Micromirror systems with concealed multi-piece hinge structures

Abstract

Micromirror systems with concealed multi-piece hinge structures are provided for reflective applications. Generally, light is reflected by these structures adapted for three-dimensional tilt as well as up-and-down or out-of-plane actuation. Devices can be produced utilizing the various optional features described herein to provide miniaturized, highly controllable solutions for use in optical switching, projection and other applications, especially optical applications.

1 . A micromirror device comprising:
 a substrate with electrical components including address circuitry;   a micromirror; and   a support structure underlying said micromirror and interconnecting said substrate and said micromirror, said support structure including at plurality of deflection members, each deflection member mounted to said substrate and said micromirror, and configured to permit rotation of said micromirror about multiple axes of rotation and drawing said micromirror toward said substrate.   
   
   
       2 . The device of  claim 1 , wherein two deflection members are provided and mounted to two opposite ends of said micromirror. 
   
   
       3 . The device of  claim 2 , wherein said two opposite ends of said micromirror are opposite corners. 
   
   
       4 . The device of  claim 2 , wherein said two opposite ends of said micromirror are opposite sides. 
   
   
       5 . The device of  claim 1 , wherein three deflection members are provided and mounted to ends of said micromirror inopposite of one another. 
   
   
       6 . The device of  claim 5 , wherein said ends of said micromirror are corners. 
   
   
       7 . The device of  claim 5 , wherein said ends of said micromirror are sides. 
   
   
       8 . The device of  claim 7 , wherein said three deflection members are mounted adjacent to corners of said micromirror. 
   
   
       9 . The device of  claim 1 , wherein said deflection members are mounted to said micromirror at substantially equally spaced intervals. 
   
   
       10 . The device of  claim 1 , wherein said deflection members are mounted to said mirror in a pattern with bilateral symmetry. 
   
   
       11 . The device of  claim 1 , wherein said deflection members are mounted to said mirror in a pattern with three-way symmetry. 
   
   
       12 . The device of  claim 1 , wherein said micromirror is substantially quadrilateral. 
   
   
       13 . The device of  claim 12 , wherein said micromirror is substantially square. 
   
   
       14 . The device of  claim 1 , wherein said micromirror is substantially hexagonal. 
   
   
       15 . The device of  claim 1 , wherein said deflection members are mounted to said substrate at a common location. 
   
   
       16 . The device of  claim 1 , wherein said deflection members are mounted to said substrate at discrete locations. 
   
   
       17 . The device of  claim 1 , wherein said deflection members comprise at least one portion having a component in one direction and another portion having a component in another direction. 
   
   
       18 . The device of  claim 17 , wherein said components are provided in a plane. 
   
   
       19 . The device of  claim 17 , wherein said portions are provided by straight sections. 
   
   
       20 . The device of  claim 19 , wherein said portions are provided by curved sections. 
   
   
       21 . The device of  claim 17 , wherein said components are provided in two different directions. 
   
   
       22 . The device of  claim 17 , wherein said components are provided in three different directions. 
   
   
       23 . The device of  claim 1 , wherein said micromirror has a diameter of less than or equal to about 1 mm. 
   
   
       24 . The device of  claim 23 , wherein said micromirror has a diameter of less than about 10 microns. 
   
   
       25 . The device of  claim 1 , wherein said electrical components further comprise electrodes adapted to apply attractive forces to said micromirror. 
   
   
       26 . The device of  claim 25 , wherein at least one of said electrodes is configured with a plurality of portions at different levels, so that portions further from a center of rotation of said micromirror are at a greater distance from the micromirror than portions closer to the center of rotation. 
   
   
       27 . The device of  claim 26 , wherein each of said electrodes comprises a stepped configuration. 
   
   
       28 . The device of  claim 26 , wherein said electrode portions of each said electrode are continuous with one another. 
   
   
       29 . The device of  claim 26 , wherein said portions are discrete members. 
   
   
       30 . The device of  claim 26 , wherein each said electrode comprises a continuous angled member. 
   
   
       31 . The device of  claim 26 , wherein said portions of each said electrode form an electrode array, and wherein at least one of said portions of at least one of said electrodes is addressable independently of the other of said portions. 
   
   
       32 . The device of  claim 31 , wherein each said portion is independently addressable. 
   
   
       33 . A micromirror array comprising, a plurality of devices as described in  claim 1 . 
   
   
       34 . The array of  claim 33 , wherein a common mounting portion to said substrate is provided for adjacent deformable members. 
   
   
       35 . An optical switching mechanism, comprising:
 a first array of optical reflectors adapted to receive and reflect optical signals from at least one optical input source; and   a second array of optical reflectors adapted to receive optical signals reflected from said first array of optical reflectors and reflect the optical signals toward at least one optical output;   wherein at least one of said optical reflectors comprising an assembly of micromirror devices according to  claim 1 .   
   
   
       36 . The optical switching mechanism of  claim 35 , wherein each said micromirror device of said at least one assembly of micromirror devices is adapted for independent three dimensional orientation. 
   
   
       37 . The optical switching mechanism of  claim 35 , wherein each said optical reflector comprises an assembly of micromirror devices. 
   
   
       38 . The optical switching mechanism of  claim 37 , wherein each said micromirror device is adapted for independent three dimensional orientation. 
   
   
       39 . The optical switching mechanism of  claim 35 , wherein each said assembly of micromirror devices forms a smart surface. 
   
   
       40 . A method of optical switching, comprising:
 providing an optical switching mechanism as described in  claim 35 ;   directing light through said optical switching mechanism; and   switching light between a plurality of channels.   
   
   
       41 . The method of  claim 40 , further comprising shaping a reflected wavefront of light with a plurality of micromirror devices according to  claim 1 .