Patent Abstract:
In one embodiment, a method of forming an out-of-plane electrode includes providing an oxide layer above an upper surface of a device layer, providing a first cap layer portion above an upper surface of the oxide layer, etching a first electrode perimeter defining trench extending through the first cap layer portion and stopping at the oxide layer, depositing a first material portion within the first electrode perimeter defining trench, depositing a second cap layer portion above the first material portion, vapor releasing a portion of the oxide layer, depositing a third cap layer portion above the second cap layer portion, etching a second electrode perimeter defining trench extending through the second cap layer portion and the third cap layer portion, and depositing a second material portion within the second electrode perimeter defining trench, such that a spacer including the first material portion and the second material portion define out-of-plane electrode.

Full Description:
[0001]    This application claims the benefit of U.S. Provisional Application No. 61/475,461, filed on Apr. 14, 2011. 
     
    
     FIELD OF THE INVENTION 
       [0002]    This invention relates to wafers and substrates such as are used in micromechanical electrical system (MEMS) devices or semiconductor devices. 
         [0003]    Background 
         [0004]    Electrostatic MEMS resonators have been a promising technological candidate to replace conventional quartz crystal resonators due to the potential for smaller size, lower power consumption and low-cost silicon manufacturing. Such devices typically suffer, however, from unacceptably large motional-impedance (R x ). MEMS devices operating in the out-of-plane direction, i.e., a direction perpendicular to the plane defined by the substrate on which the device is formed, have the advantage of large transduction areas on the top and bottom surfaces, resulting in a reduction in motional-impedances. Consequently, out-of plane devices have received an increasing amount of attention resulting in significant advances in areas such as digital micro-mirror devices and interference modulators. 
         [0005]    The potential benefit of out-of-plane electrodes is apparent upon consideration of the factors which influence the R x . The equation which describes R x  is as follows: 
         [0000]    
       
         
           
             
               
                 R 
                 x 
               
               = 
               
                 
                   c 
                   r 
                 
                 
                   η 
                   2 
                 
               
             
             ; 
           
         
       
       
         
           with 
         
       
       
         
           
             η 
             = 
             
               
                 V 
                  
                 
                   
                     ∂ 
                     C 
                   
                   
                     ∂ 
                     g 
                   
                 
               
               = 
               
                 
                   
                     ɛ 
                     0 
                   
                    
                   AV 
                 
                 
                   g 
                   2 
                 
               
             
           
         
       
     
         [0000]    wherein “c r ” is the effective damping constant of the resonator, 
         [0006]    “η” is the transduction efficiency, 
         [0007]    “g” is the gap between electrodes, 
         [0008]    “A” is the transduction area, and 
         [0009]    “V” is the bias voltage. 
         [0010]    For in-plane devices, “A” is defined as H×L, with “H” being the height of the in-plane component and “L” being the length of the in-plane component. Thus, η is a function of H/g and H/g is constrained by the etching aspect ratio which is typically limited to about 20:1. For out-of-plane devices, however, “A” is defined as L×W, with “W” being the width of the device. Accordingly, η is not a function of the height of the out-of-plane device. Rather, η is a function of (L×W)/g. Accordingly, the desired footprint of the device is the major factor in transduction efficiency. Out-of-plane devices thus have the capability of achieving significantly greater transduction efficiency compared to in-plane devices. 
         [0011]    Traditionally, out-of-plane electrodes are not fully utilized because of the difficulty in reliably fabricating such devices. For example, packaging is difficult for out-of-plane devices because out-of-plane electrodes are easily damaged during packaging processes. MEMS resonators incorporating an out-of-plane electrode are particularly challenging because such devices require a vacuum encapsulation process. 
         [0012]    What is needed therefore is a simple and reliable device with an out-of-plane electrode and method for producing the device. A device incorporating an out-of-plane electrode that is easily fabricated with an encapsulated vacuum would be further beneficial. 
       SUMMARY 
       [0013]    In one embodiment, a method of forming an out-of-plane electrode includes providing an oxide layer above an upper surface of a device layer, providing a first cap layer portion above an upper surface of the oxide layer, etching a first electrode perimeter defining trench extending through the first cap layer portion and stopping at the oxide layer, depositing a first material portion within the first electrode perimeter defining trench, depositing a second cap layer portion above the deposited first material portion, vapor releasing a portion of the oxide layer, depositing a third cap layer portion above the second cap layer portion, etching a second electrode perimeter defining trench extending through the second cap layer portion and the third cap layer portion, and depositing a second material portion within the second electrode perimeter defining trench, such that a spacer including the first material portion and the second material portion define a perimeter of an out-of-plane electrode. 
         [0014]    In a further embodiment, a device with an out-of-plane electrode includes a device layer positioned above a handle layer, a cap layer having a first cap layer portion spaced apart from an upper surface of the device layer, and an out-of-plane electrode defined within the first cap layer portion by a spacer. 
         [0015]    In yet another embodiment a method of forming an out-of-plane electrode includes providing an oxide layer above an upper surface of a device layer, epitaxially depositing a first cap layer portion above an upper surface of the oxide layer, etching a first electrode perimeter defining trench extending through the first cap layer portion and stopping at the oxide layer, depositing a first insulating material portion within the first electrode perimeter defining trench, epitaxially depositing a second cap layer portion above the deposited first material portion, performing an HF vapor etch release on a portion of the oxide layer, epitaxially depositing a third cap layer portion above the second cap layer portion, etching a second electrode perimeter defining trench extending through the second cap layer portion and the third cap layer portion, and depositing a second insulating material portion within the second electrode perimeter defining trench, such that a spacer including the first material portion and the second material portion define a perimeter of an out-of-plane electrode. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0016]      FIG. 1  depicts a side cross-sectional view of a sensor device incorporating a spacer defining an out-of-plane electrode, the spacer including two trench portions and a gasket portion in accordance with principles of the invention; 
           [0017]      FIG. 2  depicts a side cross-sectional view of a wafer with a device layer etched to define an in-plane-electrode; 
           [0018]      FIG. 3  depicts a top plan view of the wafer of  FIG. 2 ; 
           [0019]      FIG. 4  depicts the wafer of  FIG. 2  with the trenches filled with an oxide material and an oxide layer formed above the device layer; 
           [0020]      FIG. 5  depicts a top plan view of the wafer of  FIG. 4 ; 
           [0021]      FIG. 6  depicts the wafer of  FIG. 4  with an opening etched in the oxide layer above a contact portion of the device layer; 
           [0022]      FIG. 7  depicts a top plan view of the wafer of  FIG. 6 ; 
           [0023]      FIG. 8  depicts the wafer of  FIG. 6  with a first cap layer portion formed above the oxide layer and trenches formed in the oxide layer; 
           [0024]      FIG. 9  depicts a top plan view of the wafer of  FIG. 8 ; 
           [0025]      FIG. 10  depicts the wafer of  FIG. 8  with the trenches filled with an insulating material, the insulating material also forming a layer above the first cap layer portion, and an etch stop layer formed above the insulating layer; 
           [0026]      FIG. 11  depicts a top plan view of the wafer of  FIG. 10 ; 
           [0027]      FIG. 12  depicts the wafer of  FIG. 10  after the insulating layer and etch stop layer have been etched to define gaskets for an out-of-plane electrode and a device layer contact; 
           [0028]      FIG. 13  depicts a top plan view of the wafer of  FIG. 12 ; 
           [0029]      FIG. 14  depicts the wafer of  FIG. 12  after a second cap layer portion has been deposited above the first cap layer portion and the gaskets, and the second cap layer portion has been planarized; 
           [0030]      FIG. 15  depicts a top plan view of the wafer of  FIG. 14 ; 
           [0031]      FIG. 16  depicts the wafer of  FIG. 14  after vapor etch vent holes have been etched through the first cap layer portion and the second cap layer portion, and a portion of the oxide layer, the oxide material in the device layer, and a portion of a buried oxide layer have been etched, thereby electrically isolating an in-plane electrode and releasing the first cap layer portion above the in-plane electrode; 
           [0032]      FIG. 17  depicts a top plan view of the wafer of  FIG. 16 ; 
           [0033]      FIG. 18  depicts the wafer of  FIG. 16  after the vapor etch vent holes have been sealed by a third cap layer portion; 
           [0034]      FIG. 19  depicts a top plan view of the wafer of  FIG. 18 ; 
           [0035]      FIG. 20  depicts the wafer of  FIG. 18  with trenches formed through the third cap layer portion and the second cap layer portion to upper surfaces of the gaskets; 
           [0036]      FIG. 21  depicts a top plan view of the wafer of  FIG. 20 ; 
           [0037]      FIG. 22  depicts the wafer of  FIG. 20  with an insulating material deposited within the trenches and along the upper surface of the third cap layer portion, and a contact opening etched through the insulating material to expose a contact portion of the cap layer; 
           [0038]      FIG. 23  depicts a top plan view of the wafer of  FIG. 22 ; 
           [0039]      FIG. 24  depicts a side cross-sectional view of a wafer including electrode defining trenches extending through a cap layer portion to an oxide layer and etch stop trenches extending through the cap layer portion and the oxide layer to an upper surface of a device layer; 
           [0040]      FIG. 25  depicts a side cross-sectional view of the wafer of  FIG. 24  with nitride trench portions filling the electrode defining trenches, nitride etch stop portions filling the etch stop trenches, gaskets formed above the nitride trench portions and the nitride etch stop portions, and etch vent holes extending through a cap layer, wherein etching of the oxide layer has been constrained by the nitride etch stop portions; 
           [0041]      FIGS. 26-38  depict side cross-sectional views of a wafer as it is processed to provide an electrical contact on the upper surface of the device which extends to the handle layer of the device, while being isolated from the device layer and the cap layer, wherein etching of an oxide layer between the device layer and the cap layer has been constrained by nitride etch stop portions; 
           [0042]      FIG. 39  depicts a side cross-sectional view of a MEMS device with a proof mass which may be fabricated using substantially the same process described with respect to  FIGS. 26-38 , the device including two electrically isolated contacts in the device layer on opposite sides of the proof mass and optionally including an out-of-plane electrode; 
           [0043]      FIG. 40  depicts a side cross-sectional view of a MEMS device with a proof mass which may be fabricated using substantially the same process described with respect to  FIGS. 26-38 , with an optional out-of-plane electrode and two electrically isolated contacts in the device layer on opposite sides of the proof mass, wherein etching of a buried oxide layer between the device layer and the handle layer has been constrained by nitride etch stop portions; and 
           [0044]      FIGS. 41-62  depict side cross-sectional views of a wafer as it is processed to form the device of  FIG. 40 . 
       
    
    
     DESCRIPTION 
       [0045]    For the purposes of promoting an understanding of the principles of the invention, reference will now be made to the embodiments illustrated in the drawings and described in the following written specification. It is understood that no limitation to the scope of the invention is thereby intended. It is further understood that the present invention includes any alterations and modifications to the illustrated embodiments and includes further applications of the principles of the invention as would normally occur to one skilled in the art to which this invention pertains. 
         [0046]      FIG. 1  depicts a pressure sensor  100  including a handle layer  102 , a buried oxide layer  104 , and a device layer  106 . An oxide layer  108  separates the device layer  106  from a cap layer  110 . A passive layer  112  is located above the cap layer  110 . 
         [0047]    Within the device layer  106 , an in-plane electrode  114  is defined by two etch portions  116  and  118 . The in-plane electrode  114  is isolated from the cap layer  110  by an etched portion  120  of the oxide layer  108 . The etched portions  116 ,  118 , and  120  are etched through vent holes  122  which are closed by the cap layer  110 . 
         [0048]    An out-of plane electrode  124  is located above the in-plane electrode  114  and electrically isolated from the in-plane electrode  114  by the etched portion  120 . The out-of-plane electrode  124  is isolated from the rest of the cap layer  110  by two spacers  126  and  128 . The spacers  126  and  128  include a lower nitride portion  130  which extends upwardly from the etched portion  120 , and an upper oxide portion  132  which extends from the nitride portion  130  to the upper surface of the cap layer  110 . 
         [0049]    Spacers  134  and  136 , which are formed like the spacers  126  and  128 , electrically isolate a connector  138  in the cap layer  110  from the rest of the cap layer  110 . The connector  138  is in electrical communication with a connector  140  in the device layer  106 . The connector  140  is in electrical communication with the in-plane electrode  114 , as described more fully below, and isolated from the remainder of the device layer  106  by isolation posts  142  and  144 . The isolation posts  142  and  144  extend from the buried oxide layer  104  to the oxide layer  108 . A bond pad or trace  146  is located above the passive layer  112  and in electrical communication with the connector  138 . 
         [0050]    A process for forming a sensor such as the pressure sensor  100  is discussed with reference to  FIGS. 2-23 . Referring initially to  FIGS. 2 and 3 , an SOI wafer  200  including a handle layer  202 , a buried oxide layer  204 , and a device layer  206  is initially etched to define an in-plane electrode  208  and a lower contact portion  210  for the in-plane-electrode  208 . A connector  212  is etched between the in-plane electrode  208  and the lower contact portion  210 . The in-plane electrode  208  is defined by a trench portion  214 , while the lower contact portion  210  is defined by a trench portion  216  and the connector  212  is defined by a trench portion  218 . If desired, the structural or handle layer  202  may be a pressure chemical vapor deposition (LPCVD) or epi-polysilicon layer. 
         [0051]    The trench portions  214 ,  216 , and  218  are then filled with a trench oxide portion  220  as shown in  FIGS. 4 and 5  using a conformal oxide deposition. Oxide deposition further results in an oxide layer  222  on the upper surface of the device layer  206 . The thickness of the oxide layer  222  sets the gap between two electrodes as discussed more fully below. The oxide layer  222  may be planarized by any desired technique such as chemical mechanical polishing (CMP). 
         [0052]    Referring to  FIGS. 6 and 7 , a contact opening  224  is then etched through the oxide layer  222  to expose the upper surface of the lower contact portion  210 . An epi-poly deposition fills the contact opening  224  with a lower middle contact portion  226  of epi-poly while depositing a lower cap layer portion  228  above the oxide layer  222  as shown in  FIGS. 8 and 9 . The lower middle contact portion  226  thus extends from the upper surface of the lower contact portion  210  to the upper surface of the lower cap layer portion  228 . In an alternative embodiment, the lower cap layer portion  228  may be a single crystal silicon formed using a fusion bonding process followed by grinding/polishing or SmartCut technology to remove the bulk of the bonded wafer. In this alternative embodiment, electrical contacts must be formed after fusion. In a further embodiment, a polished polysilicon device layer may be used. 
         [0053]      FIGS. 8 and 9  further show trenches  230  and  232  which may be etched after CMP of the lower cap layer portion  228 . The trench  230  extends from the upper surface of the lower cap layer portion  228  to the upper surface of the oxide layer  222  to define the lower middle contact portion  226 . The trench  232  includes a trench portion  234  that defines a lower out-of-plane electrode portion  236 , a trench portion  238  that defines a connector  240 , and a trench portion  242  that defines a lower contact portion  244  for the lower out-of-plane electrode portion  236 . 
         [0054]    A low stress nitride is then used to fill the trenches  230  and  232  with trench nitride portions  250  and  252  while a low stress nitride layer  254  is deposited on the upper surface of the lower cap layer portion  228  as shown in  FIGS. 10 and 11 . A thin oxide layer  256  is provided on the upper surface of the low stress nitride layer  254 . The thin oxide layer  256  and the nitride layer  254  are then patterned and etched resulting in the configuration of  FIGS. 12 and 13 . In  FIGS. 12 and 13 , a remainder  258  of the oxide layer  256  and a remainder  260  of the nitride layer  254  form a gasket  262  for an out-of plane electrode described more fully below. A remainder  264  of the oxide layer  256  and a remainder  266  of the nitride layer  254  form a gasket  268  for a contact the in-plane-electrode  208 . The lateral extent of the gaskets  262  and  268  when viewed in cross-section may be selected to provide the desired isolation characteristics for the components defined thereby. 
         [0055]    A thin epi-poly deposition layer  270  is then formed on the upper surface of the lower cap portion  228  and the upper surface of the gaskets  262  and  268  to form a middle cap layer portion  272  (see  FIGS. 14 and 15 ). The epi-poly deposition layer may be deposited in the manner described by Candler et al., “Long-Term and Accelerated Life Testing of a Novel Single-Wafer Vacuum Encapsulation for MEMS Resonators”,  Journal of Microelectricalmechanical Systems,  vol. 15, no. 6, December 2006. The middle cap layer portion  272  may be planarized if desired. 
         [0056]    Referring to  FIGS. 16 and 17 , after vent holes  274  are formed, an HF vapor etch release is performed which releases the middle cap layer portion  272  from the in-plane-electrode  208 . The etched portion of the oxide layer  222  between the upper surface of the in-plane-electrode  208  and the lower surface of the middle cap layer portion  272  thus sets the gap between the in-plane-electrode  208  and the lower surface of what will be the out-of-plane electrode. A clean high temperature seal is then performed in an epi reactor to seal the vent holes  274 . Alternatively, the vent holes  274  may be sealed using oxide, nitride, silicon migration, etc. The resulting configuration is shown in  FIGS. 18 and 19  wherein a layer portion  276  is formed above the middle cap layer portion  272 . 
         [0057]    A trench  280  and a trench  282  are then etched as depicted in  FIGS. 20 and 21 . The trench  280  extends from the upper surface of the layer portion  276  to the upper surface of the gasket  262  which acts as an etch stop. The trench  282  extends from the upper surface of the layer portion  276  to the upper surface of the gasket  268  which acts as an etch stop. A passivation layer  284 , which may be oxide, nitride, etc., is then deposited on the upper surface of the layer portion  276  as depicted in  FIGS. 22-23 . The deposited passivation material also fills the trenches  280  and  282  with passivation portions  286  and  288 . The passivation portion  286 , the gasket  262 , and the trench nitride portion  250  thus form a spacer defining an out-of-plane electrode  290 . 
         [0058]    The passivation layer  284  is then etched to create openings  292  and  294 . A metal layer may then be deposited on the passivation layer  284 , and etched to create bond pads or traces, resulting in a configuration such as the configuration of the pressure sensor  100  of  FIG. 1 . If desired, piezoresistors may also be deposited on the passivation layer  284 . 
         [0059]    The above described process may be modified in a number of ways to provide additional features. By way of example,  FIG. 24  depicts a wafer  300  at about the same process step as the wafer  200  in  FIG. 8 . The wafer  300  includes a handle layer  302 , a buried oxide layer  304 , a device layer  306 , an oxide layer  308 , and a lower middle cap layer portion  310 .  FIG. 24  further depicts electrode isolation trenches  312  and  314  which are used to isolate an out-of plane electrode portion  316  from the remainder of the lower middle cap layer portion  310 . The wafer  300  further includes release stop trenches  318  and  320 . The trenches  318  and  320  are formed by etching through the oxide layer  308  after the trenches  312  and  314  are formed. The trenches  318  and  320  are used to provide a time-independent cap footprint. 
         [0060]    By way of example,  FIG. 25  depicts the wafer  300  after release of the lower middle cap layer portion  310 . In  FIG. 25 , a silicon rich nitride has been deposited and etched to form release stop nitride portions  322  and  324  and electrode isolation nitride portions  326  and  328 . Additionally, vent holes  330  have been etched through the lower middle cap layer portion  310  and a portion of the oxide layer  308  has been etched. The foregoing steps are accomplished substantially in the same manner as similar steps described above with respect to  FIGS. 10-17 . 
         [0061]    The primary difference between the wafer  200  and the wafer  300 , however, is that the release stop nitride portions  322  and  324  formed in the oxide layer  308  function as an etch stop. Accordingly, once the etch of the oxide layer  308  reaches the release stop nitride portions  322  and  324 , no further etching of the oxide layer  308  occurs, even as the buried oxide layer  304  continues to be etched. Thus, while in the wafer  200  the area of the oxide layer  222  which is etched to release the lower cap layer portion  228  from the device layer  206  is a function of the positioning of the vent holes  274  (see  FIGS. 16-17 ) and a relatively uncontrolled etching process, the wafer  300  includes release stop nitride portions  322  and  324  which provide a precise footprint for the released portion of the lower middle cap layer portion  310 . 
         [0062]    A further modification of the process described with reference to  FIGS. 2-23  is depicted in  FIGS. 26-37 .  FIG. 26  depicts a wafer  350  at about the same process step as the wafer  200  in  FIG. 6 . The wafer  350  includes a handle layer  352 , a buried oxide layer  354 , a device layer  356 , and an oxide layer  358 . The wafer  300  is modified to provide a substrate electrical contact, however, by etching a trench  360  completely through the oxide layer  358 , the device layer  356 , and the buried oxide layer  354 . Then, formation of a lower cap layer portion  362  (see  FIG. 27 ) further forms an epi-poly contact portion  364  which extends to the handle layer  352 . CMP may be performed on the lower cap layer portion  362 . 
         [0063]    As depicted in  FIG. 28 , release stop trenches  366  and  368  are then etched through the lower cap layer portion  362  and the oxide layer  358  followed by etching of electrode isolation trenches  370  and  372  and contact isolation trenches  374  and  376  (see  FIG. 29 ). The isolation trenches  370 ,  372 ,  374 , and  376  extend only through the lower cap layer portion  362 . 
         [0064]    A low stress nitride is then used to fill the trenches  366 ,  368 ,  370 ,  372 ,  374 , and  376  with release stop nitride portions  378  and  380 , electrode isolation nitride portions  382  and  384 , and contact isolation portions  386  and  388  while a low stress nitride layer  390  is deposited on the upper surface of the lower cap layer portion  362  as shown in  FIG. 30 . A thin oxide layer  392  is provided on the upper surface of the low stress nitride layer  390  ( FIG. 31 ). The thin oxide layer  392  and the nitride layer  390  are then patterned and etched resulting in the configuration of  FIG. 32 .  FIG. 32  shows an electrode gasket  394 , a contact gasket  396 , and an etch stop gasket  398 . 
         [0065]    A thin epi-poly deposition layer  410  is then formed on the upper surface of the lower cap portion  362  and the upper surface of the gaskets  394 ,  396 , and  398  to form a middle cap layer portion  412 . The middle cap layer portion  412  may be planarized if desired. 
         [0066]    Referring to  FIG. 34 , after vent holes  414  are formed, an HF vapor etch release is performed which releases the middle cap layer portion  412  from the in-plane-electrode  416 . The etched portion of the oxide layer  358  between the upper surface of the in-plane-electrode  416  and the lower surface of the middle cap layer portion  412  is constrained by the release stop nitride portions  378  and  380 . A clean high temperature seal is then performed in an epi reactor to seal the vent holes  414 . The resulting configuration is shown in  FIG. 35  wherein a layer portion  418  is formed above the middle cap layer portion  412 . 
         [0067]    A trench  420  and a trench  422  are then etched as depicted in  FIG. 36 . The trench  420  extends from the upper surface of the layer portion  418  to the upper surface of the gasket  394  which acts as an etch stop. The trench  422  extends from the upper surface of the layer portion  418  to the upper surface of the gasket  396  which acts as an etch stop. A passivation layer  424 , which may be oxide, nitride, etc., is then deposited on the upper surface of the layer portion  418  as depicted in  FIG. 37 . The passivation layer  418  is etched to create an out-of-plane electrode opening (not shown) and an opening  426 . A metal layer may then be deposited on the passivation layer  424 , and etched to create a bond pad or trace  428 , as shown in  FIG. 38 . In  FIG. 38 , the bond pad  428  is in electrical communication with the handle layer  352  through an epi column  430 . 
         [0068]    The various processes described above allow for a variety of devices to be made simultaneously on the same substrate. By way of example,  FIG. 39  depicts a sensor device  450  that includes a handle layer  452 , a buried oxide layer  454 , a device layer  456 , an oxide layer  458 , a cap layer  460 , and a passivation layer  462 . The sensor device  450  further includes an electrode isolation portion  464 , contact isolation portions  466 , and release or etch stop nitride portions  468 . Thus, the same sequence described above may be used to form the sensor device  450   
         [0069]    The sensor device  450 , although made using the same process as, for example, the pressure sensor  100  of  FIG. 1 , is different from the embodiments described above. For example, the device  450  includes two pads  470  and  472  which provide for electrical communication with the device layer  456 . Thus, in-plane movement of a proof mass  474  may be detected. An optional third pad  476  may be provided if an out-of-plane electrode  478  is desired. Another difference in the sensor device  450  is that the electrode isolation nitride portions  464  include an extended apron  480 . 
         [0070]    By adding an interim step to the foregoing process, the accelerometer  490  of  FIG. 40  may be simultaneously fabricated along with the above described devices. The accelerometer  490  differs from the sensor device  450  of  FIG. 39  in that a release or etch stop nitride portion  492  is included to more precisely control the amount of etching within a buried oxide layer  494 . 
         [0071]    A process for forming a sensor such as the accelerometer  490  is discussed with reference to  FIGS. 41-62 . Referring initially to  FIG. 41 , an SOI wafer  500  including a handle layer  502 , a buried oxide layer  504 , and a device layer  506  is initially covered with an oxide layer  508 . Next, a photoresist layer  510  is provided on the upper surface of the oxide layer  508  ( FIG. 42 ). The wafer  500  is then etched to form etch stop trenches  512  through the photoresist layer  510 , the oxide layer  508 , and the device layer  506 . As shown in  FIG. 43 , the trenches  512  are then extended through the buried oxide layer  504  to the upper surface of the handle layer  502 . A plasma containing oxygen may be used to oxidize (“ash”) the photoresist layer  510 . 
         [0072]    As shown in  FIG. 44 , a nitride layer  514  is then deposited on the upper surface of the oxide layer  508 . Nitride deposition further results in filling the trenches  512  with nitride etch stop columns  516 . The nitride layer  514  is then etched using the oxide layer  508  as an etch stop resulting in the configuration of  FIG. 45 , followed by etching of the oxide layer  508  using the silicon device layer  506  as an etch stop resulting in the configuration of  FIG. 46 . 
         [0073]    Next, as shown in  FIG. 47 , structure defining trenches  518  are etched through the device layer  506 . The trenches  518  define device layer contact portions  520  and  522  along with a proof mass  524 . Sacrificial etch holes  526  are etched into the proof mass  524  as shown in  FIG. 48 . Referring to  FIG. 49 , a conformal oxide layer  530  is then deposited on the upper surface of the device layer  506 . The deposition of conformal oxide also fills the trenches  518  and the etch holes  526 . Openings  532  and  534  (see  FIG. 50 ) are then etched through the oxide layer  530  to expose the device layer contact portions  520  and  522 . 
         [0074]    An epi-poly deposition fills the contact openings  532  and  534  with lower middle contact portions  536  and  538  of epi-poly while depositing a lower cap layer portion  540  above the oxide layer  530  as shown in  FIG. 51 . CMP may be performed on the lower cap layer portion  540 . Next, as shown in  FIG. 52 , etch stop trenches  542  are formed through the lower cap layer portion  540  and the oxide layer  530 . If desired, out-of-plane electrode trenches  544  may be formed through the lower cap layer portion  540  (see  FIG. 53 ). 
         [0075]    A low stress nitride is then used to fill the trenches  542  and  544  with trench nitride portions  546  and  548  while a low stress nitride layer  550  is deposited on the upper surface of the lower cap layer portion  540  as shown in  FIG. 54 . The nitride portions  546  form an etch stop for a later etch. A thin oxide layer  552  is provided on the upper surface of the low stress nitride layer  550 . The thin oxide layer  552 , which will be used as an etch stop, and the nitride layer  550  are then patterned and etched resulting in the gasket  554  of  FIG. 56 . 
         [0076]    A thin epi-poly deposition layer  560  is then formed on the upper surface of the lower cap portion  540  and the upper surface of the gasket  554  to form a middle cap layer portion  562  (see  FIG. 57 ). The middle cap layer portion  562  may be planarized if desired. 
         [0077]    Referring to  FIGS. 58 and 59 , after vent holes  564  are formed, an HF vapor etch release is performed which releases the middle cap layer portion  562  from the proof mass  524 . Horizontal etching of the oxide layer  530  is limited by the etch stop nitride portions  546 . The sacrificial etch holes  526  allow the etch to release the proof mass  524  from the handle layer  502  by etching the buried oxide layer  504 . Horizontal etching of the buried oxide layer  534  is limited by the etch stop nitride columns  516 . 
         [0078]    A clean high temperature seal is then performed in an epi reactor to seal the vent holes  564 . The resulting configuration is shown in  FIG. 60  wherein a layer portion  566  is formed above the middle cap layer portion  562 . 
         [0079]    Trenches  568  and trenches  570  are then etched as depicted in  FIG. 61 . The trenches  570  extend from the upper surface of the layer portion  566  to the upper surface of the gasket  554 , the oxide layer portion of which acts as an etch stop. The trenches  568  extend from the upper surface of the layer portion  566  to the upper surface of the oxide layer  530  which acts as an etch stop. A passivation layer  572 , which may be oxide, nitride, etc., is then deposited on the upper surface of the layer portion  566  as depicted in  FIG. 62 . The passivation layer  572  is etched to create openings  574  and  576 , and optionally  578 . A metal layer may then be deposited on the passivation layer  572 , and etched to create bond pads or traces, resulting in a configuration such as the configuration of the accelerometer  490  of  FIG. 40 . 
         [0080]    The above described procedure and variations thereof allow for resonators, inertial sensors, and other such devices to be packaged at the wafer level while incorporating an electrically isolated, out-of-plane electrode into a thin-film cap. Other sensors which may be fabricated in accordance with principles discussed above include silicon cap pressure sensors. 
         [0081]    While the invention has been illustrated and described in detail in the drawings and foregoing description, the same should be considered as illustrative and not restrictive in character. It is understood that only the preferred embodiments have been presented and that all changes, modifications and further applications that come within the spirit of the invention are desired to be protected.

Technology Classification (CPC): 1