Abstract Mechanical cross-axis coupling in biaxial scanning increases calibration workload and affects performance of tip-tilt (TT) micromirror. The integration of gimbal and inner-axis vertical comb-drive (VCD) actuator is a viable design for TT-decoupled micromirror. The key to developing such structure is guaranteeing integrated inner-axis VCD actuator insulated from the gimbal and electrically connected to the substrate while minimizing fabrication difficulty. For this purpose, this paper introduces double-silicon-on-insulator (D-SOI) wafer that has two mutually-insulated device layers into the development of TT-decoupled VCD micromirror. For both tip and tilt scanning modes, two vertical comb (VC) sets in each VCD actuator are arranged on different device layers of the D-SOI wafer. Gimbal, reflective mirror and springs are fabricated on the identical device layer of the D-SOI wafer, forming an integrated structure together with inner-axis VCD actuator. Besides, polysilicon-based interlayer through-silicon-vias (TSVs) and surface metal redistribution layers (RDLs) are employed to electrically connect all the driving signals to the wiring substrate. The D-SOI wafer is bonded to the wiring substrate using the thermocompression bonding processing before removing D-SOI handle layer and structure release. Based on the proposed structure and micromachining process, this paper fabricates 3×3 micromirror array (MMA), in which each pixel is 951×1096 μm2 in footprint and has fill factor of 50 %. Testing results of fabricated MMA exhibit a quasi-static mechanical tilt/tip angle of 1.266/1.436 ° at 35/35 volt, and RMS reflective mirror roughness of 5.323 nm.
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