Source: https://patents.google.com/patent/US8933769B2/en
Timestamp: 2019-04-25 00:42:08
Document Index: 458125394

Matched Legal Cases: ['Application No. 60', 'Application No. 60', 'Application No. 61', 'Application No. 07', 'Application No. 08', 'Application No. 08153138']

US8933769B2 - Three-dimensional microstructures having a re-entrant shape aperture and methods of formation - Google Patents
Three-dimensional microstructures having a re-entrant shape aperture and methods of formation Download PDF
US8933769B2
US8933769B2 US13/219,736 US201113219736A US8933769B2 US 8933769 B2 US8933769 B2 US 8933769B2 US 201113219736 A US201113219736 A US 201113219736A US 8933769 B2 US8933769 B2 US 8933769B2
US13/219,736
US20120189863A1 (en
2006-12-30 Priority to US87831906P priority Critical
2006-12-30 Priority to US87827806P priority
2007-12-28 Priority to US12/005,936 priority patent/US7656256B2/en
2007-12-28 Priority to US12/005,885 priority patent/US7649432B2/en
2008-10-29 Priority to US10925108P priority
2009-10-29 Priority to US12/608,870 priority patent/US8031037B2/en
2011-08-29 Priority to US13/219,736 priority patent/US8933769B2/en
2011-08-29 Application filed by Nuvotronics Inc filed Critical Nuvotronics Inc
2012-07-26 Publication of US20120189863A1 publication Critical patent/US20120189863A1/en
2014-02-06 Assigned to ROHM & HAAS ELECTRONIC MATERIALS LLC reassignment ROHM & HAAS ELECTRONIC MATERIALS LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: HOUCK, WILLIAM D., SHERRER, DAVID W.
2014-02-06 Assigned to ROHM & HAAS ELECTRONIC MATERIALS LLC reassignment ROHM & HAAS ELECTRONIC MATERIALS LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ZHOU, SHIFANG, SHERRER, DAVID W., NICHOLS, CHRISTOPHER A.
2014-07-11 Assigned to NUVOTRONICS, LLC reassignment NUVOTRONICS, LLC ASSIGNMENT OF ASSIGNORS INTEREST (SEE DOCUMENT FOR DETAILS). Assignors: ROHM AND HAAS ELECTRONIC MATERIALS LLC
2015-01-13 Publication of US8933769B2 publication Critical patent/US8933769B2/en
This application is a continuation of U.S. application Ser. No. 12/608,870 (filed Oct. 29, 2009), now U.S. Pat. No. 8,031,037, which is a continuation of U.S. patent application Ser. No. 12/005,936 (filed Dec. 28, 2007), now U.S. Pat. No 7,656,256, which claims the benefit of priority of Provisional Application No. 60/878,278, filed Dec. 30, 2006, and said U.S. patent application Ser. No. 12/608,870 is also a continuation of U.S. patent application Ser. No. 12/005,885 (filed Dec. 28, 2007), now U.S. Pat. No. 7,649,432, which claims priority to Provisional Application No. 60/878,319, filed Dec. 30, 2006, and additionally, said U.S. patent application Ser. No. 12/608,870 also claims the benefit of priority of Provisional Application No. 61/109,251, filed Oct. 29, 2008. The entire contents of all recited U.S. Patents and patent Applications are herein incorporated by reference.
The formation of three-dimensional microstructures by sequential build processes have been described, for example, in U.S. Pat. No. 7,012,489, to Sherrer et al. With reference to FIG. 1, the '489 patent discloses a coaxial transmission line microstructure 2 formed by a sequential build process. The microstructure is formed on a substrate 4, and includes an outer conductor 6, a center conductor 8 and one or more dielectric support members 10 which support the center conductor. The outer conductor includes a conductive base layer 12 forming a lower wall, conductive layers 14, 16 and 18 forming sidewalls, and conductive layer 20 forming an upper wall of the outer conductor. The volume 22 between the inner and outer conductors is air or vacuous, formed by removal of a sacrificial material from the structure which previously filled such volume,
Exemplary methods of forming the coaxial transmission line microstructure of FIG. 2 will now be described with reference to FIGS. 3-15. The transmission line is formed on a substrate 204 as shown in FIG. 3, which may take various forms. The substrate may, for example, be constructed of a ceramic, a dielectric, a semiconductor such as silicon or gallium arsenide, a metal such as copper or steel, a polymer or a combination thereof The substrate can take the form, for example, of an electronic substrate such as a printed wiring board or a semiconductor substrate, such as a silicon, silicon germanium, or gallium arsenide wafer. The substrate may be selected to have an expansion coefficient similar to the materials used in forming the transmission line, and should be selected so as to maintain its integrity during formation of the transmission line. The surface of the substrate on which the transmission line is to be formed is typically planar. The substrate surface may, for example, be ground, lapped and/or polished to achieve a high degree of planarity. Planarization of the surface of the structure being formed can be performed before or after formation of any of the layers during the process. Conventional planarization techniques, for example, chemical-mechanical-polishing (CMP), lapping, or a combination of these methods are typically used. Other known planarization techniques, for example, mechanical finishing such as mechanical machining, diamond turning, plasma etching, laser ablation, and the like, may additionally or alternatively be used.
A first layer 226a of a sacrificial photosensitive material, for example, a photoresist, is deposited over the substrate 204, and is exposed and developed to form a pattern 227 for subsequent deposition of the bottom wall of the transmission line outer conductor. The pattern includes a channel in the sacrificial material, exposing the top surface of the substrate 204. Conventional photolithography steps and materials can be used for this purpose. The sacrificial photosensitive material can be, for example, a negative photoresist such as Shipley BPR™ 100 or PHOTOPOSIT™ SN, commercially available from Rohm and Haas Electronic Materials LLC, those described in U.S. Pat. No. 6,054,252, to Lundy et al, or a dry film, such as the LAMINAR™ dry films, also available from Rohm and Haas. The thickness of the sacrificial photosensitive material layers in this and other steps will depend on the dimensions of the structures being fabricated, but are typically from 10 to 200 microns.
As shown in FIG, 4, a conductive base layer 212 is formed over the substrate 204 and forms a bottom wall of the outer conductor in the final structure. The base layer may be formed of a material having high conductivity, such as a metal or metal-alloy (collectively referred to as “metal”), for example copper, silver, nickel, aluminum, chromium, gold, titanium, alloys thereof, a doped semiconductor material, or combinations thereof, for example, multiple layers of such materials. The base layer may be deposited by a conventional process, for example, by plating such as electrolytic or electroless, or immersion plating, physical vapor deposition (PVD) such as sputtering or evaporation, or chemical vapor deposition (CVD). Plated copper may, for example, be particularly suitable as the base layer material, with such techniques being well understood in the art. The plating can be, for example, an electroless process using a copper salt and a reducing agent. Suitable materials are commercially available and include, for example, CIRCUPOSIT™ electroless copper, available from Rohm and Haas Electronic Materials LLC, Marlborough, Mass. Alternatively, the material can be plated by coating an electrically conductive seed layer, followed by electrolytic plating. The seed layer may be deposited by PVD over the substrate prior to coating of the sacrificial material 226 a. Suitable electrolytic materials are commercially available and include, for example, COPPER GLEAM™ acid plating products, available from Rohm and Haas Electronic Materials. The use of an activated catalyst followed by electroless and/or electrolytic deposition may be used. The base layer (and subsequent layers) may be patterned into arbitrary geometries to realize a desired device structure through the methods outlined.
The thickness of the base layer (and the subsequently formed other walls of the outer conductor) is selected to provide mechanical stability to the microstructure and to provide sufficient conductivity for the electrons moving through the transmission line. At microwave frequencies and beyond, structural and thermal conductivity influences become more pronounced, as the skin depth will typically be less than 1 μm. The thickness thus will depend, for example, on the specific base layer material, the particular frequency to be propagated and the intended application. For example, in instances in which the final structure is to be removed from the substrate, it may be beneficial to employ a relatively thick base layer, for example, from about 20 to 150 μm or from 20 to 80 μm, for structural integrity Where the final structure is to remain intact with the substrate, it may be desired to employ a relatively thin base layer which may be determined by the skin depth requirements of the frequencies used.
A layer 210 of a dielectric material is next deposited over the second sacrificial layer 226 b and the lower sidewall portions 214, as shown in FIG. 7. In subsequent processing, support structures are patterned from the dielectric layer to support the transmission line's center conductor to be formed. As these support structures will lie in the core region of the final transmission line structure, the support layer should be formed from a material which will not create excessive losses for the signals to be transmitted through the transmission line. The material should also be capable of providing the mechanical strength necessary to support the center conductor and should be relatively insoluble in the solvent used to remove the sacrificial material from the final transmission line structure. The material is typically a dielectric material selected from photosensitive-benzocyclobutene (Photo-BCB) resins such as those sold under the tradename Cyclotene (Dow Chemical Co.), SU-8 resist (MicroChem Corp.), inorganic materials, such as silicas and silicon oxides, SOL gels, various glasses, silicon nitride (Si3N4), aluminum oxides such as alumina (Al2O3), aluminum nitride (AlN), and magnesium oxide (MgO); organic materials such as polyethylene, polyester, polycarbonate, cellulose acetate, polypropylene, polyvinyl chloride, polyvinylidene chloride, polystyrene, polyamide, and polyimide, organic-inorganic hybrid materials such as organic silsesquioxane materials; a photodefinable dielectric such as a negative acting photoresist or photoepoxy which is not attacked by the sacrificial material removal process to be conducted. Of these, SU-8 2015 resist is typical. It is advantageous to use materials which can be easily deposited, for example, by spin-coating, roller coating, squeegee coating, spray coating, chemical vapor deposition (CVD) or lamination. The support layer 210 is deposited to a thickness that provides for the requisite support of the center conductor without cracking or breakage. In addition, the thickness should not severely impact subsequent application of sacrificial material layers from the standpoint of planarity. While the thickness of the dielectric support layer will depend on the dimensions and materials of the other elements of the microstructure, the thickness is typically from 1 to 100 microns, for example, about 20 microns.
Referring to FIG. 8, the dielectric material layer 210 of FIG. 7 is next patterned using standard photolithography and etching techniques to provide one or more dielectric support members 210′ for supporting the center conductor to be formed. In the illustrated device, the dielectric support members extend from a first side of the outer conductor to an opposite side of the center conductor. In another exemplary aspect, the dielectric support members may extend from the outer conductor and terminate at the center conductor. In this case, one end of each of the support members is formed over one or the other lower sidewall portion 214 and the opposite end extends to a position over the sacrificial layer 226 b between the lower sidewall portions. The support members 210′ are spaced apart from one another, typically at a fixed distance. The number, shape, and pattern of arrangement of the dielectric support members should be sufficient to provide support to the center conductor and its terminations while also preventing excessive signal loss and dispersion. In addition, the shape and periodicity or aperiodicity may be selected to prevent reflections at frequencies where low loss propagation is desired, as can be calculated using methods know in the art of creating Bragg gratings and filters, unless such function is desired. In the latter case, careful design of such periodic structures can provide filtering functions.
The apertures as illustrated are cylindrical in geometry. Other geometries may, of course, be used, for example, those having square, rectangular, triangular and ovular cross-sections. The aperture sidewalls may be vertical or non-vertical. Exemplary aperture structures are illustrated in FIG. 16A-16D. FIG. 16A shows an aperture 224 such as illustrated in FIG. 8 which has vertical sidewalls 228 and is cylindrical in geometry. It may be desired that the aperture have non-vertical sidewalls 228, for example, a reentrant profile such as illustrated in FIG. 16B-16D. Such structures are believed to provide a further strengthened joint between the elements of the completed microstructure as they mechanically lock in place the metal to be deposited in the aperture. This minimizes or prevents slippage of the metal filling the aperture. Such structures can also be created by using more than one layer, for example, layers 210′, 210″ as shown in FIG. 16D.
As illustrated in FIG. 10, the apertures 224 are filled and the center conductor 208 and middle sidewall portions 216 of the outer conductor are formed by depositing a suitable metal material into the channels formed in the sacrificial material 226 c. The apertures 224 may be filled in the same process and using the same material used in forming the middle sidewall portions and the center conductor. Optionally, the apertures may be filled in a separate process using the same or different materials used for the center conductor and middle sidewall portions. The metal material filling the apertures forms a joint between the dielectric support member 210′ and each of the center conductor and outer conductor for affixing the microstructural elements to one another. Appropriate materials and techniques for filling the apertures, and for forming the middle sidewall portions and center conductor are the same as those mentioned above with respect to the base layer 212 and lower sidewall portions 214, although different materials and/or techniques may be employed. Surface planarization may optionally be performed at this stage to remove any unwanted metal deposited on the top surface of the sacrificial material in addition to providing a flat surface for subsequent processing, as has been previously described and optionally applied at any stage,
With the basic structure of the transmission line being complete, additional layers may be added or the sacrificial material remaining in the structure may next be removed. The sacrificial material may be removed by known strippers based on the type of material used. In order for the material to be removed from the microstructure, the stripper is brought into contact with the sacrificial material. The sacrificial material may be exposed at the end faces of the transmission line structure. Additional openings in the transmission line such as described above may be provided to facilitate contact between the stripper and sacrificial material throughout the structure. Other structures for allowing contact between the sacrificial material and stripper are envisioned. For example, openings can be formed in the transmission line sidewalls during the patterning process. The dimensions of these openings may be selected to minimize interference with, scattering or leakage of the guided wave. The dimension can, for example, be selected to be less than ⅛, 1/10 or 1/20 of the wavelength of the highest frequency used. The impact of such openings can readily be calculated and can be optimized using software such as HFSS (High Frequency Structure Simulation) made by Ansoft, Inc.
The final transmission line structure 202 after removal of the sacrificial resist is shown in FIG. 15. The space previously occupied by the sacrificial material in and within the outer walls of the transmission line forms apertures 244 in the outer conductor and the transmission line core 222. The core volume is typically occupied by a gas such as air. It is envisioned that a gas having better dielectric properties may be used in the core. Optionally, a vacuum can be created in the core, for example, when the structure forms part of a hermetic package. As a result, a reduction in absorption from water vapor that would otherwise adsorb to the surfaces of the transmission lines can be realized. It is further envisioned that a liquid can occupy the volume 222 between the center conductor and outer conductor, as shown in FIG. 15.
FIG. 18 illustrates an additional exemplary aspect of the invention which further allows microstructural elements of the microdevice to be maintained in locked engagement with each other. This figure shows the microstructure after patterning of the dielectric support members 210′ in the manner described above. The dielectric support members are patterned with a geometry which also reduces the possibility of their pulling away from the outer conductor. In the exemplified microstructure, the dielectric support members are patterned in the form of a “T” shape during the patterning process. During subsequent processing as described above, the top portion 246 of the “T” becomes embedded in the wall of the outer conductor and acts as an anchor-type locking structure. While the illustrated structure includes an anchor-type locking structure at one end of the dielectric support members, it should be clear that multiple such structures may be used, for example, one at each end of the dielectric support members in an “I” shape. The described anchor-type structures may be used additionally or alternatively to one or more of the metallized apertures for locking the dielectric and metal microstructural elements together.
FIG. 19A-19H illustrates additional exemplary geometries which may be employed for the dielectric support members, including the one or more dielectric support members 210′described with reference to at least FIG. 2 and FIG. 18, in place of the “T” locking structures. For purposes of illustration, the structures are partial renderings of the support structures. The support structures may optionally include an anchor structure at an opposite end, which may be a mirror image of or a different geometry than the illustrated anchor structure. As a non-limiting example, one end of the dielectric support member may include a “Flat Head” locking structure as illustrated in FIG. 19A, an “Oval” locking structure as illustrated in FIG. 19B, a “Step” locking structure as illustrated in FIG. 19C, or a “Toothed” locking structure as illustrated in FIG. 19D, or a geometrically smaller version of the same locking structure at the opposite end. The opposite end of the support structure may alternatively include a “Y” locking structure as illustrated in FIG. 19E, an “Arrow” locking structure as illustrated in FIG. 19F, a “Circular” locking structure as illustrated in FIG. 19G, the “T” locking structure as illustrated in FIG. 19H, or an anchor structure including a different geometry than the illustrated anchor structure. The geometry selected should provide a change in cross-sectional geometry over at least a portion of the support member so as to be resistant to separation from the outer conductor. Reentrant profiles and other geometries providing an increase in cross-sectional geometry in the depthwise direction such as illustrated are typical. In this way, the dielectric support member becomes mechanically locked in place and has a greatly reduced likelihood of pulling away from the outer conductor wall. While the illustrated structures include a single anchor portion on one end thereof, multiple anchors, for example, on each end of the dielectric support, are envisioned. Without wishing to be bound by any particular theory, it is believed that in addition to providing mechanical locking effects, the anchor-locking structures improve adhesion as a result of reduced stress during exposure and development. It is also believed that thermally induced stresses during manufacture can be improved, for example, by removing sharp corners through the use of curvilinear shaping such as in FIG. 19B and 19G.
While the exemplified transmission lines include a center conductor formed over the dielectric support members with metallized apertures, it is envisioned that the 5 dielectric support members 210′ with metallized apertures 224 can be formed over the center conductor 208 in addition or as an alternative to the underlying dielectric support members as illustrated in FIG, 20A and 20B, which show non-reentrant and reentrant metalized apertures, respectively. In addition, the dielectric support members may be disposed within the center conductor such as in a split center conductor using a variety of 10 geometries, for example, a plus (+)-shape, a T-shape, a box or the geometries shown in FIGS. 16 and 19.
1. A method of forming a three-dimensional microstructure by a sequential build process, comprising:
disposing a plurality of layers over a substrate, wherein the layers comprise a layer of a non-conductive material, a layer of a conductive material and a layer of a sacrificial material;
forming a first microstructural element comprising the non-conductive material and having an aperture extending at least partially therethrough;
forming a second microstructural element comprising the conductive material;
depositing a conductive material in the aperture, affixing the first microstructural element to the second microstructural element; and
2. The method of claim 1, wherein the microstructure comprises a coaxial transmission line comprising a center conductor, an outer conductor and a non-conductive support member for supporting the center conductor, wherein the non-conductive support member is the first microstructural element, and the inner conductor and/or the outer conductor is the second microstructural element.
3. A three-dimensional microstructure, comprising:
a first microstructural element comprising a non-conductive material and having an aperture extending at least partially therethrough;
a second microstructural element comprising a conductive material;
a conductive material in the aperture affixing the first microstructural element to the second microstructural element; and
a non-solid volume to which the first microstructural element and/or the second microstructural element are exposed, wherein the aperture has a reentrant shape.
4. The three-dimensional microstructure of claim 3, wherein the aperture extends completely through the first microstructural element from a first surface to a second surface thereof.
5. The three-dimensional microstructure of claim 3, wherein the microstructure comprises a coaxial transmission line comprising a center conductor, an outer conductor and a non-conductive support member for supporting the center conductor, wherein the non-conductive support member is the first microstructural element, and the inner conductor and/or the outer conductor is the second microstructural element.
6. The three-dimensional microstructure of claim 5, wherein the non-solid volume is under vacuum or in a gas state, and is disposed between the center conductor and the outer conductor.
7. The three-dimensional microstructure of claim 5, wherein the coaxial transmission line has a generally rectangular coaxial geometry.
US13/219,736 2006-12-30 2011-08-29 Three-dimensional microstructures having a re-entrant shape aperture and methods of formation Active US8933769B2 (en)
US87831906P true 2006-12-30 2006-12-30
US12/005,936 US7656256B2 (en) 2006-12-30 2007-12-28 Three-dimensional microstructures having an embedded support member with an aperture therein and method of formation thereof
US12/005,885 US7649432B2 (en) 2006-12-30 2007-12-28 Three-dimensional microstructures having an embedded and mechanically locked support member and method of formation thereof
US10925108P true 2008-10-29 2008-10-29
US12/608,870 US8031037B2 (en) 2006-12-30 2009-10-29 Three-dimensional microstructures and methods of formation thereof
US13/219,736 US8933769B2 (en) 2006-12-30 2011-08-29 Three-dimensional microstructures having a re-entrant shape aperture and methods of formation
US14/563,018 US9515364B1 (en) 2006-12-30 2014-12-08 Three-dimensional microstructure having a first dielectric element and a second multi-layer metal element configured to define a non-solid volume
US12/608,870 Continuation US8031037B2 (en) 2006-12-30 2009-10-29 Three-dimensional microstructures and methods of formation thereof
US12/005,936 Continuation US7656256B2 (en) 2006-12-30 2007-12-28 Three-dimensional microstructures having an embedded support member with an aperture therein and method of formation thereof
US12/005,885 Continuation US7649432B2 (en) 2006-12-30 2007-12-28 Three-dimensional microstructures having an embedded and mechanically locked support member and method of formation thereof
US14/563,018 Continuation US9515364B1 (en) 2006-12-30 2014-12-08 Three-dimensional microstructure having a first dielectric element and a second multi-layer metal element configured to define a non-solid volume
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