FIELD OF THE INVENTION

The present invention relates generally to miniaturized electromechanical devices, and particularly to miniature scanning mirrors and actuation of such mirrors.

BACKGROUND

Miniature scanning mirrors are used in scanning beams of light in a variety of applications, for example three-dimensional (3D) sensing and mapping. Mirrors of this sort having dimensions on the order of about a centimeter or less are commonly referred to as “micromirrors” by virtue of their small size. Such micromirrors can conveniently be produced using microelectromechanical systems (MEMS) technologies.

For example, U.S. Patent 7,952,781 describes a method of scanning a light beam and a method of manufacturing a MEMS, which can be incorporated in a scanning device. In a disclosed embodiment, a rotor assembly having at least one micromirror is formed with a permanent magnetic material mounted thereon, and a stator assembly has an arrangement of coils for applying a predetermined moment on the at least one micromirror.

SUMMARY

Embodiments of the present invention that are described hereinbelow provide improved devices and methods for scanning a beam of light.

There is therefore provided, in accordance with an embodiment of the invention, a scanning device, including a frame and a planar scanning mirror disposed within the frame and having a reflective upper surface and a lower surface opposite the upper surface. A pair of flexures have respective first ends connected to the frame and respective second ends connected to the planar scanning mirror at opposing ends of a rotational axis of the planar scanning mirror. A rotor including a permanent magnet is disposed on the lower surface of the planar scanning mirror. A stator includes first and second cores disposed in proximity to the rotor on opposing first and second sides of the rotational axis of the planar scanning mirror and first and second coils of wire wound respectively on the first and second cores. A drive circuit is configured to drive the first and second coils with respective electrical currents including a first component selected so as to control a transverse displacement of the planar scanning mirror relative to a plane of the frame and a second component selected so as to control a rotation of the planar scanning mirror about the rotational axis. In a disclosed embodiment, the flexures have a serpentine shape.

Additionally or alternatively, the first and second cores are magnetized with a polarity selected so as to repel the permanent magnet in the rotor. In a disclosed embodiment, the permanent magnet in the rotor and the first and second cores are poled in opposite directions along a magnetic axis perpendicular to the plane of the frame.

In some embodiments, the stator further includes third and fourth cores disposed in proximity to the rotor on opposing first and second sides of the rotational axis of the planar scanning mirror in respective proximity to the first and second cores, and third and fourth coils of wire wound respectively on the third and fourth cores. Typically, the drive circuit is coupled to drive the third and fourth coils together with the first and second coils, respectively.

In one embodiment, the device includes one or more capacitive sensors configured to output signals indicative of the transverse displacement and rotation of the planar scanning mirror, wherein the drive circuit is configured to generate the electrical currents responsively to the signals.

In some embodiments, the frame, the planar scanning mirror, and the flexures are etched from a silicon wafer. Additionally or alternatively, the frame, the planar scanning mirror, and the flexures include a metal having a thickness less than 100 pm.

In a disclosed embodiment, the drive circuit is coupled to drive the first and second coils such that the first component of the electrical currents flows through the first and second coils in a parallel direction, while the second component of the electrical currents flows through the first and second coils in an anti-parallel direction.

There is also provided, in accordance with an embodiment of the invention, a method for scanning, which includes mounting a planar scanning mirror, having a reflective upper surface and a lower surface opposite the upper surface, within a frame by connecting respective first ends of a pair of flexures to the frame and connecting respective second ends of the flexures to the planar scanning mirror at opposing ends of a rotational axis of the planar scanning mirror. A rotor including a permanent magnet is fixed to the lower surface of the planar scanning mirror. First and second cores of a stator, on which first and second coils of wire are respectively wound, are placed in proximity to the rotor on opposing first and second sides of the rotational axis of the planar scanning mirror. The first and second coils are driven with respective electrical currents including a first component selected so as to control a transverse displacement of the planar scanning mirror relative to a plane of the frame and a second component selected so as to control a rotation of the planar scanning mirror about the rotational axis. In one embodiment, the frame, the planar scanning mirror, and the flexures are formed by etching a silicon wafer in a MEMS process.

Alternatively, the frame, the planar scanning mirror, and the flexures are formed by etching a sacrificial dielectric material, electroplating a metal onto the etched sacrificial dielectric material, and removing the sacrificial dielectric material in a LIGA process.

Further alternatively, the frame, the planar scanning mirror, and the flexures are formed by etching and cutting a metal sheet.

The present invention will be more fully understood from the following detailed description of the embodiments thereof, taken together with the drawings in which:

BRIEF DESCRIPTION OF THE DRAWINGS

Fig. 1 is a schematic, pictorial illustration of an optical scanning device, in accordance with an embodiment of the present invention;

Fig. 2 is a schematic, pictorial illustration of a scanning micromirror assembly, seen from below, in accordance with an embodiment of the invention;

Fig. 3 is a schematic, pictorial illustration of an electromagnetic stator assembly for use in an optical scanning device, in accordance with an embodiment of the invention;

Fig. 4 is a schematic pictorial illustration showing rotational movement of a micromirror, in accordance with an embodiment of the invention; and

Fig. 5 is a schematic pictorial illustration showing transverse displacement of a micromirror, in accordance with an embodiment of the invention.

DETAILED DESCRIPTION OF EMBODIMENTS

Scanning micromirror devices produced by MEMS processes have advantages of small size, light weight, and low manufacturing cost, and they can be designed to operate at high scanning speeds. As size decreases and scanning rate increases, however, such devices suffer from problems of rapid wear and short operating life. Larger, heavier scanning micromirrors may have increased lifespan but generally consume more electrical power in driving the scan.

Embodiments of the present invention that are described herein alleviate these problems in a novel design in which mechanical and magnetic forces on the micromirror are balanced, so that only minimal energy investment is required to rotate the mirror. This design reduces the stress on the flexures holding the micromirror in its frame, and thus lengthens the device lifetime while allowing the micromirror to be scanned over a wide range of frequencies. Scanners of this sort can be produced using a variety of MEMS processes, such as etching a silicon wafer or etching a sacrificial dielectric layer in a LIGA process, followed by electroplating of a metal and removal of the sacrificial layer, as is known in the art.

In the disclosed embodiments, a planar scanning mirror having a reflective upper surface is contained within a frame. The mirror is connected to the frame by a pair of flexures, each having one end connected to the frame and the other connected to the mirror at opposing ends of the rotational axis of the mirror. The mirror is scanned by an electromagnetic drive, in which the rotor comprises a permanent magnet fixed to the lower surface of the mirror, while the stator comprises one or more pairs of cores disposed on opposing sides of the rotational axis of the mirror in proximity to the rotor, with coils of wire wound on the cores. The stator cores may be magnetized with a polarity chosen to repel the rotor; for example, the rotor and stator coils may have opposing polarities perpendicular to the plane of the frame. This magnetic force, together with the mechanical resilience of the flexures, causes the micromirror to “levitate” within the frame, so that only small forces are needed to deflect the micromirror relative to this plane.

The deflecting forces are provided by a drive circuit, which drives the stator coils with respective electrical currents comprising parallel and anti-parallel components. The anti-parallel component induces a torsional force on the rotor about the rotational axis and thus controls the rotation of the micromirror about the axis. This anti-parallel component can be modulated to set the frequency and amplitude of rotational scanning of the micromirror. The parallel component of the drive current induces a transverse force, perpendicular to the plane of the frame, and thus controls the transverse displacement of the mirror relative to this plane. This parallel component thus sets the location at which the micromirror “levitates” (even if the stator cores are not magnetized) and can be used, for example, to adjust the focal distance of the scanning device.

Reference is now made to Figs. 1-3, which are schematic, pictorial illustrations of an optical scanning device 20, in accordance with an embodiment of the present invention. Fig. 1 presents an overview of device 20. Fig. 2 shows details of a scanning micromirror assembly 22, seen from below, in device 20. Fig. 3 shows an electromagnetic stator assembly 24 in device 20. (Terms referring to orientation in the present description, such as “upward,” “above” and “below,” are used solely for the sake of convenience in reference to the viewing perspectives shown in the figures, as are the X, Y and Z axes identified in the figures. The positive Z-direction is arbitrarily taken, in this context, to be the upward direction. In practice, device 20 may operate in substantially any orientation.)

Device 20 can be particularly useful as a part of a scanning 3D mapping system or other depth-sensing (LIDAR) device, in conjunction with a suitable optical transmitter, receiver, and control and processing circuits, as are known in the art. (Details of these components are omitted from the figures, however, for the sake of simplicity.) Alternatively, device 20 may be adapted for use in scanning optical beams in other applications.

Micromirror assembly 22 comprises a frame 26, with a planar scanning mirror 28 (typically a micromirror, depending on the dimensions) contained within the frame. Mirror 28 has a reflective upper surface 30, which can be formed, for example, by plating or otherwise depositing a thin metal layer over the upper surface of the material from which frame 26 is made. Mirror 28 is connected to frame 26 by a pair of flexures 34, each having an outer end connected to the frame and an inner end connected to mirror 28, at opposing ends of a rotational axis 36 of the mirror. Flexures 34 have a serpentine shape, which permits both torsional motion or mirror 28 about axis 36 (which is parallel to the X-axis in the figures) within frame 26 and transverse motion out of the plane of frame 26 (along the Z-axis). These motions are illustrated specifically in Figs. 4 and 5. Alternatively, other flexure designs that permit these two modes of motion can be used.

To drive the rotational and transverse motions of mirror 28, a rotor 38, comprising a permanent magnet, is fixed to a lower surface 32 of mirror 28. For example, mirror 28 may be about 25 pm thick, while the magnetic material of rotor is about 100 pm thick and is poled along a magnetic axis perpendicular to the plane of frame 26, i.e., in the +Z-direction. This magnetic material may comprise electroplated nickel, which also provides structural support for the thin mirror. The overall size of micromirror assembly 22 in this example is 3 x 12 mm. Alternatively, other dimensions and configurations may be used.

Stator assembly 24 comprises pairs of cores 40 and 42, which are disposed in proximity to rotor 38 on opposing sides of rotational axis 36 of mirror 28. In the pictured example, the stator assembly comprises two cores 40 and two corresponding cores 42 on opposite sides of axis 36; but alternatively, larger or smaller numbers of cores may be used. Cores 40 and 42 comprise a ferromagnetic material, which is magnetically poled in the opposite direction (the -Z-direction in the present example) from rotor 38. (Alternatively, the cores may have no permanent magnetic polarization.) Cores 40 and 42 are wound respectively with wire coils 44 and 46. In the pictured embodiment, the elements of stator assembly 24 are contained in a housing 48, which can be made from a ceramic material, for example, with frame 26 attached to the upper edge of the housing.

A drive circuit 50 drives coils 44 and 46 with respective electrical currents, which give rise to corresponding magnetic fields along the Z-axis. Drive circuit 50 comprises, for example, a DC power source, modulation circuits (digital or analog) for creating the desired drive waveforms, and amplifiers coupled to the modulation circuits for generating output currents in the appropriate amplitude range. (These elements are well known to those skilled in the art and are omitted from the figures for the sake of simplicity.) As noted earlier, the output currents typically comprise a parallel component, which flows in coils 44 and 46 in the same direction, and an anti-parallel component, which flows in coils 44 and 46 in opposite directions.

The parallel component of the current gives rise to a magnetic field along the Z-axis emanating from all of cores 40 and 42. At the baseline position of mirror 28, for example with mirror 28 in the plane of frame 26, the parallel drive current is set so that this magnetic field balances the repulsion between stator 38 and the permanent magnetic field of cores 40 and 42, and the mirror thus “levitates” in this position. Drive circuit 50 can vary the magnitude and direction of the parallel current component so as to control the transverse displacement of mirror 28 relative to the plane of frame 26.

The antiparallel component of the current gives rise to magnetic fields in opposite directions on the opposing sides of axis 36, and thus to rotation of mirror 28 about the axis. The amplitude and frequency of this antiparallel current determine the rate and amplitude of rotational scanning of the mirror.

One or more sensors can be used to monitor the transverse displacement and rotation of mirror 28 relative to frame 26, and to output corresponding signals to drive circuit 50. Capacitive sensors may be used for this purpose, for example in the form of electrodes 52 and 54 that are deposited on housing 48 and on lower surface 32 of mirror 28. The changes in capacitance as a function of the varying distance between electrodes 52 and 54 provide feedback to drive circuit 50, which then generates the electrical currents accordingly to position and rotate mirror 28 as desired.

Various manufacturing processes can be used in producing micromirror assembly 22. For example, frame 26, mirror 28, and flexures 34 may comprise silicon, which is formed by etching a silicon wafer in a MEMS process. Alternatively, frame 26, mirror 28, and flexures 34 may comprise a metal, which may have a thickness less than 100 pm. The metal may be formed in a LIGA process, as is known in the art, in which a sacrificial dielectric material, such as a suitable photoresist, is patterned and etched in a photolithographic process to define the shape of the micromirror assembly. A metal, such as nickel, is electroplated onto the etched sacrificial dielectric material, and the sacrificial dielectric material is then removed, for example in a solution of NaOH. The residual stresses in micromirror assembly 22 following this process are negligible. Further alternatively, the metal may comprise a thin metal sheet, such as a copper-titanium alloy, which is etched and cut to the desired shape. Other manufacturing processes that can be used in fabricating micromirror assembly 22 will be apparent to those skilled in the art after reading the present description and are considered to be within the scope of the present invention.

Figs. 4 and 5 are schematic pictorial illustrations showing rotational movement and transverse displacement of mirror 28, respectively, in accordance with an embodiment of the invention. These figures are simulations, assuming frame 26 to be made from a thin layer of plated nickel. Fig. 4 shows a rotation of 21° about axis 36, which is induced by an applied torque of only 0.65 pN*m. The maximum stresses on the spring elements in flexures 34 are about 110 MPa. Fig. 5 shows a transverse displacement of about 55 pm, with a spring constant of 18 N/m in flexures 34.

Although the above description and the figures show one particular design of optical scanning device 20, the principles of the present invention may similarly be implemented in devices of other sizes and shapes. It will thus be appreciated that the embodiments described above are cited by way of example, and that the present invention is not limited to what has been particularly shown and described hereinabove. Rather, the scope of the present invention includes both combinations and subcombinations of the various features described hereinabove, as well as variations and modifications thereof which would occur to persons skilled in the art upon reading the foregoing description and which are not disclosed in the prior art.