This disclosure relates to a micromirror system and to a method of manufacturing a micromirror system.
Micro-technologically manufactured beam deflection mirrors, so-called MEMS scanners, can be applied to a multitude of applications, such as laser projection displays, barcode scanners, microscopes, OCT endoscopes, LIDAR scanners, imaging spectrometers and others. The beam deflection mirrors which are designed as microactuators, for example, comprise an oscillation body which is designed as a mirror and which is suspended in a chip frame in an oscillatory manner via one or more spring elements. The chip frame thereby can be closed at one side, wherein the mirror plate and the spring elements are arranged in a cavity. The chip frame however can also be encapsulated on both sides with a glass cover.
Such micromirror systems or arrangements or beam deflection mirrors usually have very low moments of inertia which permit such miniaturised beam deflection systems to achieve very high scan speeds of up to 100 kHz. Adequately large deflection angles can be produced by way of an operation in resonance, despite very limited drive forces. This advantage is particularly useful in display technology.
However, there are applications, in which MEMS scanners or microactuators are not used and preference is given to conventionally manufactured galvanometer scanners.
A micromirror system including a chip frame, at least one spring element, and at least one mirror plate oscillatorily suspended in the chip frame via the at least one spring element. The chip frame and the at least one spring element include at least one microchannel which is provided with an inlet opening and an outlet opening for leading through a flowing coolant.
While multiple embodiments are disclosed, still other embodiments will become apparent to those skilled in the art from the following detailed description, which shows and describes illustrative embodiments. Accordingly, the drawings and detailed description are to be regarded as illustrative in nature and not restrictive.
a-f are diagrams illustrating different steps of a method for manufacturing a micromirror system or arrangement.
a-d are diagrams illustrating different steps of a method for manufacturing a micromirror system or arrangement.
a-d are diagrams illustrating different steps of a method for manufacturing a micromirror system or arrangement.
Until now, there were applications, in which MEMS scanners or microactuators could not be successfully applied. Instead, preference was given to conventionally manufactured galvanometer scanners. These applications include all vector scan applications, with which one must make do without resonant operation, and all applications in which laser powers above a few Watts must be handled by the beam reflection system. Until now it has not been the MEMS scanners, but conventional galvanometer scanners which have been applied. Finally, up to now, one had to fall back on galvanometer scanners in all applications, in which the laser beam to be scanned has a diameter above 5 mm.
These restrictions come down to one cause, which is micro-technologically manufactured beam deflection systems have forces which are many magnitudes smaller than those which are available in conventionally manufactured macroscopic scanners. This inevitably leads to the fact that the moments of inertia of MEMS scanners must be accordingly smaller, in order to achieve appreciable deflections and beam defections. Strict limits are therefore placed on the mirror diameter, the mirror thickness and the spring cross sections of MEMS mirrors. The low thermal capacity of MEMS scanners which results from this, and the low thermal power which can be dissipated to the surroundings via the thin spring cross sections until now have not permitted the applications of these MEMS mirrors in laser material machining, where laser powers of up to several kilowatts are often applied.
Even conventional mirrors must be coated with elaborate dielectric multilayer stacks, in order to achieve an as high as possible reflectivity of >99% and thus to keep the thermal loading of the mirror due to absorption as low as possible. These layer stacks produce high mechanical stress gradients which deform the mirror plate in an undesirable manner The thinner the mirror, the greater is the deformation. MEMS mirrors typically have a ratio of mirror thickness to diameter of one to ten, i.e. if a mirror of several millimetres diameter were to be coated in the mentioned manner, it would have to have a mirror thickness of up to several tenths of a millimetre, which however due to the increased moments of inertia which this entails, necessitates drive forces which cannot be achieved in a MEMS component.
A mirror arrangement which comprises an optical element received in a chamber, and a substrate forming the chamber walls, and at least one transparent cover is known from DE 10 2007 034 652 A1. A medium for thermal dissipation is provided in the chamber and moreover the chamber walls are cooled, for example interspersed with cooling channels, through which a cooling gas or a cooling liquid is led, in order to lead away the heat of the surface of the optical element, said heat caused by the beamed-in light.
The present disclosure provides a micromirror system or arrangement with a mirror plate which is oscillatorily suspended via at least one spring element, with which the heat dissipation from the mirror plate is improved, in order to realise comparatively large diameters of the active mirror plate, to keep the dynamic and static deformations low, to achieve large scan amplitudes and to ensure a high tolerance with regard to heat input.
The mirror plate 2 of the microactuator 1 in the known manner is deflected into oscillation by an electrostatic, electromagnetic, piezoelectric or thermomechanical drive.
A further embodiment example of a microactuator 1 is represented in
A micromirror system or arrangement 100 is represented in
A further embodiment example of a micromirror system or arrangement 100 is represented in
An embodiment example of a method for manufacturing a micromirror system or arrangement 100 or a microactuator 1, as described previously, is described in more detail by way of
The starting step a) shows a silicon wafer 22, into which a groove 23 is incorporated by way of anisotropic plasma etching, said groove specifying the geometric course of the microchannel 5 according to the
A multitude of micromirror arrangements are manufactured on a silicon wafer according to the steps a) to f), wherein a multitude of glass covers 8 is likewise arranged on a glass cover wafer. The wafer composite manufactured according to step f) is then singularised into the multitude of micromirror arrangements 100, wherein the microchannels 5 are released, i.e. the inlet openings and outlet openings are formed, on singularisation.
A further method is represented in the
As specified, the steps a) to c) in
In the above description, different features were mentioned with different embodiment examples. Even if a feature was only described for one embodiment example, it can be applied to all other embodiment examples, so that micromirror systems or arrangements with different combinations of described features can be provided.
As described in the disclosure, with a micromirror system or arrangement with at least one mirror plate which is oscillatorily suspended in a chip frame via one or more spring elements, at least one microchannel provided with an inlet and an outlet opening and for leading through a flowing coolant, for example liquid or gas, is arranged in the chip frame and in the one or more spring elements or in both and additionally in the at least one mirror plate, it is possible to dissipate heat via the coolant led in the microchannel. Thereby, a gaseous or fluid or multi-phase medium is used as a coolant, and this coolant can be led through the channel with the help of a pressure drop, such that a temperature gradient between the mentioned constituents, in particular the spring suspension and the mirror plate and the through-flowing medium can be utilised, in order to convectively dissipate the heat. A lateral dissipation of heat is realised, wherein the heat is transported via the springs to the surrounding substrate. Compressed air, helium, water and other fluid media which for example have a high thermal capacity can be used as a flowing coolant. It is also possible to realise MEMS mirrors for high light powers and to keep the dynamic and static mirror deformations low on account of the heat dissipation. Other fields of application can result by way of this, for example laser material machining and comparable high-power laser applications, which can then be realised with components of microtechnology. Many advantages with regard to manufacturing thereby result, and an inexpensive mass production is conceivable.
According to the disclosure, the inlet opening and the outlet opening are arranged on one side of the chip frame or on different sides of the chip frame, by which means different design possibilities result. For example, a mirror plate which is suspended on only one spring element can be realised, wherein the channel can be led back onto the same side of the chip frame in a loop-like manner, such as via the mirror plate. However, it is also possible to suspend the mirror plate on two opposite spring elements, by which means the microchannel can have its inlet opening on the one side of the chip frame and its outlet opening on the other side of the chip frame. Mirror plates suspended in a single-axis or multi-axis manner can also be realised.
In some embodiments, the inlet opening and the outlet opening of the at least one microchannel can be directed in the longitudinal direction of the part of the microchannel which connects to the respective opening, or in some embodiments the inlet opening and/or the outlet opening can run in a direction which is angled to the longitudinal direction at a non-negligible angle, such as at an angle of 90°. The design possibilities are also improved by way of these embodiments, and the coolant feed and discharge can be adapted to the surrounding conditions.
In some embodiments, the course of the at least one microchannel in the chip frame and/or the one or more spring elements and/or the at least one mirror plate can be designed in a loop-like or branched manner. The realised heat dissipation can be adapted to the expected heat input by way of this, so that the functional reliability of the micromirror arrangement is ensured.
In some embodiments, the chip frame on the upper side and/or lower side is connected to a cover provided with a cavity, in a manner such that at least a part of the chip frame, the one or more spring elements and the at least one mirror plate are encapsulated in a cavity. The microactuator which is designed as a mirror can be protected from contamination due to the fact that the encapsulation which can be implemented on the wafer level, is sealed, such as hermetically sealed. Moreover, the cavity can be subjected to a vacuum or be filled with air or another gas such as helium, by way of this. On the one hand, on account of the vacuum encapsulation, one succeeds in the flow of the flowing coolants not penetrating into the cavity or into the vacuum cavity, but only running in the microchannel. On the other hand, the viscous friction of the MEMS mirror can be significantly reduced by way of the vacuum encapsulation, by which means a very effective energy utilisation results for the commonly available electrostatic, electromagnetic, piezoelectric or thermomechanical drives, such as in the case of a resonant operation. In other applications, it can be useful to fill the cavity of the encapsulation with air or with another gas, such as helium, for further heat dissipation.
The inlet opening and the outlet opening are connected to a feed conduit and to a discharge conduit respectively, for feeding and discharging the medium flow, wherein the openings are arranged with the conduits on the chip frame outside the encapsulation, i.e. outside the cover.
The micromirror system or arrangement is designed for deflecting laser light, wherein the mirror plate can be suspended in a single-axis or multi-axis manner Very large and solid mirrors with diameters >5 mm can also be operated with comparatively large deflection angles due to the described arrangement of the mirrors in the vacuum.
The hermetically sealed microchannel on the inflow side, i.e. at the inlet opening can be provided with a narrowing, in order to obtain an additional cooling by way of the expansion of the coolant, such as gas.
The design, according to the disclosure, of the microactuator formed from the chip frame, the spring elements and at least one mirror plate permits the most varied of applications and designs.
The disclosure also relates to a method for manufacturing a micromirror system or arrangement, as is described above, with which the surface of a silicon wafer is structured according to the geometric course of the microchannel amid the application of an anisotropic plasma etching. A cavity is subsequently created below the incorporated structure by way of a isotropic plasma etching, and a silicon layer deposited (precipitated), by which means the structure is closed to the surface of the silicon wafer and a part of the cavity remains. Thereafter, the silicon wafer treated in such a manner, by way of etching, is structured into a microactuator with the spring element or elements and the at least one mirror plate, and encapsulated by way of connecting the silicon wafer to a cover comprising a cavity and/or to a further silicon wafer comprising a cavity and/or to a further cover having a cavity. The micromirror system or arrangement according to the disclosure and with an integrated microchannel can be realised relatively simply in this manner
If, with the step of the closure of the channel at its narrow location by way of depositing (precipitating) a polysilicon layer, the surface of this layer should be too rough, then the layer can be polished in an intermediate step.
A further method for manufacturing a micromirror system or arrangement according to the disclosure envisages the etching of the structure of a microactuator with a chip frame, with the spring element or spring elements and with the at least one mirror plate, from one or both surfaces of a silicon wafer and the etching of the cross section of the microchannel from a surface of the silicon wafer up to a defined depth. For example, an SOI wafer (silicon insulation wafer) is used, which comprises an oxide stop layer, so that a respective etching process (plasma silicon etching process) comes to a halt as soon as the layer is reached. This has the advantage that the end result is homogeneous and defined with respect to the depth of the etching. Subsequently, a cover provided with a cavity is deposited onto the silicon wafer, and specifically onto the surface of the structured silicon wafer which lies opposite the surface, from which the microchannel was etched. The etched cross section of the microchannel is closed by way of bonding the silicon wafer manufactured by the preceding steps, to a further silicon wafer which is etched according to the structure of the microactuator. Plasma etching can be used for the etching, but another etching method, such as wet-chemical etching in TMAH or KOH can also be applied. A manufacturing possibility of a micromirror arrangement according to the disclosure can also be provided with this method.
The further silicon wafer is likewise manufactured with the steps of the structuring of the microactuator and of the etching of the cross section of the microchannel, with the previously mentioned method, and the two structured silicon wafers with their surfaces, from which the microchannel was etched, are bonded to one another such that the microchannel is closed off in a hermetically sealed manner. This simplifies the manufacturing method, since two equal silicon wafers can be connected to one another.
The cover or covers, with which the microactuator is encapsulated, is designed as a glass wafer which can be deposited onto the respective silicon wafer.
With the respective method according to the disclosure, a multitude of microactuators is manufactured on a wafer level, wherein the several covers are also designed as glass cover wafers, and the further silicon wafer, as the case may be, is structured according to the multitude of microactuator. After bonding the cover wafer, the MEMS wafer and the base wafer onto one another, the finished wafer composite is singularised (separated or diced) and the microchannels of the individual micromirror arrangements are rendered accessible. A plurality of micromirror arrangements can thus also be manufactured.
Various modifications and additions can be made to the exemplary embodiments discussed without departing from the scope of the present disclosure. For example, while the embodiments described above refer to particular features, the scope of this disclosure also includes embodiments having different combinations of features and embodiments that do not include all of the described features. Accordingly, the scope of the present disclosure is intended to embrace all such alternatives, modifications, and variations as fall within the scope of the claims, together with all equivalents thereof
Number | Date | Country | Kind |
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10 2012 005 546.3 | Mar 2012 | DE | national |
This application is a national phase application of PCT Application No. PCT/EP2013/055852, internationally filed Mar.20, 2013, which claims priority to German Application No. 10 2012 005 546.3, filed Mar. 21, 2012, all of which are herein incorporated by reference in their entirety.
Filing Document | Filing Date | Country | Kind |
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PCT/EP2013/055852 | 3/20/2013 | WO | 00 |