layers are formed through a physical deposition whereby these metal layers usually have tensile stress. Most oxide layers are formed through a chemical deposition whereby these oxide layers usually have compressive stress. Take a MEMS apparatus as an example. The residual stress of the MEMS apparatus is an equivalent stress combining the compressive stress with the tensile stress. The MEMS apparatus can integrate an application-specific integrated circuit (ASIC) and a MEMS together in the same surface, thereby simplifying its packaging process. 
         [0004]    However, the MEMS structure of the MEMS apparatus will be affected by its residual stress. Take a common XY-axis accelerometer as an example of the MEMS apparatus. The tensile stress of the metal layer will curve the MEMS structure upward, and the compressive stress of the oxide layer will curve the MEMS structure downward. Since the oxide layer is formed with the chemically produced bonding, the oxide layer has a high temperature of deposition and the bond force may cause that the residual stress of the oxide layer is larger than the residual stress of the metal layer. Therefore, the residual stress of the oxide layer leads the MEMS structure to be curved downward. Even if the residual stress can be released through the rapid thermal annealing (RTA) system, the thermal expansion coefficient of composite material will also affect the MEMS structure. For example, the thermal expansion coefficient of aluminum is 23 ppm/° C., and the thermal expansion coefficient of the oxide layer is 0.5 ppm/° C. In this case, the thermal expansion coefficient of aluminum is 46 times the thermal expansion coefficient of the oxide layer. Since the temperature around the MEMS apparatus may change, the design of the MEMS apparatus should consider not only its residual stress but also the thermal expansion related with two different layered materials. 
         [0005]    Generally, since MEMS apparatuses nowadays are easily affected by residual stress and temperature and do not have firm structures, these MEMS apparatuses are easily deformed. Moreover, if the structural strength of the MEMS apparatus is not strong enough, the MEMS apparatus may easily be curved due to the change of external force. 
       SUMMARY 
       [0006]    According to one or more embodiments, the disclosure provides a thin film apparatus. In one embodiment, the thin film apparatus may include a plurality of thin film units, and each of the thin film units may include a crystalline layer and a surrounding layer. The crystalline layer may be polygonal. The surrounding layer may be located on and partially surround the crystalline layer. 
         [0007]    In this way, the thin film apparatus may employ the surrounding layers to respectively surround the crystalline layers which are regular hexagon, to form the thin film units, and further employ an articulation layer to connect with the thin film units, thereby enhancing the structural strength of the thin film apparatus. Therefore, the thin film apparatus may have a stable and firm structure that is not deformed, and have a better sensitivity. Moreover, the thin film apparatus may be applied to more MEMS fields. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0008]    The present disclosure will become more fully understood from the detailed description given herein below for illustration only and thus does not limit the present disclosure, wherein: 
           [0009]      FIG. 1  is top view of a thin film unit of a thin film apparatus; 
           [0010]      FIG. 2  is a lateral view of the thin film unit; 
           [0011]      FIG. 3  is a schematic view of a part of the thin film apparatus; and 
           [0012]      FIG. 4  is a flow chart of fabricating the thin film apparatus. 
       
    
    
     DETAILED DESCRIPTION 
       [0013]    In the following detailed description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of the disclosed embodiments. It will be apparent, however, that one or more embodiments may be practiced without these specific details. In other instances, well-known structures and devices are schematically shown in order to simplify the drawings. 
         [0014]    Referring to  FIG. 1 ,  FIG. 2 , and  FIG. 3 , a thin film apparatus  100  is shown according to one ore more embodiments in the disclosure. The thin film apparatus  100  may be adapted to micro-electromechanical components such as microphones, pressure sensors, altimeters, flowmeters, tactometers, or other possible sensors. In other words, the micro-electromechanical component may be capable of being embodied by the thin film apparatus  100 . The thin film apparatus  100  may comprise a plurality of thin film units  101 . Each thin film unit  101  may comprise a crystalline layer  110  and a surrounding layer  120 . 
         [0015]    The crystalline layer  110  has a first surface  112  and may be polygonal. In the thin film apparatus  100 , there may be many crystalline layers  110 , and these crystalline layers  110  may be adjacent to each other and be located on the same surface. In one embodiment, the crystalline layer  110  may be regular-hexagonal. The crystalline layer  110  may be capable of bearing horizontal components (force) or vertical components (force) in different directions, so that these horizontal components or these vertical components may be balanced. In other words, the crystalline layer  110  may be capable of absorbing horizontal or vertical deformation. In one embodiment, the crystalline layer  110  may be or contain polycrystalline silicon or other materials with a small thermal expansion coefficient, but the disclosure will not be limited thereto. 
         [0016]    The surrounding layer  120  has a second surface  122 , and may be located on the first surface  112  of the crystalline layer  110  partially and surround the crystalline layer  110 . In one embodiment, the surrounding layer  120  may support or increase the structural strength of the crystalline layer  110 . In other words, the surrounding layer  120  may also be capable of bearing the aforementioned horizontal components (force) or vertical components (force) in different directions, so that the crystalline layer  110  may be capable of absorbing or bearing horizontal or vertical deformation and be prevented from being deformed. In one embodiment, the surrounding layer  120  may contain or be made of tungsten or other possible materials with relative larger hardness, but the disclosure will not be limited thereto. 
         [0017]    In one embodiment, the thin film apparatus  100  may further comprise an articulation layer  130  for connecting the thin film units  101  with each other. The articulation layer  130  may partially be located on each thin film unit  101 . In one embodiment, this articulation layer  130  may be a seismic reduction structure such as springs, so that the articulation layer  130  may absorb external force or absorb horizontal or vertical deformation caused by vibrations. Therefore, the thin film units  101  may have a stable and firm structure that is not deformed. In one embodiment, the articulation layer  130  may be made of metal, and more particularly contain Aluminum (Al), tungsten (W), platinum (Pt) or other metallic element. 
         [0018]    For the above thin film apparatus  100 , the fabrication method of the thin film apparatus  100  is illustrated below by referring to  FIG. 4 . Firstly, as shown in step S 401 , the crystalline layers  110  may be formed on a silicon substrate. For example, the method of forming the crystalline layers  110  on the silicon substrate may be thin film deposition, and the crystalline layer  110  may be made of polycrystalline silicon. Then, a first hard mask may be formed through a first photomask, as shown in step S 402 . In one embodiment of forming the first hard mask, photoresist may be smeared on the crystalline layers  110 , and then the photoresist on the crystalline layers  110  may be photolithographed to form the first hard mask. Herein, the region not covered by the first hard mask is where the surrounding layer  120  is formed, and the surrounding layer  120  may contain tungsten. Next, a metal, such as tungsten, may be coated on the first surface  112  of each crystalline layer  110  as shown in step S 403 , and after the superfluous metal located on the first hard mask is lifted off or removed, the rest metal may form the surrounding layers  120  as shown in S 404 . In one embodiment, the method of coating the metal may be performed via an electronic gun or a sputter. 
         [0019]    Subsequently, a photoresist may be smeared again on each thin film unit  101  including the crystalline layer  110  and the surrounding layer  120 , and the photoresist may be photolithographed through a second photomask to form a second hard mask, as shown in step S 405 . Herein, the region not covered by the second hard mask is where the metallic articulation layer  130  is formed. Finally, after a metal is coated on the second surface  122  of the surrounding layers  120  as shown in step S 406 , the superfluous metal on the second hard mask may be removed and the rest of the metal may form the articulation layer  130  as shown in step S 407 . 
         [0020]    In summary, the thin film apparatus in the disclosure may employ the surrounding layers to respectively surround the crystalline layers which are regular hexagon, to form the thin film units, and further employ an articulation layer to connect with the thin film units, thereby enhancing the structural strength of the thin film apparatus. Therefore, the thin film apparatus may have a stable and firm structure that is not deformed, and have a better sensitivity. Moreover, the thin film apparatus may be applied to more MEMS fields.