Patent Abstract:
A method of making a micro electromechanical switch or tunneling sensor. A cantilevered beam structure and a mating structure are defined on a first substrate or wafer; and at least one contact structure and a mating structure are defined on a second substrate or wafer, the mating structure on the second substrate or wafer being of a complementary shape to the mating structure on the first substrate or wafer. A bonding layer, preferably a eutectic bonding layer, is provided on at least one of the mating structures. The mating structure of the first substrate is moved into a confronting relationship with the mating structure of the second substrate or wafer. Pressure is applied between the two substrates so as to cause a bond to occur between the two mating structures at the bonding or eutectic layer. Then the first substrate or wafer is removed to free the cantilevered beam structure for movement relative to the second substrate or wafer.

Full Description:
TECHNICAL FIELD  
         [0001]    The present invention relates to micro electro-mechanical (MEM) tunneling sensors using dual wafers which are bonded together preferably eutectically.  
         RELATED APPLICATIONS  
         [0002]    This invention is related to other inventions which the subject of separate patent applications filed thereon. See: U.S. patent application Ser. No. ______ entitled “A Single Crystal, Dual Wafer, Tunneling Sensor or Switch with Silicon on Insulator Substrate and a Method of Making Same” (attorney docket 617965-3) and U.S. patent application Ser. No. ______ entitled “A Single Crystal, Dual Wafer, Tunneling Sensor or Switch with Substrate Protrusion and a Method of Making Same” (attorney docket 617337-2), both of which applications have the same filing date as this application. The inventors named in this application are the inventors of the first embodiment disclosed herein with reference to FIGS.  1 A- 12 B. However, subsequent improvements have been made which reflect what is believed to be the best modes for practicing the invention. As such, this application includes a disclosure of those improvements in the embodiments after FIG. 12B to ensure that the best mode requirements of 35 USC 111 first paragraph have been satisfied.  
         BACKGROUND OF THE INVENTION  
         [0003]    The present invention provides a new process of fabricating a single crystal silicon MEM tunneling devices using low-cost bulk micromachining techniques while providing the advantages of surface micromachining. The prior art, in terms of surface micromachining, uses e-beam evaporated metal that is patterned on a silicon dioxide (SiO 2 ) layer to form the control, self-test, and tip electrodes of a tunneling MEM sensor. A cantilevered beam is then formed over the electrodes using a sacrificial resist layer, a plating seed layer, a resist mold, and metal electroplating. Finally, the sacrificial layer is removed using a series of chemical etchants. The prior art for bulk micromachining has utilized either mechanical pins and/or epoxy for the assembly of multi-Si wafer stacks, a multi-Si wafer stack using metal-to-metal bonding and an active sandwiched membrane of silicon nitride and metal, or a dissolved wafer process on quartz substrates (Si-on-quartz) using anodic bonding. None of these bulk micromachining processes allow one to fabricate a single crystal Si cantilever (with no deposited layers over broad areas on the beam which can produce thermally mismatched expansion coefficients) above a set of tunneling electrodes on a Si substrate and also electrically connect the cantilever to pads located on the substrate. The fabrication techniques described herein provide these capabilities in addition to providing a low temperature process so that CMOS circuitry can be fabricated in the Si substrate before the MEMS sensors are added. Finally, the use of single crystal Si for the cantilever provides for improved process reproductibility for controlling the stress and device geometry.  
           [0004]    Tunneling sensors may be used in various military, navigation, automotive, and space applications. Space applications include satellite stabilization in which MEM sensor technology can significantly reduce the cost, power, and weight of the presently used gyro systems. Automotive air bag deployment, ride control, and anti-lock brake systems provide other applications for MEM sensors. Military applications include high dynamic range accelerometers and low drift gyros.  
         BRIEF DESCRIPTION OF THE INVENTION  
         [0005]    Generally speaking, the present invention provides a method of making a micro electromechanical sensor wherein a cantilevered beam structure and a mating structure are defined on a first substrate or wafer and at least one contact structure and a mating structure are defined on a second substrate or wafer. The mating structure on the second substrate or wafer is of a complementary shape to the mating structures on the first substrate or wafer. A bonding or eutectic layer is provided on at least one of the mating structures and the mating structure are moved into a confronting relationship with each other. Pressure is then applied between the two substrates and heat may also be applied so as to cause a bond to occur between the two mating structures at the bonding or eutectic layer. Then the first substrate or wafer is removed to free the cantilevered beam structure for movement relative to the second substrate or wafer. The bonding or eutectic layer also provides a convenient electrical path to the cantilevered beam for making a circuit with the contact formed on the cantilevered beam.  
           [0006]    In another aspect, the present invention provides an assembly or assemblies for making a single crystal silicon MEM sensor therefrom. A first substrate or wafer is provided upon which is defined a beam structure and a mating structure. A second substrate or wafer is provided upon which is defined at least one contact structure and a mating structure, the mating structure on the second substrate or wafer being of a complementary shape to the mating structure on the first substrate or wafer. A pressure and heat sensitive bonding layer is disposed on at least one of the mating structures for bonding the mating structure defined on the first substrate or wafer with the mating structure on the second substrate in response to the application of pressure and heat therebetween. 
       
    
    
     BRIEF DESCRIPTION OF THE FIGURES  
       [0007]    [0007]FIGS. 1A through 6A depict the fabrication of a first embodiment of the cantilever portion of a MEM sensor.  
         [0008]    [0008]FIGS. 1B through 6B correspond to FIGS.  1 A- 6 A, but show the cantilever portion, during its various stages of fabrication, in plan view:  
         [0009]    [0009]FIGS. 7A through 9A show, in cross section view, the fabrication of the base portion of the first embodiment tunneling sensor;  
         [0010]    [0010]FIGS. 7B through 9B correspond to FIGS.  7 A- 9 A but show the fabrication process for the base portion in plan view;  
         [0011]    [0011]FIGS. 10 and 11 show the cantilever portion and the base portion being aligned with each other and being bonded together preferably by eutectic bonding;  
         [0012]    [0012]FIGS. 12A and 12B show in a cross sectional view and in a plan view the completed tunneling sensor according to the first embodiment of the invention:  
         [0013]    [0013]FIGS. 13A and 14A depict steps used in fabricating a second embodiment of a the cantilever portion of a MEM sensor;  
         [0014]    [0014]FIGS. 13B and 14B correspond to FIGS. 13A and 14A, but show the cantilever portion, in plan view;  
         [0015]    FIGS.  15 A- 19 A depict, in cross section view, the fabrication of the base portion of the second embodiment of the tunneling sensor;  
         [0016]    FIGS.  15 B- 19 B correspond to FIGS.  15 A- 19 A, but show the fabrication process for the second embodiment of the wafer in plan view;  
         [0017]    [0017]FIGS. 20 and 21 show the cantilever and base portion embodiment being aligned with each other and bonded together preferably by eutectic bonding;  
         [0018]    [0018]FIGS. 22A and 23 show the completed MEM sensor according to the second embodiment in cross sectional view, while FIG. 22B shows the completed MEM sensor according to the second embodiment in plan sectional view;  
         [0019]    [0019]FIGS. 24A through 29A depict, in cross sectional view, a modification applicable to both the first and second embodiments of the cantilever portion of the MEM sensor;  
         [0020]    [0020]FIGS. 24B through 29B correspond to FIGS.  24 A- 29 A, but show the fabrication process for the modification in plan view;  
         [0021]    [0021]FIG. 30 depicts a side elevational section view of another embodiment of a MEM sensor, this embodiment having a preferably eutectic bond in a central region of its columnar support;  
         [0022]    [0022]FIG. 31 depicts a side elevational section view of yet another embodiment of a MEM sensor, this embodiment having a preferably eutectic bond adjacent the cantilevered beam  12 ;  
         [0023]    [0023]FIG. 32 depicts a side elevational section view of still another embodiment of a MEM sensor, this embodiment having a preferably eutectic bond in a central region of its columnar support as in the embodiment of FIG. 30, but also having a ribbon conductor on the cantilevered beam structure;  
         [0024]    [0024]FIG. 33 depicts a side elevational section view of another embodiment of a MEM sensor, t this embodiment having a preferably eutectic bond adjacent the cantilevered beam structure as in the case of the embodiment of FIG. 31, but also having a ribbon conductor on the cantilevered beam structure;  
         [0025]    [0025]FIG. 34 depicts a side elevational section view of still another embodiment of a MEM sensor, this embodiment having a preferably eutectic bond adjacent the cantilevered beam, but also utilizing a base structure having a silicon protrusion which forms part of the columnar support structure;  
         [0026]    [0026]FIG. 35 depicts a side elevational section view of yet another embodiment of a MEM sensor, this embodiment having a preferably eutectic bond adjacent the cantilevered beam and utilizing a base structure having a silicon protrusion which forms part of the columnar support structure as in the case of the embodiment of FIG. 34, but also utilizing a ribbon conductor on the cantilevered beam structure;  
         [0027]    [0027]FIG. 36 depicts a side elevational section view of another embodiment of a MEM sensor, this embodiment having a preferably eutectic bond in a central region of its columnar support as in the embodiment of FIG. 30, but also utilizing a base structure having a silicon protrusion which forms part of the columnar support structure;  
         [0028]    [0028]FIG. 37 depicts a side elevational section view of another embodiment of a MEM sensor, this embodiment having a preferably eutectic bond in a central region of its columnar support and a base structure having a silicon protrusion which forms part of the columnar support structure as in the embodiment of FIG. 36, but also utilizing a ribbon conductor on the cantilevered beam structure;  
         [0029]    [0029]FIG. 38 depicts a side elevational section view of an embodiment of a MEM switch, this embodiment being similar to the sensor embodiment of FIG. 32, but being equipped with an additional pad which is used to apply electrostatic forces to the beam to close the switch;  
         [0030]    [0030]FIG. 39 depicts a side elevational section view of another embodiment of a MEM switch, this embodiment being similar to the switch embodiment of FIG. 38, but the preferably eutectic bond occurs adjacent the cantilevered beam as opposed in a central region of the columnar support;  
         [0031]    [0031]FIG. 40 depicts a side elevational section view of yet another embodiment of a MEM switch, this embodiment being similar to the switch embodiment of FIG. 39, but also utilizing a base structure having a silicon protrusion which forms part of the columnar support structure for the cantilevered beam; and  
         [0032]    [0032]FIG. 41 depicts a side elevational section view of yet another embodiment of a MEM switch, this embodiment being similar to the switch embodiment of FIG. 40, but including an SiO 2  layer between the ribbon conductor and the Si of the cantilevered beam. 
     
    
     DETAILED DESCRIPTION  
       [0033]    Several embodiments of the invention will be described with respect to the aforementioned figures. The first embodiment will be described with reference to FIGS. 1A through 15. A second embodiment will be discussed with reference to FIGS. 16 through 23. Further additional embodiments and modifications are described thereafter. Since some of the fabrication steps are the same for many of the embodiments, reference will often be made to earlier discussed embodiments to reduce repetition. For example, the second embodiment makes reference to FIGS.  1 A- 4 B when describing the second embodiment to reduce repetition of that material.  
         [0034]    The MEM devices shown in the accompanying figures are not drawn to scale, but rather are drawn to depict the relevant structures for those skilled in this art. Those skilled in this art realize that these devices, while mechanical in nature, are very small and are typically manufactured using generally the same type of technology used to produce semiconductor devices. Thus a thousand or more devices might well be manufactured at one time on a silicon wafer. To gain an appreciation of the small scale of these devices, the reader may wish to turn to FIG. 15 which includes size information for a preferred embodiment of a MEM sensor utilizing the present invention.  
         [0035]    Turning to FIGS. 1A and 1B, a starting wafer for the fabrication of the cantilever is depicted. The starting wafer includes a wafer of bulk n-type silicon (Si)  10  upon which is formed a thin layer of doped p-type silicon  12 . The silicon wafer  10  is preferably of a single crystalline structure having a &lt;100&gt; crystalline orientation. The p-type silicon layer  12  is preferably grown as an epitaxial layer on silicon wafer  10 . The layer  12  preferably has a thickness of in the range of 1 to 20 micrometers (μm), but can have a thickness anywhere in the range of 0.1 μm to 800 μm. Generally speaking, the longer the cantilevered beam is the thicker the beam is. Since layer  12  will eventually form the cantilevered beam, the thickness of layer  12  is selected to suit the length of the beam to be formed.  
         [0036]    Layer  12  is doped with Boron such that its resistivity is reduced to less than 0.05 Ω-cm and is preferably doped to drop its resistivity to the range of 0.01 to 0.05 Ω-cm. The resistivity of the bulk silicon wafer or substrate  10  is preferably about 10 Ω-cm. Boron is a relatively small atom compared to silicon, and therefore including it as a dopant at the levels needed (10 20 ) in order to reduce the resistivity of the layer  12  tends to induce stress which is preferably compensated for by also doping, at a similar concentration level, a non-impurity atom having a larger atom size, such as germanium. Germanium is considered a non-impurity since it neither contributes nor removes any electron carriers in the resulting material.  
         [0037]    Layer  12  shown in FIGS. 1A and 1B is patterned using well known photolithographic techniques to form a mask layer, patterned as shown at numeral  14 , preferably to assume the shape of a capital letter ‘E’. While the shape of the capital letter ‘E’ is preferred, other shapes can be used. In this embodiment, the outer peripheral portion of the E-shape will form a mating structure which will be used to join the cantilever portion of the sensor to the base portion.  
         [0038]    After the mask layer  14  has been patterned as shown in FIGS. 2A and 2B, the wafer is subjected to a plasma etch in order to etch through the thin layer of p-type doped silicon  12  and also to over etch into the silicon wafer  10  by a distance of approximately 500 Å.  
         [0039]    The mask  14  shown in FIGS. 2A and 2B is then removed and another photoresist layer  16  is applied which is patterned as shown in FIGS. 3A and 3B by providing two openings therein  16 - 1  and  16 - 2 . Opening  16 - 1  basically follows the outer perimeter of the ‘E’ shape of the underlying thin layer of p-type silicon  12  while opening  16 - 2  is disposed at or adjacent a tip of the interior leg of the ‘E’-shaped p-type silicon layer  12 .  
         [0040]    Layers of Ti/Pt/Au are next deposited over mask  16  and through openings  16 - 1  and  16 - 2  to form a post contact  18 - 1  and a tunnelling tip contact  18 - 2 . The Ti/Pt/Au layers preferably have a total thickness of about 2000 Å. The individual layers of Ti and Pt may have thicknesses in the ranges of 100-200 Å and 1000-2000 Å, respectively. After removal of the photoresist  16 , the wafer is subjected to a sintering step at approximately 520° C. to form an ohmic Ti—Si juncture between contacts  18 - 1  and  18 - 2  and the underlying layer  12 .  
         [0041]    The structures shown in FIGS. 4A and 4B are then covered with a layer of photoresist  20  which, as shown in FIG. 5A, is patterned so that is assumes the same shape as did photoresist layer  16  previously discussed with reference to FIGS. 3A and 3B. Thus, photoresist layer  20  has an opening  20 - 1  and another opening  20 - 2  therein. Those skilled in the art will appreciate that the size of the openings  16 - 1 ,  16 - 2 ,  20 - 1  and  20 - 2  are not drawn to scale on the figures and that openings  16 - 2  and  20 - 2  would tend to be significantly smaller than would be openings  16 - 1  and  20 - 1 . As such, when a rather thick layer of Ti/Pt/Au is deposited on the wafer, it basically fills opening  20 - 1  (see FIG. 5A); however, those skilled in the art will appreciate that there is some fill-in at the sides of a mask when a layer such as layer  22  is deposited because of an increasing overhang which occurs at the edges of openings  20 - 1  and  20 - 2  as the deposition process proceeds. Since the width of the opening  20 - 1  is quite wide, the effect of the fill-in is not particularly important. However, since opening  20 - 2  is rather narrow to begin with, the deposited Ti/Pt/Au  22 , as shown at numeral  20 - 2 , assumes a pyramidal-like or conical-like shape. The thickness of the deposition of Ti/Pt/Au layer  22  is sufficiently thick to assure that layer  22  will close across the top of opening  20 - 2  during the deposition process. Finally, a relatively thin layer, preferably about 100Å thick, of Au/Si  24  is deposited on the structure and through opening  20 - 1  as depicted by numeral  24 - 1 .  
         [0042]    The photoresist  20  is then dissolved lifting of the layers  22  and  24  formed thereon and leaving the structure depicted by FIGS. 6A and 6B. The height of layers  22 - 1  and  24 - 1  above layer  12  is preferably on the order of 11,500 Å while the height of the pyramidal-like or conical structure  22 - 2  is preferable on the order of 8,500 Å. The cantilevered beam portion of the MEMS sensor of this first embodiment has now been formed, and thus we will now move onto the formation of the base structure for this first embodiment of the MEM sensor. As will be seen, layers  22 - 1  and  24 - 1  form a mating structure for mating the cantilevered beam portion with its base portion.  
         [0043]    The fabrication of the base portion will now be described. Turning first to FIGS. 7A and 7B, there is shown a wafer  30  with layers of silicon dioxide  32  and  34  formed on its major surfaces. The thickness of each layer  32  and  34  is preferably on the order of 1.0 micrometers. Next, a mask is formed by a layer of photoresist  36  which is applied and patterned as shown in FIGS. 8A and 8B to form openings  36 - 1 ,  36 - 2 ,  36 - 3  and  36 - 4  therein. Opening  36 - 1  basically corresponds in shape and configuration to opening  16 - 1  discussed with reference to FIGS. 3A and 3B. Similarly, opening  36 - 2  basically corresponds to opening  16 - 2  discussed with reference to FIGS. 3A and 3B. Openings  36 - 3  and  36 - 4  allow for the deposition of control and self test electrodes  38 - 3  and  38 - 4 . A layer of Ti/Pt/Au  38  is deposited on mask  36  and through the openings therein in order to form contact electrodes  38 - 1 ,  38 - 2 ,  38 - 3  and  38 - 4  on layer  34 . Photoresist layer  36  also has openings in it so that when layer  38  is deposited, connection pads  40  are also formed for each one of the electrodes as well as interconnecting ribbon conductors  42 . Preferably, a guard ring  44  is placed around tip electrode  36 - 2  and its associated ribbon conductor  42 - 2  and connection pad  40 - 2 . The guard ring is not shown in the elevation views for ease of illustration.  
         [0044]    The photoresist layer  36  is then removed lifting off the layer  38  deposited thereon and leaving the structure shown in FIGS. 9A and 9B. Contact  38 - 1  assumes the shape of the outer periphery of a letter E and provides a mating structure for joining with the similar-shaped mating structure  22 - 1 ,  24 - 1  of the cantilevered beam portion  2 .  
         [0045]    Turning to FIG. 10, the cantilevered beam portion  2 , preferably fabricated as described with reference to FIGS.  1 A- 6 B, is mechanically aligned relative to the base portion  4  fabricated as described with reference to FIGS.  7 A- 9 B. Of course, those skilled in the art will appreciate that the patterns shown on the surfaces of wafers  10  and  30  repeat many times over the surface of a wafer so that there are many cantilevered beam forming structures  2  comprising elements  221 ,  24 - 1 ,  12  and  22 - 2  and many corresponding base structures  4  comprising elements  38 - 1  through  38 - 4  which are manufactured for mating on the silicon wafers  10  and  30 . The two wafers are brought into alignment (See FIG. 11) and subjected to pressure and heating so as to cause a eutectic bond to occur between layer  24 - 1  and layer  38 - 1 . The pressure is developed preferably by applying a force of about 5,000 N at about 400° C. between three inch (7.5 cm) wafers  2 , 4  containing 1000 devices. Of course, the force needs to be adjusted depending n the size of the wafer and the total surface area to be bonded. If the bonding is done non-eutectically, the temperature used will be higher.  
         [0046]    Layers  24 - 1  and  38 - 1  have preferably assumed the shape of the outerperpherial edge of a capital letter ‘E’ and therefore the moveable contact  22 - 2  of the MEM sensor is well protected by this physical shape. After performing the bonding, silicon layer  10  is dissolved away to arrive at the resulting MEM sensor shown in FIGS. 12A and 12B. The silicon can be dissolved with ethylenediamine pyrocatechol (EDP). This leaves only the Boron doped silicon cantilevered beam  12  with its contact  22 - 2  and its supporting or mating structure  22 - 1  and  24 - 1  bonded to the base structure  4 . Preferable dimensions for the MEM sensor are given on FIG. 12A. The beam preferably has a length of 200 to 300 μm (0.2 to 0.3 mm).  
         [0047]    Instead of using EDP as the etchant, plasma etching can be used if a thin layer of SiO 2  is used, for example, as an etch stop between layer  12  and substrate  10 .  
         [0048]    A second embodiment of a MEM sensor will now be described. As in the case of the first embodiment, this discussion will begin with the fabrication of the cantilever beam portion  2 , then go onto a discussion of the base portion  4  and the preferable eutectic bonding and the completion of the MEM sensor. As will be seen, this second embodiment differs from the first embodiment by the manner in which the cantilevered beam is supported above base portion  4 .  
         [0049]    According to the second embodiment, the fabrication of the cantilever beam forming structure  2  starts as has been described with reference to FIGS. 1A through 4B of the first embodiment. Assuming that the fabrication steps discussed with reference to FIGS. 1A through 4B have been carried out, the structure depicted in FIGS. 4A and 4B will been obtained.  
         [0050]    Alternatively, post contact  18 - 1  may be formed by layers of Ti and Au (i.e without Pt), which would involve an additional masking step to eliminate the Pt layer from post contact  18 - 1 . However, in this alternative, the sintering would cause Si to migrate into the Au to form an Au/Si eutectic at the exposed portion of post contact  18 - 1  shown in FIGS. 4A and 4B. As a further alternative, the exposed portion of the post contact  18 - 1  shown in FIGS. 4A and 4B could simply be deposited as Au/Si eutectic, in which case the Pt layer in the post contact  18 - 1  could be optionally included. Post contact  18 - 1  may be eliminated if the subsequently described bonding between the cantilevered beam portion  2  and the base portion  4  occurs non-eutectically.  
         [0051]    As a result, the exposed portion of the post contact  18 - 1  shown in FIGS. 4A and 4B is formed, according to this embodiment preferably either by Au or by Au/Si.  
         [0052]    From that point, a layer of photoresist  20 ′ is put down and patterned to have a single opening  20 - 2  therein as shown in FIGS. 13A and 13B. A layer of gold  26 , having a thickness of 15,000 Å, is applied over the photoresist  20 ′ and the gold, as it deposits upon contact  18 - 2  through opening  20 - 2 , will assume a pyramidal-like or conical-like shape so as to form a pointed contact  26 - 2  due to the formation of an overhang at the opening  20 - 2  during the deposition of the gold layer  26 . After contact  26 - 2  is formed, the remaining photoresist  20 ′ is dissolved so that the cantilever beam structure then appears as shown in FIGS. 14A and 14B. Comparing FIGS. 14A and 14B of the second embodiment with FIGS. 6A and 6B of the first embodiment, the primary difference between the two embodiments is the absence of layers  22 - 1  and  24 - 1  in the second embodiment, so that the mating structure is provided by layer  18 - 1  in this embodiment.  
         [0053]    The fabrication of the base portion  4  of the second embodiment of the MEM sensor will now be described with reference to FIGS. 15A through 19B. Turning to FIGS. 15A and 15B, a wafer  30 ′ of silicon is shown upon which a layer of photoresist S 0  has been deposited and patterned to assume preferably the outerperipheral shape of a capital letter ‘E’. The exposed silicon is then subjected to an etch, etching it back approximately 20,000 Å, to define a protruding portion  30 - 1  of wafer  30 ′ under the patterned mask  50  of the photoresist. The photoresist mask  50  is then removed and wafer  30  is oxidized to form layers of oxide  52 ,  54  on its exposed surfaces. The oxide layers are each preferably about 1 μm thick. Of course, the end surfaces shown in FIG. 16A are not shown as being oxidized because it is assumed that the pattern shown in FIG. 16A is only one of a number of repeating patterns occurring across an entire wafer  30 ′.  
         [0054]    Turning to FIGS. 17A and 17B, a layer of photoresist  56  is applied having an opening therein  56 - 1  which again assumes the outerperipheral shape of a capital letter ‘E’, as previously described. Then, a layer of Ti/Pt/Au  58 , preferably having a thickness of 2,000 Å, is deposited through opening  56 - 1  followed by the deposition of a layer  60  of an Au/Si eutectic preferably with a 1,000 Å thickness. Layers  58 - 1  of Ti/Pt/Au and  60 - 1  of the Au/Si eutectic are thus formed, which layers preferably follow the outerperipheral shape of a capital letter ‘E’, as previously described. Of course, if the post contact  18 - 1  is formed of an Au/Si eutectic, then layer  60  may be formed of simply Au or simply omitted due to the presence of Au at the exposed layer  58 - 1 .  
         [0055]    Photoresist layer  56  is then removed and a layer  62  of photoresist is applied and patterned to have (i) openings  62 - 2 ,  62 - 3  and  62 - 4 , as shown in FIG. 18A, (ii) openings for pads  40 - 1  through  40 - 4  and their associated ribbon conductors  42  and (iii) an opening for guard ring  44  and its pad, as depicted in FIG. 18B. For the ease of illustration, the opening for guard ring  44  is not shown in FIG. 18A. As is shown by FIGS. 19A and 19B, a layer  38  of Ti/Pt/Au is deposited over the photoresist and through openings  62 - 2  through  62 - 4  forming contacts  38 - 3 ,  38 - 4  and  38 - 2  as shown in FIGS. 19A and 19B. Those contacts are interconnected with their associated pads  40 - 2  through  44 - 4  by the aforementioned ribbon conductors  42 , which contacts  40  and ribbon conductors  42  are preferably formed at the same time as contacts  38 - 3 ,  38 - 4  and  38 - 2  are formed. The outerperipheral layers  58 - 1  and  60 - 1  are also connected with pad  40 - 1  by an associated ribbon conductor  42 . The layer  62  of photoresist is removed so that the base portion appears as shown in FIGS. 19A and 19B. The protrusion  30 - 1 , which preferably extends approximately 20,000 Å high above the adjacent portions of wafer  30 ′, and the relatively thin layers  58 - 1  and  60 - 1  form the mating structure for the base portion  4 .  
         [0056]    Turning to FIG. 20, the cantilever beam forming portion  2  according to the second embodiment is now bonded to base portion  4 . As is shown in FIG. 20, the two wafers  10  and  30 ′ are brought into a confronting relationship so that their mating structure  18 - 1 ,  30 - 1 ,  58 - 1  and  60 - 1  are in alignment so that layers  18 - 1  and  60 - 1  properly mate with each other. Pressure and heat (preferably by applying a force of 5,000 N at 400° C. between three inch wafers  2 ,  4  having 1000 sensors disposed thereon) are applied so that eutectic bonding occurs between layers  18 - 1  and  60 - 1  as shown in FIG. 21. Thereafter, silicon wafer  10  is dissolved so that the MEM sensor structure shown in FIG. 22 is obtained. The p-type silicon layer  12  includes a portion  12 - 2  which serves as the cantilevered beam and another portion which is attached to the base portion  4  through the underlying layers. The gold contact  26 - 2  is coupled to pad  40 - 1  by elements  18 - 2 ,  12 - 2 ,  12 - 1 ,  18 - 1 ,  60 - 1 ,  58 - 1  and its associated ribbon conductor  42 . If the bonding is done non-eutectically, then higher temperatures will be required.  
         [0057]    [0057]FIG. 23 is basically identical to FIG. 22, but shows the MEM sensor in somewhat more detail and the preferred dimensions of the MEM sensor are also shown on this figure.  
         [0058]    It will be recalled that in both the first and second embodiment discussed above with respect to FIG. 4B, a layer of Ti/Pt/Au  18  was applied forming contacts  18 - 1  and  18 - 2  which were sintered in order to form an ohmic bond with Boron-doped cantilever  12 . It was noted that sintering could be avoided by providing a ribbon conductor between contacts  18 - 1  and  18 - 2 . Such a modification is now described in greater detail and is depicted starting with FIGS.  24 A and  24 B.  
         [0059]    According to this modification, the Si epitaxial layer  12  formed on silicon wafer  10  may be (i) doped with Boron or (ii) may be either undoped or doped with other impurities. If undoped (or doped with other impurities), then a thin etch stop layer  11  is used between the Si device layer  12  and the silicon wafer  10 . This configuration is called Silicon On Insulator (SOI). The etch stop layer  11 , if used, is preferably a layer of SiO 2  having a thickness of about 1-2 μm. This etch stop layer  11  will be used to release the cantilevered beam from wafer  10 . If layer  12  is doped with Boron, it is doped to reduce the resistivity of the epitaxial layer  12  to less than 0.05 Ω-cm. At that level of doping the epitaxial layer  12  can resist a subsequent EDP etch used to release the cantilevered beam from wafer  10 .  
         [0060]    Optionally, the silicon wafer  10  with the doped or undoped Si epitaxial layer  12  formed thereon (as shown in FIGS. 24A and 24B) may be subjected to thermal oxidation to form a relatively thin layer of SiO 2  on the exposed surface of layer  12 . Layer  12  is preferably about 1.2 μm thick (but it can be thinner or thicker depending upon the application). The thickness of the optional SiO 2  layer is preferably on the order of 0.2 μm. To arrive at this point, both major surfaces may be oxidized and the oxide stripped from the bottom layer, if desired. The optional oxide layer may be used to provide an even better barrier against the diffusion of Si from the beam into the Au of the tunneling tip formed at one end of the beam. This optional oxide layer may be used with any embodiment of the cantilevered beam, but is omitted from most of the figures for case of illustration. It does appear, however, in FIGS. 37 and 41 and is identified there by element number  70 .  
         [0061]    Turning now to FIGS. 25A and 25B, a layer of photoresist  14  is then applied on layer  12  (or on the optional oxide layer, if present) and patterned preferably to assume the same “E” letter shape as the layer photoresist  14  discussed with reference to FIGS. 2A and 2B. The structure shown in FIGS. 25A and 25B is then subjected to a plasma etch which etches through layers  11  and  12  into the silicon substrate  10  by approximately 500 Å. Then a layer of photoresist  16  is applied and patterned as shown by FIGS. 26A and 26B. The layer  16  of photoresist is patterned to assume basically the same arrangement and configuration as layer  16  discussed with respect to FIGS. 3A and 3B except that an additional opening  16 - 5  is included communicating between openings  61 - 1  and  16 - 2  to provide for the formation of a ribbon conductor  18 - 5  when a layer  18  of metals, preferably Ti/Pt/Au, is subsequently deposited on photoresist  16 . After depositing the layer  18 , the photoresist  16  is removed lifting off the portions of the layer  18  formed thereon, leaving portions  18 - 1 ,  18 - 2  and  18 - 5  of layer  18  on the underlying layer  12 , as shown in FIGS. 27A and 27B, or on the optional oxide layer, if present.  
         [0062]    After arriving at the structure shown in FIGS. 27A and 27B, a tunneling tip  22  is added by appropriate masking and deposition of Au or a layer of Ti/Pt/Au, for example, thereby arriving at the structure shown by FIGS. 28A and 28B. Depending on the configuration utilized, a member  22 - 1  (see FIG. 6A) could be deposited at the same time so that the MEM sensor would be completed as previously described with reference to FIGS. 10 and 11. If instead the silicon base  30  is formed with a protrusion  30 - 1  (see FIG. 16A, for example), then the deposition of member  22 - 1  can be omitted and the MEM sensor can be completed as previously described with reference to FIGS. 20 and 21. After bonding the structure depicted by FIGS.  28 A and  28 B to the base structure  4  of FIGS. 19A and 19B and releasing the silicon wafer  10  from the cantilevered beam, the structure shown by FIGS. 29A and 29B is arrived at. The cantilevered beam  12  is preferably released by performing two plasma etches. The first etch dissolves wafer  10  and the second etch removes the etch stop layer  11 .  
         [0063]    [0063]FIG. 30 shows yet another embodiment of a MEM sensor. In this case the MEM sensor is shown in its completed form. With the information already presented herein, those skilled in the art will not find it difficult to modify the detailed description already given to produce this embodiment and still further embodiments, all of which will now be discussed. In the embodiment of FIGS.  1 A- 12 B the preferable eutectic bond occurs close to the silicon substrate  10  between layers  24 - 1  and  38 - 1 . In the embodiment of FIG. 30, the preferable eutectic bond occurs closer to a center point in the supporting arm  80  between the Au and Au/Si layers. Otherwise this embodiment is similar to the first embodiment described with reference to FIGS.  1 A- 12 B. In the embodiment of FIG. 31, the preferable eutectic bond occurs between the Au and Au/Si layers which are arranged close to the cantilevered beam  12  as opposed to close to base  4  as in the case of the first embodiment described with reference to FIGS.  1 A- 12 B. In the case of the embodiments of FIGS. 30 and 31, the cantilevered beam  12  should have good conductivity so that it acts as a conduction path between contact  22 - 2  at the end of the beam  12  and contact  40 - 1  on the base  4  (See FIG. 12B). Preferably the resistivity of the boron doped silicon cantilevered beam  12  is less than 0.05 Ω-cm. Due to the low resistivity of the beam  12 , EDP may be used to etch away substrate  10  (see FIGS. 10 and 11 and the related description) Alternatively, an SOI wafer could be used and the SiO 2  layer  11  (FIGS.  24 A- 28 B) would be used as an etch stop layer to protect the beam  12  when etching away substrate  10 .  
         [0064]    Comparing the embodiments of FIGS. 10, 23,  29  and  30 , the embodiments of FIGS. 23 and 29 are preferred since they only need a relatively thin metal mating layer and provide a more rigid Si post or protrusion  30 - 1  for better stability.  
         [0065]    The embodiments of FIGS. 32 and 33 are similar to the embodiments of FIGS. 29 and 30, but these two embodiments make use of the ribbon conductor  18 - 5  described with reference to FIGS. 24A through 29B. For these embodiments, if layer is doped with Boron, the resistivity of the cantilevered beam  12  is preferably less than 0.05 Ω-cm. The ribbon conductor allows the use of higher resistivity silicon for the cantilevered beam  12 . If layer  12  is doped with Boron, then the cantilevered beam can be released from wafer  10  using EDP as the etchant. Alternatively, an SIO construction can be utilized with a SiO 2  stop layer  11  (See FIGS.  24 A- 28 B) utilized to protect the beam  12  while the substrate  10  is etched away.  
         [0066]    The embodiments of FIGS.  34 - 37  are similar to the embodiment of FIGS. 29, 31,  30  and  32 , respectively, except instead of using a planar substrate, a substrate with a silicon protrusion  30 - 1  is utilized as described with reference to the second embodiment (see FIGS.  13 A- 23  and the related description).  
         [0067]    Generally speaking, the embodiments of FIGS.  13 A- 23  and  34 - 37  are preferred for a MEM sensor since these embodiments, which all utilize the a base substrate  30 ′ with a silicon post or protrusion  30 - 1 , are believed to give the resulting sensors and switches better mechanical stability.  
         [0068]    The structure which has been described so far has been set up as a sensor. Those skilled in the art know not only how to utilize these structures as a sensor but also know how to modify these structures, when needed, to make them function as a switch. The sensor devices shown in the preceding figures are preferably used as accelerometers, although they can be used for other types of sensors (such as gyroscopes, magnetometers, etc.) or as switches, as a matter of design choice, and with appropriate modification when needed or desired.  
         [0069]    Four embodiments of a switch version of a MEM device in accordance with the present invention will now be described with reference to FIGS.  38 - 41 . In order to function as a switch, two metal pads  26 - 3  and  26 - 4  are deposited on the cantilevered beam structure  12  instead of a pointed contact  26 - 2 . In these embodiments the cantilevered beam is preferably formed of undoped silicon. When the switch closes, the metal pad  26 - 4  bridges two contacts  38 - 5  and  38 - 6 , which are deposited at the same time that layer  38  is deposited on the base structure  4 . The ribbon conductor  18 - 5  described with reference to FIGS. 24A through 29B is utilized, due to the relatively high resistivity of undoped Si, to bring an electrical connection with metal pad  26 - 3  down to the base substrate  4 . The switch is closed by imparting an electrostatic force on the cantilevered beam  12  by applying a voltage between metal pads  38 - 3  and  26 - 3 . That voltage causes the metal pad  26 - 4  to make a circuit connecting contacts  38 - 5  and  38 - 6  when the metal pad  26 - 4  makes physical contact with those two contacts when the switch closes. Otherwise these embodiments are similar to the previously discussed embodiments. It should be noted, however, that since the cantilevered beam  12  is preferably formed of undoped silicon, the EDP etchant will not prove satisfactory. Instead the SiO 2  etch stop layer  11  described with reference to FIGS.  24 A- 29 B is preferably used to protect the beam  12  when etching away substrate  10 .  
         [0070]    In FIG. 38 the switch is formed on a generally planar base  4  and the cantilevered beam is supported by a column  80  formed of deposited metals and the Au/Si eutectic. The Au/Si eutectic is arranged towards the middle of the column in this embodiment. In the embodiment of FIG. 39 the Au/Si eutectic is arranged closer to the beam  12 . In the embodiment of FIG. 40 the Au/Si eutectic layer is disposed next to the beam and in this embodiment the base structure  4  has a protrusion  30 - 1  which acts as a portion of the column  80  which supports the beam  12 . Of the switch embodiments, the embodiment of FIG. 40 is preferred for the same reason that sensors with a protrusion  30 - 1  in their base structures  4  are also preferred, namely, it is believed to give the resulting sensors and switches better mechanical stability.  
         [0071]    In FIG. 41 an SiO 2  layer  70  is shown disposed between beam  12  and layer  18 . Layer  18  preferably is formed of layers of Ti, Pt and Au. The Pt acts as a diffusion barrier to the Si to keep it from migrating into the Au contacts. If layer  18  does not provide adequate protection for whatever metal is used in making contacts, then the use of a diffusion barrier such a SiO 2  layer  70  would be appropriate.  
         [0072]    The structures shown in the drawings has been described in many instances with reference to a capital letter ‘E’. However, this shape is not particularly critical, but it is preferred since it provides good mechanical support for the cantilevered structure formed primarily by beam portion of layer  12 . Of course, the shape of the supporting structure or mating structure around cantilever beam  12  can be changed as a matter of design choice and it need not form the perimeter of the capital letter ‘E’, but can form any convenient shape, including circular, triangular or other shapes as desired.  
         [0073]    In the embodiment utilizing a ribbon conductor on the cantilevered beam  12 , the pads and contacts (e.g.  26 - 2  and  26 - 3 ) formed on the beam  12  are generally shown as being formed over the ribbon conductor  18 - 1 ,  18 - 2 ,  18 - 5 . The ribbon conductor on the beam can be routed in any convenient fashion and could butt against or otherwise make contact with the other metal elements formed on the cantilevered beam  12  in which case elements such as  26 - 2  and  26 - 3  could be formed directly on the beam  12  itself.  
         [0074]    The contacts at the distal ends of the cantilevered beams are depicted and described as being conical or triangular. Those skilled in the art will appreciate that those contacts may have other configurations and may be flat in some embodiments.  
         [0075]    Throughout this description are references to Ti/Pt/Au layers. Those skilled in the art will appreciate that this nomenclature refers to a situation where the Ti/Pt/Au layer comprises individual layers of Ti, Pt and Au. The Ti layer promotes adhesion, while the Pt layer acts as a barrier to the diffusion of Si from adjacent layers into the Au. Other adhesion layers such as Cr and/or other diffusion barrier layers such as a Pd could also be used or could alternatively be used. It is desirable to keep Si from migrating into the Au, if the Au forms a contact, since if Si diffuses into an Au contact it will tend to form SiO 2  on the exposed surface and, since SiO 2  is a dielectric, it has deleterious effects on the ability of the Au contact to perform its intended function. As such, a diffusion barrier layer such as Pt and/or Pd is preferably employed between an Au contact and adjacent Si material.  
         [0076]    The nomenclature Au/Si or Au—Si refers a mixture of Au and Si. The Au and Si can be deposited as separate layers with the understanding that the Si will tend to migrate at elevated temperature into the Au to form an eutectic. However, for ease of manufacturing, the Au/Si eutectic is preferably deposited as a mixture except in those embodiments where the migration of Si into Au is specifically relied upon to form Au/Si.  
         [0077]    Many different embodiments of a MEM device have been described. Most are sensors and some are switches. Many more embodiments can certainly be envisioned by those skilled in the art based the technology disclosed herein. But in all cases the base structure  4  is united with the cantilevered beam forming structure  2  by applying pressure and preferably also heat, preferably to cause an eutectic bond to occur between the then exposed layers of the two structures  2  and  4 . The bonding may instead be done non-eutectically, but then higher temperatures must be used. Since it is usually desirable to reduce and/or eliminate high temperature fabrication processes, the bonding between the two structures  2  and  4  is preferably done eutectically and the eutectic bond preferably occurs between confronting layers of Si and Au/Si.  
         [0078]    Having described the invention with respect to certain preferred embodiments thereof, modification will now suggest itself to those skilled in the art. The invention is not to be limited to the foregoing description, except as required by the appended claims.

Technology Classification (CPC): 1