Patent Description:
In principle, an arbitrary wave-front can be produced, for example, from a diffractive structure with high diffraction efficiency at the design wavelength. Such a diffractive structure typically has a surface relief depth which varies continuously over every 2π-phase interval. This phase profile, with a continuous depth, is not easily fabricated. Multi-level phase structures, however, can provide a compromise that results in relatively high diffraction efficiency and ease of fabrication. Further, optical elements having a multi-level structure (i.e., three levels or more) can, in some instances, provide greater functionality than single or dual-level structures. For example, a diffractive optical element (DOE) composed of three levels can, in some instances, exhibit better optical performance than a diffractive optical element that has only one or two levels.

A first task in an overall fabrication process includes generating a set of one or more masks that contains the phase profile information. A second task is to transfer the phase profile information from the masks into the surface of the element specified by the design of the optical element. In some manufacturing methods, a master (e.g., tool or mold) or sub-master is used to form multiple optical elements by replication, which refers to a technique by means of which a given structure is reproduced.

<CIT> describes an optical element using chromium deposits that form initial surface modulations on a substrate. After an immersion step, the remaining chromium can serve as an etching mask for a further etching process.

The present disclosure describes techniques for fabricating a multi-level structure. For example, in accordance with some implementations, the disclosure describes techniques for fabricating a multi-level master (e.g., tool or mold) from which optical elements (e.g., diffractive optical elements) can be replicated either directly or by way of a sub-master. The disclosure also describes multi-level optical elements and processes for making them.

According to claim <NUM>, the present disclosure describes a method for manufacturing an optical element or a master having a multi-level structure. The method includes providing a substrate that includes a first substrate portion and a second substrate portion. The first substrate portion is on the second substrate portion and has a composition that differs from a composition of the second substrate portion. The method includes forming first trenches through a surface of the substrate, wherein the first trenches extend through the first substrate portion and partially into the second substrate portion. After forming the first trenches, the method includes depositing a mask on portions of the surface of the substrate and subsequently forming second trenches through the surface of the substrate, wherein the second trenches are disposed in portions of the substrate on which the mask is not present, and wherein a depth of the first trenches differs from a depth of the second trenches. Forming the second trenches includes etching through the first substrate portion, wherein the second substrate portion serves as an etch stop during formation of the second trenches.

Some implementations include one or more of the following features. For example, in some implementations, the method further includes providing a passivation material that at least partially fills the first trenches and that covers the surface of the substrate, and depositing a mask on portions of the passivation material. In some cases, providing a passivation material that at least partially fills the first trenches includes conformally coating bottom and side surfaces of the first trenches with the passivation material. In some cases, the second trenches are formed after depositing the mask, wherein the second trenches are disposed in portions of the substrate on which the mask is not present. Further, in some cases, before forming the second trenches, portions of the passivation material not covered by the mask are removed. In some implementations, after forming the second trenches, the mask and the passivation material are removed.

In some implementations, the first substrate portion is composed at least in part of chromium and the second substrate portion is composed at least in part of silicon. The mask can be composed, for example, at least in part of a polymeric material. In some cases, the polymeric material is a resist. The passivation material can be composed, for example, at least in part of aluminum oxide. In some instances, at least partially filling the first trenches with a passivation material includes depositing the passivation material by atomic layer deposition.

The present disclosure also describes a master for replicating sub-masters or optical elements. The master includes a substrate having a first substrate portion and a second substrate portion. The first substrate portion is on the second substrate portion has a composition that differs from a composition of the second substrate portion. The substrate has a multi-level structure including at least three different levels. An upper surface of the second substrate portion defines a first one of the levels. A surface in a same plane as a boundary between the first and second substrate portions defines a second one of the levels. A surface in a plane between upper and lower surfaces of the first substrate portions defines a third one of the levels. In some implementations, the first substrate portion is composed at least in part of chromium, and the second substrate portion is composed at least in part of silicon.

The present disclosure also describes optical elements. For example, an optical element can include a substrate having a first substrate portion and a second substrate portion. The first substrate portion is on the second substrate portion has a composition that differs from a composition of the second substrate portion. The substrate has a multi-level structure including at least three different levels. An upper surface of the second substrate portion defines a first one of the levels. A surface in a same plane as a boundary between the first and second substrate portions defines a second one of the levels. A surface in a plane between upper and lower surfaces of the first substrate portions defines a third one of the levels. The depths and positions of the first, second and third levels with respect to one another can be configured, for example, to provide a predefined optical function.

The present disclosure also describes optoelectronic modules including an optical element that has a multi-level structure and that is aligned with an active optoelectronic component.

Other aspects, features and advantages will be readily apparent from the following detailed description, the accompanying drawings, and the claims.

As shown in <FIG>, a substrate <NUM> has a first substrate portion <NUM> and a second substrate portion <NUM>. The first substrate portion <NUM>, which is disposed on the second substrate portion <NUM>, has a thickness t. The first substrate portion <NUM> may be composed, for example, at least in part of chromium. In some implementations, the first substrate portion <NUM> may be composed of other materials. The second substrate portion <NUM> may be composed, for example, of silicon. However, in some implementations, the second substrate portion <NUM> may be composed of other materials (e.g., fused or polycrystalline silica, or one or more dielectrics or metallic materials). In some instances, the substrate <NUM> is a wafer in which a lateral dimension is substantially greater than its thickness. The substrate <NUM> has a substrate surface, which establishes a first level L1 of the multi-level structure.

As shown in <FIG>, the illustrated method includes creating first trenches <NUM> in the substrate <NUM>. The first trenches <NUM> have a first depth D1 from the substrate surface and extend through the thickness of the first substrate portion <NUM> and partially into the second portion <NUM>. The bottom of the first trenches <NUM> establishes another level for the multi-level structure. This level may be referred to as a third level L3. The first trenches <NUM> may be created, for example, by electron-beam lithography and etching, although other techniques may be used in some implementations. For some implementations, the first trenches <NUM> may range in width from a few nanometers to a few microns. In some instances, the dimensions of the first trenches <NUM> and their respective disposition may be related to a predetermined optical function, such as a diffractive optical function.

Next, as shown in <FIG>, the illustrated method includes partially filling the first trenches <NUM> (i.e., conformally coating the bottom and side surfaces of the first trenches) with passivation material <NUM>, and at the same time covering at least a portion of the substrate surface at level L1 with the passivation material. In some implementations, the passivation material <NUM> is composed at least in part of aluminum oxide. Other material may be used for the passivation material <NUM> in some implementations. The passivation material <NUM> may be deposited in the first trenches <NUM> and on top of the substrate surface, for example, by atomic layer deposition, although other techniques may be used in some implementations.

As further shown in <FIG>, the illustrated method also includes selectively providing a mask <NUM> on portions of the passivation material <NUM> on the substrate surface as well as on portions of the passivation material that conformally coats the first trenches <NUM>. The mask <NUM> may be composed, for example, at least in part of polymeric material such as a resist (e.g., a photoresist). In some cases, a mask material is coated onto the substrate surface (e.g., by spin coating), and then patterned (e.g., via standard lithography techniques) to form the mask <NUM>.

As shown in <FIG>, the illustrated method includes removing the passivation material <NUM> on the substrate surface that is not covered by the mask <NUM>. Likewise, the passivation material <NUM> that coats the bottom and side surfaces of the first trenches <NUM>, and that is not covered by the mask <NUM>, is removed. Removing the passivation material <NUM> can include, for example, argon sputtering. In the example of <FIG>, the passivation material that is not covered by the mask <NUM> is removed completely. In some instances, removing the passivation material can be performed by wet etching.

As shown in <FIG>, the illustrated method includes creating second trenches <NUM> through the substrate surface, such that the second trenches have a second depth D2 relative to the substrate surface (i.e., relative to level L1). The depth D2 may be equal to (or substantially equal to) the thickness t1 of the first portion <NUM> of the substrate <NUM>. The second trenches <NUM> are created in those regions of the substrate on which the mask <NUM> is not present. The second trenches <NUM> extend to the upper surface of the second portion <NUM> of the substrate <NUM>, such that the bottom of the second trenches <NUM> establishes a further level of the multi-level structure. This further level may be referred to as a second level L2. In the illustrated method the first trenches <NUM> are deeper than the second trenches <NUM>. That is, D1 > D2, and the second level L2 is closer to the first level L1 than is the third level L3.

The second trenches <NUM> may be created, for example, by etching. Preferably, the etch used to create the second trenches <NUM> does not (or does not significantly) result in etching of the second portion <NUM> of the substrate. That is, the second portion <NUM> preferably serves as an etch stop. As a result, the depth of the second trenches <NUM> can be precisely controlled. Further, by allowing the second portion <NUM> to serve as an etch stop with respect to the etch used during formation of the second trenches <NUM>, the etch used during formation of the second trenches <NUM> will not change the depth of the first trenches <NUM>, which can help maintain precise control over the final depth of the first trenches <NUM> as well.

Next, as shown in <FIG>, the illustrated method includes removing the material of the mask <NUM>, for example, by a stripping technique. Further, as shown in <FIG>, the illustrated method includes removing the remaining passivation material <NUM>, for example, by a stripping technique.

An advantage of providing the layer of passivation material <NUM> in some implementations is that it can help eliminate or reduce the need for high-precision alignment during the subsequent lithographic steps. Further, the presence of the passivation material <NUM> during etching of the second trenches <NUM> can help prevent lateral etching into the first substrate portion <NUM> (see <FIG>). Nevertheless, is some implementations, the passivation material <NUM> need not be provided, and the mask <NUM> can be deposited directly onto the substrate <NUM>.

The resulting structure <NUM>, as shown in the example of <FIG>, has three different levels: L1, L2, L3, where the second level L2 is deeper in the substrate than is the first level L1, and where the third level L3 is deeper in the substrate (i.e., further from the first level L1) than is the second level L2. The resulting multi-level structure <NUM> is formed in a substrate that is composed of two or more portions <NUM>, <NUM> disposed one over the other, where each portion is composed of a material that differs from the other portions. At least one of the levels in the multi-level structure <NUM> (i.e., the second level L2 in the illustrated example) is in the same plane as is the boundary between the first and second portions <NUM>, <NUM> of the substrate, which have different compositions from one another.

In some implementations, the resulting multi-level structure <NUM> may function as an optical element (e.g., a DOE), that is, an optical element that has a multi-level structure, where the number of levels is at least three. Depending on the materials of the multi-level structure, the optical element may be configured to be operable for use, e.g., with infra-red (IR) or visible radiation. The depths and positions of the various levels with respect to one other can be configured according to a predefined optical function.

In some implementations, an optical element having a multi-level structure as described above can be integrated into modules that house one or more optoelectronic devices (e.g., light emitting and/or light sensing devices). The optical element can be used to modify or redirect an emitted or incoming light wave as it passes through the optical element.

As shown, for example, in <FIG>, in some implementations, a light sensing module (for example, an ambient light sensor module) <NUM> includes an active optoelectronic device <NUM> mounted on a substrate <NUM>. The optoelectronic device <NUM> can be, for example, a light sensor (e.g., a photodiode, a pixel, or an image sensor) or a light emitter (e.g., a laser such as a vertical-cavity surface-emitting laser, or a light emitting diode). The module housing may include, for example, spacers <NUM> separating the optoelectronic device <NUM> and/or the substrate <NUM> from an optical element <NUM> having a multi-level structure as described above.

In the single-channel module of <FIG>, the optical element <NUM> can be disposed so as to intersect a path of incoming light or to intersect a path of outgoing light. The optical element can be aligned with the active optoelectronic component <NUM> and can be mounted to the housing. In some cases (e.g., where the optoelectronic component is a light sensor), light incident on the module <NUM> is modified or redirected by the optical element <NUM>. For example, in some cases, the optical element <NUM> modifies one or more characteristics of the light impinging on the optical element before the light is received and sensed by the optoelectronic component <NUM>. In some instances, for example, the optical element <NUM> may focus patterned light onto the optoelectronic component <NUM>. In some instances, the optical element <NUM> may split, diffuse and/or polarize the light before it is received and sensed by the optoelectronic component <NUM>.

In some cases (e.g., where the optoelectronic component <NUM> is a light emitter), light generated by the optoelectronic component <NUM> passes through the optical element <NUM> and out of the module. In the single-channel module of <FIG>, the optical element <NUM> can be disposed so as to intersect a path of the outgoing light <NUM>. The optical element <NUM> can modify or redirect the light. For example, in some cases, one or more characteristics of the light impinging on the optical element are modified before the light exits the module <NUM>. In some cases, the module <NUM> is operable to produce, for example, one or more of structured light, diffused light, or patterned light.

Multi-channel modules also can incorporate at least one optical element having a multi-level structure as described above. A shown in <FIG>, such a multi-channel module <NUM> can include, for example, a light sensor 902A and a light emitter 902B, both of which can be mounted on the same printed circuit board (PCB) or other substrate <NUM>. In the illustrated example, an optical element <NUM> having a multi-level structure as described above is mounted to the housing over the light emitter 902B. The multi-channel module can include a light emission channel and a light detection channel, which may be optically isolated from one another by a wall that forms part of the module housing. A lens <NUM> may be provided over the light sensor 902A.

In some instances, one or more of the modules described above may be integrated, for example, into mobile phones, laptops, televisions, wearable devices, or automotive vehicles.

In some implementations, the resulting multi-level structure <NUM> of <FIG> can serve as a master (e.g., a tool or mold), which can be used for making sub-masters or for replicating optical elements having a multi-level structure corresponding to that of the master. For example, in some implementations, the replicated optical elements have the same multi-level structure as the master, whereas in another implementations, the replicated optical elements have the inverse (i.e., a negative) of the master's multi-level structure. <FIG> illustrate operations that may be performed to replicate optical elements directly from a multi-level master (e.g., having a multi-level structure such as described above in connection with <FIG>). In this context, replication refers to a technique by means of which a given structure is reproduced. In particular, a structured surface can be embossed into a liquid or plastically deformable material (a "replication material"), then the material can be hardened, e.g., by curing using ultraviolet (UV) radiation or heating, and then the structured surface can be removed so that a negative of the structured surface (a replica) is obtained.

<FIG> illustrates an example of a master <NUM> having a multi-level structure as described above. The multi-level master <NUM> can be obtained, for example, by the method described in connection with <FIG>. Then, as shown in <FIG>, polymeric replication material (e.g., uncured epoxy) <NUM> is deposited between the multi-level master <NUM> and a replica substrate <NUM>. The multi-level master <NUM> and the replica substrate <NUM> are brought into close proximity so that the multi-level structure of the master <NUM> is pressed into the replication material <NUM>. The polymeric replication material <NUM> can be cured (e.g., by ultraviolet radiation exposure and/or thermally). <FIG> depicts a replica <NUM> of the multi-level master <NUM> formed in the cured replication material. The replica <NUM> includes a plurality of multi-level elements (e.g., optical elements such as DOEs). As indicated by <FIG>, the replica <NUM> is separated (e.g., by dicing along dicing lines <NUM>) so as to create multiple individual multi-level optical elements. One or more of the singulated optical elements, each of which has a multi-level structure corresponding to that of the master <NUM>, can be incorporated, for example, into single channel or multi-channel optoelectronic modules, such as those described above in connection with <FIG>.

In some implementations, the master <NUM> may be used to replicate sub-masters, which then are used to replicate multi-level optical elements.

Claim 1:
A method for manufacturing an optical element or a master having a multi-level structure, the method comprising:
providing a substrate (<NUM>) that includes a first substrate portion (<NUM>) and a second substrate portion (<NUM>), the first substrate portion (<NUM>) being on the second substrate portion (<NUM>), and the first substrate portion (<NUM>) having a composition that differs from a composition of the second substrate portion (<NUM>);
forming first trenches (<NUM>) through a surface of the substrate (<NUM>), wherein the first trenches (<NUM>) extend through the first substrate portion (<NUM>) and partially into the second substrate portion (<NUM>),
after forming the first trenches, depositing a mask on portions of the surface of the substrate;
subsequently forming second trenches through the surface of the substrate (<NUM>), wherein the second trenches are disposed in portions of the substrate on which the mask is not present, wherein a depth (D1) of the first trenches (<NUM>) differs from a depth (D2) of the second trenches (<NUM>), and
wherein forming the second trenches (<NUM>) includes etching through the first substrate portion(<NUM>), wherein the second substrate portion (<NUM>) serves as an etch stop during formation of the second trenches (<NUM>).