METHOD OF MANUFACTURING ELECTRIC DEVICE

Provided is a method for manufacturing an electronic device. The method for manufacturing the electronic device includes mapping good elements and defective elements on a substrate, providing a first transparent structure including a first adhesive layer on the substrate, selectively providing first laser light to the defective elements to cure the first adhesive layer on the defective elements and separate the defective elements from the substrate, providing a second transparent structure including a second adhesive layer, which adheres to new elements replaced for the defective elements, on the substrate, and selectively providing second laser light to the new elements to bond the new elements to the substrate.

CROSS-REFERENCE TO RELATED APPLICATIONS

This U.S. non-provisional patent application claims priority under 35 U.S.C. § 119 of Korean Patent Application Nos. 10-2001-0071012, filed on Jun. 1, 2021, and 10-2022-0055657, filed on May 4, 2022, the entire contents of which are hereby incorporated by reference.

BACKGROUND

The present disclosure herein relates to a method for manufacturing an electronic device, and more particularly, to a method for manufacturing an electronic device, which is capable of improving productivity.

Recently, with the development of information technology, various types of electronic devices have been developed. The electronic device may include silicon/compound elements, MEMS/sensors, RF/analog elements, power semiconductor elements, and LED/display elements. A general method of manufacturing an electronic device may include a vacuum adsorption process. However, the vacuum adsorption process may have a disadvantage of increasing in thermal stress due to a difference in thermal expansion coefficient between a lower element and an upper element.

SUMMARY

The present disclosure provides a method for manufacturing an electronic device, which is capable of improving productivity.

The object of the present disclosure is not limited to the aforesaid, but other objects not described herein will be clearly understood by those skilled in the art from descriptions below.

An embodiment of the inventive concept provides a method for manufacturing an electronic device. The method for manufacturing an electronic device includes: mapping good elements and defective elements on a substrate; providing a first transparent structure comprising a first adhesive layer on the substrate; selectively providing first laser light to the defective elements to cure the first adhesive layer on the defective elements and separate the defective elements from the substrate; providing a second transparent structure including a second adhesive layer, which adheres to new elements replaced for the defective elements, on the substrate; and selectively providing second laser light to the new elements to bond the new elements to the substrate.

In an embodiment, the first laser light may include ultraviolet light, and the second laser light may include infrared light.

In an embodiment, the first adhesive layer may include an ultraviolet curable adhesive, and the second adhesive layer may include a thermoplastic resin.

In an embodiment, the first adhesive layer may include a thermosetting resin, and the second adhesive layer may include a thermoplastic resin.

In an embodiment, the first adhesive layer may include: a first lower adhesive layer on the first transparent structure; and a first upper adhesive layer on the first lower adhesive layer.

In an embodiment, the first lower adhesive layer may include a thermosetting resin, and the first upper adhesive layer may include a photo-curable resin.

In an embodiment, the first transparent structure may include a first heater layer that heats the first lower adhesive layer.

In an embodiment, the second adhesive layer may include: a second lower adhesive layer on the second transparent structure; and a second upper adhesive layer on the second lower adhesive layer.

In an embodiment, the second lower adhesive layer may include a thermoplastic resin, and the second upper adhesive layer may include a photo plastic resin.

In an embodiment, the second transparent structure may include a second heater layer that heats the second lower adhesive layer.

In an embodiment of the inventive concept, a method for manufacturing an electronic device includes: mapping good elements and defective elements on a substrate; providing a first transparent structure including a first adhesive layer on the substrate; allowing the first adhesive layer to be in contact with the good elements and the defective elements; selectively providing ultraviolet light to the defective elements to fix the defective elements to the first transparent structure by the first adhesive layer and separate the defective elements from the substrate; providing a second transparent structure including a second adhesive layer, which adheres to new elements replaced for the defective elements, on the substrate; and allowing the new elements to be in contact with the substrate; and selectively providing ultraviolet light or infrared light to the new elements to bond the new elements to the substrate.

In an embodiment, the first adhesive layer may include an ultraviolet curable adhesive, and the second adhesive layer may include a thermoplastic resin.

In an embodiment, the first adhesive layer may include: a first lower adhesive layer on the first transparent structure; and a first upper adhesive layer on the first lower adhesive layer.

In an embodiment, the first lower adhesive layer may include a thermosetting resin, and the first upper adhesive layer may include a photo-curable resin.

In an embodiment, the first transparent structure may include a first heater layer that heats the first lower adhesive layer.

In an embodiment, the second adhesive layer may include: a second lower adhesive layer on the second transparent structure; and a second upper adhesive layer on the second lower adhesive layer.

In an embodiment, the second lower adhesive layer may include a thermoplastic resin, and the second upper adhesive layer may include a photo plastic resin.

In an embodiment, the second transparent structure may include a second heater layer that heats the second lower adhesive layer.

In an embodiment, each of the first and second transparent structures may include glass, sapphire, acrylic, polyimide, epoxy, or quartz.

In an embodiment, each of the good elements and the defective elements may include a light emitting diode.

DETAILED DESCRIPTION

In the following description, the technical terms are used only for explaining a specific exemplary embodiment while not limiting the present invention. In this specification, the terms of a singular form may include plural forms unless specifically mentioned. The meaning of ‘comprises’ and/or ‘comprising’ specifies a component, a step, an operation and/or an element does not exclude other components, steps, operations and/or elements.

Additionally, the embodiment in the detailed description will be described with sectional views as ideal exemplary views of the present invention. In the figures, the dimensions of layers and regions are exaggerated for clarity of illustration. Accordingly, shapes of the exemplary views may be modified according to manufacturing techniques and/or allowable errors. Therefore, the embodiments of the present invention are not limited to the specific shape illustrated in the exemplary views, but may include other shapes that may be created according to manufacturing processes. Bonding, adhesion, and laser may be techniques widely disclosed in the fields of semiconductors. Thus, regions illustrated in the figures have schematic properties, and shapes of the regions illustrated in the figures exemplify specific forms of the regions of elements and are not intended to limit the scope of the invention.

FIG.1is a flowchart illustrating a method for manufacturing an electronic device according to the inventive concept.FIG.2is a view illustrating an example of the electronic device10according to the inventive concept.FIGS.3to9are process cross-sectional views taken along line I-I′ ofFIG.2.

Referring toFIGS.1and2, the electronic device10is inspected to map defective elements18(S10). The electronic device10may include a display device, a light emitting device, or a light source device. The electronic device10may be inspected by a test device. The test device may determine good elements16and the defective elements18of light source elements14. Each of the good elements16and the defective elements18may include a light emitting element such as an organic light emitting diode or an inorganic light emitting diode. The test device may determine positions of the good elements16and the defective elements18on a substrate12to display their positions on the display device.

Referring toFIGS.1and3, a first transparent structure20is provided on the substrate12(S20). According to an embodiment, the first transparent structure20may include a transparent flat plate. For example, the first transparent structure20may include glass, sapphire, acrylic, polyimide, epoxy, or quartz, but an embodiment of the inventive concept is not limited thereto. The first transparent structure20may have a transmittance of about 50% to about 99%. According to an embodiment, the first transparent structure20may have a first adhesive layer22. The first adhesive layer22may be formed on the first transparent structure20through methods such as screen printing, laminating, spin coating, and photolithography. The first adhesive layer22may be transparent. Also, the first adhesive layer22may be translucent. According to an embodiment, the first adhesive layer22may include an ultraviolet curable adhesive. The first adhesive layer22may further include an absorbing material such as carbon or dye, but an embodiment of the inventive concept is not limited thereto. Alternatively, the first adhesive layer22may include a thermosetting resin or a thermo-curable polymer resin. The thermosetting polymer resin may include polyacrylate. The thermosetting polymer resin may include a reducing agent, a curing agent, and a polymer resin. The thermosetting polymer resin may further include an organic material including an amine group, a carboxyl group, and siloxane bond. The organic material including the siloxane bond may include polydimethylsiloxane (PDMS) or polymerized siloxane. The polydimethylsiloxane has a chemical formula:

Referring toFIGS.1and4, the first adhesive layer22is in contact with the light source elements14(S30). The first adhesive layer22may allow the good elements16and the defective elements18to adhere to and/or be in contact with each other.

Referring toFIGS.1and5, first laser light24is selectively provided to the defective elements18(S40). The first laser light24may be provided from a VCSEL array, or a DFB laser diode array. Alternatively, the first laser light24may be provided by a scanning laser light source, but an embodiment of the inventive concept is not limited thereto.

The first laser light24may pass through the first transparent structure20and the first adhesive layer22. For example, the first laser light24may include ultraviolet light having a wavelength of about 10 nm to about 400 nm. When the first adhesive layer22includes an ultraviolet curable adhesive, the first laser light24may cure the first adhesive layer22. Alternatively, the first laser light24may include visible light or infrared light. The visible light may have a wavelength between about 400 nm and about 750 nm. The infrared light may have a wavelength of about 750 nm to about 1000 μm. When the first adhesive layer22includes the thermosetting resin, the first laser light24may cure the first adhesive layer22. The first adhesive layer22may fix the defective elements18to the first transparent structure20.

The first laser light24may be selectively provided to the defective elements18. The first laser light24may heat the defective elements18to separate the defective elements18from a substrate12. The first laser light24may be provided to the new element19in a scanning manner, a beam forming manner, or an optical phased array (OPA) manner.

FIG.10is a cross-sectional view illustrating an example of the first adhesive layer ofFIG.5.

Referring toFIG.10, the first adhesive layer22may be formed on an entire top surface of the first transparent structure20. The first adhesive layer22may adhere to the defective element18and the good element16. The first laser light24may pass through the first transparent structure20and the first adhesive layer22. The first laser light24may be selectively provided to the defective element18. A portion of the first adhesive layer22on the defective element18may be cured. The defective element18may be heated by the first laser light24. The defective element18may have solders15and an underfill. The solders15of the defective element18may be melted and then separated from the substrate12.

FIG.11is a cross-sectional view illustrating an example of the first adhesive layer ofFIG.5.

Referring toFIG.11, the first adhesive layer22may be selectively disposed on the defective elements18. The first adhesive layer22may be partially provided on the first transparent structure20by a printing method, a patterning method, or an applying method. The first adhesive layer22may be provided between the defective element18and the first transparent structure20.

Although not shown, the first laser light24may be provided on the entire surface of the first transparent structure20. A light source of the first laser light24may be a surface light source.

FIG.12is a cross-sectional view illustrating an example of the first adhesive layer ofFIG.5.

Referring toFIG.12, the first adhesive layer22may have a first adhesive protrusion23. The first adhesive protrusion23may be disposed on the first adhesive layer22. The first adhesive protrusion23may be in selective contact with the defective element18. The first adhesive layer22may be separated from the good elements16.

FIG.13is a cross-sectional view illustrating examples of the first transparent structure and the first adhesive layer ofFIG.5.

Referring toFIG.13, the first transparent structure20may have a first transparent protrusion21. The first transparent protrusion21may be selectively provided on the defective element18. The first adhesive layer22may be conformally disposed on the first transparent structure20and the first transparent protrusion21. The first adhesive layer22on the first transparent protrusion21may selectively adhere to and/or be in contact with the defective element18.

FIG.14is a cross-sectional view illustrating an example of the first adhesive layer ofFIG.5.

Referring toFIG.14, the first transparent structure20may have a first heater layer25, and the first adhesive layer22may include a first lower adhesive layer26and a first upper adhesive layer28.

The first heater layer25may be provided between the first transparent structure20and the first lower adhesive layer26. The first heater layer25may heat the first lower adhesive layer26of the first adhesive layer22. The first heater layer25may transmit the first laser light24.

The first lower adhesive layer26may be provided between the first heater layer25and the first upper adhesive layer28. The first lower adhesive layer26may be cured by being heated by the first heater layer25. The first lower adhesive layer26may include a thermosetting resin. The first lower adhesive layer26may transmit the first laser light24.

The first upper adhesive layer28may be provided on the first lower adhesive layer26. The first upper adhesive layer28may be cured by absorbing a portion of the first laser light24. The first upper adhesive layer28may include an ultraviolet curable adhesive. The first upper adhesive layer28may transmit a portion of the first laser light24.

Referring back toFIGS.1and6, the first transparent structure20, the first adhesive layer22, and the defective elements18are removed (S50). The defective elements18may be fixed to the first transparent structure20by the first adhesive layer22and removed from the substrate12. The good elements16may be separated from the first adhesive layer22to remain on the substrate12. Although not shown, the first adhesive layer22and the defective elements18may be removed from the first transparent structure20. The first transparent structure20may be cleaned by an organic solvent (e.g., alcohol or acetone).

Referring toFIGS.1and7, a second transparent structure30is provided on the substrate12(S60). The second transparent structure30may be the same as the first transparent structure20. For example, the second transparent structure30may include glass, sapphire, acrylic, polyimide, epoxy, or quartz, but an embodiment of the inventive concept is not limited thereto. The second transparent structure30may have a transmittance of about 50% to about 99%. According to an embodiment, the second transparent structure30may have a second adhesive layer32. The second adhesive layer32may be formed on the second transparent structure30through methods such as screen printing, laminating, spin coating, and photolithography. The second adhesive layer32may be different from the first adhesive layer22. According to an embodiment, the second adhesive layer32may include a thermoplastic resin. The thermoplastic resin may include polyacrylate. Alternatively, the second adhesive layer32may include a thermosetting resin.

New elements19may be provided on the second adhesive layer32. The new elements19may be replacement elements for the defective elements18ofFIG.2. The new elements19may be the same as the good elements116.

Referring toFIGS.1and8, the new elements19are in contact with the substrate12(S70).

Continuously referring toFIGS.1and8, the second laser light34is selectively provided to the new elements19(S80). The second laser light34may include visible light or infrared light. The second laser light34may be provided from a VCSEL array or a DFB laser diode array. Alternatively, the second laser light34may be provided by a scanning laser light source, but an embodiment of the inventive concept is not limited thereto.

The second laser light34may pass through the second adhesive layer32and the second transparent structure30so as to be absorbed by the new elements19. Each of the new elements19may be heated by the second laser light34and then bonded to the substrate12.

FIG.15is a cross-sectional view illustrating an example of the second adhesive layer32ofFIG.8.

Referring toFIG.15, the second adhesive layer32may be disposed to be flat on an entire top or bottom surface of the substrate12. The second adhesive layer32may be melted by heating the second adhesive layer32. The second laser light34may pass through the second transparent structure30and the second adhesive layer32. The second laser light34may heat the new element19.

The new element19may have solders15and a polymer material17. The solders15and polymer material17may be provided between new element19and substrate12. The solders15and the polymer material17may be melted by the second laser light34to bond the new element19to the substrate12. The solders15and the polymer material17may be contained at a ratio of about 8:2. The solders15may include solder powder. The solder powder may be a low melting point solder. The low melting point solder may include Sn, Bi, In, Ag, Pb, and/or Cu. For example, the low melting point solder may include 60Sn/40Bi, 52In/48Sn, 97In/3Ag, 57Bi/42Sn/1Ag, 58Bi/42Sn, 52Bi/32Pb/16Sn, 96.5Sn/3Ag/0.5Cu, 96.5Sn/3.5Ag, or Sn. The polymer material17may surround the periphery of the solders15when the solders15are melted. The polymer materials17may include resin, but an embodiment of the inventive concept is not limited thereto.

The second laser light34may be selectively provided to the new element19. The second laser light34may be provided to the new element19in a scanning manner, a beam forming manner, or an optical phased array (OPA) manner.

FIG.16is a cross-sectional view illustrating an example of the second adhesive layer32ofFIG.8.

Referring toFIG.16, the second adhesive layer32may be selectively provided on the new element19. The second adhesive layer32may be removed between the good elements16and the second transparent structure30.

FIG.17is a cross-sectional view illustrating an example of the second adhesive layer32ofFIG.8.

Referring toFIG.17, the second adhesive layer32may have a second adhesive protrusion33. The second adhesive protrusion33may be provided on the second adhesive layer32. The second adhesive protrusion33may be selectively provided between the new element19and the second adhesive layer32. The second adhesive protrusion33may allow the new element19to adhere onto the second adhesive layer32. When the new element19is in contact with the substrate12, the second adhesive layer32and the good element16may be separated from each other.

FIG.18is a cross-sectional view illustrating examples of the second transparent structure30and the second adhesive layer32ofFIG.8.

Referring toFIG.18, the second transparent structure30may have a second transparent protrusion31. The second transparent protrusion31may be selectively provided on the defective element18. The second adhesive layer32may be conformally provided on the second transparent structure30and the second transparent protrusion31. The second adhesive layer32on the second transparent protrusion31may selectively adhere to and/or be in contact with the new element19.

FIG.19is a cross-sectional view illustrating examples of the second transparent structure and the second adhesive layer ofFIG.8.

Referring toFIG.19, the second transparent structure30may have a second heater layer35, and the second adhesive layer32may include a second lower adhesive layer36and a second upper adhesive layer38.

The second heater layer35may be provided between the second transparent structure30and the second lower adhesive layer36. The second heater layer35may be melted by heating the second lower adhesive layer36. The second heater layer35may transmit the second laser light34.

The second lower adhesive layer36may be provided between the second heater layer35and the second upper adhesive layer38. The second lower adhesive layer36may be heated by the second heater layer35. The first lower adhesive layer26may include a thermoplastic adhesive. The second lower adhesive layer36may transmit the second laser light34.

The second upper adhesive layer38may be provided on the second lower adhesive layer36. The second upper adhesive layer38may absorb a portion of the second laser light34and then be melted. The second upper adhesive layer38may include an optical plastic adhesive. For example, the second upper adhesive layer38may transmit another portion of the second laser light34.

Referring again toFIGS.1and9, the second transparent structure30and the second adhesive layer32are removed (S90). The second transparent structure30and the second adhesive layer32may be separated from the new element19on the substrate12. The light source elements14of the electronic device10may include the good elements16and the new elements19. A rework process of the defective element18may be completed.

FIGS.20to22are plan views illustrating a method for manufacturing an electronic device10according to the inventive concept.

Referring toFIG.20, the electronic device10may include light source elements14including good elements16and defective elements18on a substrate12.

Referring toFIG.21, the defective element18may be removed.

Referring toFIG.22, new element19may be bonded to the substrate12by replacing the defective element18.

Therefore, in the method for manufacturing the electronic device10according to an embodiment of the inventive concept, the plurality of defective elements18may be collectively replaced with the new elements19by using a first adhesive layer22and a second adhesive layer32to improve productivity.

The method of manufacturing the electronic device according to the inventive concept may improve the productivity by collectively replacing the plurality of defective elements with the new elements by using the first and second adhesive layers.

Although the embodiment of the inventive concept is described with reference to the accompanying drawings, those with ordinary skill in the technical field of the inventive concept pertains will be understood that the present disclosure can be carried out in other specific forms without changing the technical idea or essential features. Thus, the above-disclosed embodiments are to be considered illustrative and not restrictive.