U.S. patent application number 10/820527 was filed with the patent office on 2004-09-30 for multi-tilt micromirror systems with concealed hinge structures.
This patent application is currently assigned to Exajoule LLC. Invention is credited to Aubuchon, Christopher M..
Application Number | 20040190817 10/820527 |
Document ID | / |
Family ID | 32868873 |
Filed Date | 2004-09-30 |
United States Patent
Application |
20040190817 |
Kind Code |
A1 |
Aubuchon, Christopher M. |
September 30, 2004 |
Multi-tilt micromirror systems with concealed hinge structures
Abstract
Multi-tilt mirrors, assemblies and applications of the same, and
methods of making. Micromirror devices employing a superstructure
that includes a mirror supported over a hinge set above a
substructure. Various features described are applicable to improve
manufacturability, enable further miniaturization of the elements
and/or to increase relative light return. Devices can be produced
utilizing the various optional features described herein to provide
miniaturized, highly controllable optics solutions.
Inventors: |
Aubuchon, Christopher M.;
(Palo Alto, CA) |
Correspondence
Address: |
BOZICEVIC, FIELD & FRANCIS LLP
200 MIDDLEFIELD RD
SUITE 200
MENLO PARK
CA
94025
US
|
Assignee: |
Exajoule LLC
|
Family ID: |
32868873 |
Appl. No.: |
10/820527 |
Filed: |
April 7, 2004 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
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10820527 |
Apr 7, 2004 |
|
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10374418 |
Feb 24, 2003 |
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Current U.S.
Class: |
385/18 |
Current CPC
Class: |
G02B 26/0858 20130101;
G02B 26/0841 20130101; G02B 26/085 20130101; G02B 26/0866
20130101 |
Class at
Publication: |
385/018 |
International
Class: |
G02B 006/26 |
Claims
Accordingly, I claim:
1. A micromirror device comprising: a substrate with electrical
components including address circuitry; a micromirror; and a
unitary support structure interconnecting said substrate and said
micromirror, said support structure including a first torsion
member mounted at two locations on said substrate and a second
torsion member mounted to opposite ends of said micromirror, said
torsion members configured to permit rotation of said micromirror
about multiple axes of rotation.
2. The device of claim 1, wherein said two opposite ends of said
micromirror are opposite corners.
3. The device of claim 1, wherein said two opposite ends of said
micromirror are opposite sides.
4. The device of claim 1, wherein the two locations on said
substrate to which said at least one first torsion member are
mounted are locations underlying two opposite ends of said
micromirror.
5. The device of claim 1, wherein said support structure underlies
said micromirror.
6. The device of claim 1, wherein said electrical components
further comprise electrodes adapted to apply attractive forces to
said micromirror.
7. The device of claim 6, wherein said electrodes are oriented
beneath gap locations defined by said torsion members.
8. The device of claim 6, wherein at least one of said electrodes
is configured with a plurality of portions at different levels, so
that portions further from a center of rotation of said micromirror
are at a greater distance from the micromirror than portions closer
to the center of rotation.
9. The device of claim 8, wherein each of said electrodes comprises
a stepped configuration.
10. The device of claim 6, comprising four of said electrodes each
having substantially the same shape.
11. The device of claim 6, wherein said electrodes are oriented so
that portions of said electrodes which are further from a center of
rotation of said micromirror are at a greater distance from said
micromirror than portions closer to the center of rotation.
12. The device of claim 11, wherein said electrode portions of each
said electrode are continuous with one another.
13. The device of claim 11, wherein said portions are discrete
members.
14. The device of claim 11 wherein each said electrode comprises a
continuous angled member.
15. The device of claim 6, wherein each said electrode comprises a
substantially planar electrode, wherein said electrodes are
oriented so that portions of said electrodes which are further from
a center of rotation of said micromirror are at substantially the
same distance from said micromirror as portions closer to the
center of rotation, when said micromirror is in a neutral
configuration.
16. The device of claim 15, wherein said electrodes are mounted on
via columns close to said micromirror.
17. The device of claim 13, wherein said portions of each said
electrode form an electrode array, and wherein at least one of said
portions of at least one of said electrodes is addressable
independently of the other of said portions.
18. The device of claim 17, wherein each said portion is
independently addressable.
19. The device of claim 15, wherein said portions of each said
electrode form an electrode array, and wherein at least one of said
portions of at least one of said electrodes is addressable
independently of the other of said portions.
20. The device of claim 19, wherein each said portion is
independently addressable.
21. The device of claim 1, wherein said micromirror is
substantially quadrilateral.
22. The device of claim 1, wherein said micromirror is
substantially hexagonal.
23. The device of claim 1, wherein said micromirror has a diameter
of less than or equal to about 1 mm.
24. The device of claim 23, wherein said micromirror has a diameter
of less than about 10 microns.
25. A micromirror device comprising: a substrate with electrical
components including address circuitry; a micromirror; and a
support structure underlying said micromirror and joining said
substrate with said micromirror, said support structure including a
first torsion component having first and second ends mounted to
said substrate and a second torsion component having first and
second ends mounted to opposite ends of said micromirror, said
first and second torsion components intersecting one another to
provide a universal joint configured to permit rotation of said
micromirror about multiple axes of rotation.
26. The device of claim 25, wherein said micromirror is
substantially quadrilateral having first and second pairs of
opposing corners, said first and second ends of said first torsion
component are connected to opposite corners of one of said first
and second pairs, and said first and second ends of said second
torsion component are mounted to said substrate at locations
underlying the other of said first and second pairs.
27. The device of claim 25, wherein said micromirror is
substantially quadrilateral having first and second pairs of
opposing sides, said first and second ends of said first torsion
component are connected to opposite sides of one of said first and
second pairs, and said first and second ends of said second torsion
component are mounted to said substrate at locations underlying
opposite sides of the other of said first and second pairs.
28. The device of claim 25, wherein said micromirror is
substantially hexagonal having first, second and third pairs of
opposing corners, and first, second and third pairs of opposing
sides, said first and second ends of said first torsion component
are connected to opposite corners of one of said first, second and
third pairs of opposing corners, and said first and second ends of
said second torsion component are mounted to said substrate at
locations underlying opposite sides of one of said first, second
and third pairs of opposing sides.
29. The device of claim 25, wherein said micromirror is
substantially hexagonal having first, second and third pairs of
opposing corners, and first, second and third pairs of opposing
sides, said first and second ends of said first torsion component
are connected to opposite sides of one of said first, second and
third pairs of opposing sides, and said first and second ends of
said second torsion component are mounted to said substrate at
locations underlying opposite corners of one of said first, second
and third pairs of opposing corners.
30. The device of claim 25, wherein said micromirror is
substantially hexagonal having first, second and third pairs of
opposing corners, and first, second and third pairs of opposing
sides, said first and second ends of said first torsion component
are connected to opposite sides of one of said first, second and
third pairs of opposing sides, and said first and second ends of
said second torsion component are mounted to said substrate at
locations underlying opposite sides of another of said first,
second and third pairs of opposing sides.
31. The device of claim 25, wherein said electrical components
further comprise electrodes adapted to apply attractive forces to
said micromirror, said electrodes being oriented beneath gap
locations defined by said torsion components.
32. The device of claim 31, wherein said electrodes are oriented so
that portions of said electrodes which are further from a center of
rotation of said micromirror are at a greater distance from said
micromirror than portions closer to the center of rotation.
33. The device of claim 32, wherein each of said electrodes
comprises a stepped configuration.
34. The device of claim 31, comprising four of said electrodes each
having substantially the same shape.
35. The device of claim 32, wherein said electrode portions of each
said electrode are continuous with one another.
36. The device of claim 32, wherein said portions are discrete
members.
37. The device of claim 32, wherein each said electrode comprises a
continuous angled member.
38. The device of claim 32, wherein said portions of each said
electrode form an electrode array, and wherein at least one of said
portions of at least one of said electrodes is addressable
independently of the other of said portions.
39. The device of claim 38, wherein each said portion is
independently addressable.
40. The device of claim 31, wherein each said electrode comprises a
substantially planar electrode, wherein said electrodes are
oriented so that portions of said electrodes which are further from
a center of rotation of said micromirror are at substantially the
same distance from said micromirror as portions closer to the
center of rotation, when said micromirror is in a neutral
configuration.
41. The device of claim 40, wherein said electrodes are mounted on
via columns extending from said support structure.
42. The device of claim 40, wherein said portions of each said
electrode form an electrode array, and wherein at least one of said
portions of at least one of said electrodes is addressable
independently of the other of said portions.
43. The device of claim 42, wherein each said portion is
independently addressable.
44. A micromirror assembly, comprising: a substrate with electrical
components including address circuitry; and a plurality of
micromirror devices each including a micromirror, at least one of
said micromirror devices comprising a unitary support structure
interconnecting said substrate and said micromirror, said support
structure including a first torsion member mounted to said
substrate at two locations and a second torsion member mounted to
opposite ends of said micromirror, said torsion members configured
to permit rotation of said micromirror about multiple axes of
rotation.
45. The assembly of claim 44, wherein each said micromirror device
comprises a support structure interconnecting said substrate and
said micromirror, respectively, each said support structure
including a first torsion component mounted to two locations on
said substrate and a second torsion component mounted to opposite
ends of said respective micromirror, said torsion components
configured to permit rotation of said micromirrors about multiple
axes of rotation.
46. The assembly of claim 45, wherein said first torsion components
of at least two adjacent micromirror devices are commonly mounted
to said substrate.
47. The assembly of claim 45, wherein each said support structure
comprises a universal joint, each of said first and second
respective torsion components intersecting one another.
48. The assembly of claim 47, wherein each said micromirror is
substantially quadrilateral having first and second pairs of
opposing corners, and each said second torsion component having
first and second ends connected to opposite corners of one of said
first and second pairs, and each said respective first torsion
component having first and second ends mounted to said substrate at
locations underlying the other of said first and second pairs.
49. The assembly of claim 48, wherein said ends of said first
torsion components which are adjacent one another in adjacent
micromirrors are commonly mounted to said substrate.
50. An optical switching mechanism, comprising: a first array of
optical reflectors adapted to receive and reflect optical signals
from at least one optical input source; and a second array of
optical reflectors adapted to receive optical signals reflected
from said first array of optical reflectors and reflect the optical
signals toward at least one optical output; at least one of said
optical reflectors comprising an assembly of micromirror devices;
at least one of said micromirror devices being adapted for three
dimensional orientation.
51. The optical switching mechanism of claim 50, wherein each said
micromirror device of said at least one assembly of micromirror
devices is adapted for independent three dimensional
orientation.
52. The optical switching mechanism of claim 50, wherein each said
optical reflector comprises an assembly of micromirror devices.
53. The optical switching mechanism of claim 52, wherein each said
micromirror device is adapted for independent three dimensional
orientation.
54. The optical switching mechanism of claim 50, wherein each said
assembly of micromirror devices forms a smart surface.
55. The optical switching mechanism of claim 50, wherein said at
least one micromirror device adapted for three dimensional
orientation comprises a substrate with electrical components
including address circuitry; a micromirror; and a support structure
underlying said micromirror and joining said substrate with said
micromirror, said support structure including a first torsion
component having first and second ends mounted to said substrate
and a second torsion component having first and second ends mounted
to opposite ends of said micromirror, said support structure being
configured to permit rotation of said micromirror about multiple
axes of rotation.
56. The optical switching mechanism of claim 55, wherein said
support structure comprises a universal joint, said first and
second torsion components intersecting one another.
57. The optical switching mechanism of claim 55, wherein said
micromirror is substantially quadrilateral having first and second
pairs of opposing corners, said first and second ends of said first
torsion component are connected to opposite corners of one of said
first and second pairs, and said first and second ends of said
second torsion component are mounted to said substrate at locations
underlying the other of said first and second pairs.
58. The optical switching mechanism of claim 55, wherein said
electrical components further comprise electrodes adapted to apply
attractive forces to said micromirror, said electrodes being
oriented beneath gap locations defined by said torsion
components.
59. The optical switching mechanism of claim 55, wherein said
micromirror has a diameter less than or equal to about 10 microns.
Description
FIELD OF THE INVENTION
[0001] The present invention relates generally to the field of
spatial light modulators that can modify or correct an optical
wavefront. More particularly, the invention relates to micro
electromechanical systems (MEMS) in the form of micromirror devices
used in adaptive optics, optical switching applications, or other
light manipulation applications such as displays.
BACKGROUND OF THE INVENTION
[0002] MEMS devices are small structures, typically fabricated on a
semiconductor wafer using processing techniques including optical
lithography, metal sputtering or chemical vapor deposition, and
plasma etching or other etching techniques that have been developed
for the fabrication of integrated circuits. Micromirror devices are
a type of MEMS device. Other types of MEMS devices include
accelerometers, pressure and flow sensors, fuel injectors, inkjet
ports, and gears and motors, to name a few. Micromirror devices
have already met with a great amount of commercial success.
[0003] MEMS micromirror devices are being used in a variety of
applications, including optical display systems, optical
cross-connects for switching of optical data signals and adaptive
optics for phase and other types of correction. One type of display
device that has been used with a great deal of success is the Texas
Instruments DLP.TM.. In this system, many mirrors are operated
individually in a bistable, digital fashion to create a projected
display. Although current commercial technology has been limited to
about 1.3 million pixels in the mirror array, greater mirror
densities and higher yields should improve this in the future as
the technology progresses.
[0004] Arrays of multi-axis tilting mirrors can also be found in
other applications, such as, printing, scanning, projection, among
many. Most current arrays of micromirrors can be separated into two
categories: relatively large single mirrors that direct a single
beam, or arrays of smaller mirrors, where many mirrors aim each
light beam.
[0005] Larger mirrors can offer some advantages when steering a
smaller number of discrete light beams in terms of providing an
unbroken, nominally flat surface with high reflectivity. However,
if the beams are too large for the mirrors, or if they are
misaligned, the reflected beam is clipped and has less intensity.
These types of arrays are less suitable for reflecting larger,
continuous light such as an optical image. Generally, the support
structures between actuating mirror elements leave too much space
and thus create noticeable holes in the reflected image. Arrays of
smaller mirrors also have drawbacks. Many current designs may only
move in one axis, which limits some of their potential
applications. Others that can move in a multi-axis fashion also
often have relatively large gaps from one mirror to the next that
affect the quality of the reflected beam or image. Micromirrors set
in an array such as this must have some gaps between them to allow
full movement of each mirror, but it is advantageous to decrease
the size of the gaps as much as possible. In addition, many designs
have support structures that are small, yet are part of the visible
surface. These can also contribute to the spacing between mirrors.
Supports and hinges that are hidden behind the mirror surface would
improve the overall reflective surface area.
[0006] A particularly important application for multi-axis tilting
micromirrors is in the field of optical switching. A typical
optical cross-connect for an optical networking switch includes a
switching matrix having two arrays or clusters of MEMS
micromirrors. The first array of micromirrors is arranged so that
micromirrors in the first array receive optical input signals from
one or more input sources, such as optical fiber input(s) and the
second array of micromirrors is arranged so that micromirrors in
the second array receive optical signals reflected from
micromirrors in the first array and direct the signals as optical
output signals to one or more optical outputs.
[0007] The micromirrors in each array are capable of being
adjusted, steered or tilted, so that a micromirror in the first
array is capable of directing a reflected optical signal to a
micromirror in the second array selected from a plurality of the
micromirrors in the second array. Similarly, the micromirrors in
the second array can be adjusted, steered or tilted so as to align
with a micromirror in the first array selected from a plurality of
the micromirrors in the first array. Thus, by appropriate
orientation of the micromirrors by adjustment, steering or tilting,
a first micromirror in the first array can be set to deliver an
optical signal to a first, second, or third, etc. micromirror of
the second array, as desired, and so forth, thereby providing the
switching capability of the cross-connect.
[0008] The performance of optical cross-connects that use such
arrangements of MEMS micromirrors depends upon a number of factors,
including how well the micromirrors in the first array are
optically aligned with the micromirrors in the second array,
changes in temperature, voltage drifts, and performance of the
mirror surfaces of the micromirrors, which are affected by the
shape or flatness of the mirror surface. Even under the best
circumstances, when the micromirrors in the first and second arrays
are accurately aligned and the other factors mentioned above are
minimized, current cross-connects often lose 60% to 70% (about 4-5
dB losses) of the light passing through the system.
[0009] Although factors such as an incomplete reflection of
infrared wavelengths from the mirror surfaces and poor coupling of
fiber to lenses play a role in these losses, light scattering and
other imperfections in the surfaces of mirrors are also significant
factors. There is a current need for improvements in optical
switching devices that will reduce the amount of losses in light
outputted by such devices when compared with the amount of light
inputted thereto.
[0010] Further improvements in optical switching devices, as well
as in micromirror devices in general would be desirable as regards
power consumption. The utilization of large mirrors relative to the
size of the light beam can involve rapidly switching high voltages.
One avenue for micromirror device improvement lies in continued
miniaturization of the devices. In terms of performance, smaller
sizes can improve power efficiency since smaller distances between
parts and lower mass parts will improve energy consumption. In
terms of manufacturing, continued miniaturization of mirror
elements offers greater yields for a wafer of a given size.
[0011] Various aspects of the present invention offer improvement
in terms of one or more of the considerations noted above. Of
course, certain features may be offered in one variation of the
invention, but not another. In any case, the advances offered by
aspects of the present invention represent a departure from
structural approaches represented by current micromirror
designs.
SUMMARY OF THE INVENTION
[0012] The present invention involves micromirror structures,
optionally used in adaptive optics or optical switches. Micromirror
array devices according to the present invention generally comprise
a superstructure disposed over a substructure including addressing
features. Features of the superstructure set upon and above the
substrate include electrodes, hinges, micromirrors, support members
or portions thereof. Support member pairs are provided to hold a
mirror/micromirror above the hinge and the electrode features used
to actuate it.
[0013] The invention involves supporting each micromirror element
above its respective hinge portions at or along the sides or
corners of the mirror. The hinge is then supported above the
substrate by one or more features set at different/opposite corners
or sides of the mirror with respect to the mirror supports The
structures of the hinges and supports are designed to move in a
continuous, controllable fashion simultaneously in two separate
directions.
[0014] While the supports between the hinge and mirror portions are
placed opposite each other, their location along each micromirror
may vary. Preferred placement locations include opposite corners or
sides of the mirrors. Generally, mirrors will have a polygonal plan
in which the shapes are closely-packed (e.g., triangles, hexagons,
and quadrilaterals such as squares, rectangles, trapezoids,
parallelograms, and rhombi). In operation, the micromirrors are
preferably operated in an analog fashion, rotating about an axis
formed by each hinge or hinge portion, although operation in a
digital fashion is contemplated.
[0015] The approach to mirror and hinge support or attachment
described helps maximize available reflective surface area.
Utilizing side-support features according to the present invention
enables production of certain mirror face embodiments that are
unbroken by light-scattering or non-reflective features. This
approach and other useful design characteristics are described much
more extensively in co-pending, commonly owned applications Ser.
Nos. 10/269,796; 10/269,763 and 10/269,478, each filed Oct. 11,
2002 and each incorporated by reference herein in its entirety.
Particularly, in connection with a side-supported mirror approach,
manufacturing techniques are taught in which support precursor
regions that are ultimately removed are temporarily located where
space is to be opened upon releasing the individual micromirror
elements of an array. As such, the space required for effectively
depositing/forming support structures is not wasted but falls
within space that must be left open anyway in order to allow mirror
actuation. In other variations of the invention, more traditional
columnar mirror supports formed within "vias" are provided.
However, these are still located at opposite sides of a given
mirror.
[0016] The present invention includes any of these improvements
described either individually, or in combination. Additional
optional features may be appreciated in connection with U.S. Patent
Application Attorney Docket No. EXAJ-005, entitled "Micromirror
Systems with Concealed Multi-Piece Hinge Structures," filed on even
date herewith and incorporated by reference in its entirety.
Systems employing micromirror devices including the improved
superstructure form aspects of the invention, as does methodology
associated with the use and manufacture of apparatus according to
the present invention.
BRIEF DESCRIPTION OF THE DRAWINGS
[0017] FIG. 1 is a perspective view showing prior art of a generic
torsion bar mirror and gimbal assembly.
[0018] FIG. 2 shows a top view of prior art showing a single mirror
using flexure hinges as part of an optical switching array.
[0019] FIG. 3A shows a perspective view of the present invention in
its preferred embodiment; FIG. 3B shows the same views as FIG. 3A
but with the mirror removed; and FIG. 3C shows the same element
from as a side view.
[0020] FIGS. 4A-G show a process for making the device shown in
FIG. 3.
[0021] FIG. 5A is a perspective view of a sample 7.times.7 array of
mirrors shown in FIG. 3 with some of the mirror tops removed; FIG.
5B is a perspective view of a 2.times.2 array of another example of
micromirror devices, with the mirror tops removed.
[0022] FIGS. 6A-E are perspective views showing the array of FIG.
5A used as a programmable "Fresnel mirror".
[0023] FIG. 7 is a top view of a simple linear 3 by 3 optical
switch showing the mirror elements and light beams.
[0024] FIG. 8 is a close up view of a single light path of FIG. 7,
including optical fiber coupling using a single mirror switching
device.
[0025] FIG. 9 is a close up view of a single light path of FIG. 7,
including optical fiber coupling using a multiple mirror switching
device.
[0026] FIG. 10 is a perspective view of a three-dimensional 4 by 4
optical switch showing the mirror elements and light beams.
[0027] FIG. 11 is a perspective view of the same switch as shown in
FIG. 10, but with two mirrors replaced by multi-mirror arrays.
[0028] FIGS. 12A-C show the same views of a variant element of FIG.
3 using a hexagonal mirror with side mirror supports and corner
hinge supports.
[0029] FIGS. 13A-C show the same views of a hexagonal mirror
element with side mirror and hinge supports.
[0030] FIGS. 14A-C show several types of segmented electrode
designs with varying heights.
DEFINITIONS
[0031] The phrase "beam steering" refers to operation of one or
more micromirror devices in analog mode by charging address
electrode(s) to a voltage corresponding to a desired deflection of
the mirror to direct or "steer" the light reflected off the mirror
in the intended direction.
[0032] The term "diameter," is defined herein to mean the distance
across any long axis that may be defined. Stated otherwise, the
diameter will correspond to that of any circle in which the
structure can be circumscribed.
[0033] The phrases "dim space" or "dead space" refers to areas or
spaces in the reflective surface(s) of a micromirror or micromirror
assembly which are not reflective.
DETAILED DESCRIPTION OF THE INVENTION
[0034] In describing the invention in greater detail than provided
in the Summary above, applicable technology is first described.
Following this is a detailed description of exemplary micromirror
devices and assemblies according to the present invention, as well
as an exemplary process of production. Application of the invention
as a programmable lens surface is also discussed. This discussion
is followed by description of a known optical switching matrix and
its function. Finally, the applicability of the micromirrors of the
present invention to optical switch technology, as well as to other
fields of adaptive optics is discussed.
[0035] Before the present invention is described in such detail,
however, it is to be understood that this invention is not limited
to particular variations set forth, as such may, of course, vary.
Various changes may be made to the invention described and
equivalents may be substituted without departing from the true
spirit and scope of the invention. It is also to be understood that
the terminology used herein is for the purpose of describing
particular embodiments only, and is not intended to be limiting,
since the scope of the present invention will be limited only by
the appended claims.
[0036] Methods recited herein may be carried out in any order of
the recited events which is logically possible, unless the recited
language clearly indicates otherwise. Where a range of values is
provided, it is understood that each intervening value, to the
tenth of the unit of the lower limit unless the context clearly
dictates otherwise, between the upper and lower limits of that
range is also specifically disclosed. Each smaller range between
any stated value or intervening value in a stated range and any
other stated or intervening value in that stated range is
encompassed within the invention. The upper and lower limits of
these smaller ranges may independently be included or excluded in
the range, and each range where either, neither or both limits are
included in the smaller ranges is also encompassed within the
invention, subject to any specifically excluded limit in the stated
range. Where the stated range includes one or both of the limits,
ranges excluding either or both of those included limits are also
included in the invention.
[0037] Also, it is contemplated that any optional feature of the
inventive variations described may be set forth and claimed
independently, or in combination with any one or more of the
features described herein.
[0038] Unless defined otherwise, all technical and scientific terms
used herein have the same meaning as commonly understood by one of
ordinary skill in the art to which this invention belongs. Although
any methods and materials similar or equivalent to those described
herein can be used in the practice or testing of the present
invention, the preferred methods and materials are now described.
All publications mentioned herein are incorporated herein by
reference to disclose and describe the methods and/or materials in
connection with which the publications are cited.
[0039] It must be noted that as used herein and in the appended
claims, the singular forms "a", "and", and "the" include plural
referents unless the context clearly dictates otherwise. Thus, for
example, reference to "a micromirror" includes a plurality of such
micromirrors and reference to "the input" includes reference to one
or more inputs and equivalents thereof known to those skilled in
the art, and so forth.
[0040] All existing subject matter mentioned herein (e.g.,
publications, patents, patent applications and hardware) is
incorporated by reference herein in its entirety except insofar as
the subject matter may conflict with that of the present invention
(in which case what is present herein shall prevail). The
referenced items are provided solely for their disclosure prior to
the filing date of the present application. Nothing herein is to be
construed as an admission that the present invention is not
entitled to antedate such publication by virtue of prior invention.
Further, the dates of publication provided may be different from
the actual publication dates which may need to be independently
confirmed.
[0041] Turning now to FIG. 1, a common type of multi-axis mirror is
shown in simplified form; this type of design should be well known
to those who have ordinary skill in the art. This is a
mirror/gimbal device, and works by electrostatic attraction of the
mirror to four individually controlled electrodes placed underneath
the mirror surface. Restoring force to bring the mirror back to a
central position and stabilize it at many intermediate positions is
provided by torsion bars. FIG. 1 shows a single multi-axis mirror
20, consisting of a mirror surface 22 connected via two torsion
bars 24 to a frame 26 that allows rotation around the Y axis. The
frame 26 is in turn connected by two more torsion bars 28 to a
stationary base 30. The frame and mirror assembly may then rotate
around the X axis. Four electrodes 33-36, set in an array 32 can
then be charged to various voltages to allow analog control of the
position of the mirror in both axes. For instance, if electrode 33
is charged to a given voltage while electrodes 34, 35, and 36
remain uncharged, the mirror will rotate in both axes toward that
electrode. By careful control of the voltages of each electrode,
nearly any angle within the range of the device can be set on one
particular mirror, as the two axes of motion are able to rotate
independently.
[0042] This style of micromirror is most often used to steer a
single beam of light, and is thus relatively large, that is on the
order of 1.times.1 mm. The gimbal 26 only moves in one dimension,
and the base 30 does not move at all, which makes these portions of
the mirror unsuitable for control. In the figure, the gaps between
mirror, gimbal, and base have been exaggerated for clarity, but
still must exist to allow free movement of the constituent parts.
In an array of mirror assemblies 20, a large percentage of the
total surface of the matrix is unusable.
[0043] FIG. 2 shows a different style of known micromirror 38,
shown here in a simplified form. In this design, a mirror 40 is
attached to a stationary base via four posts 42 by rotationally
symmetric flexure bars 44. Here the primary restoring force is
flexure as opposed to torsion, but the primary axes of movement are
the same as the mirror shown in FIG. 1. The mirror is mounted over
an electrode array 32 similar to that shown in FIG. 1. Once again,
this type of mirror is designed to aim a single beam of light, so
there is a significant amount of dead space between different
mirrors used for the flexure bars and other parts of the stationary
frame. Even for aiming discrete beams however, it would be
advantageous for either of the systems shown in FIGS. 1 or 2 for
this dead space to be substantially reduced or eliminated. When
packed in an array, mirrors such as this can direct hundreds of
beams at once. With less dead space between mirrors, a greater
number of beams could be switched with the same device, as the
controllable angle for each mirror is limited.
[0044] FIG. 3A shows a perspective view of a single micromirror
device 46, which will be referred to for purposes of describing
techniques for making the devices according to the present
invention. The details of the materials employed, intermediate
preparation steps and further constructional details associated
with the methodology described are known by those with skill in the
art, within the scope of reasonable experimentation by the same
and/or may be appreciated by reference to the Background section
noted above or the following U.S. patents: U.S. Pat. No. 5,083,857
to Hornbeck, entitled "Multi-level Deformable Mirror Device"; U.S.
Pat. No. 5,096,279 to Hornbeck, et al., entitled "Spatial Light
Modulator and Method"; U.S. Pat. No. 5,212,582 to Nelson, entitled
"Electrostatically Controlled Beam Steering Device and Method";
U.S. Pat. No. 5,535,047 to Hornbeck, entitled "Active Yoke Hidden
Hinge Digital Micromirror Device"; U.S. Pat. No. 5,583,688 to
Hornbeck, entitled "Multi-level Digital Micromirror Device"; U.S.
Pat. No. 5,600,383 to Hornbeck, entitled "Multi-level Deformable
Mirror Device with Torsion Hinges Placed in a layer Different From
the Torsion Beam Layer"; U.S. Pat. No. 5,835,256 to Huibers,
entitled "Reflective spatial Light Modulator with Encapsulated
Micro-Mechanical Element"; U.S. Pat. No. 6,028,689 to Michalicek,
et al., entitled "Multi-Motion Micromirror"; U.S. Pat. No.
6,028,690 to Carter, et al., entitled "Reduced Micromirror Mirror
Gaps for Improved Contrast Ratio"; U.S. Pat. No. 6,198,180 to
Garcia, entitled Micromechanisms with Floating Pivot"; U.S. Pat.
No. 6,323,982 to Hornbeck, entitled "Yield Superstructure for
Digital Micromirror Device"; U.S. Pat. No. 6,337,760 to Huibers,
entitled: "Encapsulated Multi-Directional Light Beam Steering
Device"; U.S. Pat. No. 6,6,348,907 to Wood, entitled "Display
Apparatus with Digital Micromirror Device"; U.S. Pat. No. 6,356,378
to Huibers, entitled "Double Substrate Reflective Spatial Light
Modulator"; U.S. Pat. No. 6,369,931 to Funk, et al, entitled
"Method for Manufacturing a Micromechanical Device"; U.S. Pat. No.
6,388,661 to Richards, entitled "Monochrome and Color Digital
Display System and Methods"; U.S. Pat. No. 6,396,619 to Huibers, et
al., entitled "Deflectable Spatial Light Modulator Having Stopping
Mechanisms. In any case, micromirror devices according to the
present invention may be produced and/or operated according to the
same details or otherwise.
[0045] Regarding the features of the present invention, FIG. 3A
shows a micromirror device 46 according to the present invention.
FIG. 3B shows the micromirror device 46 minus its mirror 48. FIG.
3C shows the same device pictured in FIG. 3B as a side view. The
mirror surface 48 shown in FIG. 3A is uninterrupted, thereby
providing superior reflection characteristics. While the "potential
face" of the mirror surface 48 (indicated by solid and dashed lines
together) may be somewhat larger than the actual face of the mirror
(the area indicated by solid lines alone) reflection losses
occurring from "dim" or "dead" space resulting from gaps 50 and the
spaces between the individual micromirror devices 46 in an assembly
of devices 46 is more than compensated for by the ability to orient
the individual devices to direct light that would otherwise be lost
due to scatter, misalignment, etc., as discussed above. Further, as
described below, the "dim" or "dead" space resulting from gaps 50
may be minimized or even eliminated according to an aspect of the
present invention with careful design of the mirror supports
52.
[0046] As an alternative to the mirror supports 52 columnar
supports or posts (not shown) may be utilized which may be created
by filling in vias produced in sacrificial material. As in other
variations of the invention pictured, each of the pair of supports
is positioned opposite one another and across the body of mirror
48. Supports may have a wall at the edge of mirror (each may have
four walls or more or may define curved surfaces--depending on the
original via shape that is filled-in to create the structure). Yet,
the supports may be inset from the side/corner or edge of a mirror
(depending on the style of micromirror device chosen) to which they
are closest. However, it may be preferred to position the supports
in such a way as to maximize hinge or torsion member length in view
of the mirror style/format selected (i.e., square with corner
support positions, hexagonal with corner supported positions,
hexagonal with side support positions, etc.). In which case, the
base of each support (or an intermediate structure) will be
positioned at the end of any hinge portions. Further details about
these support variations can be found in co-pending, commonly owned
applications Ser. No. 10/269,796, entitled, "Micromirror Systems
with Side-Supported Mirrors and Concealed Flexure Members,"
incorporated by reference, in its entirety, above (e.g., see FIG.
9A' in that application).
[0047] First, general features of micromirror device 46 under the
mirror 48 are described. One such aspect concerns the manner in
which mirror 48 is attached to its hinge. Supports 52 on opposite
sides of mirror element 48 secure it to hinge portions 54 of hinge
56. Portions 58 of the hinge 56 defined are attached to substrate
60 by hinge joints 62 which underlie end portions (corners, in the
example shown in FIG. 3B) of the mirror element 48. Thus, the hinge
56 is elevated above the substrate to permit torsion about portions
54 and/or 58 as the mirror element 48 is tilted or rotated about
various axes of rotation. The hinge joints 62 are bridge-type
support structures, preferably open underneath the hinge center 64,
which is attached to a spanning segment 66 between vertical support
segments 68. Feet 70 may additionally be provided to stabilize the
support structure. Yet another option is to produce support
segments 68 at an angle relative to the surface of the substrate
(i.e., having both vertical and horizontal components).
[0048] As shown, hinge 56 is a unitary crossed bar structure which
forms a "universal joint" type of connection. This not only
provides a solid support for the mirror, but also allows creation
in a single step of a hinge that can move in two axes. A base 72 of
each support 52 may directly connect each hinge portion 54.
Alternatively, an intermediate layer or nub 74 of material (e.g.,
serving as a bonding interface) may be is employed, as shown in
FIGS. 3A-3B.
[0049] In any case, the device is configured so that the hinge is
set some distance (as little as about 0.1 micron, or less) above
the surface of substrate 60 and mirror 48 is set some distance (as
little as about 0.1 micron, or less) above the hinges (as little as
about 0.2 micron, or less, above the surface of substrate 60).
Avoidance of a central yoke that holds the mirror structure allows
creation of very low profile micromirror devices by the invention
that are still able to attain high deflection angles (typically
about +/-10 deg., even upwards of about +/-15 deg., to about +/-20
deg. or more). Of course, mirror/micromirror devices according to
the present invention may be advantageously manufactured on a
larger scale (even using MEMS techniques) and may utilize other
actuation techniques, including electromagnetic, electrostatic,
thermo-mechanical or piezo-based approaches.
[0050] An aspect of the invention that facilitates provision of
adequate electrostatic attraction in response to hinge restoring
forces that increase with angular deflection has to do with the
configuration of electrodes 76. The electrodes may be configured
with a plurality of portions 78 and 80 (or more) at different
levels. Whether provided in a series of steps by continuous members
(as shown with a support portion 82 between each stage 78/80), by
steps formed with discrete members or a continuous angled member,
the electrodes are configured so that portions further from the
center or point of rotation of the mirror are at a lower level. In
this configuration, all four electrodes 76 are of nearly identical
shape, with small deviations from each other to allow for different
sizes of mirror support base 72 and hinge support 62. Similar
electrode shapes and areas simplify the process of actuating a
multi-axis mirror system, but other configurations of electrode
shapes and sizes, including asymmetric variants are possible.
[0051] The electrode configuration shown with higher portions
closer to the center and lower portions more distant provides
clearance for the mirror as it is tilted at an angle. Furthermore,
the configuration provides for sequential attraction of mirror 48.
When the mirror is angled away from a set of electrodes, the upper
electrode portion is the first to exert significant attractive
electrostatic force on the mirror (in light of the inverse squared
relationship between electrostatic attraction and distance between
objects). As the upper electrode portion(s) effectively attract the
mirror drawing downward (i.e., towards the upper electrode
portion), the influence of the electrode lower portion(s) increase
as the distance between the lower portion(s) and the mirror
decreases. Further aiding attraction of the mirror to its full
angular displacement is the increased mechanical advantage or lever
arm offered at more remote regions of the mirror interacting with
lower electrode portion 80. This and other variants of possible
electrode shapes are explored more fully in application Ser. No.
10/269,763, entitled "Micromirror Systems with Electrodes
Configured for Sequential Mirror Attraction," which is incorporated
by reference herein in its entirety.
[0052] Device 46 is actuatable to move in a plurality of axes.
Advantageously, the scale of the present invention may be made is
much smaller than currently available micromirrors, with the
diameter of each mirror element being on the order of magnitude of
10-20 microns, or more. An array of hundreds or thousands of these
micromirrors may be used to replace a single mirror element having
a scale on the order of those shown in FIGS. 1 and 2. A greater
number of micromirrors for each portion of the incoming wavefront
provides for much more customization of the properties of the
outgoing wavefront. Miniaturizing the individual mirror size
carries a number of other benefits which will be detailed later.
Nevertheless, it is contemplated that the size of the mirror
diameter may be increased to as high as about 1 mm or more, with
dimensions of other components of the device having increased
dimensions in proportion thereto. This would allow a single mirror
element of the present invention to effectively control an entire
light beam.
[0053] A manner in which a micromirror device 46 according to the
present invention may be produced is illustrated in FIGS. 4A-G. Of
course, the process steps employed will vary depending on which
inventive features are actually employed in a given variation of
the invention, as would be readily apparent to those of ordinary
skill in the art. In FIG. 4A, a sacrificial layer of material 84 is
set upon substrate 60. It is patterned with a first mask 86 to
define a substrate-level portion 88 upon etching. In FIG. 4B, a
hinge metal layer 90 is deposited over the entire surface including
a portion of the sacrificial layer. A second mask 92 is utilized in
defining a passivation layer (not shown) over the region(s) of
layer 90 serving as a hinge precursor region 94. Metal layer 90
fills in vias 96 provided in substrate 60 to form a connection 98
between underlying address circuitry beneath an oxide layer of the
substrate. The same approach to addressing and substrate
construction may be employed as described above, or another manner
of electrical control of device superstructure produced may be
utilized. This holds true with respect to connectivity between the
device elements as well as the configuration of substrate 60.
[0054] As shown in FIG. 4C, a thicker layer of conductive material
100 is deposited over the hinge material. This layer builds-up the
electrodes 76 and nubs 74, and hinge supports 62 for hinge portions
58. Layer 100 also further fills in vias 96 and connecting
structures 98. A third mask 102 is employed to define a protective
layer (not shown) over the region of layer 100 serving as electrode
precursor(s) 104, nub precursors 106, and hinge support precursors
108.
[0055] In FIG. 4D, layers 90 and 100 are shown selectively etched
to reveal hinge 56, support spanners (hinge supports or anchors)
62, and electrode portions 76. In FIG. 4E, one can see another
sacrificial layer 110 which then covers these structures. A fourth
mask 112 is used to pattern sacrificial layer 110 to form support
precursor regions 114 upon etching the sacrificial layer.
[0056] FIG. 4F shows sacrificial layer 110 as it is selectively
etched, and then coated with a layer 116 of conductive material
suitable to serve as a mirror (or a substrate that may be
subsequently coated with a highly reflective metal or dielectric
material). A fifth mask 118 is used in order to define a
passivation layer over mirror precursor regions 120 to be retained,
but not the adjacent borders 122, which are removed to form spaces
between adjacent micromirrors 46.
[0057] FIG. 4G shows a micromirror element 46 according to aspects
of the invention after all sacrificial materials have been removed.
As discussed above, the mirror is supported at or along its
opposite sides or edges by supports attached to a hinge, which is
in turn supported above the device substrate. In addition to being
placed at opposite sides/portions of the mirror, the support
members may be characterized as being "open" in nature. Progressive
or dual-stage electrodes are shown as well.
[0058] FIG. 5A shows an exemplary 7 by 7 array assembly 124 of
micromirrors 46. Part of the tops of the surface of the mirrors 48
have been removed to show the underlying structures. This type of
mirror array, comprised of potentially millions of individually
controlled mirrors can be used for a number of applications. Not
only can the micromirrors 46 of assembly 124 be positioned to mimic
a tilting of micromirror device 20 about either of its tilt axes
(or some combination of both) and thus represent a flat reflective
surface, but the micromirrors 46 can be independently positioned to
form a "smart surface", i.e., one that can be adapted to modify the
shape of a reflected wavefront, in response to a given wavefront
that is made incident thereon. For this reason, the assembly 124
can be described as a "Fresnel mirror" or a "programmable lens".
FIG. 5A can also be seen as only a small section of a much larger
array.
[0059] Array 124 as shown in FIG. 5A has some advantages because of
its simplicity in layout. Additionally, addressing for this layout
would be consistent for each mirror element 46. However, it may be
preferred to use a different layout of mirror elements 46 as shown
in FIG. 5B. Here, a smaller 2 by 2 section of a slightly different
array 126 is displayed. In this configuration, the mirror elements
46 are identical to the previous array 124, but the orientation of
the elements 46 varies. Every other mirror element 46 is rotated by
90.degree. in a checkerboard pattern. The main advantage is seen in
the position of the hinge supports 62, for which each support 62
meets at a corner with three other supports 62 to make one large
support 128. Large support 128 reduces the number of discrete
features to be manufactured, and is more structurally stable than
individually manufactured supports 62 in addition, because it is a
combined structure instead of four free standing pieces, the
overall dimensions of the support can be made smaller, which can
lead to longer hinges and more mobility of the hinge.
[0060] Micromirror arrays 124/126 provide great versatility in
their ability to form surfaces for performing wavefront
correction/shaping, and by their ability to be oriented to form
other than flat surfaces, including configurations which form
effective programmable lenses. Examples of such configurations are
shown schematically in FIGS. 6A-6E. FIG. 6A displays the same array
assembly 124 as seen in FIG. 5A. For illustrative purposes, a
lowercase "e" 130 is used as a sample object to be reflected off
mirror assembly 124. The image 132 results from the particular
configuration of the micromirrors. A dotted line 134 portrays where
the "e" is reflected on the mirror surface, and the path of light
follows an arrow 136. In FIG. 6A, the array is set completely flat,
so there is little change in the image other than simple
reflection. For comparison to later figures, the image 132 is set
against a reference set of crosshairs 138.
[0061] For simplicity, FIGS. 6B-E will all use the same object 130
as seen in FIG. 6A, which will be omitted in these figures. Only
the final image 132 will be shown. FIG. 6B shows mirror array 140,
which is the same array as 124, but with all of the mirrors tilted
in the same direction. The image 142 size is unchanged, but its
position has moved. Thus the array 140 acts here as a tilting flat
mirror. FIG. 6C displays an array 142, once again the same array
124, but this time individual elements 46 are tilted to approximate
the surface of a focusing mirror, as can be seen in the resulting
image 146, shown having a reduced size.
[0062] FIG. 6D shows a similar array 148 that is now set with
mirror elements 46 approximating a defocusing mirror, which again
can been seen in a correspondingly larger image 150. In FIG. 6E,
array 152 displays both tilt and focus on the same set of mirrors,
with the results showing up in image 154. Because each mirror
element can be set independently of each other, potentially several
types of correction could be implemented simultaneously. Although
tilt and focus can be addressed on the same set of mirrors, note
that this leads to some limitations. Depending on the dimensions of
the components, tilt angles of individual mirrors might be only as
much as 10.degree. in each axis. However, tilt angles of some
designs may be as large as 20.degree. or more. If a set of mirrors
is tilted acting as a flat mirror so that all of the mirrors are
near or at their maximum angle, it will not be able to further
focus or defocus the beam. In addition, tilting of curved surfaces
can lead to astigmatism in the reflected beam, although this can be
corrected by careful shaping of the programmable lens at the
specified angle.
[0063] Although they are not shown here, many other types of
wavefront shaping are possible. Various types of lenses other than
spherical can be created, such as cylindrical or parabolic mirrors.
Distortions in the incoming beam due to imperfections in earlier
surfaces can be detected and corrected. Any number of other
surfaces can be created subject to the angular limitations of the
micromirrors.
[0064] In practical use, such a small subset 124 of a much larger
mirror array would not be used for shaping beams or images, but
this size is used here for illustrative purposes. The mirrors in a
somewhat larger portion of the array shaped in this manner would
not be seen as clearly to have a curvature because the differences
from one mirror to the next would be slight. One advantage to the
independently addressable nature of these mirrors is that the array
as a whole can be divided into many fields, each with their own
properties. One simple way to accomplish this is to use a defined
grid, where the center of each subsection of the grid is set to be
the center of a programmable Fresnel mirror, each with its own
focal length and tilt angle. The present invention is not limited
to this manner of controlling the micromirrors. Any arbitrary
number or shape of field may be independently controlled.
[0065] Another important application of the present invention is in
the area of switches for optical networking. Looking at FIG. 7, a
schematic representation of a switching matrix 154 is shown. For
simplicity of explanation and drawing, only a linear matrix 154 is
shown, although two-dimensional matrices are also commonly used.
The matrix of FIG. 7 includes two arrays 156, 166 of steerable
micromirrors (158, 160, 162 and 168, 170, 172, respectively). Each
of the micromirrors are "steerable" by their operation in analog
mode, which involve actuation of micromirrors 158, 160, 162, 168,
170, 172 to a voltage corresponding to a desired deflection of the
mirror surface of the micromirror, as is known to those of ordinary
skill in the art.
[0066] In this way, each of the three micromirrors 158, 160, 162
can be tilted about an axis of rotation so as to direct an optical
signal received from its input channel (163, 164, 165 respectively)
toward any one of micromirrors 168, 170, 172 that corresponds to
the output channel 173, 174, 175 that is desired to be outputted
to. Input and output channels are often optical fibers with
focusing optics. For example, micromirror 158 can be oriented to
reflect an input signal received from input channel 163 to
micromirror 168, which, in such instance, is also tilted to
optically couple the output from micromirror 158 with optical
output fiber 173. Alternatively, the voltage can be varied to the
electrode(s) of micromirrors 158 and 172 so that they are optically
coupled with one another in which case the optical input from
optical input fiber 163 is outputted to optical output fiber 175,
and so forth. U.S. Pat. No. 6,389,190 describes a switching matrix
of the type shown in FIG. 7 in detail, including an example of MEMS
micromirrors that may be employed in the construction of such a
switching matrix.
[0067] As noted in the Background section of the present
application, currently available optical switching mechanisms
experience a significant loss of the optical signals passing from
an input to the output thereof, i.e. on the order of a 60% to 70%
loss. Significant contributions to these losses are due to scatter
of light from the light signal as it passes from an input optical
fiber to first and second mirrors (in input and output mirror
arrays) and finally to an optical output fiber. Aberrations in the
surfaces of the micromirrors on the input and output arrays can
contribute to the scattering of light as well as to deformation of
the light beam to the extent that a portion of the light beam can
become misaligned with the output optical fiber by the time that
the input optical signal (light beam) has been reflected off an
input side micromirror and an output side micromirror. Misalignment
of the fibers to the mirrors can be a significant source of loss,
in addition to loss coupling into the output fiber due to
mismatched beam sizes.
[0068] Another source of error can be created if the tilt axes of
the input and output mirrors are not parallel in an arrangement
such as shown in FIG. 7, although this primarily affects only
arrays of mirrors that only have a single axis of movement. In such
a case, opposing input and output mirror surfaces of input and
output side micromirrors, which are intended to be aligned to
optically couple an input optical fiber and an output optical
fiber, can never be aligned in parallel, which results in a skewing
of the optical beam such that a portion of the output signal does
not enter the output optical fiber. Similar negative effects can
occur due to thermal and other environmental effects, as well as
aging of the components.
[0069] The present invention can be applied to optical switching
configurations to correct for, and thereby substantially eliminate
sources of losses due to misalignment of mirrors, imperfections in
mirror surfaces and other physical causes of light loss through a
switching mechanism. FIG. 8 is a schematic, two-dimensional
representation of a switching arrangement which shows only one
micromirror device (158, 168 respectively) from each of the input
and output arrays, for simplicity of discussion. An optical input
signal is incident upon micromirror device 158 as delivered by
input channel 163. Seven light rays 177-183 representing parts of a
single light beam are schematically represented in FIG. 8 as being
incident on the mirror surface of micromirror device 158, from
which they are then reflected toward micromirror device 168 and are
then directed to output channel 173, where 158a and 168a represent
the axis of rotation of these mirrors. In this example, light rays
177 and 183 become misaligned with the mirror surface of
micromirror device 168 due to expansion of the beam hitting the
mirrors. Similarly, light ray 179 is misdirected and is not
delivered to output channel, due to light scattering which may be
caused by a lack of flatness in the mirror surface of micromirror
device 158 or other malformation which causes misalignment of the
light reflecting off of a portion of the mirror.
[0070] Note that although the micromirror devices 158 and 168 are
adjustable by tilting about axes 158a, 168a, that any further
adjustment of the micromirror devices 158, 168 in FIG. 8 would not
result in a reduction of light loss. For example, if micromirror
158 were tilted by a slight rotation in the clockwise direction,
then ray 183 might be directed onto the surface of micromirror 168,
but at the same time, ray 178 might then miss the reflective
surface of micromirror 168, and certainly ray 177 would still not
be reflected off of micromirror 168. Similarly, while rotation of
micromirror 168 in the counter clockwise direction might direct ray
177 into the optical output channel 173, it would also misdirect
ray 178 at the same time, so as to no longer be channeled into the
output channel 173.
[0071] By replacing each of the micromirror devices 158, 168 with a
plurality of smaller and more controllable micromirror devices 46
as shown in FIG. 9 according to the present invention, a
micromirror assembly (184, 186, respectively) is provided to
replace each of the micromirror devices 158, 168 of FIG. 8. Each
micromirror assembly is made up of a plurality (seven, in the
non-limiting schematic example shown) of micromirror devices 46
(labeled here as 46-1 through 46-14), each of which is
independently controllable for movement of a mirror surface about
two axes of rotation independently, or about an unlimited number of
axes of rotation defined by the resultant vectors occurring when
rotating to varying degrees about both axes of rotation. In the
example shown, the micromirror device 46-1 has been rotated or
tilted in the clockwise direction so as to align ray 177 with the
corresponding micromirror (46-8) on assembly 186, so that ray 177
is now properly channeled to the optical output channel 173. It is
noted that the rotation of micromirror 46-1 is shown in an
exaggerated fashion for purposes of explanation, and that the
actual rotation of the mirror would be much less, so as to be
essentially imperceptible, while having the effect of "flattening"
the reflective surface in this location for reflecting the ray 177
in the correct direction. Similarly, micromirror 46-7 is tilted or
rotated somewhat counterclockwise, so as to accurately direct light
ray 183 to be incident upon micromirror device 46-14, which in turn
directs the ray 183 into the optical output channel 173. The
micromirror device 46-3 in assembly 184 has been tilted or rotated
in the counterclockwise direction to redirect ray 179 into the
proper position on assembly 186 to permit proper direction into the
output channel.
[0072] In this particular example seen in FIGS. 8 and 9, the light
beam from optical input channel 163 is shown slightly expanding to
illustrate details of the present invention. In an actual system,
the light beam would be carefully focused to keep the spatial
profile of the beam as small as possible throughout the length of
the optical switch. By keeping the beam size small, the size of the
individual mirrors and the spacing between them can be made smaller
as well, which allows for a high density switching matrix. This is
desirable, since MEMS micromirror designs generally have a limited
usable angular range of movement, so a greater density leads
directly to a higher port count in the switch. Changing the beam
size in this manner has several adverse consequences however. Even
if all of the rays are focused so that they hit the focusing lens
at the output channel, the outgoing angle of each ray (177-183) may
not be best for good coupling efficiency into the fiber. Adjustment
of both of the switching mirrors for best coupling does not
eliminate much of the loss. To accommodate for relatively large
spacing between the mirrors, often a long distance between mirrors
is needed. Maintaining small beam spot sizes throughout a longer
distance requires very good uniformity of focusing elements on the
incoming beams. These constraints can make it difficult to create a
working device with a high port count when using large flat
mirrors.
[0073] By providing a plurality of independently adjustable
micromirrors 46 to form each micromirror assembly (such as 184 and
186), input and output arrays of these assemblies can then be
constructed in making an optical switching or cross-connect
apparatus which is capable of reducing the amount of light loss, as
compared with those currently available. The ability to
independently adjust devices 46, in effect, gives the assemblies
the ability to optically adapt to the wavefront of the optical
signal that is being received, and to manipulate that wavefront to
maximize the amount of the signal which is ultimately received at
the output end of the switching device. The reflective surfaces of
the micromirrors 46 in assemblies 184 and 186, as has been
previously mentioned, can thus be used as programmable Fresnel
mirrors to focus the light received and reflected so as to minimize
losses. It is much easier to keep light focused properly over a
short distance as opposed to a long distance. Using a plurality of
mirrors allows any focusing element after an input fiber to be
optimized for only a short distance to the first mirror array. The
first mirror array can focus properly to the second mirror array,
and the second mirror array will then focus properly for good
coupling into the output fiber.
[0074] Although a small amount of light is lost due to the spacing
between the micromirror devices 46 in each array, this loss is
small compared to the amount of light that would ordinarily be lost
by a system such as shown in FIG. 8, but which is recaptured by
proper orientation of the micromirrors 46 as discussed with regard
to FIG. 9. Although the example of FIG. 9 has been described with
regard to a one dimensional assembly of micromirrors 46 to form the
assemblies 184, 186 (i.e., a 1.times.7 array of the micromirrors 46
in each assembly), it is to be noted that the present invention is
in no way limited to such arrangement, as such arrangement has been
described only for purposes of simplicity. In fact, the more likely
assembly is to include a two-dimensional array of micromirrors 46
to form each assembly, even with a switching setup as shown in FIG.
7. For example, a micromirror device 20 can be replaced by a
10.times.10 or 100.times.100 array of micromirrors 46 to form an
assembly such as the array 124 shown in FIG. 5. Because the
micromirrors 46 have the ability to tilt or rotate about two axes
(or combinations thereof, as noted above) it is preferable to form
a two-dimensional array of the micromirrors in each assembly, for
three-dimensional redirecting, or focusing, of incident light
signals
[0075] FIG. 10 is a schematic representation of a three-dimensional
cross-connect arrangement 190. In this arrangement, the micromirror
devices can be three-dimensionally positioned so as to optically
connect any micromirror in the optical input array 192 with any
micromirror in the optical output array 198. Thus, for example, by
appropriate position of micromirror 194 and a corresponding
micromirror in the optical output array 198, the optical input 204
can be directed to be outputted to any of optical outputs 206-209
by appropriate optical connection of micromirror 194 with
respective ones of optical output micromirrors 200-203. Each of
input side micromirrors 195-197 has similar possibilities, with the
appropriate corresponding adjustment of the output
micromirrors.
[0076] FIG. 11 is a three-dimensional cross-connect 210 similar to
the cross-connect 190 in FIG. 10, but with two of the mirror
elements 194 and 196 being replaced by exemplary 5.times.5 arrays
214 and 216. Replacing the single mirror elements has a number of
advantages already addressed, but which may be more apparent as
seen in this figure. In this example, the two arrays are set to act
as two different focusing elements for the beams being switched. If
input beam 204 has slightly changed focusing characteristics than
input beam 218, the array elements can be adjusted independently to
maximize the coupling efficiency. Most often, the input beams of an
optical switch are focused coming out of an optical fiber by either
a lens array or an individual lens on each fiber. Uniformity of
focal lengths for these lenses can be very difficult to achieve,
yet small changes in the consistency of these lenses can have a
large effect on the focusing of the beam, and thus on the
efficiency of coupling light back into the output fiber. Using a
small array of mirrors to act as an additional lens element as a
part of the optical path allows for slight changes in the input
beam without sacrificing power throughput into the output. In an
actual system based on these designs, all of the rest of the input
and output mirrors 195, 197, 200-203 would be represented by a
similar array of micromirrors.
[0077] Another advantage of the multimirror array is that of
positioning. In a single mirror system as shown in FIG. 10, each
input fiber must be precisely aligned to the center of its
corresponding mirror along with all the other input fibers. Small
irregularities may make the input beam clip on the edge of the
mirror or miss it altogether. Individual adjustments of each fiber
and/or focusing components is commonly not possible, so much of the
time, the entire array of input fibers and lenses are aimed to find
the best compromise position, even though throughput on many of the
channels suffers as a result. Achieving exact uniformity is no
simple task. One possible solution for this problem is to make the
size of each individual mirror in the arrays 192 and 198 larger.
While this reduces the problem of losing power from the beam at the
edges of each mirror, it does have the drawback of lowering the
density of the mirror array as a whole, which, as has already been
discussed, will lower the total port count of the switch. In FIG.
11, a single mirror is replaced by an array of mirrors. In
actuality, each single mirror would be replaced by an array of
mirrors with no particular boundaries between the original surfaces
of the single micromirrors, but which was displayed in this fashion
for clarity. In FIG. 11, between array 214 and 216 would appear a
number of identical mirrors; in aggregate, all of the mirrors would
make a single large array. If the center of a single fiber was
tilted incorrectly by a small amount to change the position of its
input beam on the mirror array, this new location could be chosen
as the center of its steering set of mirrors with no extra loss to
the beam falling off an edge. Of course, uniformity of the input
fibers and beams cannot be so poor as to overlap parts of more than
one beam at any one place on the array as a whole, but small
changes that would adversely affect performance on single-mirror
systems will not harm throughput here. In addition, the lack of
boundaries for the array domain of a single light beam allows a
tighter spacing of the beams, which as has been mentioned
previously, would allow for a higher density switch with greater
port count.
[0078] FIG. 5A showed an assembly of micromirror devices 46 that
comprise the present invention which form a micromirror assembly
124 effective to replace micromirror device 194 (or any of the
other micromirror devices 195-197 and 200-203) in FIG. 10, although
this size of array is not limiting. A typical micromirror device
currently used in the optical switching field employs a mirror
surface having width and length dimensions of about 1 mm.times.1
mm. Using present techniques, micromirror devices 46 according to
the present invention may be made to have a mirror surface as small
as about 8 microns by 8 microns. Thus, an assembly of 15,000
micromirrors (i.e., a 125.times.125 array) could be provided to
replace a single micromirror device in the prior art. As noted
previously, the present invention is not limited to this size of
micromirror, as micromirrors having dimensions larger than 8
microns by 8 microns can certainly be made, such that an assembly
having a plurality, but a lesser number than one hundred
micromirror devices 46 could be assembled to replace a single known
micromirror device. Also, it is contemplated that even smaller
micromirror devices 46 will be possible as the state of the
manufacturing arts progresses.
[0079] A number of other variants to the design of the present
invention are possible other than the one shown in FIG. 3. FIGS.
12A-C provide details of a micromirror 220 with a hexagonal-shaped
mirror top supported at opposite corner positions. Its construction
and appearance closely resemble the micromirror elements 46 shown
in FIGS. 3A-C, and views for each part of the figure are the same.
However, the hexagonal mirror format offers certain advantages in
use. For one, they can be closely packed in a manner like a
honeycomb, where sequential rows (or columns) overlap. Such overlap
provides the ability in image creation to mimic higher resolution
output where there is overlap. The principles of such operation are
well documented and may be understood in reference to U.S. Pat. No.
6,232,936 to Gove, et al., entitled "DMD Architecture to Improve
Horizontal Resolution." In this variant of the device, the
hexagonally shaped mirror is attached to the hinge portions 54 at
its corner supports 52, and the hinge portions 58 are attached to
hinge supports 66 on the side of the hexagonal substrate 60. This
type of structure has another advantage in manufacturing, as the
substrate supports for the hinges 66 on the side can be shared by
adjacent hexagonal pixels. One simple variant for this design, (not
pictured here) is to switch the relative positions of the mirror
supports and the hinge supports. That is, the supports 52 for the
mirror can be connected at the side of the mirror, and the supports
62 for the hinges can be connected to the substrate 60 at opposite
corners.
[0080] One other difference in this design is shown in the
electrode design. In this design, a single flat electrode 222
replaced each staggered multi-level electrode 76, described in
previous examples. Although a staggered electrode may be preferred
in that less voltage should be needed to achieve the same degree of
electrostatic attraction, the single, flat design may be preferred
for manufacturability purposes, as this electrode may be simpler to
use for any of the micromirror designs presented here. Of course,
the electrode design described with regard to the example in FIG.
12B is not limited to the micromirror shown in FIG. 12B, but may be
applied to any of the other designs described herein.
[0081] FIGS. 13A-C display yet another variation in mirror design.
Assembly 224 is also a hexagonal mirror design, where both mirror
and hinge support legs attach at the sides of the hexagon. Although
any position along the side could have been chosen, in this case
the crossbar hinge was rotated 15.degree. from the axis aligned
from opposite corners of the hexagon. One advantage of this
configuration is that the lengths of the hinge portions 54 and 58
may be made to be substantially the same, and thus should provide
nearly the same restoring force in each direction. Another variant
in electrode design 226 that may be applied to any of the other
mirror variants is illustrated in FIG. 13B. Using a via column 228,
the entire electrode surface 230 is raised close to the mirror.
This configuration allows for the maximum electrostatic attraction
of the three designs.
[0082] Note that regardless of the choice of electrode
configuration on any of these variants, the hinges, mirror, and
electrodes have been designed not to interfere with each other.
Because the hinge and electrode layers are constructed at the same
time, there is no overlap between them. At the mirror's maximum
angular extension in both axes, the mirror touches down only on the
substrate 60 or on the hinge supports 62. While in normal
operation, the mirror and attached metal structure are charged up
to a bias voltage, and the addressing electrodes are charged to a
different voltage, there is no danger that the structures will
short out and potentially damage or disable one or many other
mirrors.
[0083] One other type of variant has to do with multiple electrodes
replacing any of the electrodes shown in FIGS. 3, 12, and 13. Some
of these possible designs are shown in FIGS. 14A-14C. FIG. 14A
shows substantially the same element as is seen in FIG. 3B, but
with the hinge substructure removed so that only the substrate 60
and the electrodes 232 are shown. In this case, each of the
electrodes 76 (e.g., from the embodiment of FIG. 3B) has been
replaced by an electrode array 232. Although various types of
electrodes have been proposed with different shapes and height
configurations, the electrode array 232 is different than
previously mentioned ones because each element of the array 232 can
be addressed independently.
[0084] FIG. 14B shows a different type of electrode array 234 used
in place of single electrodes 76. Here, not only the shape of each
subelectrode is varied, but also the height, to vary the field
strength of each element in the array 234. FIG. 14C displays yet
another potential variation, where electrode arrays 236 are broken
up further in two dimensions. Single element electrodes 76 require
fine control of voltage to enable analog movement of the mirror for
continuous positioning. Using a multi-element electrode, control
circuitry for each mirror element 46 may be considerably less
complex. Potentially, with sufficient numbers of addressable
electrodes underneath a mirror, near analog control of a mirror may
be possible using digital addressing.
[0085] Other configurations of electrodes and overall mirror and
related hinge connection configurations are within the scope of the
present invention. In the embodiments of the invention shown and
such others as may be envisioned, it can be appreciated that
variation may also be presented, for example, with respect to the
vertical spacing of elements.
[0086] Notably, the height or relative spacing of selected items
may impact the size and/or orientation of components such as the
electrode regions. That is, electrode shape and height may require
customization to avoid interference in meeting desired deflection
ranges of the micromirror. In any case, these parameters may be
tuned as desired.
[0087] In addition, it is noted that features described herein in
connection with MEMS processing may be applied on a relatively
large scale. That is to say, as used herein the term "micromirror"
may be applicable to mirror structures upwards of 1 mm in diameter,
height and/or length. Such larger structures may find applications
outside the fields mentioned here. In all, it is to be appreciated
that devices made according to the present invention may be
employed not only in the context discussed referring to optical
switching arrangements, but further applications involving adaptive
optics may apply.
[0088] The breadth of the present invention is to be limited only
by the literal or equitable scope of the following claims. Efforts
have been made to express known equivalent structures and/or
features as may be applicable. That any such item or items may not
be expressed herein is not intended to exclude coverage of the same
in any way.
* * * * *