US20170146794A1 - Method for manufacturing electro-optical device, electro-optical device, and electronic apparatus - Google Patents
Method for manufacturing electro-optical device, electro-optical device, and electronic apparatus Download PDFInfo
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- US20170146794A1 US20170146794A1 US15/381,282 US201615381282A US2017146794A1 US 20170146794 A1 US20170146794 A1 US 20170146794A1 US 201615381282 A US201615381282 A US 201615381282A US 2017146794 A1 US2017146794 A1 US 2017146794A1
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B26/00—Optical devices or arrangements for the control of light using movable or deformable optical elements
- G02B26/08—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light
- G02B26/0816—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light by means of one or more reflecting elements
- G02B26/0833—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light by means of one or more reflecting elements the reflecting element being a micromechanical device, e.g. a MEMS mirror, DMD
- G02B26/0841—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light by means of one or more reflecting elements the reflecting element being a micromechanical device, e.g. a MEMS mirror, DMD the reflecting element being moved or deformed by electrostatic means
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- G—PHYSICS
- G02—OPTICS
- G02B—OPTICAL ELEMENTS, SYSTEMS OR APPARATUS
- G02B26/00—Optical devices or arrangements for the control of light using movable or deformable optical elements
- G02B26/08—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light
- G02B26/0816—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light by means of one or more reflecting elements
- G02B26/0833—Optical devices or arrangements for the control of light using movable or deformable optical elements for controlling the direction of light by means of one or more reflecting elements the reflecting element being a micromechanical device, e.g. a MEMS mirror, DMD
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- G—PHYSICS
- G03—PHOTOGRAPHY; CINEMATOGRAPHY; ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ELECTROGRAPHY; HOLOGRAPHY
- G03B—APPARATUS OR ARRANGEMENTS FOR TAKING PHOTOGRAPHS OR FOR PROJECTING OR VIEWING THEM; APPARATUS OR ARRANGEMENTS EMPLOYING ANALOGOUS TECHNIQUES USING WAVES OTHER THAN OPTICAL WAVES; ACCESSORIES THEREFOR
- G03B21/00—Projectors or projection-type viewers; Accessories therefor
- G03B21/005—Projectors using an electronic spatial light modulator but not peculiar thereto
- G03B21/008—Projectors using an electronic spatial light modulator but not peculiar thereto using micromirror devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L21/00—Processes or apparatus adapted for the manufacture or treatment of semiconductor or solid state devices or of parts thereof
- H01L21/70—Manufacture or treatment of devices consisting of a plurality of solid state components formed in or on a common substrate or of parts thereof; Manufacture of integrated circuit devices or of parts thereof
- H01L21/77—Manufacture or treatment of devices consisting of a plurality of solid state components or integrated circuits formed in, or on, a common substrate
- H01L21/78—Manufacture or treatment of devices consisting of a plurality of solid state components or integrated circuits formed in, or on, a common substrate with subsequent division of the substrate into plural individual devices
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/28—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection
- H01L23/31—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape
- H01L23/3107—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed
- H01L23/3121—Encapsulations, e.g. encapsulating layers, coatings, e.g. for protection characterised by the arrangement or shape the device being completely enclosed a substrate forming part of the encapsulation
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/52—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames
- H01L23/522—Arrangements for conducting electric current within the device in operation from one component to another, i.e. interconnections, e.g. wires, lead frames including external interconnections consisting of a multilayer structure of conductive and insulating layers inseparably formed on the semiconductor body
- H01L23/528—Geometry or layout of the interconnection structure
- H01L23/5283—Cross-sectional geometry
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L23/00—Details of semiconductor or other solid state devices
- H01L23/544—Marks applied to semiconductor devices or parts, e.g. registration marks, alignment structures, wafer maps
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L24/42—Wire connectors; Manufacturing methods related thereto
- H01L24/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L24/49—Structure, shape, material or disposition of the wire connectors after the connecting process of a plurality of wire connectors
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2223/00—Details relating to semiconductor or other solid state devices covered by the group H01L23/00
- H01L2223/544—Marks applied to semiconductor devices or parts
- H01L2223/54453—Marks applied to semiconductor devices or parts for use prior to dicing
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2224/00—Indexing scheme for arrangements for connecting or disconnecting semiconductor or solid-state bodies and methods related thereto as covered by H01L24/00
- H01L2224/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L2224/42—Wire connectors; Manufacturing methods related thereto
- H01L2224/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L2224/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
- H01L2224/4805—Shape
- H01L2224/4809—Loop shape
- H01L2224/48091—Arched
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L24/00—Arrangements for connecting or disconnecting semiconductor or solid-state bodies; Methods or apparatus related thereto
- H01L24/01—Means for bonding being attached to, or being formed on, the surface to be connected, e.g. chip-to-package, die-attach, "first-level" interconnects; Manufacturing methods related thereto
- H01L24/42—Wire connectors; Manufacturing methods related thereto
- H01L24/47—Structure, shape, material or disposition of the wire connectors after the connecting process
- H01L24/48—Structure, shape, material or disposition of the wire connectors after the connecting process of an individual wire connector
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/00014—Technical content checked by a classifier the subject-matter covered by the group, the symbol of which is combined with the symbol of this group, being disclosed without further technical details
Definitions
- the present invention relates to a method for manufacturing an electro-optical device including a mirror, an electro-optical device, and an electronic apparatus.
- a projection type display device or the like As an electronic apparatus, for example, a projection type display device or the like is known.
- the projection type display device or the like modulates light emitted from a light source with a plurality of mirrors (micromirrors) of an electro-optical device called a DMD (digital mirror device), and then enlarges and projects the modulated light with a projection optical system to thereby display an image onto a screen.
- the electro-optical device used for the projection type display device or the like includes an element substrate 1 as shown in FIG. 11D .
- the element substrate 1 includes, on one surface 1 s side, mirrors 50 and terminals 17 provided at positions next to the mirrors 50 in a plan view.
- the element substrate 1 is sealed by a spacer 61 and a plate-like light-transmitting cover 71 .
- the spacer 61 is bonded on the one surface 1 s side of the element substrate 1 so as to surround the mirrors 50 and the terminals 17 in the plan view.
- the light-transmitting cover 71 is supported to an edge of the spacer 61 on the side opposite to the element substrate 1 .
- FIG. 11D To manufacture the electro-optical device shown in FIG. 11D , for example, a manufacturing method described below is proposed (see U.S. Pat. No. 6,856,014 B1).
- a first wafer 10 including the mirrors 50 and the terminals 17 on one surface 10 s side is formed, while a wafer 60 for spacer in which through-holes 66 are formed and a light-transmitting wafer 70 are stacked and bonded together to form a second wafer 20 .
- the through-holes 66 serve as bottomed recesses 21 .
- the first wafer 10 and the second wafer 20 are bonded together in a manner such that the recesses 21 overlap the mirrors 50 in a plan view.
- a dicing blade 82 for second wafer is advanced to the second wafer 20 from the side opposite to the first wafer 10 to dice the second wafer 20 and expose the terminals 17 .
- the first wafer 10 is diced with a dicing blade 81 for first wafer to obtain a plurality of electro-optical devices 100 .
- the second wafer 20 is stacked in a state of being in contact with the terminals 17 as shown in FIG. 11B . Accordingly, when the second wafer 20 is diced in the step shown in FIG. 11C , there is a problem in that the dicing blade 82 for second wafer may come in contact with the terminal 17 and cause damage to the terminal 17 .
- An advantage of some aspects of the invention is to provide a method for manufacturing an electro-optical device by which even when a stacked and bonded wafer is diced to expose a terminal, damage to the terminal can be prevented, an electro-optical device, and an electronic apparatus.
- a method for manufacturing an electro-optical device includes: preparing a first wafer including, on a first surface side, a first mirror, a first terminal, a second mirror, and a second terminal, the first terminal being provided at a position next to the first mirror in a plan view, the first terminal being electrically connected to a first drive element driving the first mirror, the second mirror being located on the side opposite to the first mirror with respect to the first terminal, the second terminal being provided between the first terminal and the second mirror, the second terminal being electrically connected to a second drive element driving the second mirror; forming a second wafer including a second surface provided with a first recess having a light-transmitting bottom portion, a second recess having a light-transmitting bottom portion, and a groove between the first recess and the second recess; bonding the first surface of the first wafer and the second surface of the second wafer together in a manner such that the first recess overlaps the first mirror in the plan view, that the second
- the first wafer and the second wafer for sealing are bonded together, the first wafer and the second wafer are diced to manufacture a plurality of electro-optical devices.
- the groove overlapping in the plan view the first terminal, the second terminal, and the area interposed between the first terminal and the second terminal is previously formed in the second wafer in addition to the first recess overlapping the first mirror and the second recess overlapping the second mirror.
- the second wafer is separated from the first terminal and the second terminal in a state where the first wafer and the second wafer are bonded together. For this reason, the first terminal and the second terminal are not bonded to the second wafer.
- the second wafer is diced before the dicing blade for second wafer comes close to the first terminal and the second terminal. Accordingly, the dicing blade for second wafer is less likely to come into contact with the first terminal and the second terminal and cause damage to the first terminal and the second terminal. Hence, the yield of the electro-optical device can be improved.
- the invention may employ a configuration in which the thickness of the second dicing blade is smaller than the thickness of the first dicing blade and in the dicing of the first wafer, the first wafer is diced by advancing the second dicing blade to the first wafer from the second surface side. According to the configuration, after the dicing of the second wafer, a step of turning over a stacked body of the first wafer and the second wafer is not necessary before the dicing of the first wafer.
- the invention may employ a configuration in which the thickness of the first dicing blade is greater than the width of the groove.
- An electro-optical device manufactured according to this configuration includes: an element substrate including a mirror and a terminal on a first surface side, the terminal being provided at a position next to the mirror in a plan view, the terminal being electrically connected to a drive element driving the mirror; and a sealing member including a spacer and a plate-like light-transmitting cover, the spacer being bonded on the first surface side of the element substrate and surrounding the mirror in the plan view, the light-transmitting cover being supported to an edge of the spacer on the side opposite to an edge thereof facing the element substrate, the light-transmitting cover overlapping the mirror in the plan view, wherein in a side surface of the sealing member, a second portion closer to the element substrate than a first portion projects opposite to the mirror beyond the first portion.
- the configuration it is easy to connect the terminal provided on the substrate with another terminal by wire bonding. Also in this case, since the area (bonding width) of bonding the sealing member with the substrate is not reduced, a sealing property between the sealing member and the substrate is not reduced.
- the invention may employ a configuration in which the thickness of the first dicing blade is smaller than the width of the groove.
- An electro-optical device manufactured according to this configuration includes: an element substrate including a mirror and a terminal on a first surface side, the terminal being provided at a position next to the mirror in a plan view, the terminal being electrically connected to a drive element driving the mirror; and a sealing member including a spacer and a plate-like light-transmitting cover, the spacer being bonded on the first surface side of the element substrate and surrounding the mirror in the plan view, the light-transmitting cover being supported to an edge of the spacer on the side opposite to an edge thereof facing the element substrate, the light-transmitting cover overlapping the mirror in the plan view, wherein in a side surface of the sealing member, a second portion closer to the element substrate than a first portion is recessed to the mirror side beyond the first portion.
- a multistage blade including the second dicing blade and the first dicing blade stacked together in a thickness direction is used, and that the dicing of the second wafer and the dicing of the first wafer are continuously performed by advancing the multistage blade to the first wafer from the second wafer side.
- the invention may employ a configuration in which the forming of the second wafer includes forming a first through-hole, a second through-hole, and the groove in a third wafer, and stacking and bonding a light-transmitting fourth wafer on and to a surface of the third wafer on the side opposite to the side where the groove is opened.
- the invention may employ a configuration in which the forming of the second wafer includes forming a first through-hole and a second through-hole in a third wafer, stacking and bonding the third wafer and a light-transmitting fourth wafer together, and forming the groove in a surface of the third wafer on the side opposite to a surface thereof bonded with the fourth wafer.
- the electro-optical device to which the invention is applied can be used for various types of electronic apparatuses, and in this case, the electronic apparatus is provided with a light source unit that irradiates the mirror with light source light. Moreover, when a projection type display device is configured as the electronic apparatus, the electronic apparatus is further provided with a projection optical system that projects light modulated by the mirror.
- FIG. 1 is a schematic view showing an optical system of a projection type display device as an electronic apparatus to which the invention is applied.
- FIGS. 2A and 2B are explanatory views schematically showing a basic configuration of an electro-optical device to which the invention is applied.
- FIGS. 3A and 3B are explanatory views schematically showing a cross section taken along the line A-A′ at a main portion of the electro-optical device to which the invention is applied.
- FIG. 4 is a cross-sectional view of the electro-optical device to which the invention is applied.
- FIGS. 5A to 5D are step cross-sectional views showing a method for manufacturing the electro-optical device to which the invention is applied.
- FIGS. 6A to 6F are step views showing a method for manufacturing a second wafer, etc. used for the manufacture of the electro-optical device to which the invention is applied.
- FIGS. 7A to 7C are step cross-sectional views showing a step of sealing a substrate with a substrate and a sealing resin in the manufacturing process of the electro-optical device to which the invention is applied.
- FIGS. 8A and 8B are explanatory views showing Modified Examples 1 and 2 of the method for manufacturing the electro-optical device to which the invention is applied.
- FIGS. 9A and 9B are explanatory views showing Modified Example 3 of the method for manufacturing the electro-optical device to which the invention is applied.
- FIGS. 10A to 10D are explanatory views showing Modified Example 4 of the method for manufacturing the electro-optical device to which the invention is applied.
- FIGS. 11A to 11D are step cross-sectional views showing a method for manufacturing an electro-optical device according to a reference example of the invention.
- FIG. 1 is a schematic view showing an optical system of a projection type display device as an electronic apparatus to which the invention is applied.
- the projection type display device 1000 shown in FIG. 1 includes a light source unit 1002 , an electro-optical device 100 that modulates light emitted from the light source unit 1002 in response to image information, and a projection optical system 1004 that projects as a projection image the light modulated by the electro-optical device 100 onto a projected object 1100 such as a screen.
- the light source unit 1002 includes a light source 1020 and a color filter 1030 .
- the light source 1020 emits white light.
- the color filter 1030 emits lights of respective colors as the color filter rotates.
- the electro-optical device 100 modulates incident light at the timing in synchronization with the rotation of the color filter 1030 .
- a phosphor substrate that converts the light emitted from the light source 1020 into lights of respective colors may be used.
- the light source unit 1002 and the electro-optical device 100 may be provided for each of lights of respective colors.
- FIGS. 2A and 2B are explanatory views schematically showing a basic configuration of the electro-optical device 100 to which the invention is applied, in which FIG. 2A is an explanatory view showing a main portion of the electro-optical device 100 , and FIG. 2B is an exploded perspective view of a main portion of the electro-optical device 100 .
- FIGS. 3A and 3B are explanatory views schematically showing a cross section taken along the line A-A′ at the main portion of the electro-optical device 100 to which the invention is applied, in which FIG. 3A is an explanatory view schematically showing a state where a mirror is inclined to one side, and FIG. 3B is an explanatory view schematically showing a state where the mirror is inclined to the other side.
- the electro-optical device 100 includes a plurality of mirrors 50 disposed in a matrix on one surface 1 s (first surface) side of an element substrate 1 .
- the mirrors 50 are separated from the element substrate 1 .
- the element substrate 1 is, for example, a silicon substrate.
- the mirror 50 is, for example, a micromirror having a planar size with a side length of, for example, from 10 ⁇ m to 30 ⁇ m.
- the mirrors 50 are arranged in, for example, from an 800 ⁇ 600 array to a 1028 ⁇ 1024 array.
- One mirror 50 corresponds to one pixel in an image.
- the surface of the mirror 50 is a reflective surface made of a reflective metal film such as aluminum.
- the electro-optical device 100 includes a first level portion 100 a including a substrate-side bias electrode 11 and substrate-side address electrodes 12 and 13 all of which are formed on the one surface 1 s of the element substrate 1 , a second level portion 100 b including elevated address electrodes 32 and 33 and a hinge 35 , and a third level portion 100 c including the mirrors 50 .
- an addressing circuit 14 is formed in the element substrate 1 .
- the addressing circuit 14 includes memory cells for selectively controlling operation of each of the mirrors 50 , and wiring lines 15 of word lines and bit lines.
- the addressing circuit 14 has a circuit configuration similar to a RAM (Random Access Memory) including a CMOS circuit 16 .
- the second level portion 100 b includes the elevated address electrodes 32 and 33 , the hinge 35 , and a mirror post 51 .
- the elevated address electrodes 32 and 33 conduct with the substrate-side address electrodes 12 and 13 via electrode posts 321 and 331 , and are supported by the substrate-side address electrodes 12 and 13 .
- Hinge arms 36 and 37 extend from both ends of the hinge 35 .
- the hinge arms 36 and 37 conduct with the substrate-side bias electrode 11 via an arm post 39 , and are supported by the substrate-side bias electrode 11 .
- the mirror 50 conducts with the hinge 35 via the mirror post 51 , and is supported by the hinge 35 .
- the mirror 50 conducts with the substrate-side bias electrode 11 via the mirror post 51 , the hinge 35 , the hinge arms 36 and 37 , and the arm post 39 , so that a bias voltage is applied from the substrate-side bias electrode 11 to the mirror 50 .
- stoppers 361 , 362 , 371 , and 372 that come into contact with the mirror 50 when the mirror 50 is inclined to thereby prevent contact between the mirror 50 and the elevated address electrodes 32 and 33 are formed.
- the elevated address electrodes 32 and 33 constitute a drive element 30 that generates an electrostatic force between the mirror 50 and the elevated address electrodes 32 and 33 to drive the mirror 50 in an inclined manner.
- the substrate-side address electrodes 12 and 13 are configured also so as to generate an electrostatic force between the mirror 50 and the substrate-side address electrodes 12 and 13 to drive the mirror 50 in an inclined manner.
- the drive element 30 is composed of the elevated address electrodes 32 and 33 and the substrate-side address electrodes 12 and 13 .
- the hinge 35 is twisted when the mirror 50 is inclined so as to be attracted to the elevated address electrode 32 or the elevated address electrode 33 by the application of a drive voltage to the elevated address electrodes 32 and 33 as shown in FIGS. 3A and 3B , so that the hinge 35 provides a force to return the mirror 50 to its parallel posture relative to the element substrate 1 when the attractive force for the mirror 50 disappears with the stop of the application of the drive voltage to the elevated address electrodes 32 and 33 .
- an on-state is established in which the light emitted from the light source unit 1002 is reflected by the mirror 50 toward the projection optical system 1004 .
- an off-state is established in which the light emitted from the light source unit 1002 is reflected by the mirror 50 toward a light-absorbing device 1005 . In the off-state, the light is not reflected toward the projection optical system 1004 .
- Such driving is performed in each of the plurality of mirrors 50 , and as a result, the light emitted from the light source unit 1002 is modulated by the plurality of mirrors 50 into image light, the image light is projected from the projection optical system 1004 , and thus an image is displayed.
- a flat plate-like yoke facing the substrate-side address electrodes 12 and 13 may be provided integrally with the hinge 35 , and an electrostatic force acting between the substrate-side address electrodes 12 and 13 and the yoke may be used in addition to the electrostatic force generated between the elevated address electrodes 32 and 33 and the mirror 50 to drive the mirror 50 .
- FIG. 4 is a cross-sectional view of the electro-optical device 100 to which the invention is applied.
- the element substrate 1 in which the plurality of mirrors 50 described with reference to FIGS. 2A to 3B are formed is sealed at the one surface 1 s with a sealing member 75 composed of a frame-like spacer 61 and a flat plate-like light-transmitting cover 71 having a light-transmitting property.
- the element substrate 1 is fixed to a substrate mount portion 93 of a substrate, and then sealed with a sealing resin 98 .
- the substrate mount portion 93 is a bottomed recess surrounded by a side plate portion 92 .
- the element substrate 1 is fixed to a bottom plate portion 91 of the substrate 90 with an adhesive 97 .
- an edge 61 e of the spacer 61 on the element substrate 1 side is bonded to the one surface 1 s of the element substrate 1 .
- the light-transmitting cover 71 is bonded to an edge 61 f that is an edge of the spacer 61 on the side opposite to the edge facing the element substrate 1 , and is supported to the edge 61 f .
- the light-transmitting cover 71 faces the surfaces of the mirrors 50 at a position spaced from the mirrors 50 with a predetermined distance. Accordingly, light passes through the light-transmitting cover 71 and is incident on the mirror 50 , and thereafter, the light reflected by the mirror 50 passes through the light-transmitting cover 71 and is emitted.
- the light-transmitting cover 71 is made of glass.
- the spacer 61 may be made of glass, silicon, metal, or resin, and in the embodiment, a glass substrate or a silicon substrate is used as the spacer 61 .
- the sealing member 75 is not limited to that formed of separated bodies (a plurality of members) like the spacer 61 and the light-transmitting cover 71 , and the spacer 61 and the light-transmitting cover 71 may be formed into one body.
- a plurality of terminals 17 are formed at an edge (outside the spacer 61 ) not overlapping the mirrors 50 .
- the terminals 17 are disposed in two rows so as to interpose the mirrors 50 therebetween.
- a portion of the plurality of terminals 17 is electrically connected to the elevated address electrodes 32 and 33 (the drive element 30 ) via the addressing circuit 14 or the substrate-side address electrodes 12 and 13 described with reference to FIGS. 2A to 3B .
- Another portion of the plurality of terminals 17 is electrically connected to the mirrors 50 via the addressing circuit 14 , the substrate-side bias electrode 11 , and the hinge 35 described with reference to FIGS. 2A to 3B .
- Yet another portion of the plurality of terminals 17 is electrically connected to a driver circuit, etc. provided in front of the addressing circuit 14 described with reference to FIGS. 2A to 3B .
- the terminals 17 are in an open state on the side opposite to the element substrate 1 , the terminals 17 are electrically connected with internal terminals 94 formed on a surface 91 s of the bottom plate portion 91 of the substrate 90 on the element substrate 1 side by means of wires 99 for wire bonding.
- the bottom plate portion 91 of the substrate 90 is a multilayer wiring board, and the internal terminals 94 conduct with external terminals 96 formed on an outer surface 91 t of the bottom plate portion 91 on the side opposite to the element substrate 1 via a multilayer wiring portion 95 composed of through-holes and wiring lines formed in the bottom plate portion 91 .
- the sealing resin 98 is provided on the inside (recess) of the side plate portion 92 of the substrate 90 .
- the sealing resin 98 covers the wires 99 , junctions between the wires 99 and the terminals 17 , junctions between the wires 99 and the internal terminals 94 , the perimeter of the element substrate 1 , and the perimeter of a bonding portion of the spacer 61 and the element substrate 1 .
- the sealing resin 98 also covers the side surface of the light-transmitting cover 71 up to the middle portion in the thickness direction.
- FIGS. 5A to 5D are step cross-sectional views showing the method for manufacturing the electro-optical device 100 to which the invention is applied.
- FIGS. 6A to 6F are step views showing a method for manufacturing a second wafer 20 , etc. used for the manufacture of the electro-optical device 100 to which the invention is applied.
- a plan view of a wafer in each step is shown, and also a cutaway end view thereof is shown below the plan view.
- FIGS. 6A to 6F a plan view of a wafer in each step is shown, and also a cutaway end view thereof is shown below the plan view.
- FIGS. 5A to 5D are step cross-sectional views showing a step of sealing the element substrate 1 with the substrate 90 and the sealing resin 98 in the manufacturing process of the electro-optical device 100 to which the invention is applied.
- the mirrors are not illustrated in FIG. 6B .
- the number of mirrors 50 is reduced in FIGS. 5A to 5D , in which three mirrors 50 are shown on the assumption that three mirrors 50 are formed on one element substrate 1 .
- a plurality of element substrates 1 , etc. are obtained from a wafer.
- the mirror 50 and the terminal 17 that are formed in an area from which one substrate is obtained, in the plurality of element substrates 1 obtained from a wafer are denoted by “a” appended to the reference numerals, and described as “first mirror 50 a ” and “first terminal 17 a ”, respectively.
- the mirror 50 and the terminal 17 that are formed in an area next to the area where the first mirror 50 a and the first terminal 17 a are formed are denoted by “b” appended to the reference numerals, and described as “second mirror 50 b ” and “second terminal 17 b ”, respectively.
- the components are described without appending the “a” or “b” to the reference numerals.
- a large-sized first wafer 10 from which a plurality of element substrates 1 can be obtained is prepared in a first-wafer preparing step.
- the first wafer 10 includes, on one surface 10 s (first surface) thereof, the mirrors 50 and the terminals 17 formed in each of areas by which the element substrate 1 is divided.
- the terminals 17 are formed at positions next to the mirrors 50 in a plan view (e.g., in a plan view when viewed from the one surface 10 s side of the first wafer 10 ), and electrically connected to the drive element 30 (see FIGS. 2A to 3B ) that drives the mirror 50 .
- the first mirrors 50 a are formed, and also the first terminals 17 a electrically connected to a first drive element 30 a (see FIGS. 2A to 3B ) that drives the first mirrors 50 a are formed at positions next to the first mirror 50 a in the plan view.
- the second mirrors 50 b are formed on the side opposite to the first mirrors 50 a with respect to the first terminal 17 a , and also the second terminals 17 b electrically connected to a second drive element 30 b (see FIGS.
- the first wafer 10 may be prepared by forming, on the one surface 10 s of the large-sized first wafer 10 from which a plurality of element substrates 1 can be obtained, the mirrors 50 in each of areas by which the element substrate 1 is divided, and also forming the terminals 17 electrically connected to the drive element 30 (see FIGS. 2A to 3B ) that drives the mirrors 50 at positions next to the mirrors 50 in the plan view.
- a large-sized second wafer 20 from which a plurality of spacers 61 and a plurality of light-transmitting covers 71 can be obtained is prepared in a second-wafer forming step.
- a recess 21 having a light-transmitting bottom portion is formed in each of areas by which the spacer 61 and the light-transmitting cover 71 are divided, and also bottomed grooves 22 extending in two directions that intersect each other at right angles and surrounding each of the plurality of recesses 21 are formed.
- One of the plurality of recesses 21 is a first recess 21 a
- the recess 21 next to the first recess 21 a is a second recess 21 b
- the bottomed grooves 22 extending along and between the first recess 21 a and the second recess 21 b are formed in the second surface 20 s of the second wafer 20 .
- steps shown in FIG. 6C to 6F are performed in the second-wafer forming step.
- a light-transmitting wafer 70 (fourth wafer) from which a plurality of light-transmitting covers 71 can be obtained is prepared.
- through-holes 66 for constituting the recesses 21 are formed by a process such as etching in the wafer 60 for spacer in a first step.
- One of the plurality of through-holes 66 is a first through-hole 66 a for constituting the first recess 21 a
- the through-hole 66 next to the first through-hole 66 a is a second through-hole 66 b for constituting the second recess 21 b
- the bottomed grooves 22 extending in the two directions that intersect each other at right angles and surrounding each of the plurality of recesses 21 are formed by a process such as half-etching.
- the grooves 22 are formed after the through-holes 66 are formed, but the through-holes 66 may be formed after the grooves 22 are formed.
- the light-transmitting cover 71 is made of glass.
- the wafer 60 for spacer may be made of glass, silicon, metal, or resin.
- the light-transmitting wafer 70 is stacked on and bonded to a surface 60 t of the wafer 60 for spacer on the side opposite to a surface 60 s thereof in which the grooves 22 are opened.
- the second wafer 20 including the wafer 60 for spacer and the light-transmitting wafer 70 stacked together is formed.
- the surface 60 s of the wafer 60 for spacer constitutes the second surface 20 s of the second wafer 20
- a surface of the light-transmitting wafer 70 on the side opposite to the wafer 60 for spacer constitutes a third surface 20 t of the second wafer 20 .
- one open end of the through-hole 66 (the first through-hole 66 a and the second through-hole 66 b ) is closed by the light-transmitting wafer 70 , so that the recess 21 (the first recess 21 a and the second recess 21 b ) having the light-transmitting bottom portion is formed.
- the one surface 10 s of the first wafer 10 and the second surface 20 s of the second wafer 20 are bonded together in a manner such that the recesses 21 overlap the mirrors 50 in a plan view (e.g., in a plan view when the first wafer 10 is viewed from the one surface 10 s side), and that the grooves 22 overlap the terminals 17 .
- the first recess 21 a overlaps the first mirrors 50 a in the plan view
- the second recess 21 b overlaps the second mirrors 50 b in the plan view
- a common groove 22 overlaps in the plan view the first terminal 17 a , the second terminal 17 b , and an area interposed between the first terminal 17 a and the second terminal 17 b .
- a portion interposed between the first recess 21 a and the groove 22 in the second wafer 20 is bonded between the first mirror 50 a and the first terminal 17 a
- a portion interposed between the second recess 21 b and the groove 22 in the second wafer 20 is bonded between the second mirror 50 b and the second terminal 17 b .
- the first terminal 17 a and the second terminal 17 b are not bonded to the second wafer 20 .
- the second wafer 20 is diced along the grooves 22 by advancing a dicing blade 82 for second wafer (first dicing blade) from the third surface 20 t composed of a surface of the second wafer 20 on the side opposite to the second surface 20 s .
- a dicing blade 82 for second wafer first dicing blade
- the second wafer 20 is divided, a flat plate portion divided from the light-transmitting wafer 70 in the second wafer 20 constitutes the light-transmitting cover 71 , and a frame portion divided from the wafer 60 for spacer in the second wafer 20 constitutes the spacer 61 .
- a thickness W 2 of the dicing blade 82 for second wafer is equal to a width W 0 of the groove 22 .
- the first wafer 10 is diced with a dicing blade 81 for first wafer (second dicing blade) along an area (area interposed between the first terminal 17 a and the second terminal 17 b ) by which the element substrate 1 is divided in the first wafer 10 .
- the first wafer 10 is diced between the first terminal 17 a and the second terminal 17 b .
- a thickness W 1 of the dicing blade 81 for first wafer is smaller than the thickness W 2 of the dicing blade 82 for second wafer.
- the first wafer 10 is diced by advancing the dicing blade 81 for first wafer to the first wafer 10 from the second wafer 20 side into a cut portion (between the light-transmitting covers 71 next to each other and between the spacers 61 next to each other) of the second wafer 20 .
- the element substrate 1 is fixed to the bottom portion of the substrate mount portion 93 with the adhesive 97 as shown in FIG. 7B .
- the terminals 17 of the element substrate 1 and the internal terminals 94 of the substrate 90 are electrically connected by means of the wires 99 for wire bonding.
- the sealing resin 98 is injected inside the side plate portion 92 of the substrate 90 , the sealing resin 98 is cured to seal the element substrate 1 with the sealing resin 98 .
- the electro-optical device 100 in which the element substrate 1 is sealed by the spacer 61 , the light-transmitting cover 71 , the substrate 90 , and the sealing resin 98 can be obtained.
- the first wafer 10 and the second wafer 20 for sealing are bonded together, the first wafer 10 and the second wafer 20 are diced to manufacture a plurality of electro-optical devices 100 .
- the groove 22 overlapping in the plan view the first terminal 17 a , the second terminal 17 b , and the area interposed between the first terminal 17 a and the second terminal 17 b is previously formed in the second wafer 20 .
- the second wafer 20 is separated from the first terminal 17 a and the second terminal 17 b in a state where the first wafer 10 and the second wafer 20 are bonded together.
- the first terminal 17 a and the second terminal 17 b are not bonded to the second wafer 20 .
- the second wafer 20 is diced before the dicing blade 82 for second wafer comes close to the first terminal 17 a and the second terminal 17 b . Accordingly, the dicing blade 82 for second wafer is less likely to come into contact with the first terminal 17 a and the second terminal 17 b and cause damage to the first terminal 17 a and the second terminal 17 b .
- the yield of the electro-optical device 100 can be improved.
- the first-wafer dicing step and the second-wafer dicing step are separately performed. Therefore, less chipping or cracking occurs in the first wafer 10 .
- FIGS. 8A and 8B are explanatory views showing Modified Examples 1 and 2 of the method for manufacturing the electro-optical device 100 to which the invention is applied, in which FIG. 8A is a cross-sectional view of the electro-optical device 100 according to Modified Examples 1, and FIG. 8B is a cross-sectional view of the electro-optical device 100 according to Modified Examples 2.
- the thickness W 2 of the dicing blade 82 for second wafer shown in FIG. 5C is equal to the width W 0 of the groove 22 . Therefore, as shown in FIG. 4 , the side surface 71 w of the light-transmitting cover 71 and an outer side surface 61 w of the spacer 61 on the side opposite to the mirror 50 form a continuous plane over the entire side surface.
- the thickness W 2 of the dicing blade 82 for second wafer shown in FIG. 5C is greater than the width W 0 of the groove 22 .
- the edge 61 e of the spacer 61 on the element substrate 1 side is a projection 61 g that projects opposite to the mirror 50 beyond a portion of the spacer 61 located on the side opposite to the element substrate 1 .
- the projection 61 g which is a second portion closer to the element substrate 1 than a first portion and projects opposite to the mirror 50 beyond the first portion, is formed on the side surface (the side surface 71 w of the light-transmitting cover 71 and the outer side surface 61 w of the spacer 61 ) of the sealing member 75 composed of the spacer 61 and the light-transmitting cover 71 .
- the terminal 17 is greatly opened on the side opposite to the element substrate 1 , it is easy to perform wire bonding.
- the area (bonding width) of bonding the spacer 61 with the element substrate 1 is not reduced, a sealing property between the spacer 61 and the element substrate 1 is not reduced.
- the thickness W 2 of the dicing blade 82 for second wafer shown in FIG. 5C is smaller than the width W 0 of the groove 22 .
- the edge 61 e of the spacer 61 on the element substrate 1 side is a recess 61 h recessed to the mirror 50 side beyond the portion of the spacer 61 located on the side opposite to the element substrate 1 .
- the recess 61 h which is a second portion closer to the element substrate 1 than a first portion and recessed to the mirror 50 side beyond the first portion, is formed in the side surface (the side surface 71 w of the light-transmitting cover 71 and the outer side surface 61 w of the spacer 61 ) of the sealing member 75 composed of the spacer 61 and the light-transmitting cover 71 . Also in this case, since the area (bonding width) of bonding the spacer 61 with the light-transmitting cover 71 is not reduced, a sealing property between the spacer 61 and the light-transmitting cover 71 is not reduced.
- FIGS. 9A and 9B are explanatory views showing Modified Example 3 of the method for manufacturing the electro-optical device 100 to which the invention is applied, in which FIG. 9A is an explanatory view of a dicing blade used in Modified Examples 3, and FIG. 9B is an explanatory view showing a state of dicing the first wafer 10 and the second wafer 20 with the dicing blade used in Modified Examples 3.
- a multistage blade 85 including the dicing blade 81 for first wafer and the dicing blade 82 for second wafer concentrically stacked together in the thickness direction is used in the second-wafer dicing step and the first-wafer dicing step shown in FIGS. 5C and 5D .
- the dicing blade 81 for first wafer has a diameter greater than the dicing blade 82 for second wafer, and the dicing blade 82 for second wafer projects from both surfaces of the dicing blade 81 for first wafer.
- the thickness W 2 of the dicing blade 82 for second wafer is greater than the thickness W 1 of the dicing blade 81 for first wafer.
- the second-wafer dicing step and the first-wafer dicing step can be continuously performed in the same step by advancing the multistage blade 85 to the first wafer 10 from the second wafer 20 side.
- the thickness W 2 of the dicing blade 82 for second wafer is greater than the width W 0 of the groove 22 in the step shown in FIG. 9B , the thickness W 2 of the dicing blade 82 for second wafer may be smaller than the width W 0 of the groove 22 .
- FIGS. 10A to 10D are explanatory views showing Modified Example 4 of the method for manufacturing the electro-optical device 100 to which the invention is applied
- FIGS. 10A to 10D are step views showing a method for manufacturing the second wafer 20 , etc. used for the manufacture of the electro-optical device 100 .
- a plan view of a wafer in each step is shown, and also a cutaway end view thereof is shown below the plan view.
- the light-transmitting wafer 70 from which a plurality of light-transmitting covers 71 can be obtained is first prepared as shown in FIG. 10A .
- the through-holes 66 for constituting the recesses 21 are formed in the wafer 60 for spacer by a process such as etching in a first step.
- One of the plurality of through-holes 66 is the first through-hole 66 a for constituting the first recess 21 a , and the through-hole 66 next to the first through-hole 66 a is the second through-hole 66 b for constituting the second recess 21 b.
- the wafer 60 for spacer and the light-transmitting wafer 70 are stacked and bonded together.
- one open end of the through-hole 66 (the first through-hole 66 a and the second through-hole 66 b ) is closed by the light-transmitting wafer 70 , so that the recess 21 (the first recess 21 a and the second recess 21 b ) having the light-transmitting bottom portion is formed.
- the bottomed grooves 22 extending in the two directions that intersect each other at right angles and surrounding each of the plurality of recesses 21 are formed by a process such as half-etching in the surface 60 s of the wafer 60 for spacer on the side opposite to the surface bonded with the light-transmitting wafer 70 .
- the second wafer 20 including the wafer 60 for spacer and the light-transmitting wafer 70 stacked together is formed.
- the surface 60 s of the wafer 60 for spacer constitutes the second surface 20 s of the second wafer 20
- the surface of the light-transmitting wafer 70 on the side opposite to the wafer 60 for spacer constitutes the third surface 20 t of the second wafer 20 .
- the recess 21 (the through-hole 66 ) and the groove 22 are formed by a process such as etching.
- the second wafer 20 in which the recesses 21 and the grooves 22 are formed may be formed by molding, etc.
- the second wafer 20 may be formed using the wafer 60 for spacer in which the through-holes 66 and the grooves 22 are formed by molding, etc.
- planar shape of a wafer may be rectangular, etc.
Abstract
After a first wafer on which mirrors and terminals are formed and a second wafer for sealing are stacked and bonded together, the first wafer and the second wafer are diced to manufacture electro-optical devices. In doing so, in a second surface of the second wafer, recesses overlapping the mirrors in a plan view are previously formed, and also grooves overlapping the terminals in the plan view are previously formed. For this reason, when the second wafer is diced along the grooves by advancing a dicing blade for second wafer from a third surface of the second wafer, the dicing blade for second wafer can be prevented from coming into contact with the terminal.
Description
- This is a Continuation of application Ser. No. 15/018,086 filed Feb. 8, 2016, which claims the benefit of Japanese Application No. 2015-065932 filed Mar. 27, 2015. The disclosures of the prior applications are hereby incorporated by reference herein in their entirety.
- 1. Technical Field
- The present invention relates to a method for manufacturing an electro-optical device including a mirror, an electro-optical device, and an electronic apparatus.
- 2. Related Art
- As an electronic apparatus, for example, a projection type display device or the like is known. The projection type display device or the like modulates light emitted from a light source with a plurality of mirrors (micromirrors) of an electro-optical device called a DMD (digital mirror device), and then enlarges and projects the modulated light with a projection optical system to thereby display an image onto a screen. The electro-optical device used for the projection type display device or the like includes an
element substrate 1 as shown inFIG. 11D . Theelement substrate 1 includes, on onesurface 1 s side,mirrors 50 andterminals 17 provided at positions next to themirrors 50 in a plan view. Moreover, theelement substrate 1 is sealed by aspacer 61 and a plate-like light-transmittingcover 71. Thespacer 61 is bonded on the onesurface 1 s side of theelement substrate 1 so as to surround themirrors 50 and theterminals 17 in the plan view. The light-transmittingcover 71 is supported to an edge of thespacer 61 on the side opposite to theelement substrate 1. - To manufacture the electro-optical device shown in
FIG. 11D , for example, a manufacturing method described below is proposed (see U.S. Pat. No. 6,856,014 B1). First, as shown inFIG. 11A , afirst wafer 10 including themirrors 50 and theterminals 17 on onesurface 10 s side is formed, while awafer 60 for spacer in which through-holes 66 are formed and a light-transmittingwafer 70 are stacked and bonded together to form asecond wafer 20. As a result, the through-holes 66 serve as bottomedrecesses 21. Next, as shown inFIG. 11B , thefirst wafer 10 and thesecond wafer 20 are bonded together in a manner such that therecesses 21 overlap themirrors 50 in a plan view. Next, as shown inFIG. 11C , adicing blade 82 for second wafer is advanced to thesecond wafer 20 from the side opposite to thefirst wafer 10 to dice thesecond wafer 20 and expose theterminals 17. Next, as shown inFIG. 11D , thefirst wafer 10 is diced with adicing blade 81 for first wafer to obtain a plurality of electro-optical devices 100. - In the manufacturing method shown in
FIGS. 11A to 11D , however, thesecond wafer 20 is stacked in a state of being in contact with theterminals 17 as shown inFIG. 11B . Accordingly, when thesecond wafer 20 is diced in the step shown inFIG. 11C , there is a problem in that thedicing blade 82 for second wafer may come in contact with theterminal 17 and cause damage to theterminal 17. - An advantage of some aspects of the invention is to provide a method for manufacturing an electro-optical device by which even when a stacked and bonded wafer is diced to expose a terminal, damage to the terminal can be prevented, an electro-optical device, and an electronic apparatus.
- A method for manufacturing an electro-optical device according to an aspect of the invention includes: preparing a first wafer including, on a first surface side, a first mirror, a first terminal, a second mirror, and a second terminal, the first terminal being provided at a position next to the first mirror in a plan view, the first terminal being electrically connected to a first drive element driving the first mirror, the second mirror being located on the side opposite to the first mirror with respect to the first terminal, the second terminal being provided between the first terminal and the second mirror, the second terminal being electrically connected to a second drive element driving the second mirror; forming a second wafer including a second surface provided with a first recess having a light-transmitting bottom portion, a second recess having a light-transmitting bottom portion, and a groove between the first recess and the second recess; bonding the first surface of the first wafer and the second surface of the second wafer together in a manner such that the first recess overlaps the first mirror in the plan view, that the second recess overlaps the second mirror in the plan view, and that the groove overlaps in the plan view the first terminal, the second terminal, and an area interposed between the first terminal and the second terminal; dicing the second wafer along the groove by advancing a first dicing blade from a third surface of the second wafer on the side opposite to the second surface; and dicing the first wafer between the first terminal and the second terminal with a second dicing blade.
- In the aspect of the invention, after the first wafer and the second wafer for sealing are bonded together, the first wafer and the second wafer are diced to manufacture a plurality of electro-optical devices. In doing so, the groove overlapping in the plan view the first terminal, the second terminal, and the area interposed between the first terminal and the second terminal is previously formed in the second wafer in addition to the first recess overlapping the first mirror and the second recess overlapping the second mirror. For this reason, the second wafer is separated from the first terminal and the second terminal in a state where the first wafer and the second wafer are bonded together. For this reason, the first terminal and the second terminal are not bonded to the second wafer. Moreover, in the dicing of the second wafer, the second wafer is diced before the dicing blade for second wafer comes close to the first terminal and the second terminal. Accordingly, the dicing blade for second wafer is less likely to come into contact with the first terminal and the second terminal and cause damage to the first terminal and the second terminal. Hence, the yield of the electro-optical device can be improved.
- The invention may employ a configuration in which the thickness of the second dicing blade is smaller than the thickness of the first dicing blade and in the dicing of the first wafer, the first wafer is diced by advancing the second dicing blade to the first wafer from the second surface side. According to the configuration, after the dicing of the second wafer, a step of turning over a stacked body of the first wafer and the second wafer is not necessary before the dicing of the first wafer.
- The invention may employ a configuration in which the thickness of the first dicing blade is greater than the width of the groove. An electro-optical device manufactured according to this configuration includes: an element substrate including a mirror and a terminal on a first surface side, the terminal being provided at a position next to the mirror in a plan view, the terminal being electrically connected to a drive element driving the mirror; and a sealing member including a spacer and a plate-like light-transmitting cover, the spacer being bonded on the first surface side of the element substrate and surrounding the mirror in the plan view, the light-transmitting cover being supported to an edge of the spacer on the side opposite to an edge thereof facing the element substrate, the light-transmitting cover overlapping the mirror in the plan view, wherein in a side surface of the sealing member, a second portion closer to the element substrate than a first portion projects opposite to the mirror beyond the first portion. According to the configuration, it is easy to connect the terminal provided on the substrate with another terminal by wire bonding. Also in this case, since the area (bonding width) of bonding the sealing member with the substrate is not reduced, a sealing property between the sealing member and the substrate is not reduced.
- The invention may employ a configuration in which the thickness of the first dicing blade is smaller than the width of the groove. An electro-optical device manufactured according to this configuration includes: an element substrate including a mirror and a terminal on a first surface side, the terminal being provided at a position next to the mirror in a plan view, the terminal being electrically connected to a drive element driving the mirror; and a sealing member including a spacer and a plate-like light-transmitting cover, the spacer being bonded on the first surface side of the element substrate and surrounding the mirror in the plan view, the light-transmitting cover being supported to an edge of the spacer on the side opposite to an edge thereof facing the element substrate, the light-transmitting cover overlapping the mirror in the plan view, wherein in a side surface of the sealing member, a second portion closer to the element substrate than a first portion is recessed to the mirror side beyond the first portion.
- In the aspect of the invention, it is preferable that a multistage blade including the second dicing blade and the first dicing blade stacked together in a thickness direction is used, and that the dicing of the second wafer and the dicing of the first wafer are continuously performed by advancing the multistage blade to the first wafer from the second wafer side.
- The invention may employ a configuration in which the forming of the second wafer includes forming a first through-hole, a second through-hole, and the groove in a third wafer, and stacking and bonding a light-transmitting fourth wafer on and to a surface of the third wafer on the side opposite to the side where the groove is opened.
- The invention may employ a configuration in which the forming of the second wafer includes forming a first through-hole and a second through-hole in a third wafer, stacking and bonding the third wafer and a light-transmitting fourth wafer together, and forming the groove in a surface of the third wafer on the side opposite to a surface thereof bonded with the fourth wafer.
- The electro-optical device to which the invention is applied can be used for various types of electronic apparatuses, and in this case, the electronic apparatus is provided with a light source unit that irradiates the mirror with light source light. Moreover, when a projection type display device is configured as the electronic apparatus, the electronic apparatus is further provided with a projection optical system that projects light modulated by the mirror.
- The invention will be described with reference to the accompanying drawings, wherein like numbers reference like elements.
-
FIG. 1 is a schematic view showing an optical system of a projection type display device as an electronic apparatus to which the invention is applied. -
FIGS. 2A and 2B are explanatory views schematically showing a basic configuration of an electro-optical device to which the invention is applied. -
FIGS. 3A and 3B are explanatory views schematically showing a cross section taken along the line A-A′ at a main portion of the electro-optical device to which the invention is applied. -
FIG. 4 is a cross-sectional view of the electro-optical device to which the invention is applied. -
FIGS. 5A to 5D are step cross-sectional views showing a method for manufacturing the electro-optical device to which the invention is applied. -
FIGS. 6A to 6F are step views showing a method for manufacturing a second wafer, etc. used for the manufacture of the electro-optical device to which the invention is applied. -
FIGS. 7A to 7C are step cross-sectional views showing a step of sealing a substrate with a substrate and a sealing resin in the manufacturing process of the electro-optical device to which the invention is applied. -
FIGS. 8A and 8B are explanatory views showing Modified Examples 1 and 2 of the method for manufacturing the electro-optical device to which the invention is applied. -
FIGS. 9A and 9B are explanatory views showing Modified Example 3 of the method for manufacturing the electro-optical device to which the invention is applied. -
FIGS. 10A to 10D are explanatory views showing Modified Example 4 of the method for manufacturing the electro-optical device to which the invention is applied. -
FIGS. 11A to 11D are step cross-sectional views showing a method for manufacturing an electro-optical device according to a reference example of the invention. - An embodiment of the invention will be described with reference to the drawings. In the following description, a projection type display device will be described as an electronic apparatus to which the invention is applied. In the drawings to be referred to in the following description, layers or members are shown in different scales so that each of the layers or members has a recognizable size on the drawings. The numbers of mirrors, etc. shown in the drawings are set in a manner such that the mirror, etc. have a recognizable size on the drawings, but a larger number of mirrors, etc. than those shown in the drawings may be provided.
-
FIG. 1 is a schematic view showing an optical system of a projection type display device as an electronic apparatus to which the invention is applied. The projectiontype display device 1000 shown inFIG. 1 includes alight source unit 1002, an electro-optical device 100 that modulates light emitted from thelight source unit 1002 in response to image information, and a projectionoptical system 1004 that projects as a projection image the light modulated by the electro-optical device 100 onto a projectedobject 1100 such as a screen. Thelight source unit 1002 includes alight source 1020 and acolor filter 1030. Thelight source 1020 emits white light. Thecolor filter 1030 emits lights of respective colors as the color filter rotates. The electro-optical device 100 modulates incident light at the timing in synchronization with the rotation of thecolor filter 1030. Instead of thecolor filter 1030, a phosphor substrate that converts the light emitted from thelight source 1020 into lights of respective colors may be used. Moreover, thelight source unit 1002 and the electro-optical device 100 may be provided for each of lights of respective colors. -
FIGS. 2A and 2B are explanatory views schematically showing a basic configuration of the electro-optical device 100 to which the invention is applied, in whichFIG. 2A is an explanatory view showing a main portion of the electro-optical device 100, andFIG. 2B is an exploded perspective view of a main portion of the electro-optical device 100.FIGS. 3A and 3B are explanatory views schematically showing a cross section taken along the line A-A′ at the main portion of the electro-optical device 100 to which the invention is applied, in whichFIG. 3A is an explanatory view schematically showing a state where a mirror is inclined to one side, andFIG. 3B is an explanatory view schematically showing a state where the mirror is inclined to the other side. - As shown in
FIGS. 2A to 3B , the electro-optical device 100 includes a plurality ofmirrors 50 disposed in a matrix on onesurface 1 s (first surface) side of anelement substrate 1. Themirrors 50 are separated from theelement substrate 1. Theelement substrate 1 is, for example, a silicon substrate. Themirror 50 is, for example, a micromirror having a planar size with a side length of, for example, from 10 μm to 30 μm. Themirrors 50 are arranged in, for example, from an 800×600 array to a 1028×1024 array. Onemirror 50 corresponds to one pixel in an image. - The surface of the
mirror 50 is a reflective surface made of a reflective metal film such as aluminum. The electro-optical device 100 includes afirst level portion 100 a including a substrate-side bias electrode 11 and substrate-side address electrodes surface 1 s of theelement substrate 1, asecond level portion 100 b includingelevated address electrodes hinge 35, and athird level portion 100 c including themirrors 50. In thefirst level portion 100 a, an addressingcircuit 14 is formed in theelement substrate 1. The addressingcircuit 14 includes memory cells for selectively controlling operation of each of themirrors 50, andwiring lines 15 of word lines and bit lines. The addressingcircuit 14 has a circuit configuration similar to a RAM (Random Access Memory) including aCMOS circuit 16. - The
second level portion 100 b includes theelevated address electrodes hinge 35, and amirror post 51. Theelevated address electrodes side address electrodes electrode posts side address electrodes Hinge arms hinge 35. Thehinge arms side bias electrode 11 via anarm post 39, and are supported by the substrate-side bias electrode 11. Themirror 50 conducts with thehinge 35 via themirror post 51, and is supported by thehinge 35. Accordingly, themirror 50 conducts with the substrate-side bias electrode 11 via themirror post 51, thehinge 35, thehinge arms arm post 39, so that a bias voltage is applied from the substrate-side bias electrode 11 to themirror 50. At the tips of thehinge arms stoppers mirror 50 when themirror 50 is inclined to thereby prevent contact between themirror 50 and theelevated address electrodes - The
elevated address electrodes mirror 50 and theelevated address electrodes mirror 50 in an inclined manner. In some cases, the substrate-side address electrodes mirror 50 and the substrate-side address electrodes mirror 50 in an inclined manner. In this case, the drive element 30 is composed of theelevated address electrodes side address electrodes hinge 35 is twisted when themirror 50 is inclined so as to be attracted to theelevated address electrode 32 or theelevated address electrode 33 by the application of a drive voltage to theelevated address electrodes FIGS. 3A and 3B , so that thehinge 35 provides a force to return themirror 50 to its parallel posture relative to theelement substrate 1 when the attractive force for themirror 50 disappears with the stop of the application of the drive voltage to theelevated address electrodes - In the electro-
optical device 100, when themirror 50 is inclined to theelevated address electrode 32 side as one side as shown inFIG. 3A for example, an on-state is established in which the light emitted from thelight source unit 1002 is reflected by themirror 50 toward the projectionoptical system 1004. In contrast, when themirror 50 is inclined to theelevated address electrode 33 side as the other side as shown inFIG. 3B , an off-state is established in which the light emitted from thelight source unit 1002 is reflected by themirror 50 toward a light-absorbingdevice 1005. In the off-state, the light is not reflected toward the projectionoptical system 1004. Such driving is performed in each of the plurality ofmirrors 50, and as a result, the light emitted from thelight source unit 1002 is modulated by the plurality ofmirrors 50 into image light, the image light is projected from the projectionoptical system 1004, and thus an image is displayed. - A flat plate-like yoke facing the substrate-
side address electrodes hinge 35, and an electrostatic force acting between the substrate-side address electrodes elevated address electrodes mirror 50 to drive themirror 50. -
FIG. 4 is a cross-sectional view of the electro-optical device 100 to which the invention is applied. As shown inFIG. 4 , in the electro-optical device 100 of the embodiment, theelement substrate 1 in which the plurality ofmirrors 50 described with reference toFIGS. 2A to 3B are formed is sealed at the onesurface 1 s with a sealingmember 75 composed of a frame-like spacer 61 and a flat plate-like light-transmittingcover 71 having a light-transmitting property. Thereafter, theelement substrate 1 is fixed to asubstrate mount portion 93 of a substrate, and then sealed with a sealingresin 98. In thesubstrate 90, thesubstrate mount portion 93 is a bottomed recess surrounded by aside plate portion 92. Theelement substrate 1 is fixed to abottom plate portion 91 of thesubstrate 90 with an adhesive 97. - Here, an
edge 61 e of thespacer 61 on theelement substrate 1 side is bonded to the onesurface 1 s of theelement substrate 1. The light-transmittingcover 71 is bonded to anedge 61 f that is an edge of thespacer 61 on the side opposite to the edge facing theelement substrate 1, and is supported to theedge 61 f. In this state, the light-transmittingcover 71 faces the surfaces of themirrors 50 at a position spaced from themirrors 50 with a predetermined distance. Accordingly, light passes through the light-transmittingcover 71 and is incident on themirror 50, and thereafter, the light reflected by themirror 50 passes through the light-transmittingcover 71 and is emitted. In the embodiment, the light-transmittingcover 71 is made of glass. Thespacer 61 may be made of glass, silicon, metal, or resin, and in the embodiment, a glass substrate or a silicon substrate is used as thespacer 61. The sealingmember 75 is not limited to that formed of separated bodies (a plurality of members) like thespacer 61 and the light-transmittingcover 71, and thespacer 61 and the light-transmittingcover 71 may be formed into one body. - On the one
surface 1 s of theelement substrate 1, a plurality ofterminals 17 are formed at an edge (outside the spacer 61) not overlapping themirrors 50. In the embodiment, theterminals 17 are disposed in two rows so as to interpose themirrors 50 therebetween. A portion of the plurality ofterminals 17 is electrically connected to theelevated address electrodes 32 and 33 (the drive element 30) via the addressingcircuit 14 or the substrate-side address electrodes FIGS. 2A to 3B . Another portion of the plurality ofterminals 17 is electrically connected to themirrors 50 via the addressingcircuit 14, the substrate-side bias electrode 11, and thehinge 35 described with reference toFIGS. 2A to 3B . Yet another portion of the plurality ofterminals 17 is electrically connected to a driver circuit, etc. provided in front of the addressingcircuit 14 described with reference toFIGS. 2A to 3B . - Here, since the
terminals 17 are in an open state on the side opposite to theelement substrate 1, theterminals 17 are electrically connected withinternal terminals 94 formed on asurface 91 s of thebottom plate portion 91 of thesubstrate 90 on theelement substrate 1 side by means ofwires 99 for wire bonding. Thebottom plate portion 91 of thesubstrate 90 is a multilayer wiring board, and theinternal terminals 94 conduct withexternal terminals 96 formed on anouter surface 91 t of thebottom plate portion 91 on the side opposite to theelement substrate 1 via amultilayer wiring portion 95 composed of through-holes and wiring lines formed in thebottom plate portion 91. - The sealing
resin 98 is provided on the inside (recess) of theside plate portion 92 of thesubstrate 90. The sealingresin 98 covers thewires 99, junctions between thewires 99 and theterminals 17, junctions between thewires 99 and theinternal terminals 94, the perimeter of theelement substrate 1, and the perimeter of a bonding portion of thespacer 61 and theelement substrate 1. The sealingresin 98 also covers the side surface of the light-transmittingcover 71 up to the middle portion in the thickness direction. - A method for manufacturing the electro-
optical device 100 to which the invention is applied will be described with reference toFIGS. 5A to 7C .FIGS. 5A to 5D are step cross-sectional views showing the method for manufacturing the electro-optical device 100 to which the invention is applied.FIGS. 6A to 6F are step views showing a method for manufacturing asecond wafer 20, etc. used for the manufacture of the electro-optical device 100 to which the invention is applied. InFIGS. 6A to 6F , a plan view of a wafer in each step is shown, and also a cutaway end view thereof is shown below the plan view.FIGS. 7A to 7C are step cross-sectional views showing a step of sealing theelement substrate 1 with thesubstrate 90 and the sealingresin 98 in the manufacturing process of the electro-optical device 100 to which the invention is applied. The mirrors are not illustrated inFIG. 6B . Compared toFIG. 4 , the number ofmirrors 50 is reduced inFIGS. 5A to 5D , in which threemirrors 50 are shown on the assumption that threemirrors 50 are formed on oneelement substrate 1. - In the embodiment, a plurality of
element substrates 1, etc. are obtained from a wafer. For this reason, in the following description, for example, themirror 50 and the terminal 17 that are formed in an area from which one substrate is obtained, in the plurality ofelement substrates 1 obtained from a wafer, are denoted by “a” appended to the reference numerals, and described as “first mirror 50 a” and “first terminal 17 a”, respectively. Moreover, in the plurality ofelement substrates 1, for example, themirror 50 and the terminal 17 that are formed in an area next to the area where thefirst mirror 50 a and the first terminal 17 a are formed are denoted by “b” appended to the reference numerals, and described as “second mirror 50 b” and “second terminal 17 b”, respectively. However, when it is not necessary to specify anyelement substrate 1, the components are described without appending the “a” or “b” to the reference numerals. - To manufacture the electro-
optical device 100 of the embodiment, as shown inFIGS. 5A, 6A, and 6B , a large-sizedfirst wafer 10 from which a plurality ofelement substrates 1 can be obtained is prepared in a first-wafer preparing step. Thefirst wafer 10 includes, on onesurface 10 s (first surface) thereof, themirrors 50 and theterminals 17 formed in each of areas by which theelement substrate 1 is divided. Theterminals 17 are formed at positions next to themirrors 50 in a plan view (e.g., in a plan view when viewed from the onesurface 10 s side of the first wafer 10), and electrically connected to the drive element 30 (seeFIGS. 2A to 3B ) that drives themirror 50. - On the one
surface 10 s of thefirst wafer 10, thefirst mirrors 50 a are formed, and also the first terminals 17 a electrically connected to afirst drive element 30 a (seeFIGS. 2A to 3B ) that drives thefirst mirrors 50 a are formed at positions next to thefirst mirror 50 a in the plan view. Moreover, on the onesurface 10 s of thefirst wafer 10, thesecond mirrors 50 b are formed on the side opposite to thefirst mirrors 50 a with respect to the first terminal 17 a, and also the second terminals 17 b electrically connected to asecond drive element 30 b (seeFIGS. 2A to 3B ) that drives thesecond mirror 50 b are formed between the first terminals 17 a and thesecond mirrors 50 b. For example, as shown inFIGS. 5A, 6A , and 6B, thefirst wafer 10 may be prepared by forming, on the onesurface 10 s of the large-sizedfirst wafer 10 from which a plurality ofelement substrates 1 can be obtained, themirrors 50 in each of areas by which theelement substrate 1 is divided, and also forming theterminals 17 electrically connected to the drive element 30 (seeFIGS. 2A to 3B ) that drives themirrors 50 at positions next to themirrors 50 in the plan view. - As shown in
FIG. 5A , a large-sizedsecond wafer 20 from which a plurality ofspacers 61 and a plurality of light-transmitting covers 71 can be obtained is prepared in a second-wafer forming step. On asecond surface 20 s composed of one surface of thesecond wafer 20, arecess 21 having a light-transmitting bottom portion is formed in each of areas by which thespacer 61 and the light-transmittingcover 71 are divided, and also bottomedgrooves 22 extending in two directions that intersect each other at right angles and surrounding each of the plurality ofrecesses 21 are formed. One of the plurality ofrecesses 21 is a first recess 21 a, and therecess 21 next to the first recess 21 a is a second recess 21 b. Accordingly, the first recess 21 a having the light-transmitting bottom portion, the second recess 21 b having the light-transmitting bottom portion, and the bottomedgrooves 22 extending along and between the first recess 21 a and the second recess 21 b are formed in thesecond surface 20 s of thesecond wafer 20. - In the formation of the
second wafer 20, for example, steps shown inFIG. 6C to 6F are performed in the second-wafer forming step. First, as shown inFIG. 6C , a light-transmitting wafer 70 (fourth wafer) from which a plurality of light-transmitting covers 71 can be obtained is prepared. Moreover, as shown inFIG. 6D , after a wafer 60 (third wafer) for spacer from which a plurality ofspacers 61 can be obtained is prepared, through-holes 66 for constituting therecesses 21 are formed by a process such as etching in thewafer 60 for spacer in a first step. One of the plurality of through-holes 66 is a first through-hole 66 a for constituting the first recess 21 a, and the through-hole 66 next to the first through-hole 66 a is a second through-hole 66 b for constituting the second recess 21 b. Next, as shown inFIG. 6E , the bottomedgrooves 22 extending in the two directions that intersect each other at right angles and surrounding each of the plurality ofrecesses 21 are formed by a process such as half-etching. In the first step, thegrooves 22 are formed after the through-holes 66 are formed, but the through-holes 66 may be formed after thegrooves 22 are formed. In the embodiment, the light-transmittingcover 71 is made of glass. Thewafer 60 for spacer may be made of glass, silicon, metal, or resin. - Next, in a second step as shown in
FIG. 6F , the light-transmittingwafer 70 is stacked on and bonded to asurface 60 t of thewafer 60 for spacer on the side opposite to asurface 60 s thereof in which thegrooves 22 are opened. As a result, thesecond wafer 20 including thewafer 60 for spacer and the light-transmittingwafer 70 stacked together is formed. In thesecond wafer 20, thesurface 60 s of thewafer 60 for spacer constitutes thesecond surface 20 s of thesecond wafer 20, while a surface of the light-transmittingwafer 70 on the side opposite to thewafer 60 for spacer constitutes athird surface 20 t of thesecond wafer 20. Moreover, one open end of the through-hole 66 (the first through-hole 66 a and the second through-hole 66 b) is closed by the light-transmittingwafer 70, so that the recess 21 (the first recess 21 a and the second recess 21 b) having the light-transmitting bottom portion is formed. - Next, in a bonding step as shown in
FIG. 5B , the onesurface 10 s of thefirst wafer 10 and thesecond surface 20 s of thesecond wafer 20 are bonded together in a manner such that therecesses 21 overlap themirrors 50 in a plan view (e.g., in a plan view when thefirst wafer 10 is viewed from the onesurface 10 s side), and that thegrooves 22 overlap theterminals 17. As a result, the first recess 21 a overlaps thefirst mirrors 50 a in the plan view, the second recess 21 b overlaps thesecond mirrors 50 b in the plan view, and acommon groove 22 overlaps in the plan view the first terminal 17 a, the second terminal 17 b, and an area interposed between the first terminal 17 a and the second terminal 17 b. In this state, a portion interposed between the first recess 21 a and thegroove 22 in thesecond wafer 20 is bonded between thefirst mirror 50 a and the first terminal 17 a, and a portion interposed between the second recess 21 b and thegroove 22 in thesecond wafer 20 is bonded between thesecond mirror 50 b and the second terminal 17 b. Accordingly, the first terminal 17 a and the second terminal 17 b are not bonded to thesecond wafer 20. - Next, in a second-wafer dicing step as shown in
FIG. 5C , thesecond wafer 20 is diced along thegrooves 22 by advancing adicing blade 82 for second wafer (first dicing blade) from thethird surface 20 t composed of a surface of thesecond wafer 20 on the side opposite to thesecond surface 20 s. As a result, thesecond wafer 20 is divided, a flat plate portion divided from the light-transmittingwafer 70 in thesecond wafer 20 constitutes the light-transmittingcover 71, and a frame portion divided from thewafer 60 for spacer in thesecond wafer 20 constitutes thespacer 61. In the embodiment, a thickness W2 of thedicing blade 82 for second wafer is equal to a width W0 of thegroove 22. - Next, in a first-wafer dicing step as shown in
FIG. 5D , thefirst wafer 10 is diced with adicing blade 81 for first wafer (second dicing blade) along an area (area interposed between the first terminal 17 a and the second terminal 17 b) by which theelement substrate 1 is divided in thefirst wafer 10. As a result, thefirst wafer 10 is diced between the first terminal 17 a and the second terminal 17 b. In the embodiment, a thickness W1 of thedicing blade 81 for first wafer is smaller than the thickness W2 of thedicing blade 82 for second wafer. Accordingly, in the first-wafer dicing step, thefirst wafer 10 is diced by advancing thedicing blade 81 for first wafer to thefirst wafer 10 from thesecond wafer 20 side into a cut portion (between the light-transmitting covers 71 next to each other and between thespacers 61 next to each other) of thesecond wafer 20. - As a result, a plurality of electro-
optical devices 100 in which the onesurface 1 s of theelement substrate 1 including a plurality ofmirrors 50 formed thereon is sealed by thespacer 61 and the light-transmittingcover 71 are manufactured. When the electro-optical device 100 is further sealed by thesubstrate 90 and the sealingresin 98 as shown inFIG. 4 , steps shown inFIGS. 7A to 7C are performed. - First, as shown in
FIG. 7A , after thesubstrate 90 having thesubstrate mount portion 93 as a recess surrounded by theside plate portion 92 is prepared, theelement substrate 1 is fixed to the bottom portion of thesubstrate mount portion 93 with the adhesive 97 as shown inFIG. 7B . Next, as shown inFIG. 7C , theterminals 17 of theelement substrate 1 and theinternal terminals 94 of thesubstrate 90 are electrically connected by means of thewires 99 for wire bonding. Next, as shown inFIG. 4 , after the sealingresin 98 is injected inside theside plate portion 92 of thesubstrate 90, the sealingresin 98 is cured to seal theelement substrate 1 with the sealingresin 98. As a result, the electro-optical device 100 in which theelement substrate 1 is sealed by thespacer 61, the light-transmittingcover 71, thesubstrate 90, and the sealingresin 98 can be obtained. - In the embodiment as has been described above, after the
first wafer 10 and thesecond wafer 20 for sealing are bonded together, thefirst wafer 10 and thesecond wafer 20 are diced to manufacture a plurality of electro-optical devices 100. In doing so, thegroove 22 overlapping in the plan view the first terminal 17 a, the second terminal 17 b, and the area interposed between the first terminal 17 a and the second terminal 17 b is previously formed in thesecond wafer 20. Accordingly, in the embodiment, thesecond wafer 20 is separated from the first terminal 17 a and the second terminal 17 b in a state where thefirst wafer 10 and thesecond wafer 20 are bonded together. For this reason, the first terminal 17 a and the second terminal 17 b are not bonded to thesecond wafer 20. Moreover, in the second-wafer dicing step, thesecond wafer 20 is diced before thedicing blade 82 for second wafer comes close to the first terminal 17 a and the second terminal 17 b. Accordingly, thedicing blade 82 for second wafer is less likely to come into contact with the first terminal 17 a and the second terminal 17 b and cause damage to the first terminal 17 a and the second terminal 17 b. Hence, the yield of the electro-optical device 100 can be improved. - Moreover, in the embodiment, the first-wafer dicing step and the second-wafer dicing step are separately performed. Therefore, less chipping or cracking occurs in the
first wafer 10. -
FIGS. 8A and 8B are explanatory views showing Modified Examples 1 and 2 of the method for manufacturing the electro-optical device 100 to which the invention is applied, in whichFIG. 8A is a cross-sectional view of the electro-optical device 100 according to Modified Examples 1, andFIG. 8B is a cross-sectional view of the electro-optical device 100 according to Modified Examples 2. In the embodiment described above, the thickness W2 of thedicing blade 82 for second wafer shown inFIG. 5C is equal to the width W0 of thegroove 22. Therefore, as shown inFIG. 4 , theside surface 71 w of the light-transmittingcover 71 and anouter side surface 61 w of thespacer 61 on the side opposite to themirror 50 form a continuous plane over the entire side surface. - In contrast, in Modified Examples 1, the thickness W2 of the
dicing blade 82 for second wafer shown inFIG. 5C is greater than the width W0 of thegroove 22. For this reason, as shown inFIG. 8A , in theside surface 71 w of the light-transmittingcover 71 and theouter side surface 61 w of thespacer 61 as a surface on the side opposite to a surface facing themirror 50, theedge 61 e of thespacer 61 on theelement substrate 1 side is aprojection 61 g that projects opposite to themirror 50 beyond a portion of thespacer 61 located on the side opposite to theelement substrate 1. In other words, theprojection 61 g, which is a second portion closer to theelement substrate 1 than a first portion and projects opposite to themirror 50 beyond the first portion, is formed on the side surface (theside surface 71 w of the light-transmittingcover 71 and theouter side surface 61 w of the spacer 61) of the sealingmember 75 composed of thespacer 61 and the light-transmittingcover 71. For this reason, since the terminal 17 is greatly opened on the side opposite to theelement substrate 1, it is easy to perform wire bonding. Also in this case, since the area (bonding width) of bonding thespacer 61 with theelement substrate 1 is not reduced, a sealing property between thespacer 61 and theelement substrate 1 is not reduced. - In Modified Examples 2, on the other hand, the thickness W2 of the
dicing blade 82 for second wafer shown inFIG. 5C is smaller than the width W0 of thegroove 22. For this reason, as shown inFIG. 8B , in theside surface 71 w of the light-transmittingcover 71 and theouter side surface 61 w of thespacer 61 on the side opposite to themirror 50, theedge 61 e of thespacer 61 on theelement substrate 1 side is arecess 61 h recessed to themirror 50 side beyond the portion of thespacer 61 located on the side opposite to theelement substrate 1. In other words, therecess 61 h, which is a second portion closer to theelement substrate 1 than a first portion and recessed to themirror 50 side beyond the first portion, is formed in the side surface (theside surface 71 w of the light-transmittingcover 71 and theouter side surface 61 w of the spacer 61) of the sealingmember 75 composed of thespacer 61 and the light-transmittingcover 71. Also in this case, since the area (bonding width) of bonding thespacer 61 with the light-transmittingcover 71 is not reduced, a sealing property between thespacer 61 and the light-transmittingcover 71 is not reduced. -
FIGS. 9A and 9B are explanatory views showing Modified Example 3 of the method for manufacturing the electro-optical device 100 to which the invention is applied, in whichFIG. 9A is an explanatory view of a dicing blade used in Modified Examples 3, andFIG. 9B is an explanatory view showing a state of dicing thefirst wafer 10 and thesecond wafer 20 with the dicing blade used in Modified Examples 3. - In Modified Example 3, as shown in
FIGS. 9A and 9B , amultistage blade 85 including thedicing blade 81 for first wafer and thedicing blade 82 for second wafer concentrically stacked together in the thickness direction is used in the second-wafer dicing step and the first-wafer dicing step shown inFIGS. 5C and 5D . In themultistage blade 85, thedicing blade 81 for first wafer has a diameter greater than the dicingblade 82 for second wafer, and thedicing blade 82 for second wafer projects from both surfaces of thedicing blade 81 for first wafer. Accordingly, the thickness W2 of thedicing blade 82 for second wafer is greater than the thickness W1 of thedicing blade 81 for first wafer. According to themultistage blade 85, the second-wafer dicing step and the first-wafer dicing step can be continuously performed in the same step by advancing themultistage blade 85 to thefirst wafer 10 from thesecond wafer 20 side. - Although the thickness W2 of the
dicing blade 82 for second wafer is greater than the width W0 of thegroove 22 in the step shown inFIG. 9B , the thickness W2 of thedicing blade 82 for second wafer may be smaller than the width W0 of thegroove 22. -
FIGS. 10A to 10D are explanatory views showing Modified Example 4 of the method for manufacturing the electro-optical device 100 to which the invention is applied, andFIGS. 10A to 10D are step views showing a method for manufacturing thesecond wafer 20, etc. used for the manufacture of the electro-optical device 100. InFIGS. 10A to 10D , a plan view of a wafer in each step is shown, and also a cutaway end view thereof is shown below the plan view. - In Modified Example 4, in the second-wafer forming step of forming the
second wafer 20 shown inFIG. 5A , the light-transmittingwafer 70 from which a plurality of light-transmitting covers 71 can be obtained is first prepared as shown inFIG. 10A . Moreover, as shown inFIG. 10B , after thewafer 60 for spacer from which a plurality ofspacers 61 can be obtained is prepared, the through-holes 66 for constituting therecesses 21 are formed in thewafer 60 for spacer by a process such as etching in a first step. One of the plurality of through-holes 66 is the first through-hole 66 a for constituting the first recess 21 a, and the through-hole 66 next to the first through-hole 66 a is the second through-hole 66 b for constituting the second recess 21 b. - In a second step, the
wafer 60 for spacer and the light-transmittingwafer 70 are stacked and bonded together. As a result, one open end of the through-hole 66 (the first through-hole 66 a and the second through-hole 66 b) is closed by the light-transmittingwafer 70, so that the recess 21 (the first recess 21 a and the second recess 21 b) having the light-transmitting bottom portion is formed. - Next, in a third step, the bottomed
grooves 22 extending in the two directions that intersect each other at right angles and surrounding each of the plurality ofrecesses 21 are formed by a process such as half-etching in thesurface 60 s of thewafer 60 for spacer on the side opposite to the surface bonded with the light-transmittingwafer 70. As a result, thesecond wafer 20 including thewafer 60 for spacer and the light-transmittingwafer 70 stacked together is formed. In thesecond wafer 20, thesurface 60 s of thewafer 60 for spacer constitutes thesecond surface 20 s of thesecond wafer 20, and the surface of the light-transmittingwafer 70 on the side opposite to thewafer 60 for spacer constitutes thethird surface 20 t of thesecond wafer 20. - In the embodiment described above, the recess 21 (the through-hole 66) and the
groove 22 are formed by a process such as etching. However, thesecond wafer 20 in which therecesses 21 and thegrooves 22 are formed may be formed by molding, etc. Moreover, thesecond wafer 20 may be formed using thewafer 60 for spacer in which the through-holes 66 and thegrooves 22 are formed by molding, etc. - In the embodiment described above, a circular wafer is used. However, the planar shape of a wafer may be rectangular, etc.
Claims (6)
1. An electro-optical device comprising:
an element substrate including a mirror and a terminal on a first surface side, the terminal being provided at a position next to the mirror in a plan view, the terminal being electrically connected to a drive element driving the mirror; and
a sealing member including a spacer and a plate-like light-transmitting cover, the spacer being bonded on the first surface side of the element substrate and surrounding the mirror in the plan view, the light-transmitting cover being supported to an edge of the spacer on the side opposite to an edge thereof facing the element substrate, the light-transmitting cover overlapping the mirror in the plan view, wherein
in a side surface of the sealing member, a second portion closer to the element substrate than a first portion projects opposite to the mirror beyond the first portion.
2. The electro-optical device according to claim 1 , wherein
the first portion projects opposite to the mirror beyond the first portion beyond an edge of the cover such that the spacer has a curved outer wall.
3. An electronic apparatus comprising the electro-optical device according to claim 1 , wherein
the electronic apparatus includes a light source unit that irradiates the mirror with light source light.
4. An electro-optical device comprising:
an element substrate including a mirror and a terminal on a first surface side, the terminal being provided at a position next to the mirror in a plan view, the terminal being electrically connected to a drive element driving the mirror; and
a sealing member including a spacer and a plate-like light-transmitting cover, the spacer being bonded on the first surface side of the element substrate and surrounding the mirror in the plan view, the light-transmitting cover being supported to an edge of the spacer on the side opposite to an edge thereof facing the element substrate, the light-transmitting cover overlapping the mirror in the plan view, wherein
in aside surface of the sealing member, a second portion closer to the element substrate than a first portion is recessed to the mirror side beyond the first portion.
5. The electro-optical device according to claim 4 , wherein
the first portion that is recessed to the mirror side beyond the first portion defines a recessed portion within an edge of the cover such that the spacer has a stepwise outer wall forming a gap between the cover and the element substrate
6. An electronic apparatus comprising the electro-optical device according to claim 4 , wherein
the electronic apparatus includes a light source unit that irradiates the mirror with light source light.
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US15/381,282 US20170146794A1 (en) | 2015-03-27 | 2016-12-16 | Method for manufacturing electro-optical device, electro-optical device, and electronic apparatus |
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JP2015065932A JP2016186526A (en) | 2015-03-27 | 2015-03-27 | Method for manufacturing electro-optic device, electro-optic device, and electronic apparatus |
JP2015-065932 | 2015-03-27 | ||
US15/018,086 US9557561B2 (en) | 2015-03-27 | 2016-02-08 | Method for manufacturing electro-optical device, electro-optical device, and electronic apparatus |
US15/381,282 US20170146794A1 (en) | 2015-03-27 | 2016-12-16 | Method for manufacturing electro-optical device, electro-optical device, and electronic apparatus |
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US15/018,086 Continuation US9557561B2 (en) | 2015-03-27 | 2016-02-08 | Method for manufacturing electro-optical device, electro-optical device, and electronic apparatus |
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US15/381,282 Abandoned US20170146794A1 (en) | 2015-03-27 | 2016-12-16 | Method for manufacturing electro-optical device, electro-optical device, and electronic apparatus |
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US20170276930A1 (en) * | 2015-03-26 | 2017-09-28 | Seiko Epson Corporation | Electro-optical device, manufacturing method thereof, and electronic apparatus |
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EP4237895A1 (en) * | 2020-11-12 | 2023-09-06 | Huawei Technologies Co., Ltd. | Micromechanical resonator wafer assembly and method of fabrication thereof |
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JP3881888B2 (en) * | 2001-12-27 | 2007-02-14 | セイコーエプソン株式会社 | Optical device manufacturing method |
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JP2005055670A (en) * | 2003-08-04 | 2005-03-03 | Seiko Epson Corp | Mems device, method of manufacturing the same, and mems module |
US6856014B1 (en) * | 2003-12-29 | 2005-02-15 | Texas Instruments Incorporated | Method for fabricating a lid for a wafer level packaged optical MEMS device |
TWI292186B (en) * | 2006-01-18 | 2008-01-01 | Touch Micro System Tech | Method of wafer level packaging and cutting |
JP4285551B2 (en) * | 2007-02-19 | 2009-06-24 | セイコーエプソン株式会社 | ELECTRO-OPTICAL DEVICE, MANUFACTURING METHOD THEREOF, AND ELECTRONIC DEVICE |
JP2009048009A (en) | 2007-08-21 | 2009-03-05 | Hitachi Metals Ltd | Mirror device |
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2015
- 2015-03-27 JP JP2015065932A patent/JP2016186526A/en not_active Withdrawn
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2016
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- 2016-03-21 CN CN201610159373.2A patent/CN106019575B/en active Active
- 2016-12-16 US US15/381,282 patent/US20170146794A1/en not_active Abandoned
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US6754950B2 (en) * | 1995-06-30 | 2004-06-29 | Kabushiki Kaisha Toshiba | Electronic component and method of production thereof |
US20050005733A1 (en) * | 2001-07-24 | 2005-01-13 | Mitsubishi Heavy Industries Ltd. | Ni-based sintered alloy |
US7898724B2 (en) * | 2008-11-05 | 2011-03-01 | Texas Instruments Incorporated | Thermal conduction by encapsulation |
US20130208359A1 (en) * | 2012-02-14 | 2013-08-15 | Seiko Epson Corporation | Optical filter device and manufacturing method for the optical filter device |
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US20170276930A1 (en) * | 2015-03-26 | 2017-09-28 | Seiko Epson Corporation | Electro-optical device, manufacturing method thereof, and electronic apparatus |
US10054787B2 (en) * | 2015-03-26 | 2018-08-21 | Seiko Epson Corporation | Electro-optical device, manufacturing method thereof, and electronic apparatus |
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US9557561B2 (en) | 2017-01-31 |
JP2016186526A (en) | 2016-10-27 |
US20160282608A1 (en) | 2016-09-29 |
CN106019575B (en) | 2020-03-24 |
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