Patent ID: 8858811

Claim:
A method for manufacturing a mirror device comprising deflectable mirrors supported on a deflectable hinge extending vertically along approximately a perpendicular direction from a substrate wherein the method comprises: forming electrodes on the substrate and covering the electrodes with an insulation layer wherein the step of forming the electrodes further comprising a step of forming the electrodes having a horizontally and outwardly extended convex-shaped extension horizontally extended away from the hinge with sharp-edge upper corner with significantly reduced contacting area for contacting and stopping the deflectable mirrors of the mirror device; forming a first and a second sacrificial layers covering over the insulation layer; opening a vertical trench penetrating through the first sacrificial layer and the second sacrificial layer and depositing a deflectable hinge material into the vertical trench; forming the deflectable mirror by depositing a reflective layer directly on top of the second sacrificial layer wherein the reflective layer directly contacting a top surface of the hinge material deposited in the vertical trench; and removing the first and second sacrificial layers to expose the insulation layer covering the electrodes and the hinge material constituting the vertical hinge for supporting and deflecting the mirror to different deflection angles and stopped by the contacting points of the electrodes contact the deflectable mirrors.