Patent Grant
9128277
In general, the invention relates to the field of imaging displays, in particular, the invention relates to designs of light modulators to address stresses imparted on beams incorporated therein during the manufacturing of those beams.
Displays built from mechanical light modulators are an attractive alternative to displays based on liquid crystal technology. Mechanical light modulators are fast enough to display video content with good viewing angles and with a wide range of color and grey scale. Mechanical light modulators have been successful in projection display applications, and have recently been proposed for direct view applications. There is a need in the art for fast, bright, low-powered mechanically actuated displays. Specifically, there is a need for mechanically actuated displays that can be driven at high speeds and at low voltages for improved image quality and reduced power consumption.
According to one aspect, the invention relates to a spatial light modulator that includes a substrate and a modulation assembly coupled to the substrate. The modulation assembly includes a modulation element and a compliant beam. The modulation assembly is configured to limit the bending of the compliant beam towards an opposing surface that would otherwise be caused by inherent stresses within the compliant beam. In one embodiment, the limitation of bending yields an intended beam rest position. In another embodiment, the compliant beam is shaped to promote the bending of the beam being limited by the modulation assembly configuration.
In another embodiment, the compliant beam has first and second ends and is coupled to the substrate at a first anchor. For example, in one embodiment, the compliant beam is coupled to the first anchor at the first end. In another example, the compliant beam is shaped to extend away from the first anchor from the first end and curve back towards the first anchor towards the second end. In another example, the compliant beam is coupled to the first anchor between the first and second ends. In another example, the compliant beam is further coupled to the substrate at a second anchor.
In another embodiment, the compliant beam has first and second ends that couple to a common anchor deposited on the substrate. The shape of the compliant beam forms a loop. For example, in one embodiment, the loop has a first loop portion extending away from the common anchor and a second loop portion returning to the common anchor. The length of the first loop portion may be substantially greater than the length of the second loop portion. The first loop portion and/or the second loop portion may include a secondary loop.
In another embodiment, the modulation assembly includes a second compliant beam. Both the compliant beam and the second compliant beam attach to the modulation element.
In another embodiment, the modulation assembly includes a stationary structure that is not coupled to the compliant beam, where the stationary structure limits the bending of the compliant beam. For example, in one embodiment, the stationary structure includes a sliding surface.
In another embodiment, a plurality of attachment points couple the compliant beam to the substrate at positions on the compliant beam selected to promote the bending of the beam being limited by the modulation assembly configuration.
In another embodiment, the compliant beam includes first and second beam materials coupled to one another. The first beam material has a first stress state, and the second beam material has a second, different stress state, thereby promoting the bending of the beam being limited by the modulation assembly configuration.
According to another aspect, the invention relates to a method of manufacturing a spatial light modulator. The method includes the steps of forming a modulation assembly that includes a modulation element and a compliant beam and releasing the modulation assembly. The compliant beam is formed in a pre-release position to have an intended inherent stress state. As a result of the stress state in the compliant beam, upon release of the compliant beam, the compliant beam bends into a rest position which is different than the pre-release position. The rest position is based in part on the intended inherent stress state. In one embodiment, the inherent stress state includes a stress gradient. In another embodiment, upon release, the beam bends into an intended rest position.
In another embodiment, the compliant beam includes first and second faces, each perpendicular to a surface of a substrate. The intended inherent stress state includes stress components local to the first face that substantially differ from stress components local to the second face. For example, in one embodiment, the magnitude of the stress components local to the first face are greater than the stress components local to the second face. In another example, stress components local to the first face are tensile while stress components local to the second face are compressive.
In another embodiment, the intended inherent stress state is selected such that a portion of the compliant beam, in the rest position, is separated from an opposing surface by no more than a predetermined distance. Upon actuation, the compliant beam is drawn towards the opposing surface.
In another embodiment, the intended inherent stress state is selected such that a portion of the compliant beam, in the rest position, is separated from an opposing surface by at least a predetermined distance. Upon actuation, the compliant beam is drawn towards the opposing surface.
In another embodiment, the intended inherent stress state is selected such that a portion of the compliant beam, in the rest position, is separated from an opposing surface by no more than a predetermined distance. Upon actuation, the compliant beam is drawn away from the opposing surface.
In another embodiment, the intended inherent stress state is selected such that a portion of the compliant beam in the rest position is separated from an opposing surface by at least a predetermined distance. Upon actuation, the compliant beam is drawn away from the opposing surface. For example, in one embodiment, the beam, in its rest position, is curved.
In another embodiment, the step of forming the modulation assembly includes forming the compliant beam by coupling first and second beam materials to one another. The first beam material has a first stress state. The second beam material has a second, different stress state. In another embodiment, the step of forming the modulation assembly includes forming the compliant beam to have a first shape prior to releasing the modulation assembly and to have a different shape in the rest position.
The foregoing discussion will be understood more readily from the following detailed description of the invention with reference to the following drawings:
To provide an overall understanding of the invention, certain illustrative embodiments will now be described, including apparatus and methods for displaying images. However, it will be understood by one of ordinary skill in the art that the systems and methods described herein may be adapted and modified as is appropriate for the application being addressed and that the systems and methods described herein may be employed in other suitable applications, and that such other additions and modifications will not depart from the scope hereof.
In the display apparatus 100, each light modulator 102 corresponds to a pixel 106 in the image 104. In other implementations, the display apparatus 100 may utilize a plurality of light modulators to form a pixel 106 in the image 104. For example, the display apparatus 100 may include three color-specific light modulators 102. By selectively opening one or more of the color-specific light modulators 102 corresponding to a particular pixel 106, the display apparatus 100 can generate a color pixel 106 in the image 104. In another example, the display apparatus 100 includes two or more light modulators 102 per pixel 106 to provide grayscale in an image 104. With respect to an image, a “pixel” corresponds to the smallest picture element defined by the resolution of the image. With respect to structural components of the display apparatus 100, the term “pixel” refers to the combined mechanical and electrical components utilized to modulate the light that forms a single pixel of the image.
Display apparatus 100 is a direct-view display in that it does not require imaging optics. The user sees an image by looking directly at the display apparatus 100. In alternate embodiments the display apparatus 100 is incorporated into a projection display. In such embodiments, the display forms an image by projecting light onto a screen or onto a wall. In projection applications the display apparatus 100 is substantially smaller than the projected image 104.
Direct-view displays may operate in either a transmissive or reflective mode. In a transmissive display, the light modulators filter or selectively block light which originates from a lamp or lamps positioned behind the display. The light from the lamps is optionally injected into a light guide or “backlight”. Transmissive direct-view display embodiments are often built onto transparent or glass substrates to facilitate a sandwich assembly arrangement where one substrate, containing the light modulators, is positioned directly on top of the backlight. In some transmissive display embodiments, a color-specific light modulator is created by associating a color filter material with each modulator 102. In other transmissive display embodiments colors can be generated, as described below, using a field sequential color method by alternating illumination of lamps with different primary colors.
Each light modulator 102 includes a shutter 108 and an aperture 109. To illuminate a pixel 106 in the image 104, the shutter 108 is positioned such that it allows light to pass through the aperture 109 towards a viewer. To keep a pixel 106 unlit, the shutter 108 is positioned such that it obstructs the passage of light through the aperture 109. The aperture 109 is defined by an opening patterned through a reflective or light-absorbing material.
The display apparatus also includes a control matrix connected to the substrate and to the light modulators for controlling the movement of the shutters. The control matrix includes a series of electrical interconnects (e.g., interconnects 110, 112, and 114), including at least one write-enable interconnect 110 (also referred to as a “scan-line interconnect”) per row of pixels, one data interconnect 112 for each column of pixels, and one common interconnect 114 providing a common voltage to all pixels, or at least to pixels from both multiple columns and multiples rows in the display apparatus 100. In response to the application of an appropriate voltage (the “write-enabling voltage, Vwe”), the write-enable interconnect 110 for a given row of pixels prepares the pixels in the row to accept new shutter movement instructions. The data interconnects 112 communicate the new movement instructions in the form of data voltage pulses. The data voltage pulses applied to the data interconnects 112, in some implementations, directly contribute to an electrostatic movement of the shutters. In other implementations, the data voltage pulses control switches, e.g., transistors or other non-linear circuit elements that control the application of separate actuation voltages, which are typically higher in magnitude than the data voltages, to the light modulators 102. The application of these actuation voltages then results in the electrostatic driven movement of the shutters 108.
In other cases the data drivers 154 are configured to apply only a reduced set of 2, 3, or 4 digital voltage levels to the control matrix. These voltage levels are designed to set, in digital fashion, either an open state or a closed state to each of the shutters 108.
The scan drivers 152 and the data drivers 154 are connected to digital controller circuit 156 (also referred to as the “controller 156”). The controller 156 includes an input processing module 158, which processes an incoming image signal 157 into a digital image format appropriate to the spatial addressing and the gray scale capabilities of the display 100. The pixel location and gray scale data of each image is stored in a frame buffer 159 so that the data can be fed out as needed to the data drivers 154. The data is sent to the data drivers 154 in mostly serial fashion, organized in predetermined sequences grouped by rows and by image frames. The data drivers 154 can include series to parallel data converters, level shifting, and for some applications digital to analog voltage converters.
The display 100 apparatus optionally includes a set of common drivers 153, also referred to as common voltage sources. In some embodiments the common drivers 153 provide a DC common potential to all light modulators within the array of light modulators 103, for instance by supplying voltage to a series of common interconnects 114. In other embodiments the common drivers 153, following commands from the controller 156, issue voltage pulses or signals to the array of light modulators 103, for instance global actuation pulses which are capable of driving and/or initiating simultaneous actuation of all light modulators in multiple rows and columns of the array 103.
All of the drivers (e.g., scan drivers 152, data drivers 154, and common drivers 153) for different display functions are time-synchronized by a timing-control module 160 in the controller 156. Timing commands from the module 160 coordinate the illumination of red, green and blue and white lamps (162, 164, 166, and 167 respectively) via lamp drivers 168, the write-enabling and sequencing of specific rows within the array of pixels 103, the output of voltages from the data drivers 154, and the output of voltages that provide for light modulator actuation.
The controller 156 determines the sequencing or addressing scheme by which each of the shutters 108 in the array 103 can be re-set to the illumination levels appropriate to a new image 104. Details of suitable addressing, image formation, and gray scale techniques can be found in U.S. patent application Ser. Nos. 11/326,696 and 11/643,042, incorporated herein by reference. New images 104 can be set at periodic intervals. For instance, for video displays, the color images 104 or frames of video are refreshed at frequencies ranging from 10 to 300 Hertz. In some embodiments the setting of an image frame to the array 103 is synchronized with the illumination of the lamps 162, 164, and 166 such that alternate image frames are illuminated with an alternating series of colors, such as red, green, and blue. The image frames for each respective color is referred to as a color sub-frame. In this method, referred to as the field sequential color method, if the color sub-frames are alternated at frequencies in excess of 20 Hz, the human brain will average the alternating frame images into the perception of an image having a broad and continuous range of colors. In alternate implementations, four or more lamps with primary colors can be employed in display apparatus 100, employing primaries other than red, green, and blue.
In some implementations, where the display apparatus 100 is designed for the digital switching of shutters 108 between open and closed states, the controller 156 determines the addressing sequence and/or the time intervals between image frames to produce images 104 with appropriate gray scale. The process of generating varying levels of grayscale by controlling the amount of time a shutter 108 is open in a particular frame is referred to as time division gray scale. In one embodiment of time division gray scale, the controller 156 determines the time period or the fraction of time within each frame that a shutter 108 is allowed to remain in the open state, according to the illumination level or gray scale desired of that pixel. In other implementations, for each image frame, the controller 156 sets a plurality of sub-frame images in multiple rows and columns of the array 103, and the controller alters the duration over which each sub-frame image is illuminated in proportion to a gray scale value or significance value employed within a coded word for gray scale. For instance, the illumination times for a series of sub-frame images can be varied in proportion to the binary coding series 1, 2, 4, 8 . . . . The shutters 108 for each pixel in the array 103 are then set to either the open or closed state within a sub-frame image according to the value at a corresponding position within the pixel's binary coded word for gray level.
In other implementations, the controller alters the intensity of light from the lamps 162, 164, and 166 in proportion to the gray scale value desired for a particular sub-frame image. A number of hybrid techniques are also available for forming colors and gray scale from an array of shutters 108. For instance, the time division techniques described above can be combined with the use of multiple shutters 108 per pixel, or the gray scale value for a particular sub-frame image can be established through a combination of both sub-frame timing and lamp intensity. Details of these and other embodiments can be found in U.S. patent application Ser. No. 11/643,042, referenced above.
In some implementations the data for an image state 104 is loaded by the controller 156 to the modulator array 103 by a sequential addressing of individual rows, also referred to as scan lines. For each row or scan line in the sequence, the scan driver 152 applies a write-enable voltage to the write enable interconnect 110 for that row of the array 103, and subsequently the data driver 154 supplies data voltages, corresponding to desired shutter states, for each column in the selected row. This process repeats until data has been loaded for all rows in the array. In some implementations the sequence of selected rows for data loading is linear, proceeding from top to bottom in the array. In other implementations the sequence of selected rows is pseudo-randomized, in order to minimize visual artifacts. And in other implementations the sequencing is organized by blocks, where, for a block, the data for only a certain fraction of the image state 104 is loaded to the array, for instance by addressing only every 5th row of the array in sequence.
In some implementations, the process for loading image data to the array 103 is separated in time from the process of actuating the shutters 108. In these implementations, the modulator array 103 may include data memory elements for each pixel in the array 103 and the control matrix may include a global actuation interconnect for carrying trigger signals, from common driver 153, to initiate simultaneous actuation of shutters 108 according to data stored in the memory elements. Various addressing sequences, many of which are described in U.S. patent application Ser. No. 11/643,042, can be coordinated by means of the timing control module 160.
In alternative embodiments, the array of pixels 103 and the control matrix that controls the pixels may be arranged in configurations other than rectangular rows and columns. For example, the pixels can be arranged in hexagonal arrays or curvilinear rows and columns. In general, as used herein, the term scan-line shall refer to any plurality of pixels that share a write-enabling interconnect.
The display 100 is comprised of a plurality of functional blocks including the timing control module 160, the frame buffer 159, scan drivers 152, data drivers 154, and drivers 153 and 168. Each block can be understood to represent either a distinguishable hardware circuit and/or a module of executable code. In some implementations the functional blocks are provided as distinct chips or circuits connected together by means of circuit boards and/or cables. Alternately, many of these circuits can be fabricated along with the pixel array 103 on the same substrate of glass or plastic. In other implementations, multiple circuits, drivers, processors, and/or control functions from block diagram 150 may be integrated together within a single silicon chip, which is then bonded directly to the transparent substrate holding pixel array 103.
The controller 156 includes a programming link 180 by which the addressing, color, and/or gray scale algorithms, which are implemented within controller 156, can be altered according to the needs of particular applications. In some embodiments, the programming link 180 conveys information from environmental sensors, such as ambient light or temperature sensors, so that the controller 156 can adjust imaging modes or backlight power in correspondence with environmental conditions. The controller 156 also comprises a power supply input 182 which provides the power needed for lamps as well as light modulator actuation. Where necessary, the drivers 152153, 154, and/or 168 may include or be associated with DC-DC converters for transforming an input voltage at 182 into various voltages sufficient for the actuation of shutters 108 or illumination of the lamps, such as lamps 162, 164, 166, and 167.
MEMS Light Modulators
Each actuator 205 includes a compliant load beam 206 connecting the shutter 202 to a load anchor 208. The load anchors 208 along with the compliant load beams 206 serve as mechanical supports, keeping the shutter 202 suspended proximate to the surface 203. The load anchors 208 physically connect the compliant load beams 206 and the shutter 202 to the surface 203 and electrically connect the load beams 206 to a bias voltage, in some instances, ground.
Each actuator 205 also includes a compliant drive beam 216 positioned adjacent to each load beam 206. The drive beams 216 couple at one end to a drive beam anchor 218 shared between the drive beams 216. The other end of each drive beam 216 is free to move. Each drive beam 216 is curved such that it is closest to the load beam 206 near the free end of the drive beam 216 and the anchored end of the load beam 206.
The surface 203 includes one or more apertures 211 for admitting the passage of light. If the shutter assembly 200 is formed on an opaque substrate, made for example from silicon, then the surface 203 is a surface of the substrate, and the apertures 211 are formed by etching an array of holes through the substrate. If the shutter assembly 200 is formed on a transparent substrate, made for example of glass or plastic, then the surface 203 is a surface of a light blocking layer deposited on the substrate, and the apertures are formed by etching the surface 203 into an array of holes 211. The apertures 211 can be generally circular, elliptical, polygonal, serpentine, or irregular in shape.
In operation, a display apparatus incorporating the light modulator 200 applies an electric potential to the drive beams 216 via the drive beam anchor 218. A second electric potential may be applied to the load beams 206. The resulting potential difference between the drive beams 216 and the load beams 206 pulls the free ends of the drive beams 216 towards the anchored ends of the load beams 206, and pulls the shutter ends of the load beams 206 toward the anchored ends of the drive beams 216, thereby driving the shutter 202 transversely towards the drive anchor 218. The compliant members 206 act as springs, such that when the voltage across the beams 206 and 216 is removed, the load beams 206 push the shutter 202 back into its initial position, releasing the stress stored in the load beams 206.
The shutter assembly 200, also referred to as an elastic shutter assembly, incorporates a passive restoring force, such as a spring, for returning a shutter to its rest or relaxed position after voltages have been removed. A number of elastic restore mechanisms and various electrostatic couplings can be designed into or in conjunction with electrostatic actuators, the compliant beams illustrated in shutter assembly 200 being just one example. Other examples are described in U.S. patent application Ser. Nos. 11/251,035 and 11/326,696, incorporated herein by reference. For instance, a highly non-linear voltage-displacement response can be provided which favors an abrupt transition between “open” vs “closed” states of operation, and which, in many cases, provides a bi-stable or hysteretic operating characteristic for the shutter assembly. Other electrostatic actuators can be designed with more incremental voltage-displacement responses and with considerably reduced hysteresis, as may be preferred for analog gray scale operation.
The actuator 205 within the elastic shutter assembly is said to operate between a closed or actuated position and a relaxed position. The designer, however, can choose to place apertures 211 such that shutter assembly 200 is in either the “open” state, i.e. passing light, or in the “closed” state, i.e. blocking light, whenever actuator 205 is in its relaxed position. For illustrative purposes, it is assumed below that elastic shutter assemblies described herein are designed to be open in their relaxed state.
In many cases it is preferable to provide a dual set of “open” and “closed” actuators as part of a shutter assembly so that the control electronics are capable of electrostatically driving the shutters into each of the open and closed states.
Display apparatus 100, in alternative embodiments, includes light modulators other than transverse shutter-based light modulators, such as the shutter assembly 200 described above. For example,
In one embodiment, the tap element 256 is formed as part of beam 258 of flexible, transparent material. Electrodes 260 coat portions of one side of the beam 258. Opposing electrodes 260 are disposed on the light guide 254. By applying a voltage across the electrodes 260, the position of the tap element 256 relative to the light guide 254 can be controlled to selectively extract light 252 from the light guide 254.
The roller-based light modulator 220 and light tap 250 are not the only examples of MEMS light modulators suitable for inclusion in various embodiments of the invention. It will be understood that other MEMS light modulators can exist and can be usefully incorporated into the invention.
U.S. patent application Ser. Nos. 11/251,035 and 11/326,696 have described a variety of methods by which an array of shutters can be controlled via a control matrix to produce images, in many cases moving images, with appropriate gray scale. In some cases, control is accomplished by means of a passive matrix array of row and column interconnects connected to driver circuits on the periphery of the display. In other cases it is appropriate to include switching and/or data storage elements within each pixel of the array (the so-called active matrix) to improve either the speed, the gray scale and/or the power dissipation performance of the display.
The control matrix 300 is fabricated as a diffused or thin-film-deposited electrical circuit on the surface of a substrate 304 on which the shutter assemblies 302 are formed. The control matrix 300 includes a scan-line interconnect 306 for each row of pixels 301 in the control matrix 300 and a data-interconnect 308 for each column of pixels 301 in the control matrix 300. Each scan-line interconnect 306 electrically connects a write-enabling voltage source 307 to the pixels 301 in a corresponding row of pixels 301. Each data interconnect 308 electrically connects a data voltage source, (“Vd source”) 309 to the pixels 301 in a corresponding column of pixels 301. In control matrix 300, the data voltage Vd provides the majority of the energy necessary for actuation of the shutter assemblies 302. Thus, the data voltage source 309 also serves as an actuation voltage source.
Referring to
In operation, to form an image, the control matrix 300 write-enables each row in the array 320 in a sequence by applying Vwe to each scan-line interconnect 306 in turn. For a write-enabled row, the application of Vwe to the gates of the transistors 310 of the pixels 301 in the row allows the flow of current through the data interconnects 308 through the transistors 310 to apply a potential to the actuator 303 of the shutter assembly 302. While the row is write-enabled, data voltages Vd are selectively applied to the data interconnects 308. In implementations providing analog gray scale, the data voltage applied to each data interconnect 308 is varied in relation to the desired brightness of the pixel 301 located at the intersection of the write-enabled scan-line interconnect 306 and the data interconnect 308. In implementations providing digital control schemes, the data voltage is selected to be either a relatively low magnitude voltage (i.e., a voltage near ground) or to meet or exceed Vat (the actuation threshold voltage). In response to the application of Vat to a data interconnect 308, the actuator 303 in the corresponding shutter assembly 302 actuates, opening the shutter in that shutter assembly 302. The voltage applied to the data interconnect 308 remains stored in the capacitor 312 of the pixel 301 even after the control matrix 300 ceases to apply Vwe to a row. It is not necessary, therefore, to wait and hold the voltage Vwe on a row for times long enough for the shutter assembly 302 to actuate; such actuation can proceed after the write-enabling voltage has been removed from the row. The capacitors 312 also function as memory elements within the array 320, storing actuation instructions for periods as long as is necessary for the illumination of an image frame.
The pixels 301 as well as the control matrix 300 of the array 320 are formed on a substrate 304. The array includes an aperture layer 322, disposed on the substrate 304, which includes a set of apertures 324 for respective pixels 301 in the array 320. The apertures 324 are aligned with the shutter assemblies 302 in each pixel. In one implementation the substrate 304 is made of a transparent material, such as glass or plastic. In another implementation the substrate 304 is made of an opaque material, but in which holes are etched to form the apertures 324.
Components of shutter assemblies 302 are processed either at the same time as the control matrix 300 or in subsequent processing steps on the same substrate. The electrical components in control matrix 300 are fabricated using many thin film techniques in common with the manufacture of thin film transistor arrays for liquid crystal displays. Available techniques are described in Den Boer, Active Matrix Liquid Crystal Displays (Elsevier, Amsterdam, 2005), incorporated herein by reference. The shutter assemblies are fabricated using techniques similar to the art of micromachining or from the manufacture of micromechanical (i.e., MEMS) devices. Many applicable thin film MEMS techniques are described in Rai-Choudhury, ed., Handbook of Microlithography, Micromachining & Microfabrication (SPIE Optical Engineering Press, Bellingham, Wash. 1997), incorporated herein by reference. Fabrication techniques specific to MEMS light modulators formed on glass substrates can be found in U.S. patent application Ser. Nos. 11/361,785 and 11/731,628, incorporated herein by reference. For instance, as described in those applications, the shutter assembly 302 can be formed from thin films of amorphous silicon, deposited by a chemical vapor deposition process.
The shutter assembly 302 together with the actuator 303 can be made bi-stable. That is, the shutters can exist in at least two equilibrium positions (e.g. open or closed) with little or no power required to hold them in either position. More particularly, the shutter assembly 302 can be mechanically bi-stable. Once the shutter of the shutter assembly 302 is set in position, no electrical energy or holding voltage is required to maintain that position. The mechanical stresses on the physical elements of the shutter assembly 302 can hold the shutter in place.
The shutter assembly 302 together with the actuator 303 can also be made electrically bi-stable. In an electrically bi-stable shutter assembly, there exists a range of voltages below the actuation voltage of the shutter assembly, which if applied to a closed actuator (with the shutter being either open or closed), holds the actuator closed and the shutter in position, even if an opposing force is exerted on the shutter. The opposing force may be exerted by a spring such as spring 207 in shutter-based light modulator 200, or the opposing force may be exerted by an opposing actuator, such as an “open” or “closed” actuator.
The light modulator array 320 is depicted as having a single MEMS light modulator per pixel. Other embodiments are possible in which multiple MEMS light modulators are provided in each pixel, thereby providing the possibility of more than just binary “on” or “off” optical states in each pixel. Certain forms of coded area division gray scale are possible where multiple MEMS light modulators in the pixel are provided, and where apertures 324, which are associated with each of the light modulators, have unequal areas.
In other embodiments the roller-based light modulator 220 and the light tap 250, as well as other MEMS-based light modulators, can be substituted for the shutter assembly 302 within the light modulator array 320.
The shutter 406 includes two shutter apertures 412 through which light can pass. The aperture layer 407 includes a set of three apertures 409. In
Each aperture has at least one edge around its periphery. For example, the rectangular apertures 409 have four edges. In alternative implementations in which circular, elliptical, oval, or other curved apertures are formed in the aperture layer 407, each aperture may have only a single edge. In other implementations the apertures need not be separated or disjoint in the mathematical sense, but instead can be connected. That is to say, while portions or shaped sections of the aperture may maintain a correspondence to each shutter, several of these sections may be connected such that a single continuous perimeter of the aperture is shared by multiple shutters.
In order to allow light with a variety of exit angles to pass through apertures 412 and 409 in the open state, it is advantageous to provide a width or size for shutter apertures 412 which is larger than a corresponding width or size of apertures 409 in the aperture layer 407. In order to effectively block light from escaping in the closed state, it is preferable that the light blocking portions of the shutter 406 overlap the apertures 409.
The electrostatic actuators 402 and 404 are designed so that their voltage-displacement behavior provides a bi-stable characteristic to the shutter assembly 400. For each of the shutter-open and shutter-close actuators there exists a range of voltages below the actuation voltage, which if applied while that actuator is in the closed state (with the shutter being either open or closed), will hold the actuator closed and the shutter in position, even after an actuation voltage is applied to the opposing actuator. The minimum voltage needed to maintain a shutter's position against such an opposing force is referred to as a maintenance voltage Vm. A number of control matrices which take advantage of the bi-stable operation characteristic are described in U.S. patent application Ser. No. 11/607,715, referenced above.
The display apparatus 500 includes an optional diffuser 512 and/or an optional brightness enhancing film 514 which separate the substrate 504 from a planar light guide 516. The light guide is comprised of a transparent, i.e. glass or plastic material. The light guide 516 is illuminated by one or more light sources 518, forming a backlight. The light sources 518 can be, for example, and without limitation, incandescent lamps, fluorescent lamps, lasers, or light emitting diodes (LEDs). A reflector 519 helps direct light from lamp 518 towards the light guide 516. A front-facing reflective film 520 is disposed behind the backlight 516, reflecting light towards the shutter assemblies 502. Light rays such as ray 521 from the backlight that do not pass through one of the shutter assemblies 502 will be returned to the backlight and reflected again from the film 520. In this fashion light that fails to leave the display to form an image on the first pass can be recycled and made available for transmission through other open apertures in the array of shutter assemblies 502. Such light recycling has been shown to increase the illumination efficiency of the display.
The light guide 516 includes a set of geometric light redirectors or prisms 517 which re-direct light from the lamps 518 towards the apertures 508 and hence toward the front of the display. The light re-directors can be molded into the plastic body of light guide 516 with shapes that can be alternately triangular, trapezoidal, or curved in cross section. The density of the prisms 517 generally increases with distance from the lamp 518.
In alternate embodiments the aperture layer 506 can be made of a light absorbing material, and in alternate embodiments the surfaces of shutter 503 can be coated with either a light absorbing or a light reflecting material. In alternate embodiments the aperture layer 506 can be deposited directly on the surface of the light guide 516. In alternate embodiments the aperture layer 506 need not be disposed on the same substrate as the shutters 503 and anchors 505 (see the MEMS-down configuration described below). These and other embodiments for a display illumination system are described in detail in the U.S. patent application Ser. Nos. 11/218,690 and 11/528,191, incorporated herein by reference.
In one implementation the light sources 518 can include lamps of different colors, for instance, the colors red, green, and blue. A color image can be formed by sequentially illuminating images with lamps of different colors at a rate sufficient for the human brain to average the different colored images into a single multi-color image. The various color-specific images are formed using the array of shutter assemblies 502. In another implementation, the light source 518 includes lamps having more than three different colors. For example, the light source 518 may have red, green, blue and white lamps or red, green, blue, and yellow lamps.
A cover plate 522 forms the front of the display apparatus 500. The rear side of the cover plate 522 can be covered with a black matrix 524 to increase contrast. In alternate implementations the cover plate includes color filters, for instance distinct red, green, and blue filters corresponding to different ones of the shutter assemblies 502. The cover plate 522 is supported a predetermined distance away from the shutter assemblies 502 forming a gap 526. The gap 526 is maintained by mechanical supports or spacers 527 and/or by an adhesive seal 528 attaching the cover plate 522 to the substrate 504.
The adhesive seal 528 seals in a working fluid 530. The working fluid 530 is engineered with viscosities preferably below about 10 centipoise and with relative dielectric constant preferably above about 2.0, and dielectric breakdown strengths above about 104 V/cm. The working fluid 530 can also serve as a lubricant. In one implementation, the working fluid 530 is a hydrophobic liquid with a high surface wetting capability. In alternate implementations the working fluid 530 has a refractive index that is either greater than or less than that of the substrate 504.
Note this is short version of
A sheet metal or molded plastic assembly bracket 532 holds the cover plate 522, the substrate 504, the backlight 516 and the other component parts together around the edges. The assembly bracket 532 is fastened with screws or indent tabs to add rigidity to the combined display apparatus 500. In some implementations, the light source 518 is molded in place by an epoxy potting compound. Reflectors 536 help return light escaping from the edges of light guide 516 back into the light guide. Not shown in
Further details and alternate configurations for the display apparatus 500, including manufacturing methods therefore, can be found in the U.S. patent application Ser. Nos. 11/361,785 and 11/731,628, incorporated herein by reference
Display apparatus 500 is referred to as the MEMS-up configuration, wherein the MEMS based light modulators are formed on a front surface of substrate 504, i.e. the surface that faces toward the viewer. The shutter assemblies 502 are built directly on top of the reflective aperture layer 506. In an alternate embodiment of the invention, referred to as the MEMS-down configuration, the shutter assemblies are disposed on a substrate separate from the substrate on which the reflective aperture layer is formed. The substrate on which the reflective aperture layer is formed, defining a plurality of apertures, is referred to herein as the aperture plate. In the MEMS-down configuration, the substrate that carries the MEMS-based light modulators takes the place of the cover plate 522 in display apparatus 500 and is oriented such that the MEMS-based light modulators are positioned on the rear surface of the top substrate, i.e. the surface that faces away from the viewer and toward the back light 516. The MEMS-based light modulators are thereby positioned directly opposite to and across a gap from the reflective aperture layer. The gap can be maintained by a series of spacer posts connecting the aperture plate and the substrate on which the MEMS modulators are formed. In some implementations the spacers are disposed within or between each pixel in the array. The gap or distance that separates the MEMS light modulators from their corresponding apertures is preferably less than 10 microns, or a distance that is less than the overlap between shutters and apertures, such as overlap 416. Further details and alternate embodiments for the MEMS-down display configuration can be found in the U.S. patent application Ser. Nos. 11/361,785, 11/528,191, and 11/731,628 referenced above.
In other embodiments, the roller-based light modulator 220 or the light tap 250, as well as other MEMS-based light modulators, can be substituted for the shutter assemblies 502 within the display assembly 500.
Shutter Manufacturing
In some implementations the order of the layers in composite shutter assembly 600 can be inverted, such that the outside of the sandwich is comprised of a conducting layer while the inside of the sandwich is comprised of a mechanical layer.
Further description of materials for use in shutter 601, including the incorporation of materials selected for the absorption or reflection of incident light can be found in the U.S. patent application Ser. No. 11/361,785, entitled “Display Apparatus and Methods For Manufacture Thereof,” filed Feb. 23, 2006 incorporated herein by reference.
Shutter assembly 600 includes an encapsulating dielectric layer 611. Dielectric coatings can be applied in conformal fashion, such that all bottom, tops, and side surfaces of the shutters and beams are uniformly coated. Such thin films can be grown by thermal oxidation and/or by conformal chemical vapor deposition of an insulator such as Al2O3, Cr2O3, TiO2, HfO2, V2O5, Nb2O5, Ta2O5, SiO2, or Si3N4, or by depositing similar materials by means of atomic layer deposition. The dielectric coating layer can be applied with thicknesses in the range of 10 nm to 1 micron. In some cases sputtering and evaporation can be used to deposit the dielectric coating onto sidewalls.
Next the sacrificial layer 613 is patterned to expose holes or vias at the anchor regions 604. The preferred polyimide material and other polymer resins can be formulated to include photoactive agents—enabling regions exposed through a UV photomask to be preferentially removed in a developer solution. Other sacrificial layers 613 can be patterned by coating the sacrificial layer in an additional layer of photoresist, photopatterning the photoresist, and finally using the photoresist as an etching mask. Other sacrificial layers can be patterned by coating the sacrificial layer with a hard mask, which can be a thin layer of SiO2 or metal such as chromium. A photopattern is then transferred to the hard mask by means of photoresist and wet chemical etching. The pattern developed in the hard mask can be very resistant to dry chemical, anisotropic, or plasma etching—techniques which can be used to impart very deep and narrow anchor holes into the sacrificial layer.
After the anchor 604 or via regions have been opened in the sacrificial layer, the exposed and underlying conducting surface 614 can be etched, either chemically or via the sputtering effects of a plasma, to remove any surface oxide layers. Such a contact etching step can improve the ohmic contact between the underlying conductor and the shutter material.
After patterning of the sacrificial layer, any photoresist layers or hard masks can be removed through use of either solvent cleans or acid etching.
Next, in the process for building shutter assembly 600, as shown in
In addition to the PECVD technique, alternate techniques available for the growth of shutter layers 605 or 609 include RF or DC sputtering, metal-organic chemical vapor deposition, evaporation, electroplating or electroless plating.
For the conducting layer 607, a metal thin film such as Al is preferred, although alternates such as Cu, Ni, Mo, or Ta can be chosen. The inclusion of such a conducting material serves two purposes. It reduces the overall sheet resistance of the shutter material and it helps to block the passage of visible light through the shutter material. (Amorphous silicon, if grown to thicknesses of less than 2 microns can transmit visible light to some degree.) The conducting material can be deposited either by sputtering or, in a more conformal fashion, by chemical vapor deposition techniques, electroplating, or electroless plating.
The process for building the shutter assembly 600 continues in
The pattern shapes applied through the photomask at
The process for building the shutter assembly 600 continues as depicted in
In a final process, not shown in
Finally, anti-stiction coatings can be applied to the surfaces of all shutters 601 and beams 602. These coatings prevent the unwanted stickiness or adhesion between two independent beams of an actuator. Applicable coatings include carbon films (both graphite and diamond-like) as well as fluoropolymers, and/or low vapor pressure lubricants. These coatings can be applied by either exposure to a molecular vapor or by decomposition of a precursor compounds by means of chemical vapor deposition. Anti-stiction coatings can also be created by the chemical alteration of shutter surfaces, as in the fluoridation, silanization, siloxidation, or hydrogenation of insulating surfaces.
The Sidewall Beams Process
U.S. patent application Ser. No. 11/251,035 describes a number of useful designs for shutter assemblies and actuators. One class of suitable actuators for use in MEMS-based shutter displays include compliant actuator beams for controlling shutter motion that is transverse to or in-the-plane of the display substrate. The voltage necessary for the actuation of such shutter assemblies decreases as the actuator beams become more compliant. The control of actuated motion also improves if the beams are shaped such that in-plane motion is preferred or promoted with respect to out-of-plane motion. In a preferred design the compliant actuator beams have a rectangular cross section, such as beam 602 of
The stiffness of a long rectangular beam with respect to bending within a particular plane scales with the thinnest dimension of that beam in that plane to the third power. It is of interest, therefore, to reduce the width of the compliant beams as far as possible to reduce the actuation voltages for in-plane motion. When using conventional photolithography equipment to define and fabricate the shutter and actuator structures, however, the minimum width of the beams is usually limited to the resolution of the optics. And although photolithography equipment has been developed for defining patterns in photoresist with features as narrow as 15 nanometers, such equipment is expensive and the areas over which can be patterning can be accomplished in a single exposure are limited. For economical photolithography over large panels of glass, the patterning resolution or minimum feature size is typically limited to 1 micron or 2 microns or greater.
U.S. patent application Ser. No. 11/361,785 describes a technique, illustrated in
The process of forming a shutter assembly 700 with sidewall beams begins, as shown in
The process of forming sidewall beams continues with the deposition and patterning of a second sacrificial material 705.
Materials for use as sacrificial materials 701 and 705 are described above with respect to sacrificial material 613.
The process of forming sidewall beams continues with the deposition and patterning of the shutter material onto all of the exposed surfaces of the sacrificial mold 703, as depicted in
Particular equipment and chemistries are also chosen for the etching process used at the step shown in
The anisotropic etch used to form sidewall beams 716 can be achieved in either an RF or DC plasma etching device as long as provision for electrical bias of the substrate, or of an electrode in close proximity of the substrate, is supplied. For the case of RF plasma etching, an equivalent self-bias can be obtained by disconnecting the substrate holder from the grounding plates of the excitation circuit, thereby allowing the substrate potential to float in the plasma. In one implementation it is possible to provide an etching gas such as CHF3, C4F8, or CHCl3 in which both carbon and hydrogen and/or carbon and fluorine are constituents in the etch gas. When coupled with a directional plasma, achieved again through voltage biasing of the substrate, the liberated C, H, and/or F atoms can migrate to the sidewalls 709 where they build up a passive or protective quasi-polymer coating. This quasi-polymer coating further protects the sidewall beams 716 from etching or chemical attack.
The process of forming sidewall beams is completed with the removal of the remainder of the second sacrificial layer 705 and the first sacrificial layer 701, the result being shown in
An optional step, not illustrated above but included as part of the process leading to
As a final step in the sidewall process, an encapsulating dielectric, such as dielectric 611 is deposited around the outside surfaces of the sidewall beams.
In order to protect the shutter material deposited on sidewalls 709 of the mold 703 and to produce sidewall beams 716 of substantially uniform cross section, some particular process guidelines can be followed. For instance, in
Another process specification that helps during sidewall beam processing regards the conformality of the shutter material deposition. The surfaces of the mold 703 are preferably covered with similar thicknesses of shutter material, regardless or the orientation of those surfaces, either vertical or horizontal. Such conformality can be achieved when depositing with a chemical vapor deposition technique (CVD). In particular, the following conformal techniques can be employed: plasma enhanced chemical vapor deposition (PECVD), low pressure chemical vapor deposition (LPCVD), and atomic or self-limited layer deposition (ALD). In the above CVD techniques the growth rate of the thin film can be limited by reaction rates on a surface as opposed to exposing the surface to a directional flux of source atoms. In such conformal deposition techniques, the thickness of material grown on vertical surfaces is preferably at least 50% of the thickness of material grown on horizontal surfaces. Alternatively, shutter materials can be conformally deposited from solution by electroless plating or electroplated, as long as a metal seed layer is provided that uniformly coats all surfaces before plating.
Designs Incorporating Compliant Beams Under Stress
The sidewall beam process, illustrated in
For shutter assembly 800, the compliant support beam 804 and the electrode 806 are formed by means of a sidewall beam process. Each of the beams 804 and 806 is suspended above the substrate surface, and is attached to the substrate at anchors 809 and 812, respectively. In cross section, each of the beams has an aspect ratio greater than one, where the vertical faces, i.e. those perpendicular to the substrate surface, have a dimension substantially taller or higher than the narrow dimension in the plane of the substrate.
The different stress states imposed by materials 836 and 838 creates the equivalent of a bending moment on the beam 824, causing the beam 824 to bend toward the aperture 828 after release from the sacrificial mold. The sacrificial mold is not shown in
The support beam 824 bends into a rest or relaxed position, as is illustrated in
The different stress states imposed by materials 856 and 858 creates the equivalent of a bending moment on the beam 844, causing the beam to bend toward a relaxed position in a direction closer to and even overlapping the aperture 848. The minimum distance to be traversed by the shutter 842 between the open (or rest) position and the closed (or actuated) position is indicated by the marker D3. The distance D3 in shutter assembly 840 is less than the distance D1 in shutter assembly 800.
Comparing the bending positions at rest for the beams in shutter assemblies 820 and 840, the shutter assembly 820 is preferred. This is because, due to the bending stresses carried within the beam 844, the shutter 842 is unable to completely clear the aperture hole 848 in its rest state. The shutter assembly 840 suffers a loss in illumination intensity in its open position compared to the situation in shutter assembly 820.
The voltages required to actuate the shutter assemblies 800, 820, and 840 are directly related to the distances required for actuation. The actuation voltage for shutter assembly 840 will be the least, because as noted above D3<D1<D2. Theoretically, then, the shutter assembly 800 would provide the best combination of a design with a relatively low actuation voltage (compared to shutter assembly 840) wherein the aperture 808 will not be obstructed in the rest state. Unfortunately, the theoretical situation of shutter assembly 800 is difficult to achieve, since a variety of stresses or unbalancing of stresses can and often are imparted to sidewall beams during manufacture, as a result of the beam deposition process. In shutter assembly 820, however, a pair of materials is provided for the beam 824—materials 836 and 838 being disposed on opposite faces of the beam and with a predetermined relation in their stress states. The shutter assembly 820 is an improved design because the direction of movement or bending of beam 824 after release can be predicted based on the predetermined relation between the stress states at the two faces. The rest position of the beam 824 is therefore to a large extent controllable despite other extraneous variations to the stress state in beams that might be imparted during the manufacturing process.
It should be noted that the electrode beams 826 and 846 also possess the same pair of materials employed for their respective support beams, as they were deposited at the same time during a sidewall deposition process. However, the electrode beams are connected and at each end to anchors 832 and 852 respectively. By pinning the beam 826 with two anchors 832, one at each end, the degree of bending or shape change of the electrode 826 can be reduced or eliminated.
For shutter assembly 900 the two support beams 904 and 905 are designed as redundant and substantially parallel support beams. The symmetrical design of the beams 904 and 905 helps to ensure that stresses induced during a sidewall manufacturing process do not lead to bending moments which might alter or displace the as-designed rest position for the shutter 902. In one example of a sidewall beam process, the sacrificial mold material (such as mold 703) can be situated in the interstitial space 907 between the beams 904 and 905. If an unbalanced stress distribution is imparted during deposition of the beam 904 attached to one sidewall of the mold, then, a similar and mirror-image stress distribution will be imparted to the beam 905 as it is formed on the opposite sidewall of the same mold. If the beams 904 and 905 are left with mirror-image stress distributions, then the equivalent bending moment experienced at the point where the beams connect to the shutter 902 will be reduced or removed and the shutter will not move substantially after the sacrificial mold is removed.
As a result, the use of substantially parallel support beams with mirror-image stress states provides another method for controlling the rest position of the shutter assembly 900. There is some voltage penalty to the use of parallel support beams, since the bending forces required to move or actuate a cantilevered shutter with parallel support beams are higher than those required of a shutter connected to a single support beam, but at least in shutter assembly 900 the rest position of the shutter can be controlled despite stresses imparted during the manufacturing process.
An Example of Stress Distributions Before and after Release
Numerous techniques are available for controlling the degree and direction of curvature in beams where the bend is in a direction parallel to the substrate (i.e. transverse to an optical axis) by controlling stress distributions in the beams during the sidewall manufacturing process. For the particular case described above, the sacrificial molds for beams 804, 824, and 844 were each drawn with similar shapes in the photomask; for instance with the same straight-line beam shape as shown for beam 804. But the stresses imparted by the use of composite beam materials, such as those employed in beams 824 and 844, caused the beams to move and bend after the sacrificial mold was removed. By advantageously controlling stress distributions within a beam, the rest or relaxed shape of the beam (with no voltage applied) can be different from whatever shape is drawn in the photomask or initially produced after deposition onto the mold.
An illustration of how stress is distributed through the composite compliant beam 824, both before and after release from the mold, is given in
The bending of the beam 824 is initiated by the stress difference imparted to the two faces of the beam after deposition. In
The stress values illustrated in
The stress distributions in
The bending of the beam 824 is initiated by the stress difference imparted to the two faces of the beam after deposition. A useful value for the stress difference, such as the stress value 1010, which leads to significant bending after release can be any stress difference in excess of 30 Mpa (mega-Pascals). In certain implementations, stress differences between the two faces of a beam in excess of about 400 Mpa are imparted for this purpose. As a result of the beam bending the stress values on the faces will change, but remain as is evident from the differences in stress values 1020 and 1024. A stress difference between the values 1020 and 1024 which is indicative of a beam which has been bent because of an initially anisotropic stress state can be any value in excess of 30 Mpa.
Analytical techniques exist for measuring the stress difference between two faces of a beam, but the techniques can be difficult to apply in every circumstance. In many cases it is easier to establish that a relative difference in strain values exists between two surfaces, as strain is a straightforward measurement of the relative expansion or contraction of a crystal lattice and these strains will be related to the stresses by means of the materials' elastic modulus. A simple test is available, however, to confirm whether a beam has been bent under the influence of anisotropic stresses or stress gradients. A wet chemical etch, a sputtering plasma, or an ion beam can be used to selectively remove material from one of the two surfaces of a narrow compliant beam. If the shape of the original beam was not originally established by the presence of anisotropic stresses or stress gradients, then the shape of the beam will not be altered after the removal of any further material from one of the faces. For the case of a stressed beam, however, such as is illustrated in
Numerous techniques are known in the art for creating thin film materials with predetermined stress states. Generally speaking the refractive materials (melting temperatures in excess of 1200 C) are deposited with more substantial states of tensile stress than materials with lower melting points. The metals W, Ta, Nb, Mo, Ti, V, Cr, and Si are examples of metals that are available for deposition into a tensile stress state, commonly with stresses in excess of 100 Mpa. The dielectrics SiO2, Al2O3, and Ta2O5 are examples of dielectric materials that are commonly deposited in a tensile stress state, particularly when deposited by means of sputter deposition. Even the lower melting point materials such as Al, Cu, Ni, Ga, Ge, Ag, and Au can be deposited with significant tensile stress state if measures are taken to reduce the density or increase porosity in the material. The use of fast deposition rates can lead to porosities in excess of 10% and tensile states >30 Mpa. Alternately, if the materials are formed in an environment of excess oxygen, hydrogen, or argon gas the result is a thin film with stress in excess of 30 Mpa.
In an alternate manufacturing process for the shutter assembly 820, the right-hand material 838 can be initially deposited in a compressive stress state while the left-hand material 836 can be deposited with a stress state near zero. The net result would be a relaxed stress distribution similar to that shown in
Numerous techniques are known in the art for depositing a thin film in a compressive stress state. Plasma atmospheres can be employed for the deposition, or a substrate bias, or an ion emission source can be employed which accelerates ions toward a substrate—the result of which is a thin film in a compressive stress below 30 Mpa. Slower deposition rates can also be employed, particularly in conjunction with a chemical vapor deposition process, to create atomically dense thin films that also demonstrate compressive stresses below 30 Mpa. Dielectric materials such as SiO2, Al2O3, and Ta2O5, when deposited by means of chemical vapor deposition, are often deposited in a compressive stress state. In some implementations a thermal annealing process can be employed to convert a thin film with an initially tensile stress state into a thin film with a significantly compressive stress state. In other implementations a doping or alloy material, preferably a material with a larger atomic radius, can be added to the thin film after deposition in order to create a compressive stress state below 30 Mpa.
In an alternate manufacturing process for the shutter assembly 820, both the left-hand and the right hand materials 836 and 838 can be deposited into either a tensile or a compressive stress state. In order to effect a bending in the desired direction after release, i.e. a bend that carries the shutter 822 away from the aperture 828, it is only necessary that the stress at the face 1004 be less by at least 30 Mpa than the stress at the face 1006, i.e. the face 1004 should be relatively more compressive than the face 1006.
Many deposition processes occur at elevated temperatures. As a consequence, when a two or more layers of different materials are grown, the stack of materials experiences a thermal stress after the substrate is cooled to room temperature. Generally the materials in the stack with greater coefficients of thermal expansion (CTE) will experience a tensile stress on cooldown. The materials with relatively lower CTE will be under compression.
In an alternate manufacturing process for the shutter assembly 820 multiple layers of different materials, i.e. more than 2, can be used for the construction of the compliant beam. Three or more thin film layers of different materials can be employed, including the sandwich structures described above with respect to
In an alternate manufacturing process, the stress differences between the two faces of a compliant beam need not arise discontinuously across an interface, such as the interface at point 1008 between the materials 836 and 838 in beam 824. Instead a more gradual change in the stress properties of a thin film can be imparted as a function of thickness in the thin film. For instance a thin film made from a single or variable chemical composition can be deposited whose stress varies from a relatively compressive state near the mold surface to a relatively tensile state at the opposite surface. For instance, in one embodiment, the deposition rate can be gradually increased during the growth process of a thin film. (Conversely, a gradient from relatively tensile to relatively compressive stress can be achieved by slowing-down a deposition rate.) In alternate embodiments, a stress gradient or stress variation can be imposed on a single thin film through gradual changes in the thin film composition or doping properties, or by changing the flux of an incident ion beam, or by changing the energy density in a plasma as a function of growth time, or by changing the temperature of substrate during deposition.
Stress Compensation Techniques or Designing Mold Shapes for Stress Compensation
In some implementations of the manufacturing processes described above, the differences in stress values between the two faces of the fabricated compliant beams are unavoidable due to the materials, equipment, or processes employed. Such stress differences can arise, for instance, when the atomic density of a thin film which is grown near to a mold interface is different from the density which develops during the later stages of a deposition. Stress differences can also arise due to surface temperature changes on the deposition substrate during deposition. In some cases external design considerations dictate the thin film structure and dominant stress characteristics. For instance, the designer might prefer that a low-melting point or reactive metal be the first material to be deposited for the beams during a sidewall process.
Even in a situation where the sign or magnitude of stresses difference between two faces of a compliant beam is a secondary effect and not an ab initio design consideration, the designer still has options for using stress to his advantage. For instance, the designer can control the motion of a compliant beam in any of two directions by appropriate choice of the mold position and shape.
A beneficial choice in mold position can be illustrated with respect to
Let one assume for purposes of illustration, however, that in a particular sidewall manufacturing operation the first material to be deposited is generally more tensile than the last material to be deposited. For the same mold position or shape, then, the beam would be expected to bend toward the aperture, toward the unfavorable position. In this situation, assuming that the sign of the stresses as manufactured are reproducible, the designer can still achieve a favorable position for the beam if the conformation or the shape of the mold is reversed. In an alternative embodiment, the mold can be patterned such that the sidewall on which first growth occurs is located at the position 1006, so that the beam material now grows from left to right instead of from right to left. With such a reversal to the mold pattern, the first material to be grown, in a relatively tensile state, is now created along the edge 1006 (the left side of beam 824) and after release the beam 824 will bend in a favorable direction, i.e. away from the aperture 828 after release.
By reversing the mold shape as described in the above embodiment, (inverted mold, OK) the designer can compensate for stress differences regardless of whether the first material to be grown is in a relatively tensile or relatively compressive stress state. This technique is useful in cases where the sign of the stress difference as given by the manufacturing process is reproducible but the magnitude is not.
A more refined or quantitative method of stress compensation is possible where the magnitude of stresses imparted to the two surfaces is also reproducible and controllable. If the magnitude of the residual stresses can be predicted to within an accuracy of +/−100 Mpa, or preferably within an accuracy of +/−30 Mpa, then it is possible to predict and control with some precision the final rest position of a compliant beam after release. In one alternative embodiment of the invention the designer includes pre-compensating curvature to the mold. (Pre-curve)
For instance, if the statistical data is available showing that the beam 824 will tend to move to the left and away from aperture 828 by for example 12+/−3 microns, then it is possible to design the beam on the mold with a compensating curvature. For instance, in this alternative embodiment the mold can be designed such that the beam before release has a shape that looks similar to the rest shape of beam 844, i.e. where in its initial (before release) position the shutter 822 actually occludes as much as 9 microns of the aperture 828. Then, after release, all of the beams (or perhaps >than 99.99% of them) will relax and move to the left completely uncovering the aperture. The final rest position might look approximately straight, i.e. similar to the shape of the beam 804. By employing statistical data on beam motion after release along with a compensating curvature, the distance D2 can be kept to a minimum with only a small probability that the aperture 828 will be occluded. Average actuation voltages can thereby be decreased.
In a converse example, if it is known that the beam 804 will tend to move toward the right after release by for example 12+/−3 microns, then it is possible to design the beam on the mold with a curved shape that looks more similar to the rest position of curved beam 824, i.e. with an initial position where the shutter 804 is actually curved away by a safety margin of 15 microns from the aperture 828. Then, after release of the beam 804, all of the beams (or perhaps >than 99.99% of them) will relax and move to the right. The beam 804 in its final rest position will look approximately straight, as shown in
Stopping Structures
Judicious choice of mold shape is be useful in determining the direction of beam bending after release. Further control over the degree of shape change in a support beam can be realized by means of stopping structures. An example is shown in
Beneficial Bend, Non-Sidewall Structures
It is not necessary that a compliant beam be formed using the sidewall technique of
Stress Control in Dual Compliant Actuators
Exemplary anchors 1312 and 1314 are described in U.S. Provisional Application No. 61/108,783 filed Oct. 27, 2008, the entirety of which is incorporated by reference.
Because of stresses imparted onto the compliant beams, the relaxed shape of the drive beams can differ from the as-designed shape, such as shape 1306, provided on the mold during processing. In some instances the stressed drive beams will bend away from the load beams 1308, as is illustrated by beams 1305, and in other instances the stressed drive beams can bend toward the load beams 1308 as is illustrated by beams 1307. In many processes, including the sidewall process described with respect to
For the case, illustrated by stressed drive beam 1305, where the beam 1305 is curved away from the load beam 1308 the voltage required to initiate actuation will be unfavorably increased.
The designer seeks a situation where the drive beam 1306 approaches the load beam 1308 in its relaxed state as closely as possible, within the capabilities of the manufacturing process, while avoiding the situation where the drive beam 1306 actually touches the load beam 1308. For the ideal case where no residual stresses are present and the beams do not change shape after release (cf the as-designed shape of beam 1306) the gap or distance of closest approach between the beams will be determined by the resolution capability of lithography equipment used in the manufacturing process. For the case wherein stresses lead to beam deformation, a number of methods for managing the gap or separation between beams are available as will be described in the succeeding examples.
The nominal shape of beam 1378, which is the shape imparted to the beam while it is still attached to the mold, consists of 3 nominally straight sections which are rotated by about 90 degrees from each other. After release and relaxation, however, as illustrated by beam 1358, the nominally straight sections become curved and the orientations of the three sections become substantially greater or less than 90 degrees from each other. The shape changes illustrated by comparing beams 1358 and 1378 can be created by any of the stress distributions described with respect to
The relaxed and curved load beam 1358 is relatively more parallel to the drive beam 1356 when compared to the pair of beams 1378 and 1376. The distance of closest approach between the beams 1356 and 1358 is also closer than that shown for the as-designed beams 1378 and 1376, and closer than a distance allowed by the resolution capability of lithography equipment. The design of the beams 1356 and 1358 in their rest position makes it possible to design for a separation between the beams that is no more than a predetermined distance. As a consequence the actuation voltage within actuator 1354 is less than that for actuator 1374.
The stresses have induced a curvature in the beam 1358 that did not exist while the beam was attached to the mold. Similar beneficial shape changes can occur in any stressed beam which is free to move or bend while suspended between two rigid structures, such as between the anchor 1362 and the shutter 1360, or for beams suspended between two anchoring points. If the stresses imparted to the beams in manufacturing are predictable and reproducible, then a compensating shape or curvature can be designed into the mold so that after release the beam 1358 will bend or curve into the desired shape.
By designing particular shapes in the mold, the designer can compensate for stresses which are inherent in a compliant beam, as was described above under the section titled “Stress Compensation Techniques”. For instance, to a large degree the separation between the beams 1358 and 1356 can be optimized through variations in the shape of the sacrificial mold. It is also possible to alter the direction of the curvature in a beam after release by choosing an alternate or reversed shape for the sacrificial mold. For instance in a first mold shape a gap, a trench, or an open space can be formed in the space in between the sidewalls, on which will be formed the beams 1356 and 1358. For this first or normal mold shape the beams 1356 and 1358 might be expected to bend toward each other after release from the mold. An alternative design is possible, employing a second mold shape, wherein the mold is continuous or solid in the space between the sidewalls which will be used to form the beams 1356 and 1358. (The trenches or open spaces for this second mold would be placed in spaces to the outside of the beams 1356 and 1358.) For this second or inverted mold shape, the beams 1356 and 1358 might be expected to bend away from each other after release from the mold.
Dual Anchors
The supplementary drive beam anchors 1416 act to limit the deformation or shape change which might otherwise occur within the drive beams 1406. A mechanical beam, such as beam 1406, which is fixed, supported, or anchored at two points along its length will more easily retain its shape even under the influence of residual stresses or external loads. Note that the drive beam 1406 is still free to move or deform at points in between the anchors 1414 and 1416 and therefore partially compliant, so that the actuation voltage of the actuators 1404 is still less than would be the case with a completely rigid drive beam.
Looped Beams
Partial or Asymmetrical Looped Beams
The supplementary drive beam anchors 1616 are positioned and the drive beams 1606 are shaped so as to form partial loops. Along each loop there is a section of beam which extends out from the central anchor 1614 which is substantially parallel to a returning section of the same beam before it is attached to the supplementary anchor 1616. The lengths of these two straight line sections in the loop are not equal. This asymmetry in shape provides the opportunity to create or allow for an advantageous shape change in the loop after release from the mold. Either because of residual stresses, or because of a length change (shrinkage or expansion) along the drive beam 1606, the forces experienced at the distal end of the loop can cause it to move in a direction parallel to the substrate on which the shutter assembly 1602 is formed. Because of the stiffness created by the dual anchors 1614 and 1616, however, the motion of the distal end will not be nearly so severe as those experienced by the cantilevered drive beams 1305 or 1307 illustrated in
In contrast to the shape of loop 1506, the lengths of the sides of the drive beam loop 1656 are not equal. One side of the loop 1656 is in fact provided with an additional set of corners or bends at areas 1670 (the “elongating portion”) such that the two sides of loop 1656 have substantially different lengths. The elongating portion 1670 of the compliant beam 1656 can in addition to taking the form of a simple secondary loop as depicted in
The elongating portion 1670 of the compliant beam 1656 provides an asymmetry to the shape of compliant beam 1656 such that, upon release from the mold, the beam 1656 will bend or deform into a desired direction. The motion will be driven by residual stresses in the beams. The desired direction of movement may be such that, after release from the mold, the separation between beams 1656 and 1658 is decreased from what was allowed by the resolution capability of lithography equipment. A separation between beams 1658 and 1656 in their rest position can thereby be provided that is no more than or no less than a predetermined distance.
Actuator Beam Stops
The drive beam stop 1718 is positioned and configured to limit and control the motion or deformation of the drive beam 1706. The as-designed shape of the drive beam 1706 (which can differ from the relaxed shape after release from the mold), includes a gap or distance H1 between the drive beam 1706 and the stop 1718 which is less than the gap or distance H2 between the drive beam 1706 and the load beam 1708. Therefore, even though the drive beam 1706 may deform after release and bend toward the load beam 1708, its motion will be limited by the presence of the stop 1718 such that in the non-actuated and relaxed state the drive beam 1706 and the load beam 1708 cannot touch. Significantly in this fashion, it is possible to create a gap or separation between the drive beam 1706 and the load beam 1708, in their relaxed state, which is greater than zero but substantially less than the resolution limits allowed by the lithography equipment employed in the manufacturing. Note also that in the actuator 1704 the load anchor 1712 is positioned and the load beam 1708 is designed to provide the shape of a partial loop. This partial loop provides more compliance to the load beam 1708 than that which is found in load beams 1508 or 1608. With this extra compliance, it is easier for the load beam 1708 to approach the drive beam 1706 during actuation, even while the motion of the drive beam 1706 is limited by the presence of the stop 1718.
The drive beam 1806 and the drive beam stop 1818 are designed for more precise control over the rest position of the drive beam 1806 after release from the mold.
The advanced design of the actuator 1804 allows for more precision in determining the rest position of the beams, such that at rest the final separation between the beams 1806 an 1808 can be held to no more than or no less than a predetermined distance. This precision is be achieved despite variations in the residual stress in the drive beam 1806 due to manufacturing variations. The precision is achieved in part by providing a compensating shape to the drive beam in its as-designed shape, as is illustrated in
The sliding contact between the beam 1806 and the stop 1818 helps to maintain a particular separation distance between the beams 1806 and 1808, despite variations in residual stress. Two contact positions 1820 and 1822 are illustrated in
While the concepts highlighted in
The invention may be embodied in other specific forms without departing from the spirit or essential characteristics thereof. The forgoing embodiments are therefore to be considered in all respects illustrative, rather than limiting of the invention.
This application is a continuation of U.S. patent application Ser. No. 12/370,471, filed on Feb. 12, 2009, which is a continuation-in-part of U.S. patent application Ser. No. 12/045,518, filed Mar. 10, 2008, now Abandoned, which is a continuation of U.S. patent application Ser. No. 11/361,785, filed Feb. 23, 2006, now U.S. Pat. No. 7,405,852 issued Jul. 29, 2008, and claims priority to U.S. Provisional Application No. 61/028,137 filed Feb. 12, 2008, U.S. Provisional Application No. 61/108,783 filed Oct. 27, 2008, and U.S. Provisional Application No. 61/109,045 filed Oct. 28, 2008. The entirety of each of these applications is incorporated herein by reference.
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| 20130335806 A1 | Dec 2013 | US |
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