Source: http://www.google.com/patents/US7372616?dq=6,977,809&ei=-AObT5vAOoSgiQL_5qznDg
Timestamp: 2017-02-22 20:38:49
Document Index: 323976022

Matched Legal Cases: ['Application No. 10', 'application No. 09', 'application No. 09', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 60', 'application No. 10', 'application No. 60', 'application No. 60', 'application No. 60']

Patent US7372616 - Complex microdevices and apparatus and methods for fabricating such devices - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inPatentsVarious embodiments of the invention are directed to various microdevices including sensors, actuators, valves, scanning mirrors, accelerometers, switches, and the like. In some embodiments the devices are formed via electrochemical fabrication (EFAB™)....http://www.google.com/patents/US7372616?utm_source=gb-gplus-sharePatent US7372616 - Complex microdevices and apparatus and methods for fabricating such devicesAdvanced Patent SearchTry the new Google Patents, with machine-classified Google Scholar results, and Japanese and South Korean patents.Publication numberUS7372616 B2Publication typeGrantApplication numberUS 11/139,391Publication dateMay 13, 2008Filing dateMay 27, 2005Priority dateDec 6, 2001Fee statusPaidAlso published asUS20050221529, US20090015903, US20100133952Publication number11139391, 139391, US 7372616 B2, US 7372616B2, US-B2-7372616, US7372616 B2, US7372616B2InventorsChristopher A. Bang, Adam L. Cohen, Michael S. Lockard, John D. EvansOriginal AssigneeMicrofabrica, Inc.Export CitationBiBTeX, EndNote, RefManPatent Citations (31), Non-Patent Citations (9), Referenced by (14), Classifications (22), Legal Events (2) External Links: USPTO, USPTO Assignment, EspacenetComplex microdevices and apparatus and methods for fabricating such devices
US 7372616 B2Abstract
1. A process for forming a multilayer microdevice, comprising:
(a) forming a layer comprising at least two materials on a substrate that may include one or more previously deposited layers, each comprising at least two materials, wherein one of the at least two materials is a structural material and another of the at least two materials is a sacrificial material;
(b) repeating the forming operation of “(a)” one or more times to form at least one subsequent layer, comprising at least two materials on at least one previously formed layer to build up a three-dimensional structure from a plurality layers;
wherein the forming of at least a plurity of layers, comprises:
(1) supplying a substrate;
(2) supplying a mask on a surface of the substrate having a desired pattern of openings through which a first material of the at least two materials can be effectively deposited or etched to yield a desired pattern of the first material;
(3) depositing the first material within the openings or etching the first material from the openings;
(4) removing the mask;
(5) depositing a second material of the at least two materials to fill the void in the deposited material; and
(6) planarizing the deposited first and second materials to provide a planarized layer; and
(c) after formation of the plurality of layers removing the sacrificial material from the deposited structural material, to reveal the three-dimensional structure,
wherein the microdevice includes a 3D tilt mirror.
2. The process of claim 1 wherein the depositing of the first material comprises electrodepositing the first material and the depositing of the second material comprises electrodepositing the second material.
3. The microdevice of claim 2 wherein the first and second deposited materials are metals.
4. The microdevice of claim 3 wherein the microdevice comprises a structure of overall dimension less than 1 centimeter with at least some design features having dimensions smaller than 500 microns.
5. The microdevice of claim 4 wherein at least some of the design features are smaller the 100 microns.
6. The microdevice of claim 5 wherein at least some of the design features are smaller than 25 microns.
7. The microdevice of claim 3 wherein the mirror comprises a rotatable structure with a reflective surface that is supported by at least one spring-like structure, wherein the spring-like structure is formed from the same material as that which forms the reflective surface.
8. The microdevice of claim 7 where the mirror can rotate around a first axis and about a second axis that is substantially perpendicular to the first axis, wherein the first axis is defined by first and second rod-like elements which produce a return force when twisted, wherein the first and second rod-like elements are supported by a loop shaped structure, which loop shaped structure is in turn supported by third and fourth rod-like elements which produce a return force when twisted, wherein the first and second rod-like elements are substantially co-linear along a first line and the third and fourth rod-like elements are substantially co-linear along a second line where-in the first and second lines are substantially perpendicular to one another.
9. The microdevice of claim 8 wherein the rotatable structure with the reflective surface has thickness dimension that is at least in part substantially thicker than the thickness dimension of the first and second rod-like elements, wherein portions of the rotatable structure may be thinner than a maximum thickness of the rotatable structure such that the moment of inertia of the rotatable structure is reduced.
10. The microdevice of claim 9 wherein the loop shaped structure has a thickness dimension that is substantially thicker than the thickness dimension of the third and forth rod-like elements.
11. The microdevice of claim 9 wherein the loop shaped structure has thickness dimension that is substantially thicker than the thickness dimension of the first and second rod-like elements.
12. The microdevice of claim 9 wherein the mirror is caused to rotate by activation of one or more of a plurality of electrodes located between the mirror and a substrate, wherein at least a plurality of the electrodes are separated from the substrate.
13. The microdevice of claim 12 wherein a parasitic capacitance of a circuit comprising the electrodes and the substrate is reduced from what the parasitic capacitance would have been if the electrodes were formed on the substrate.
14. The microdevice of claim 3 wherein the mirror is caused to rotate by activation of one or more of a plurity of electrodes located between a dielectric substrate and the mirror where each of the plurity of electrodes is formed from a plurality of layers with the configuration of structural material forming each electrode on each layer configured to provided closer proximity to the mirror when in an undeflected state in regions where tilting is less and further seperation in regions where the mirror tilts further during deflection such that the electrodes provide enhanced driving force without obstructing movement of the mirror.
15. The microdevice of claim 3 wherein a plane of a reflective surface of the mirror as formed is coincident with a boundary level of one of the layers.
This application is a continuation of U.S. Non-Provisional Patent Application No. 10/313,795 filed on Dec. 6, 2002 now U.S. Pat. No. 7,185,546 which in turn claims benefit to U.S. Provisional Patent Application Nos.: 60/364,261 filed on Mar. 13, 2002; 60/340,372 filed on Dec. 6, 2001; 60/379,133 filed on May 7, 2002; 60/415,371 filed on Oct. 1, 2002; 60/379,135 filed on May 7, 2002; 60/379,182 filed on May 7, 2002; 60/430,809 filed on Dec. 3, 2002; 60/379,184 filed on May 7, 2002; 60/415,374 25-A filed on Oct. 1, 2002; 60/392,531 filed on Jun. 27, 2002; 60/422,007 filed on Oct. 29, 2002; 60/422,982 filed on Nov. 1, 2002; 60/429,483 filed on Nov. 26, 2002; 60/429,484 filed on Nov. 26, 2002. Each of these applications is incorporated herein by reference as if set forth in full. U.S. patent application Ser. Nos. 60/379,177, filed on May 7, 2002, 60/379,130 filed on May 7, 2002, and 10/309,521, filed Dec. 3, 2002 are also incorporated herein by reference.
1. A. Cohen, G. Zhang, F. Tseng, F. Mansfeld, U. Frodis and P. Will, “EFAB: Batch production of functional, fully-dense metal parts with micro-scale features”, Proc. 9th Solid Freeform Fabrication, The University of Texas at Austin, p161, August 1998. 2. A. Cohen, G. Zhang, F. Tseng, F. Mansfeld, U. Frodis and P. Will; “EFAB: Rapid, Low-Cost Desktop Micromachining of High Aspect Ratio True 3-D MEMS”, Proc. 12th IEEE Micro Electro Mechanical Systems Workshop, IEEE, p244, January 1999. 3. A. Cohen, “3-D Micromachining by Electrochemical Fabrication”, Micromachine Devices, March 1999. 4. G. Zhang, A. Cohen, U. Frodis, F. Tseng, F. Mansfeld, and P. Will, “EFAB: Rapid Desktop Manufacturing of True 3-D Microstructures”, Proc. 2nd International Conference on Integrated MicroNanotechnology for Space Applications, The Aerospace Co., April 1999. 5. F. Tseng, U. Frodis, G. Zhang, A. Cohen, F. Mansfeld, and P. Will, “EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures using a Low-Cost Automated Batch Process”, 3rd International Workshop on High Aspect Ratio MicroStructure Technology (HARMST'99), June 1999. 6. A. Cohen, U. Frodis, F. Tseng, G. Zhang, F. Mansfeld, and P. Will, “EFAB: Low-Cost, Automated Electrochemical Batch Fabrication of Arbitrary 3-D Microstructures”, Micromachining and Microfabrication Process Technology, SPIE 1999 Symposium on Micromachining and Microfabrication, September 1999. 7. F. Tseng, G. Zhang, U. Frodis, A. Cohen, F. Mansfeld, and P. Will, “EFAB: High Aspect Ratio, Arbitrary 3-D Metal Microstructures using a Low-Cost Automated Batch Process”, MEMS Symposium, ASME 1999 International Mechanical Engineering Congress and Exposition, November, 1999. 8. A. Cohen, “Electrochemical Fabrication (EFABTM)”, Chapter 19 of The MEMS Handbook, edited by Mohamed Gad-El-Hak, CRC Press, 2002. 9. “Microfabrication - Rapid Prototyping's Killer Application”, pages 1-5 of the Rapid Prototyping Report, CAD/CAM Publishing, Inc., June 1999. The disclosures of these nine publications are hereby incorporated herein by reference as if set forth in full herein.
SUMMARY OF THE INVENTION An object of various aspects of the invention is to provide devices (e.g. structures, objects, parts, components, and the like) having improved characteristics.
FIGS. 31A-31C depicts various electrode and beam relationships according to different embodiments of the invention.
In alternative embodiments more then three pairs of capacitor plates may be used. In some embodiments a single pair of capacitor plates may suffice while in other embodiments many pairs of capacitor plates might be appropriate. In some embodiments the hermetic sealing techniques set forth in U.S. patent application Ser. No. 60/379,182 and in U.S. patent application Ser. No. 60/430,809 filed Dec. 4, 2002 having MEMGen Corporation Docket No. P-US021-B-MG may be used to form pressure sensors. In some alternative embodiments conductive leads 106 and 104 may extend from a wall of the sensor as opposed to through the base. In such alternative embodiments, if the walls form part of the conductive path that lead to a set of the capacitor plates, then the conductive lead for the other set of plates may be separated from the wall by a dielectric material where the dielectric material may be added to the structure after its formation or may be added to the structure during its formation such as during formation on a layer-by-layer basis by electrochemical fabrication. In still other embodiments the walls and the exposed surface of lid 112 may be of the dielectric material or a dielectric coated conductor. In still other embodiments fixed capacitor plates 118(a)-118(c) may be connected to a portion of the walls as opposed to being mounted on the base. In some embodiments the sensors may detect, for example, pressure, displacement, or function as enhanced-sensitivity accelerometers (assuming the lid 112 doesn't effective displacement significantly and that moveable plates 116(a)-116(c) have sufficient mass).
Though a check valve is illustrated in FIG. 10, a wide range of microfluidic devices are possible, including various pumps and valves. As an example of another fluid control device, FIG. 11, depicts a pressure controlled bellows valve that can be made using electrochemical fabrication. Application of positive and negative relative hydraulic or pneumatic pressure to the bellows 332 via channel 336 can cause the bellows 332 to seal against valve seat 334 to block fluid flow between chamber 338 and channel 342 A further example of a manufacturing process for a valve is illustrated in FIGS. 12A-12F. The valve illustrated in these figures is capable of proportional flow. In FIG. 12A, the valve has been fabricated partway using an electrochemical fabrication process of selective depositions, blanket depositions and planarization operations. FIG. 12A depicts the block of material as including a selective patterning of a sacrificial material 402 and a structural material 404. The embedded valve is shown as having a poppet 406, a valve seat 408, an inlet channel 412 and an outlet channel 414. FIG. 12B depicts that a portion of the sacrificial material 402 has been etched away using the top layer of structural material 404 as a temporary masking layer. In FIG. 12C the temporary masking layer has been planarized away and a layer of shape memory alloy 416 (SMA, e.g., nickel-titanium) has been deposited (e.g., by removing the substrate from the EFAB system and placing in a sputtering chamber). In FIG. 1D, the structure has been planarized, creating a layer that contains structural material 404, sacrificial material 402, and SMA 416. The pattern of the SMA material is defined by the apertures that were in the temporary masking layer and the resulting partial etch of sacrificial material illustrated in FIG. 12B and was selected to form bendable supports for the poppet 406 of structural material. It should be noted that these supports only occupy a portion of the gap between poppet and surrounding material (they do not form a continuous membrane). One result of this is that the upper and lower volumes of sacrificial material are interconnected to allow for etching of the upper volume. FIG. 12E illustrate that additional electrochemical fabrication steps have been performed to form a cap of structural material. Finally, in FIG. 12F the sacrificial material has been etched, forming fluid channels and cavities and freeing the SMA supports to move the poppet against the valve seat. The valve may be prepared for use by applying a force to the poppet (e.g., by deforming the cap so as to provide a springy membrane that pushes the poppet down) so as to preload the poppet against the valve seat, causing the valve to close and the SMA material to be deformed from its as-fabricated state. By heating the SMA supports (e.g., by heating the valve overall, or passing current through the SMA material), the SMA material will return to its original state, opening the valve. Proportional action may be obtained by controlling the amount of heating: a small amount of heating will open the valve only slightly, while a large amount will open it fully. It is noted that the inlet and outlet ports can be reversed from what is shown. In other embodiments shape memory alloys may be used in the formation cause biasing of various types of components. In still other embodiments the halting of electrochemical fabrication operations may be performed for the purpose of performing other operations that etching and SMA deposition.
U.S. application No. 09/488,142
U.S. application No. 09/755,985
U.S. application No. 60/379,136
U.S. application No. 60/379,131
U.S. application No. 60/379,132
U.S. application No. 60/329,654
U.S. application No. 60/379,129
U.S. application No. 60/379,134
An electrochemical fabrication process for producing three-dimensional
U.S. application No. 60/364,261
U.S. application No. 60/379,133
U.S. application No. 60/379,176
U.S. application No. 60/379,135
Methods of and Apparatus for Molding Structures Using Sacrificial Metal Patterns
Molded structures, methods of and apparatus for producing the molded
U.S. application No. 60/379,177
U.S. application No. 60/379,182
U.S. application No. TBD
Dkt No. P-U.S.021-B-MG
U.S. application No. 60/379,184
U.S. application No. 60/392531
U.S. application No. 60/415,374
U.S. application No. 10/271,574
U.S. application No. 60/422,008
U.S. application No. 60/422,007
U.S. application No. 60/422,982
Dkt No. P-U.S.042-B-MG
Dkt No. P-U.S.043-A-MG
Dkt No. P-U.S.044-A-MG
provided that may be monolithic, that may be formed from a plurality of
1. Multiple authors, The MEMS Handbook, edited by Mohamed Gad-El-Hak, CRC Press, 2002. 2. M. Madou, Fundamentals of Microfabrication, CRC Press, 2002. 3. Multiple authors, Micromechanics and MEMS, edited by William Trimmer, IEEE Press, 1997. Various other embodiments of the present invention exist. Some of these embodiments may be based on a combination of the teachings herein with various teachings incorporated herein by reference. Some embodiments may not use any blanket deposition process and/or they may not use a planarization process. Some embodiments may involve the selective deposition of a plurality of different materials on a single layer or on different layers. Some embodiments may use blanket deposition processes that are not electrodeposition processes. Some embodiments may use selective deposition processes on some layers that are not conformable contact masking processes and are not even electrodeposition processes. Some embodiments may use the non-conformable contact mask or non-contact masking techniques set forth in the above referenced U.S. Provisional Application corresponding to P-US042-B-MG.
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