Method and system for providing MEMS device package with secondary seal

Abstract

A MEMS device package comprises a substrate with a MEMS device formed thereon, a backplane, and a primary seal, wherein the primary seal is positioned between the backplane and the substrate to encapsulate and seal the MEMS device package from ambient conditions. The MEMS device package further comprises a secondary seal in contact with at least the backplane and the substrate.

Description

BACKGROUND

1. Field of the Invention

The field of the invention relates to microelectromechanical systems (MEMS), and more particularly, to methods and systems for packaging MEMS devices.

2. Description of the Related Technology

Microelectromechanical systems (MEMS) include micro mechanical elements, actuators, and electronics. Micromechanical elements may be created using deposition, etching, and or other micromachining processes that etch away parts of substrates and/or deposited material layers or that add layers to form electrical and electromechanical devices. One type of MEMS device is called an interferometric modulator. An interferometric modulator may comprise a pair of conductive plates, one or both of which may be transparent and/or reflective in whole or part and capable of relative motion upon application of an appropriate electrical signal. One plate may comprise a stationary layer deposited on a substrate, the other plate may comprise a metallic membrane separated from the stationary layer by an air gap. Such devices have a wide range of applications, and it would be beneficial in the art to utilize and/or modify the characteristics of these types of devices so that their features can be exploited in improving existing products and creating new products that have not yet been developed.

SUMMARY

The system, method, and devices of the invention each have several aspects, no single one of which is solely responsible for its desirable attributes. Without limiting the scope of this invention, its more prominent features will now be discussed briefly. After considering this discussion, and particularly after reading the section entitled “Detailed Description of Certain Embodiments” one will understand how the features of this invention provide advantages over other display devices.

One embodiment of a microelectromechanical system (MEMS) device comprises a substrate, a MEMS device formed on the substrate, a backplane, a primary seal positioned proximate a perimeter of the MEMS device and in contact with the substrate and the backplane, and a secondary seal positioned proximate an outer periphery of the primary seal and in contact with the substrate and the backplane.

The primary seal or the secondary seal may each be either a continuous or a non-continuous seal. In some embodiments, the secondary seal comprises an anisotropic conductive film (ACF). The ACF may comprise a tailored sealing portion proximate the outer periphery of the primary seal.

In some embodiments, the secondary seal is in contact with the primary seal. The secondary seal may comprise a hydrophobic material, an adhesive, and/or a metal. In some embodiments, the MEMS device comprises an interferometric modulator array.

The MEMS device may comprise a display system comprising a processor that is in electrical communication with the MEMS device, the processor being configured to process image data, and a memory device in electrical communication with the processor. The display system may further comprise a first controller configured to send at least one signal to the MEMS device, and a second controller configured to send at least a portion of the image data to the first controller.

In some embodiments, the display system further comprises an image source module configured to send the image data to the processor. In addition, the image source module may comprise at least one of a receiver, transceiver, and transmitter.

In certain embodiments, the display system further comprises an input device configured to receive input data and to communicate the input data to the processor.

One embodiment of a method of sealing a MEMS device package comprises providing a MEMS device package comprising a backplane and a substrate, wherein a MEMS device is formed on the substrate, providing a primary seal formed proximate a perimeter of the MEMS device and between the backplane and the substrate, and forming a secondary seal proximate an outer periphery of the primary seal and in contact with the substrate and the backplane.

In some embodiments, the primary seal is formed on at least one of the backplane and the substrate. In certain embodiments, forming the secondary seal comprises placing a solder preform proximate an outer periphery of the primary seal, and melting the solder preform to contact the substrate and the backplane. In addition, placing the solder preform may occur before the backplane, the primary seal, and the substrate are assembled, wherein the melting occurs after the assembly.

One embodiment of a system for sealing a MEMS device package comprises a MEMS device package comprising a backplane and a substrate, wherein a MEMS device is formed on the substrate, a primary seal formed proximate a perimeter of the MEMS device and between the backplane and the substrate, and means for sealing an outer periphery of the primary seal, wherein the means is in contact with the substrate and the backplane.

One embodiment of a MEMS device package comprises a primary inner seal and a secondary outer seal, wherein the package is produced by a method comprising providing a MEMS device package comprising a backplane and a substrate, wherein a MEMS device is formed on the substrate, providing a primary seal formed proximate a perimeter of the MEMS device and between the backplane and the substrate, and forming a secondary seal proximate an outer periphery of the primary seal and in contact with the substrate and the backplane.

One embodiment of a MEMS device package comprises a substrate, a MEMS device formed on the substrate, a backplane, a seal positioned proximate a perimeter of the MEMS device and in contact with the substrate and the backplane, a flexible circuit, and an anisotropic conductive film in contact with the flexible circuit, the substrate, and the backplane. In some embodiments, the anisotropic conductive film is in contact with the seal.

The MEMS device may comprise an interferometric modulator array, and the anisotropic conductive film may comprise a tailored sealing portion proximate the seal.

One embodiment of a method of assembling a MEMS device package comprises contacting a flexible circuit, an anisotropic conductive film, and a substrate, wherein the substrate comprises a MEMS device thereon, and a seal proximate a perimeter of the MEMS device and in contact with the substrate and a backplane, and applying a force to the flexible circuit so as to force the anisotropic conductive film into contact with the backplane.

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is an isometric view depicting a portion of one embodiment of an interferometric modulator display in which a movable reflective layer of a first interferometric modulator is in a released position and a movable reflective layer of a second interferometric modulator is in an actuated position.

FIG. 2 is a system block diagram illustrating one embodiment of an electronic device incorporating a 3×3 interferometric modulator display.

FIG. 3 is a diagram of movable mirror position versus applied voltage for one exemplary embodiment of an interferometric modulator of FIG. 1.

FIG. 4 is an illustration of a set of row and column voltages that may be used to drive an interferometric modulator display.

FIGS. 5A and 5B illustrate one exemplary timing diagram for row and column signals that may be used to write a frame of display data to the 3×3 interferometric modulator display of FIG. 2.

FIGS. 6A and 6B are system block diagrams illustrating an embodiment of a display device.

FIG. 7A is a cross-sectional view of the device of FIG. 1.

FIG. 7B is a cross-sectional view of an alternative embodiment of an interferometric modulator.

FIG. 7C is a cross-sectional view of another alternative embodiment of an interferometric modulator.

FIG. 8 is a cross-sectional view of a basic package structure for an interferometric modulator device.

FIG. 9 is a cross-sectional view of one embodiment of a package structure for an interferometric modulator device with a primary seal and secondary seal.

FIG. 10 is a flow diagram of one embodiment of a method of sealing an interferometric modulator device package.

FIG. 11 is a cross-sectional view of one embodiment of a package structure for an interferometric modulator device with a primary seal and a secondary seal, wherein the secondary seal is integrated with an electrical connection of a driver circuit to the interferometric modulator device.

FIG. 12 is a flow diagram of one embodiment of a method of sealing an interferometric modulator device package.

DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

The following detailed description is directed to certain specific embodiments of the invention. However, the invention can be embodied in a multitude of different ways. In this description, reference is made to the drawings wherein like parts are designated with like numerals throughout. As will be apparent from the following description, the embodiments may be implemented in any device that is configured to display an image, whether in motion (e.g., video) or stationary (e.g., still image), and whether textual or pictorial. More particularly, it is contemplated that the embodiments may be implemented in or associated with a variety of electronic devices such as, but not limited to, mobile telephones, wireless devices, personal data assistants (PDAs), hand-held or portable computers, GPS receivers/navigators, cameras, MP3 players, camcorders, game consoles, wrist watches, clocks, calculators, television monitors, flat panel displays, computer monitors, auto displays (e.g., odometer display, etc.), cockpit controls and/or displays, display of camera views (e.g., display of a rear view camera in a vehicle), electronic photographs, electronic billboards or signs, projectors, architectural structures, packaging, and aesthetic structures (e.g., display of images on a piece of jewelry). MEMS devices of similar structure to those described herein can also be used in non-display applications such as in electronic switching devices.

A plurality of embodiments of MEMS device package structures including improved sealant structures are described below. In one embodiment, the MEMS device is packaged between a backplane and a substrate which are held together by a primary seal. The MEMS device package structure further comprises a second seal that is located around a perimeter of the primary seal and may be in contact with at least the substrate and the backplane. In some embodiments, the second seal is also in contact with the primary seal. One embodiment of a method of sealing a MEMS device package including a second seal comprises forming a second seal with an anisotropic conductive film, wherein the anisotropic conductive film also forms an electrical connection between a flexible circuit and conductive leads on a periphery of the package substrate. During attachment or contact of the flexible circuit and anisotropic conductive film to the substrate, a force is applied to the flexible circuit so as to force the anisotropic conductive film into contact with the backplane, thereby forming a second seal. These embodiments are discussed in more detail below in reference to FIGS. 7-11.

One interferometric modulator display embodiment comprising an interferometric MEMS display element is illustrated in FIG. 1. In these devices, the pixels are in either a bright or dark state. In the bright (“on” or “open”) state, the display element reflects a large portion of incident visible light to a user. When in the dark (“off” or “closed”) state, the display element reflects little incident visible light to the user. Depending on the embodiment, the light reflectance properties of the “on” and “off” states may be reversed. MEMS pixels can be configured to reflect predominantly at selected colors, allowing for a color display in addition to black and white.

FIG. 1 is an isometric view depicting two adjacent pixels in a series of pixels of a visual display, wherein each pixel comprises a MEMS interferometric modulator. In some embodiments, an interferometric modulator display comprises a row/column array of these interferometric modulators. Each interferometric modulator includes a pair of reflective layers positioned at a variable and controllable distance from each other to form a resonant optical cavity with at least one variable dimension. In one embodiment, one of the reflective layers may be moved between two positions. In the first position, referred to herein as the relaxed, the movable layer is positioned at a relatively large distance from a fixed partially reflective layer. In the second position, the movable layer is positioned more closely adjacent to the partially reflective layer. Incident light that reflects from the two layers interferes constructively or destructively depending on the position of the movable reflective layer, producing either an overall reflective or non-reflective state for each pixel.

The depicted portion of the pixel array in FIG. 1 includes two adjacent interferometric modulators 12a and 12b. In the interferometric modulator 12a on the left, a movable and highly reflective layer 14a is illustrated in a relaxed position at a predetermined distance from a fixed partially reflective layer 16a. In the interferometric modulator 12b on the right, the movable highly reflective layer 14b is illustrated in an actuated position adjacent to the fixed partially reflective layer 16b.

The fixed layers 16a, 16b are electrically conductive, partially transparent and partially reflective, and may be fabricated, for example, by depositing one or more layers each of chromium and indium-tin-oxide onto a transparent substrate 20. The layers are patterned into parallel strips, and may form row electrodes in a display device as described further below. The movable layers 14a, 14b may be formed as a series of parallel strips of a deposited metal layer or layers (orthogonal to the row electrodes 16a, 16b) deposited on top of posts 18 and an intervening sacrificial material deposited between the posts 18. When the sacrificial material is etched away, the deformable metal layers 14a, 14b are separated from the fixed metal layers by a defined gap 19. A highly conductive and reflective material such as aluminum may be used for the deformable layers, and these strips may form column electrodes in a display device.

With no applied voltage, the cavity 19 remains between the layers 14a, 16a and the deformable layer is in a mechanically relaxed state as illustrated by the pixel 12a in FIG. 1. However, when a potential difference is applied to a selected row and column, the capacitor formed at the intersection of the row and column electrodes at the corresponding pixel becomes charged, and electrostatic forces pull the electrodes together. If the voltage is high enough, the movable layer is deformed and is forced against the fixed layer (a dielectric material which is not illustrated in this Figure may be deposited on the fixed layer to prevent shorting and control the separation distance) as illustrated by the pixel 12b on the right in FIG. 1. The behavior is the same regardless of the polarity of the applied potential difference. In this way, row/column actuation that can control the reflective vs. non-reflective pixel states is analogous in many ways to that used in conventional LCD and other display technologies.

FIGS. 2 through 5 illustrate one exemplary process and system for using an array of interferometric modulators in a display application.

FIG. 2 is a system block diagram illustrating one embodiment of an electronic device that may incorporate aspects of the invention. In the exemplary embodiment, the electronic device includes a processor 21 which may be any general purpose single- or multi-chip microprocessor such as an ARM, Pentium®, Pentium II®, Pentium III®, Pentium IV®, Pentium® Pro, an 8051, a MIPS®, a Power PC®, an ALPHA®, or any special purpose microprocessor such as a digital signal processor, microcontroller, or a programmable gate array. As is conventional in the art, the processor 21 may be configured to execute one or more software modules. In addition to executing an operating system, the processor may be configured to execute one or more software applications, including a web browser, a telephone application, an email program, or any other software application.

In one embodiment, the processor 21 is also configured to communicate with an array controller 22. In one embodiment, the array controller 22 includes a row driver circuit 24 and a column driver circuit 26 that provide signals to a display array or panel 30. The cross section of the array illustrated in FIG. 1 is shown by the lines 1-1 in FIG. 2. For MEMS interferometric modulators, the row/column actuation protocol may take advantage of a hysteresis property of these devices illustrated in FIG. 3. It may require, for example, a 10 volt potential difference to cause a movable layer to deform from the relaxed state to the actuated state. However, when the voltage is reduced from that value, the movable layer maintains its state as the voltage drops back below 10 volts. In the exemplary embodiment of FIG. 3, the movable layer does not relax completely until the voltage drops below 2 volts. There is thus a range of voltage, about 3 to 7 V in the example illustrated in FIG. 3, where there exists a window of applied voltage within which the device is stable in either the relaxed or actuated state. This is referred to herein as the “hysteresis window” or “stability window.” For a display array having the hysteresis characteristics of FIG. 3, the row/column actuation protocol can be designed such that during row strobing, pixels in the strobed row that are to be actuated are exposed to a voltage difference of about 10 volts, and pixels that are to be relaxed are exposed to a voltage difference of close to zero volts. After the strobe, the pixels are exposed to a steady state voltage difference of about 5 volts such that they remain in whatever state the row strobe put them in. After being written, each pixel sees a potential difference within the “stability window” of 3-7 volts in this example. This feature makes the pixel design illustrated in FIG. 1 stable under the same applied voltage conditions in either an actuated or relaxed pre-existing state. Since each pixel of the interferometric modulator, whether in the actuated or relaxed state, is essentially a capacitor formed by the fixed and moving reflective layers, this stable state can be held at a voltage within the hysteresis window with almost no power dissipation. Essentially no current flows into the pixel if the applied potential is fixed.

In typical applications, a display frame may be created by asserting the set of column electrodes in accordance with the desired set of actuated pixels in the first row. A row pulse is then applied to the row 1 electrode, actuating the pixels corresponding to the asserted column lines. The asserted set of column electrodes is then changed to correspond to the desired set of actuated pixels in the second row. A pulse is then applied to the row 2 electrode, actuating the appropriate pixels in row 2 in accordance with the asserted column electrodes. The row 1 pixels are unaffected by the row 2 pulse, and remain in the state they were set to during the row 1 pulse. This may be repeated for the entire series of rows in a sequential fashion to produce the frame. Generally, the frames are refreshed and/or updated with new display data by continually repeating this process at some desired number of frames per second. A wide variety of protocols for driving row and column electrodes of pixel arrays to produce display frames are also well known and may be used in conjunction with the present invention.

FIGS. 4 and 5 illustrate one possible actuation protocol for creating a display frame on the 3×3 array of FIG. 2. FIG. 4 illustrates a possible set of column and row voltage levels that may be used for pixels exhibiting the hysteresis curves of FIG. 3. In the FIG. 4 embodiment, actuating a pixel involves setting the appropriate column to −V_bias, and the appropriate row to +ÿV, which may correspond to −5 volts and +5 volts respectively Relaxing the pixel is accomplished by setting the appropriate column to +V_bias, and the appropriate row to the same +ÿV, producing a zero volt potential difference across the pixel. In those rows where the row voltage is held at zero volts, the pixels are stable in whatever state they were originally in, regardless of whether the column is at +V_bias, or −V_bias. As is also illustrated in FIG. 4, it will be appreciated that voltages of opposite polarity than those described above can be used, e.g., actuating a pixel can involve setting the appropriate column to +V_bias, and the appropriate row to −ΔV. In this embodiment, releasing the pixel is accomplished by setting the appropriate column to −V_bias, and the appropriate row to the same −ΔV, producing a zero volt potential difference across the pixel.

FIG. 5B is a timing diagram showing a series of row and column signals applied to the 3×3 array of FIG. 2 which will result in the display arrangement illustrated in FIG. 5A, where actuated pixels are non-reflective. Prior to writing the frame illustrated in FIG. 5A, the pixels can be in any state, and in this example, all the rows are at 0 volts, and all the columns are at +5 volts. With these applied voltages, all pixels are stable in their existing actuated or relaxed states.

In the FIG. 5A frame, pixels (1,1), (1,2), (2,2), (3,2) and (3,3) are actuated. To accomplish this, during a “line time” for row 1, columns 1 and 2 are set to −5 volts, and column 3 is set to +5 volts. This does not change the state of any pixels, because all the pixels remain in the 3-7 volt stability window. Row 1 is then strobed with a pulse that goes from 0, up to 5 volts, and back to zero. This actuates the (1,1) and (1,2) pixels and relaxes the (1,3) pixel. No other pixels in the array are affected. To set row 2 as desired, column 2 is set to −5 volts, and columns 1 and 3 are set to +5 volts. The same strobe applied to row 2 will then actuate pixel (2,2) and relax pixels (2,1) and (2,3). Again, no other pixels of the array are affected. Row 3 is similarly set by setting columns 2 and 3 to −5 volts, and column 1 to +5 volts. The row 3 strobe sets the row 3 pixels as shown in FIG. 5A. After writing the frame, the row potentials are zero, and the column potentials can remain at either +5 or −5 volts, and the display is then stable in the arrangement of FIG. 5A. It will be appreciated that the same procedure can be employed for arrays of dozens or hundreds of rows and columns. It will also be appreciated that the timing, sequence, and levels of voltages used to perform row and column actuation can be varied widely within the general principles outlined above, and the above example is exemplary only, and any actuation voltage method can be used with the systems and methods described herein.

FIGS. 6A and 6B are system block diagrams illustrating an embodiment of a display device 40. The display device 40 can be, for example, a cellular or mobile telephone. However, the same components of display device 40 or slight variations thereof are also illustrative of various types of display devices such as televisions and portable media players.

The display device 40 includes a housing 41, a display 30, an antenna 43, a speaker 44, an input device 48, and a microphone 46. The housing 41 is generally formed from any of a variety of manufacturing processes as are well known to those of skill in the art, including injection molding, and vacuum forming. In addition, the housing 41 may be made from any of a variety of materials, including but not limited to plastic, metal, glass, rubber, and ceramic, or a combination thereof. In one embodiment the housing 41 includes removable portions (not shown) that may be interchanged with other removable portions of different color, or containing different logos, pictures, or symbols.

The display 30 of exemplary display device 40 may be any of a variety of displays, including a bi-stable display, as described herein. In other embodiments, the display 30 includes a flat-panel display, such as plasma, EL, OLED, STN LCD, or TFT LCD as described above, or a non-flat-panel display, such as a CRT or other tube device, as is well known to those of skill in the art. However, for purposes of describing the present embodiment, the display 30 includes an interferometric modulator display, as described herein.

The components of one embodiment of exemplary display device 40 are schematically illustrated in FIG. 6B. The illustrated exemplary display device 40 includes a housing 41 and can include additional components at least partially enclosed therein. For example, in one embodiment, the exemplary display device 40 includes a network interface 27 that includes an antenna 43 which is coupled to a transceiver 47. The transceiver 47 is connected to a processor 21, which is connected to conditioning hardware 52. The conditioning hardware 52 may be configured to condition a signal (e.g. filter a signal). The conditioning hardware 52 is connected to a speaker 44 and a microphone 46. The processor 21 is also connected to an input device 48 and a driver controller 29. The driver controller 29 is coupled to a frame buffer 28, and to an array driver 22, which in turn is coupled to a display array 30. A power supply 50 provides power to all components as required by the particular exemplary display device 40 design.

The network interface 27 includes the antenna 43 and the transceiver 47 so that the exemplary display device 40 can communicate with one ore more devices over a network. In one embodiment the network interface 27 may also have some processing capabilities to relieve requirements of the processor 21. The antenna 43 is any antenna known to those of skill in the art for transmitting and receiving signals. In one embodiment, the antenna transmits and receives RF signals according to the IEEE 802.11 standard, including IEEE 802.11(a), (b), or (g). In another embodiment, the antenna transmits and receives RF signals according to the BLUETOOTH standard. In the case of a cellular telephone, the antenna is designed to receive CDMA, GSM, AMPS or other known signals that are used to communicate within a wireless cell phone network. The transceiver 47 pre-processes the signals received from the antenna 43 so that they may be received by and further manipulated by the processor 21. The transceiver 47 also processes signals received from the processor 21 so that they may be transmitted from the exemplary display device 40 via the antenna 43.

In an alternative embodiment, the transceiver 47 can be replaced by a receiver. In yet another alternative embodiment, network interface 27 can be replaced by an image source, which can store or generate image data to be sent to the processor 21. For example, the image source can be a digital video disc (DVD) or a hard-disc drive that contains image data, or a software module that generates image data.

Processor 21 generally controls the overall operation of the exemplary display device 40. The processor 21 receives data, such as compressed image data from the network interface 27 or an image source, and processes the data into raw image data or into a format that is readily processed into raw image data. The processor 21 then sends the processed data to the driver controller 29 or to frame buffer 28 for storage. Raw data typically refers to the information that identifies the image characteristics at each location within an image. For example, such image characteristics can include color, saturation, and gray-scale level.

In one embodiment, the processor 21 includes a microcontroller, CPU, or logic unit to control operation of the exemplary display device 40. Conditioning hardware 52 generally includes amplifiers and filters for transmitting signals to the speaker 44, and for receiving signals from the microphone 46. Conditioning hardware 52 may be discrete components within the exemplary display device 40, or may be incorporated within the processor 21 or other components.

The driver controller 29 takes the raw image data generated by the processor 21 either directly from the processor 21 or from the frame buffer 28 and reformats the raw image data appropriately for high speed transmission to the array driver 22. Specifically, the driver controller 29 reformats the raw image data into a data flow having a raster-like format, such that it has a time order suitable for scanning across the display array 30. Then the driver controller 29 sends the formatted information to the array driver 22. Although a driver controller 29, such as a LCD controller, is often associated with the system processor 21 as a stand-alone Integrated Circuit (IC), such controllers may be implemented in many ways. They may be embedded in the processor 21 as hardware, embedded in the processor 21 as software, or fully integrated in hardware with the array driver 22.

Typically, the array driver 22 receives the formatted information from the driver controller 29 and reformats the video data into a parallel set of waveforms that are applied many times per second to the hundreds and sometimes thousands of leads coming from the display's x-y matrix of pixels.

In one embodiment, the driver controller 29, array driver 22, and display array 30 are appropriate for any of the types of displays described herein. For example, in one embodiment, driver controller 29 is a conventional display controller or a bi-stable display controller (e.g., an interferometric modulator controller). In another embodiment, array driver 22 is a conventional driver or a bi-stable display driver (e.g., an interferometric modulator display). In one embodiment, a driver controller 29 is integrated with the array driver 22. Such an embodiment is common in highly integrated systems such as cellular phones, watches, and other small area displays. In yet another embodiment, display array 30 is a typical display array or a bi-stable display array (e.g., a display including an array of interferometric modulators).

The input device 48 allows a user to control the operation of the exemplary display device 40. In one embodiment, input device 48 includes a keypad, such as a QWERTY keyboard or a telephone keypad, a button, a switch, a touch-sensitive screen, a pressure- or heat-sensitive membrane. In one embodiment, the microphone 46 is an input device for the exemplary display device 40. When the microphone 46 is used to input data to the device, voice commands may be provided by a user for controlling operations of the exemplary display device 40.

Power supply 50 can include a variety of energy storage devices as are well known in the art. For example, in one embodiment, power supply 50 is a rechargeable battery, such as a nickel-cadmium battery or a lithium ion battery. In another embodiment, power supply 50 is a renewable energy source, a capacitor, or a solar cell, including a plastic solar cell, and solar-cell paint. In another embodiment, power supply 50 is configured to receive power from a wall outlet.

In some implementations control programmability resides, as described above, in a driver controller which can be located in several places in the electronic display system. In some cases control programmability resides in the array driver 22. Those of skill in the art will recognize that the above-described optimization may be implemented in any number of hardware and/or software components and in various configurations.

The details of the structure of interferometric modulators that operate in accordance with the principles set forth above may vary widely. For example, FIGS. 7A-7C illustrate three different embodiments of the moving mirror structure. FIG. 7A is a cross section of the embodiment of FIG. 1, where a strip of metal material 14 is deposited on orthogonally extending supports 18. In FIG. 7B, the moveable reflective material 14 is attached to supports at the corners only, on tethers 32. In FIG. 7C, the moveable reflective material 14 is suspended from a deformable layer 34. This embodiment has benefits because the structural design and materials used for the reflective material 14 can be optimized with respect to the optical properties, and the structural design and materials used for the deformable layer 34 can be optimized with respect to desired mechanical properties. The production of various types of interferometric devices is described in a variety of published documents, including, for example, U.S. Published Application 2004/0051929. A wide variety of known techniques may be used to produce the above described structures involving a series of material deposition, patterning, and etching steps.

The moving parts of a MEMS device, such as an interferometric modulator array, preferably have a protected space in which to move. Packaging techniques for a MEMS device will be described in more detail below. A schematic of a basic package structure for a MEMS device, such as an interferometric modulator array, is illustrated in FIG. 8. As shown in FIG. 8, a basic package structure 70 includes a substrate 72 and a backplane cover or “cap” 74, wherein an interferometric modulator array 76 is formed on the substrate 72. This cap 74 is also called a “backplane”.

The substrate 72 and the backplane 74 are joined by a seal 78 to form the package structure 70, such that the interferometric modulator array 76 is encapsulated by the substrate 72, backplane 74, and the seal 78. This forms a cavity 79 between the backplane 74 and the substrate 72. The seal 78 may be a non-hermetic seal, such as a conventional epoxy-based adhesive. In other embodiments, the seal 78 may be a polyisobutylene (sometimes called butyl rubber, and other times PIB), o-rings, polyurethane, thin film metal weld, liquid spin-on glass, solder, polymers, or plastics, among other types of seals that may have a range of permeability of water vapor of about 0.2-4.7 g mm/m2 kPa day. In still other embodiments, the seal 78 may be a hermetic seal and may comprise, for example, metals, welds, and glass frits. Methods of hermetic sealing comprise, for example, metal or solder thin film or preforms, laser or resistive welding techniques, and anodic bonding techniques, wherein the resulting package structure may or may not require a desiccant to achieve the desired internal package requirements.

The seal 78 may be implemented as a closed seal (continuous) or an open seal (non-continuous), and may be applied or formed on the substrate 72, backplane 74, or both the substrate and backplane 74 in a method of packaging the interferometric modulator array 76. The seal 78 may be applied through simple in-line manufacturing processes and may have advantages for lower temperature processes, whereas the techniques of welding and soldering may require very high temperature processes that can damage the package structure 20, are relatively expensive. In some cases, localized heating methods can be used to reduce the process temperatures and yield a viable process solution.

In some embodiments, the package structure 70 includes a getter such as a desiccant 80 configured to reduce moisture within the cavity 79. The skilled artisan will appreciate that a desiccant may not be necessary for a hermetically sealed package, but may be desirable to control moisture resident within the package. In one embodiment, the desiccant 80 is positioned between the interferometric modulator array 76 and the backplane 74. Desiccants may be used for packages that have either hermetic or non-hermetic seals. In packages having a hermetic seal, desiccants are typically used to control moisture resident within the interior of the package. In packages having a non-hermetic seal, a desiccant may be used to control moisture moving into the package from the environment. Generally, any substance that can trap moisture while not interfering with the optical properties of the interferometric modulator array may be used as the desiccant 80. Suitable getter and desiccant materials include, but are not limited to, zeolites, molecular sieves, surface adsorbents, bulk adsorbents, and chemical reactants.

The desiccant 80 may be in different forms, shapes, and sizes. In addition to being in solid form, the desiccant 80 may alternatively be in powder form. These powders may be inserted directly into the package or they may be mixed with an adhesive for application. In an alternative embodiment, the desiccant 80 may be formed into different shapes, such as cylinders, rings, or sheets, before being applied inside the package.

The skilled artisan will understand that the desiccant 80 can be applied in different ways. In one embodiment, the desiccant 80 is deposited as part of the interferometric modulator array 76. In another embodiment, the desiccant 80 is applied inside the package 70 as a spray or a dip coat.

The substrate 72 may be a semi-transparent or transparent substance capable of having thin film, MEMS devices built upon it. Such transparent substances include, but are not limited to, glass, plastic, and transparent polymers. The interferometric modulator array 76 may comprise membrane modulators or modulators of the separable type. The skilled artisan will appreciate that the backplane 74 may be formed of any suitable material, such as glass, metal, foil, polymer, plastic, ceramic, or semiconductor materials (e.g., silicon).

The packaging process may be accomplished in a vacuum, pressure between a vacuum up to and including ambient pressure, normal atmospheric pressure conditions, or pressure higher than ambient pressure. The packaging process may also be accomplished in an environment of varied and controlled high or low pressure during the sealing process. There may be advantages to packaging the interferometric modulator array 76 in a completely dry environment, but it is not necessary. Similarly, the packaging environment may be of an inert gas at ambient conditions. Packaging at ambient conditions allows for a lower cost process and more potential for versatility in equipment choice because the device may be transported through ambient conditions without affecting the operation of the device.

Generally, it is desirable to minimize the permeation of water vapor into the package structure 70, and thus control the environment in the cavity 79 of the package structure 70 and hermetically seal it to ensure that the environment remains constant. When the humidity or water vapor level within the package exceeds a level beyond which surface tension from the water vapor becomes higher than the restoration force of a movable element (not shown) in the interferometric modulator array 76, the movable element may become permanently adhered to the surface. There is thus a need to reduce the moisture level within the package.

MEMS devices, such as interferometric modulator displays, have a lifetime based at least in part on the amount of moisture to which the device is exposed. Thus, the lifetime of an interferometric modulator display may be determined based at least in part on the level of moisture control provided by the desiccant within a package structure and the water vapor permeability of the seal between the backplane and the substrate. The lifetime of a display device can be defined as the time at which the desiccant is saturated with water. The water saturating the desiccant includes the water vapor that naturally enters the package structure through the seal and is absorbed into the desiccant. The value can be designed to be very low, such as on the order of 0.0001 grams per day, such that the lifetime is on the order of about 10 years or more. The seal material may be selected according to its water vapor permeability properties depending on the expected lifetime of the interferometric modulator display. For example, an interferometric modulator display intended for use in inexpensive and/or disposable devices, such as children's toys and disposable cameras, may comprise a seal with a higher water vapor permeability rate than a device intended to have a longer lifetime.

FIG. 9 is a side-view illustration of one embodiment of the package structure 70 including a secondary seal 82. The secondary seal 82 is formed or positioned substantially around the perimeter of the backplane 74 and the outer periphery of the primary seal 48, and in contact with the substrate 72, thereby sealing the junction of the backplane 74, primary seal 48, and the substrate 72 from ambient conditions. The secondary seal 82 may be formed as a fillet, or have a plurality of different cross-sectional geometries, such as circular, ovular, or rectangular. The secondary seal 82 may comprise a non-hermetic seal, such as a conventional epoxy-based adhesive or silicone based adhesive. In some embodiments, the secondary seal 82 comprises PIB (polyisobutylene), a UV curable adhesive, one or more o-rings, polyurethane, thin film metal weld, liquid spin-on glass, solder (such as a solder preform), polymers, plastics, or hydrophobic film or liquid, or a combination thereof. In other embodiments, the secondary seal 82 may be a hermetic seal. As described above, the outer seal provides a means for sealing the outer periphery of the primary seal.

As will be appreciated by those skilled in the art, the secondary seal 82 may be formed or applied to the package structure through a plurality of methods, such as application in a liquid or semi-liquid state and curing through exposure to air, elevated temperatures, UV light, and/or placement. Exemplary methods of forming and placing a secondary seal are discussed in more detail hereinafter in reference to FIGS. 9 and 11.

In certain embodiments, the combined water vapor permeability of the secondary seal 82 and the primary seal 78 accords with a desired total water vapor permeability for the package structure 70. In some embodiments, a material with a higher water vapor permeability coefficient and lower effective lifetime than the primary seal may be used for the secondary seal 82. The addition of the secondary seal 82 provides for relaxed constraints on the properties of the primary seal 78, thereby reducing testing procedures and costs in optimization of the primary seal 78. The package structure for interferometric modulator displays intended for short use, for example, such as in inexpensive and/or disposable devices, can be modified to reduce material reliability constraints. Relaxed constraints on the properties of the package structure seal can reduce costs for the package structure, thereby making the implementation of interferometric modulator displays in short use devices cost effective.

As discussed above, the secondary seal 82 may be formed, applied, or placed using a plurality of methods known in the art. FIG. 10 is a flow diagram illustrating one embodiment of a method 900 of sealing a MEMS device, such as an interferometric modulator device, package with a secondary seal. The method 900 begins in a step 902 and proceeds to a step 904 wherein a solder preform is placed on a substrate proximate a perimeter of a MEMS device formed on the substrate. The solder preform may comprise, for example, lead or tin. Following placement of the solder preform in step 904, the method proceeds to a step 906 wherein a primary seal, the substrate, and a backplane are contacted so as to seal the MEMS device from ambient conditions. The primary seal preferably contacts the substrate between the MEMS device formed thereon and the solder preform, and the primary seal may be initially positioned on the substrate, the backplane, or both the substrate and the backplane. The method 900 proceeds to a step 908 wherein the solder preform is melted so as to contact the backplane and form a secondary seal in contact with the substrate and the backplane. The solder may also be melted so as to contact the primary seal. The method ends in a step 910. In some embodiments of the method 900, the solder preform is placed on the substrate after the primary seal, substrate, and backplane are contacted.

In certain embodiments, contacting the primary seal, substrate, and backplane in step 906 functions primarily to align and/or affix the backplane with the substrate, wherein, for example, the primary seal comprises an adhesive. The secondary seal formed from the solder preform may then function as the major environmental seal for the device package, wherein the primary seal provides minor sealant attributes to the device package.

FIG. 11 is a side-view illustration of another embodiment of an interferometric modulator display package structure 70 with a secondary seal. As discussed above in reference to FIG. 1, the position of the movable layer of each element of the interferometric modulator array is controlled by the application of a voltage across the two layers which form the cavity. In order to apply the voltage, each interferometric modulator array element is coupled to conductive leads 1002 on the substrate 72, and the conductive leads 1002 are coupled to a driver circuit 1004 configured to control the voltage applied to each interferometric modulator array element, such as the array driver 22. In certain embodiments, the driver circuit 1004 is coupled to the conductive leads 1004 at a perimeter of the substrate 72 via a flexible circuit or conductive tape 1006 and an anisotropic conductive film (ACF) 1008. As is known in the art, ACF comprises a thermoset adhesive binder and a matrix of conductive particles or spheres 1010. The flexible circuit 1006 typically includes a plurality of conductive leads, which are electrically coupled to the conductive leads 1002 on the substrate 72 via the conductive particles 1010 in the ACF 1008.

During attachment of the flexible circuit 1006 and ACF 1008 to the substrate 72, the ACF adhesive is in a solid state (or semi-solid state) and may be applied in a tape form. In one embodiment, the ACF melts with the application of an elevated temperature and subsequently solidifies when cooled to room temperature. Accordingly, the final position of the ACF can be manipulated by applying pressure to the flexible circuit 1006 to force a quantity or portion of the ACF 1008 to contact the backplane 74, thereby forming a secondary seal in contact with the backplane 74 and the substrate 72. In some embodiments, the ACF 1008 is also in contact with the primary seal. The secondarily sealed interferometric modulator device package structure of FIG. 11 advantageously includes improved seal properties without additional material cost or assembly/manufacturing processes for a second seal.

One embodiment of a method 1100 of sealing an interferometric modulator array package structure with a secondary seal is illustrated in the flow diagram of FIG. 12. As illustrated in FIG. 12, the method 1100 begins in a step 1102 and proceeds to a step 1104 wherein a primary seal is provided between a backplane and a substrate, wherein a MEMS device, such as an interferometric modulator device, is formed on the substrate. The method further comprises contacting an ACF to conductive leads on the substrate in a step 1106, wherein the ACF provides electrical connection between the conductive leads on the substrate and a flexible circuit. The flexible circuit can be configured for connection to an array driver circuit, for example. Following step 1106, the method proceeds to a step 1108 wherein a force is applied to the flexible circuit sufficient to force a portion of the ACF in contact with the package backplane and primary seal. In some embodiments, the ACF is in contact with only the substrate and the backplane, and not the primary seal. In certain embodiments, the method 1100 additionally comprises forming a third seal or barrier, such as a hydrophobic seal, on the ACF, thereby further reducing the water permeability of the package structure.

In another embodiment, the ACF may comprise a sealing region wherein a portion of the ACF is specifically tailored for sealing. For example, the material at the sealing region of the ACF may comprise both a resin and conductive particles, wherein the resin is configured with a hydrophobic property or highly water impermeable barrier for implementation as a secondary seal.

As will be appreciated by those skilled in the art, the above described and illustrated methods and apparatus are exemplary in nature and other embodiments are within the scope of the invention. For example, the secondary seal may have a plurality of forms and configurations, and may comprise a plurality of materials. In addition, the methods of formation of the secondary seal may include more or fewer steps, and may, for example take place before, during, or after encapsulation of a MEMS device within a packaging structure.

The foregoing description details certain embodiments of the invention. It will be appreciated, however, that no matter how detailed the foregoing appears in text, the invention can be practiced in many ways. As is also stated above, it should be noted that the use of particular terminology when describing certain features or aspects of the invention should not be taken to imply that the terminology is being re-defined herein to be restricted to including any specific characteristics of the features or aspects of the invention with which that terminology is associated. The scope of the invention should therefore be construed in accordance with the appended claims and any equivalents thereof.

Claims

1. A microelectromechanical system (MEMS) device, comprising: a substrate; a MEMS device formed on said substrate; a backplane; a primary seal positioned proximate a perimeter of the MEMS device and in contact with said substrate and said backplane; and a secondary seal positioned proximate an outer periphery of said primary seal and in contact with said substrate and said backplane.

2. The MEMS device of claim 1, wherein said primary seal is one of a continuous and a non-continuous seal.

3. The MEMS device of claim 1, wherein said secondary seal is one of a continuous and non-continuous seal.

4. The MEMS device of claim 1, wherein said secondary seal comprises an anisotropic conductive film (ACF).

5. The MEMS device of claim 4, wherein the ACF comprises a tailored sealing portion proximate said outer periphery of said primary seal.

6. The MEMS device of claim 1, wherein said secondary seal is in contact with said primary seal.

7. The MEMS device of claim 1, wherein said secondary seal comprises a hydrophobic material.

8. The MEMS device of claim 1, wherein said secondary seal comprises one of an adhesive and a metal.

9. The MEMS device of claim 1, wherein said MEMS device comprises an interferometric modulator array.

10. The MEMS device of claim 1, wherein said device comprises a display system comprising: a processor that is in electrical communication with said MEMS device, said processor being configured to process image data; and a memory device in electrical communication with said processor.

11. The MEMS device as recited in claim 10, further comprising: a first controller configured to send at least one signal to said MEMS device; and a second controller configured to send at least a portion of said image data to said first controller.

12. The MEMS device as recited in claim 10, further comprising: an image source module configured to send said image data to said processor.

13. The MEMS device as recited in claim 12, wherein said image source module comprises at least one of a receiver, transceiver, and transmitter.

14. The MEMS device as recited in claim 10, further comprising: an input device configured to receive input data and to communicate said input data to said processor.

15. A method of sealing a microelectromechanical system (MEMS) device package, comprising: providing a MEMS device package comprising a backplane and a substrate, wherein a MEMS device is formed on said substrate; providing a primary seal formed proximate a perimeter of said MEMS device and between said backplane and said substrate; and forming a secondary seal proximate an outer periphery of said primary seal and in contact with said substrate and said backplane.

16. The method of claim 15, wherein said primary seal is formed on at least one of said backplane and said substrate.

17. The method of claim 15, wherein forming said secondary seal comprises placing a solder preform proximate an outer periphery of said primary seal, and melting said solder preform to contact said substrate and said backplane.

18. The method of claim 17, wherein said placing occurs before said backplane, said primary seal, and said substrate are assembled, and wherein said melting occurs after said assembly.

19. The method of claim 15, wherein said secondary seal is formed in contact with said primary seal.

20. The method of claim 15, wherein said primary seal is one of a continuous and a non-continuous seal.

21. The method of claim 15, wherein said secondary seal comprises an anisotropic conductive film.

22. The method of claim 15, wherein said secondary seal comprises a hydrophobic material.

23. The method of claim 15, wherein said secondary seal comprises one of an adhesive and a metal.

24. The method of claim 15, wherein said MEMS device comprises an interferometric modulator array.

25. A system for sealing a microelectromechanical system (MEMS) device package, comprising: a MEMS device package comprising a backplane and a substrate, wherein a MEMS device is formed on said substrate; a primary seal formed proximate a perimeter of said MEMS device and between said backplane and said substrate; and means for sealing an outer periphery of said primary seal, wherein said means is in contact with said substrate and said backplane.

26. The system of claim 25, wherein said means for sealing comprises a solder preform placed proximate an outer periphery of said primary seal, and means for melting said solder preform to contact said substrate and said backplane.

27. The system of claim 25, wherein said means for sealing is in contact with said primary seal.

28. The system of claim 25, wherein said primary seal is one of a continuous and a non-continuous seal.

29. The system of claim 25, wherein said means for sealing comprises an anisotropic conductive film.

30. The system of claim 25, wherein said means for sealing comprises a hydrophobic material.

31. The system of claim 25, wherein said means for sealing comprises one of an adhesive and a metal.

32. The system of claim 25, wherein said MEMS device comprises an interferometric modulator array.

33. A microelectromechanical system (MEMS) device package comprising a primary inner seal and a secondary outer seal, wherein said package is produced by a method comprising: providing a MEMS device package comprising a backplane and a substrate, wherein a MEMS device is formed on said substrate; providing a primary seal formed proximate a perimeter of said MEMS device and between said backplane and said substrate; and forming a secondary seal proximate an outer periphery of said primary seal and in contact with said substrate and said backplane.

34. The MEMS device package of claim 33, wherein said primary seal is formed on at least one of said backplane and said substrate.

35. The MEMS device package of claim 33, wherein forming said secondary seal comprises placing a solder preform proximate an outer periphery of said primary seal, and melting said solder preform to contact said substrate and said backplane.

36. The MEMS device package of claim 35, wherein said placing occurs before said backplane, said primary seal, and said substrate are assembled, and wherein said melting occurs after said assembly.

37. The MEMS device package of claim 33, wherein said secondary seal is formed in contact with said primary seal.

38. The MEMS device package of claim 33, wherein said primary seal is one of a continuous and a non-continuous seal.

39. The MEMS device package of claim 33, wherein said secondary seal comprises an anisotropic conductive film.

40. The MEMS device package of claim 33, wherein said secondary seal comprises a hydrophobic material.

41. The MEMS device package of claim 33, wherein said secondary seal comprises one of an adhesive and a metal.

42. The MEMS device package of claim 33, wherein said MEMS device comprises an interferometric modulator array.

43. A microelectromechanical system (MEMS) device package, comprising: a substrate; a MEMS device formed on said substrate; a backplane; a seal positioned proximate a perimeter of said MEMS device and in contact with said substrate and said backplane; a flexible circuit; and an anisotropic conductive film in contact with said flexible circuit, said substrate, and said backplane.

44. The MEMS device package of claim 43, wherein said anisotropic conductive film is in contact with said seal.

45. The MEMS device package of claim 43, wherein said MEMS device comprises an interferometric modulator array.

46. The MEMS device package of claim 43, wherein said anisotropic conductive film comprises a tailored sealing portion proximate said seal.

47. A method of assembling a microelectromechanical system (MEMS) device package, comprising: contacting a flexible circuit, an anisotropic conductive film, and a substrate, wherein said substrate comprises a MEMS device thereon, and a seal proximate a perimeter of said MEMS device and in contact with said substrate and a backplane; and applying a force to said flexible circuit so as to force said anisotropic conductive film into contact with said backplane.

48. The method of claim 47, wherein said anisotropic conductive film is in contact with said seal.