Electronic device package, electronic device structure and method of fabricating electronic device package

According to embodiments of the disclosure, an electronic device package may include a wire layer and a rigid element. The wire layer includes a first surface and a second surface opposite to each other, and the second surface of the wire layer has at least one coarse structure. A portion of the second surface having the coarse structure has a greater roughness than another portion of the second surface. The rigid element is disposed on the first surface of the wire layer, wherein a stiffness of the rigid element is greater than a stiffness of the wire layer and a projection area of the coarse structure on the first surface of the wire layer overlaps an edge of the rigid element.

TECHNICAL FIELD

The disclosure relates to an electronic device package, electronic device structure and method of fabricating electronic device package.

BACKGROUND

A flexible device needs a flexible substrate to achieve the characteristic of flexibility. However, the flexibility characteristic of the flexible substrate causes the issue that an electronic element may not be directly fabricated on the flexible substrate. To fabricate an electronic element on the flexible substrate, the flexible substrate needs to be adhered on a rigid carrier or machine, so as to provide a suitable support via the carrier or the machine, and thereby the electronic element may be formed on the flexible substrate. In this way, after the fabrication of the electronic element is complete, the flexible substrate needs to be removed from the rigid carrier or machine.

A release layer may be used to join the flexible substrate and the carrier, after the fabrication of the electronic element is complete, the flexible substrate may be removed from the carrier. A suitable peel force is applied via a mechanical stripping technique to separate the flexible substrate from the carrier. The adhesion provided by the release layer is not high, and therefore a large peel force does not need to be applied during mechanical stripping. However, when an electronic element is fabricated on the flexible substrate, the stiffness of the overall device is not uniform, that is, the stiffness of some areas is relative greater, and therefore different peel forces need to be applied during mechanical stripping. Damage to elements may occur in the area to which a greater peel force is applied, which is not good for production yield.

SUMMARY

According to one embodiment of the disclosure, an electronic device package including a wire layer and a rigid element is provided. The wire layer includes a first surface and a second surface opposite to each other, and the second surface of the wire layer has at least one coarse structure. A portion of the second surface having the coarse structure has a greater roughness than another portion of the second surface. The rigid element is disposed on the first surface of the wire layer, wherein a stiffness of the rigid element is greater than a stiffness of the wire layer and a projection area of one of the at least one coarse structure on the first surface of the wire layer overlaps an edge of the rigid element.

According to one embodiment of the disclosure, an electronic device structure including a carrier, a wire layer, a plurality of rigid elements and a releasing layer is provided. The wire layer is disposed on the carrier, wherein the wire layer has a first surface and a second surface opposite to each other, the second surface has at least one coarse structure, and a portion of the second surface having the coarse structure has a greater roughness than another portion of the second surface. The rigid elements are disposed on the wire layer, wherein each of the rigid elements is disposed on the first surface, a stiffness of the each of the rigid elements is greater than a stiffness of the wire layer, and a projection area of the coarse structure on the first surface of the wire layer overlaps an edge of the each of the rigid elements. The releasing layer is disposed between the carrier and the wire layer.

According to one embodiment of the disclosure, a method of fabricating an electronic device package is provided. A wire layer is temporarily disposed on a carrier with a releasing layer located between the carrier and the wire layer. The wire layer has a first surface and a second surface, and the second surface is in contact with the release layer. At least one rigid element is formed on the first surface of the wire layer to form a first area and a second area, and a stiffness of a portion of the first area is greater than a stiffness of the second area. A laser beam irradiates from the carrier toward the release layer located in the first area, wherein a predetermined path of the laser beam falls in the first area.

DETAILED DESCRIPTION OF DISCLOSED EMBODIMENTS

FIG. 1Ais a top view of a step of a fabrication method of a flexible device of the first embodiment of the disclosure,FIG. 1Bis a cross-sectional view along line A-A ofFIG. 1A, andFIG. 1Cis a cross-sectional view along line B-B ofFIG. 1A. Referring toFIG. 1AtoFIG. 1C, a flexible substrate110may be temporarily adhered on a carrier20via a release layer10, wherein the flexible substrate110has a first surface112and a second surface114opposite to each other, and the second surface114is in contact with the release layer10. The material of the flexible substrate110is, for instance, a flexible material such as polyimide (PI), polycarbonate (PC), polyethersulfone (PES), polyacrylate (PA), polynorbornene (PNB), polyethylene terephthalate (PET), polyetheretherketone (PEEK), polyethylene naphthalate (PEN), or polyetherimide (PEI). The flexible substrate110may also have a gas barrier layer. Using PI as example, such type of flexible material may be first coated in liquid state on the carrier20on which the release layer10is formed, and then a curing step is performed to form the flexible substrate110, wherein the curing step may include a photocuring step, a thermal curing step, or other steps. In other embodiments, the PI material is fabricated into a thin-film flexible substrate110, and in the present step, the flexible substrate110is temporarily adhered on the carrier20via the release layer10. Moreover, since the release layer10is used to temporarily adhere the flexible substrate110on the carrier20, the adhesion of the release layer10does not need to be very strong. In other words, the flexible substrate110may be removed from the release layer10in a subsequent fabrication step.

As shown inFIG. 1AtoFIG. 1C, at least one element120is formed on the first surface112of the flexible substrate110to constitute a flexible device100. In the present embodiment, the element120includes a rigid element122and a functional element124, wherein the stiffness of the rigid element122is greater than that of the flexible substrate110and also greater than that of the functional element124. Therefore, the flexible device100may be divided into a first area102and a second area104, wherein the rigid element122is located in the first area102and the functional element124is located in the second area104. Since the rigid element122is disposed in the first area102, the stiffness of the flexible device100in the first area102is greater than the stiffness of the flexible device100in the second area104.

In an embodiment, the rigid element122may be, for instance, a driving chip, and the functional element124may be, for instance, an organic light-emitting element, an inorganic light-emitting element, a sensing element, a display element, or a combination thereof. In other embodiments, the rigid element122may be an electrode, and the functional element124may be a battery element. In these embodiments, the rigid element122may be electrically connected to the functional element124. Moreover, the rigid element122may be a relatively stiff member in the device, such as a seal or a lateral barrier layer, and the rigid element122may be disposed in the periphery of the functional element124. The so-called stiffness may substantially be comprehensively determined via, for instance, the thickness and the Young's modulus of each layer of the element.

In general, by temporarily adhering the flexible substrate110on the carrier20, desired accuracy and yield may be retained in the fabrication process of the element120. After the needed elements120are all fabricated on the flexible substrate110, the entire flexible device100needs to be removed from the carrier20so as to complete the independent flexible device100. The adhesion provided by the release layer10does not have to be as strong as the average permanent adhesive layer, and therefore the flexible substrate110may be removed from the carrier20by only applying a sufficient peel force. However, when the portion to be peeled has greater stiffness or worse flexibility, the peel force needed to remove the flexible substrate110from the carrier20is significantly increased. For instance, in an embodiment, when the rigid element122is a packaged driving chip and the functional element124is an organic light-emitting element, a release force of about 3.867 kg is needed to separate the flexible substrate110of the location of the rigid element122(such as the first area102of the present embodiment) and the carrier20, and a release force of less than 0.15 kg is needed to separate the other portions (such as the second area104of the present embodiment) from the carrier20. Such a release force is likely to cause damage to members on the flexible substrate110, such as wires fabricated on the flexible substrate110or the flexible substrate110itself which may break as a result, thus causing poor production yield.

In the present embodiment, before the flexible device100and the carrier20are separated, the following steps may be performed.FIG. 2Ais a top view of a step of a fabrication method of a flexible device of the first embodiment of the disclosure,FIG. 2Bis a cross-sectional view along line A-A ofFIG. 2A, andFIG. 2Cis a cross-sectional view along line B-B ofFIG. 2A. Referring toFIG. 2AtoFIG. 2Cat the same time, a laser beam L is for instance irradiated from one side of the carrier20toward the release layer10located in the first area102, and the irradiation path of the laser beam L falls in the first area102. At this point, the release layer10irradiated by the laser beam L is decomposed or modified and converted into a release layer10A. In the present embodiment, the path direction of the laser beam L is, for instance, from a first side S1of the flexible substrate110toward a second side S2of the flexible substrate110, such that the release layer10A is continuously distributed from the first side S1to the second side S2, and the first side S1and the second side S2are opposite sides.

FIG. 3Ais a top view of a step of a fabrication method of a flexible device of the first embodiment of the disclosure,FIG. 3Bis a cross-sectional view along line A-A ofFIG. 3A, andFIG. 3Cis a cross-sectional view along line B-B ofFIG. 3A. Referring toFIG. 3AtoFIG. 3Cat the same time, after the irradiation of the laser beam L is conducted, the flexible device100is removed from the carrier20, such that the flexible substrate110and the carrier20are separated. Here, the step of removing the flexible device100may include applying a peel force at one side of the flexible substrate110and peeling the flexible substrate110from the carrier20along a peeling direction DP.

In the step ofFIG. 2A, the adhesion of the release layer10A is damaged and is reduced when comparing with the release layer10without being irradiated by the laser beam L. Therefore, in the step ofFIG. 3A, the peel force does not need to be significantly increased during the removal process of the first area102in order to separate the flexible substrate110of the first area102and the carrier20. In an embodiment, when the rigid element122is a packaged driving chip and the functional element124is an organic light-emitting element, and the release layer10is converted to the release layer10A via the processing steps ofFIG. 2AtoFIG. 2C, about 0.187 kg of peel force is needed to separate the flexible substrate110of the location of the rigid element122(such as the first area102of the present embodiment) and the carrier20, which is a lot less than the peel force of 3.867 kg needed before the release layer10is processed. Therefore, in the present embodiment, members on the flexible substrate110are not readily damaged during the peeling process of the first area102from the carrier20, such that the production yield of the flexible device100may be increased.

FIG. 4Ais a top view of a flexible device of the first embodiment of the disclosure,FIG. 4Bis a top view of a flexible device of the first embodiment of the disclosure,FIG. 4Cis a cross-sectional view along line A-A ofFIG. 4A, andFIG. 4Dis a cross-sectional view along line B-B ofFIG. 4A. Referring toFIG. 4AtoFIG. 4Dat the same time, the flexible device100fabricated via the above steps has a first area102and a second area104, wherein the stiffness of the first area102is greater than the stiffness of the second area104. Moreover, the flexible device100may include a flexible substrate110and an element120disposed on the flexible substrate110, wherein the element120may include a rigid element122and a functional element124. The flexible substrate110includes a first surface112and a second surface114opposite to each other. Moreover, the rigid element122is disposed on the first surface112of the flexible substrate110and located in the first area102, wherein the stiffness of the rigid element122is greater than the stiffness of the flexible substrate110and a projection area of a coarse structure114A on the flexible substrate110overlaps the rigid element122.

It may be known fromFIG. 4BtoFIG. 4Dthat, the second surface114of the flexible substrate110has a coarse structure114A in the first area102, such that the surface roughness of the second surface114in the first area102is greater than the surface roughness of the second surface114in the second area104. The coarse structure114A may be formed by, for instance, the laser irradiation step ofFIG. 2AtoFIG. 2C. According to the above steps, the laser irradiation step is performed in the first area102, and therefore the coarse structure114A also falls in the first area102. The laser irradiation step is performed to reduce the adhesion of the release layer10where the rigid element122is located, and therefore the irradiation range of the laser beam overlaps the disposition area of the rigid element122. Moreover, in the present embodiment, the flexible device100further includes a functional element124disposed in the second area104, and the stiffness of the rigid element122is greater than the stiffness of the functional element124, but in other embodiments, the functional element124may also be optionally omitted. In other words, the flexible device100may include only the flexible substrate110and the rigid element122.

FIG. 5is a micrograph of a second surface of a flexible substrate of the first embodiment of the disclosure. It may be known fromFIG. 5that, the second surface114has a coarse structure114A in the first area102, and the second surface114appears smooth or translucent in the second area104, such that the functional element124used as a display element is observed. Here, the functional element124used as a display element is exemplified by an organic light-emitting display pixel, but is not limited thereto.

It may be known from the first embodiment that, in the laser irradiation step, the release layer material is decomposed to reduce the adhesion of the release layer10in the first area102, thus increasing the production yield of the flexible device100. However, in the case that the decomposition of the release layer material generates gas, if the gas generated in the process may not be released or is excessively accumulated, deformation to the first area102may readily occur due to the pressure generated by the gas. Therefore, in the first embodiment, as shown inFIG. 2B, the irradiation path of the laser beam L starts from the first side S1of the flexible substrate110and travels toward the second side S2of the flexible substrate110, and the first side S1and the second side S2are opposite sides. However, the fabrication method of the flexible device100is not limited thereto.

FIG. 6Ais a top view of a step of a fabrication method of a flexible device of the second embodiment of the disclosure,FIG. 6Bis a cross-sectional view along line C-C ofFIG. 6A, andFIG. 6Cis a cross-sectional view along line D-D ofFIG. 6A. In the present embodiment, the flexible substrate110may be temporarily adhered on the carrier20via the release layer10according to the steps ofFIG. 1AtoFIG. 3A, and the element120is fabricated on the flexible substrate110when the flexible substrate110is adhered on the carrier20. Then, referring toFIG. 6AtoFIG. 6C, a processing step is performed to fabricate at least one via TH on the flexible substrate110to form a flexible substrate210. The processing step of forming the via TH may be, for instance, cutting with a round blade, laser cutting, or punching, but is not limited thereto. Here, the number of the vias TH (via TH1and via TH2) is two, but this is only exemplary. In other embodiments, the number of the vias TH may be one or more than two.

In the present embodiment, the rigid element122is located between the via TH1and the via TH2, and the via TH1and the via TH2respectively define two ends of a first area202. Therefore, the area outside of the first area202may be regarded as a second area204. The entire rigid element122falls within the first area202. Moreover, the via TH1and the via TH2may pass through the flexible substrate210to expose the release layer10, or pass through the flexible substrate210and the release layer10at the same time and expose the carrier20, and the latter is exemplified in the following figures.

FIG. 7Ais a top view of a step of a fabrication method of a flexible device of the second embodiment of the disclosure,FIG. 7Bis a cross-sectional view along line C-C ofFIG. 7A, andFIG. 7Cis a cross-sectional view along line D-D ofFIG. 7A. The steps represented inFIG. 7AtoFIG. 7Cinclude, for instance, irradiating a laser beam L from one side of the carrier20toward the release layer10located in the first area202to form a release layer10A in the first area202. In the present embodiment, the irradiation path of the laser beam L starts at the location of the first via TH1and ends at the location of the second via TH2. In other words, the laser beam L moves along a moving direction DL.

FIG. 7DtoFIG. 7Fare the irradiation process of a laser beam L along an irradiation path. It may be known fromFIG. 7DtoFIG. 7Fthat, since the irradiation path of the laser beam L starts at the location of the first via TH1and travels toward the second via TH2, when the material of the release layer10is decomposed by laser energy, the generated gas may be dissipated from the first via TH1(as shown inFIG. 7DandFIG. 7E). Moreover, when the irradiation point of the laser beam L is close to the second via TH2, the generated gas may be dissipated from the second via TH2and the first via TH1. Therefore, accumulation of gas does not readily occur at the location of the release layer10A, such that the flexible substrate210is not deformed or the flexible device200is not damaged. In other words, the via TH1may facilitate the dissipation of gas generated in the fabrication process, thus facilitating increase in production yield.

FIG. 8Ais a top view of a step of a fabrication method of a flexible device of the second embodiment of the disclosure,FIG. 8Bis a cross-sectional view along line C-C ofFIG. 8A, andFIG. 8Cis a cross-sectional view along line D-D ofFIG. 8A. The steps represented byFIG. 8AtoFIG. 8Care similar to the steps ofFIG. 3AtoFIG. 3C, which include the removal of the flexible device200from the carrier20. Specific steps ofFIG. 8AtoFIG. 8Care as described forFIG. 3AtoFIG. 3C. In the first embodiment and the second embodiment, the flexible substrate110or210is separated from the carrier20along the peeling direction DP, that is, the flexible substrate110or210is separated from the carrier20from the side of the flexible substrate110or210closer to the rigid element122toward the opposite side. However, the peeling direction DP is not limited to the direction represented in the figure. In other embodiments, the flexible substrate110or210may also be separated from the carrier20along a direction opposite to the peeling direction DP, that is, the flexible substrate110or210may be separated from the carrier20from the side of the flexible substrate110or210farther from the rigid element122toward the opposite side.

FIG. 9Ais a top view of a flexible device of the second embodiment of the disclosure, andFIG. 9Bis a top view of a flexible device of the second embodiment of the disclosure. Referring toFIG. 9AandFIG. 9B, the flexible device200fabricated according to steps such asFIG. 6AtoFIG. 8Amay be substantially similar to the flexible device100of the first embodiment. The flexible device200has a first area202and a second area204, wherein the stiffness of the first area202may be greater than the stiffness of the second area204. Moreover, the flexible device200includes a flexible substrate210and an element120disposed on the flexible substrate210, wherein the element120may include a rigid element122and a functional element124. The flexible substrate210includes a first surface212(shown inFIG. 6B) and a second surface214(shown inFIG. 6B) opposite to each other, and has vias TH1and TH2. Moreover, the rigid element122is disposed on the first surface212of the flexible substrate210and located in the first area202, wherein the stiffness of the rigid element122may be greater than the stiffness of the flexible substrate210. Moreover, the second surface214of the flexible substrate210has a coarse structure214A in the first area202and a projection area of the coarse structure214A on the flexible substrate210overlaps the area of the rigid element122. In other words, the flexible substrate210has two vias TH1and TH2. However, in other embodiments, the flexible substrate210may also only include one via TH, or more than two vias TH.

For instance,FIG. 10Ais a top view of a flexible device of the third embodiment of the disclosure, andFIG. 10Bis a top view of a flexible device of the third embodiment of the disclosure. Referring toFIG. 10AandFIG. 10B, a flexible device300may be substantially similar to the flexible device100of the first embodiment. The flexible device300has a first area302and a second area304, wherein the stiffness of the first area302may be greater than the stiffness of the second area304. Moreover, the flexible device300includes a flexible substrate310and an element320disposed on the flexible substrate310, wherein the element320may include rigid elements322A and322B and a functional element124. The flexible substrate310includes a first surface (first surface represented inFIG. 10A) and a second surface (second surface represented inFIG. 10B) opposite to each other, and has vias TH1, TH2, and TH3. Moreover, the rigid elements322A and322B are disposed on the first surface of the flexible substrate310and located in the first area302, wherein the stiffness of each of the rigid elements322A and322B is greater than the stiffness of the flexible substrate310. Moreover, when the flexible device300is fabricated and when the release layer is, for instance, irradiated via laser, the via TH3may be located in the irradiation path of the laser beam or the irradiation path of the laser beam may pass through the via TH3. As a result, the second surface of the flexible substrate310has a coarse structure314A in the first area302, and a projection area of the coarse structure314A on the flexible substrate overlaps the rigid elements322A and322B. In other words, the flexible substrate310has three vias TH1, TH2, and TH3, and the flexible substrate310has two rigid elements322A and322B. In the three vias TH1, TH2, and TH3, the vias TH1and TH2define two ends of the first area302, and the via TH3is located inside the first area302. The rigid element322A is located between the via TH1and the via TH3, and the rigid element322B is located between the via TH2and the via TH3. Moreover, the rigid elements322A and322B may be packaged driving chips, but are not limited thereto.

FIG. 11Ais a top view of a step of a fabrication method of a flexible device of the fourth embodiment of the disclosure,FIG. 11Bis a cross-sectional view along line E-E ofFIG. 11A, andFIG. 11Cis a cross-sectional view along line F-F ofFIG. 11A. Referring toFIG. 11AtoFIG. 11Cat the same time, the present step includes temporarily adhering a flexible substrate410on a carrier20via a release layer10, wherein the area of the release layer10is less than the flexible substrate410such that the flexible substrate410is partially in contact with the carrier20. Here, a portion410A of the carrier20in contact with the flexible substrate410surrounds the release layer10. The flexible substrate410has a first surface412and a second surface414, and a portion of the second surface414is in contact with the release layer10. Moreover, in the present step, at least one element120is also formed on the first surface412of the flexible substrate410. Here, the fabrication method of the flexible substrate410is the same as the fabrication method of the flexible substrate110ofFIG. 1AtoFIG. 1C, and the fabrication, the type, and the location . . . etc. of the elements120are also as described in the first embodiment.

FIG. 12Ais a top view of a step of a fabrication method of a flexible device of the fourth embodiment of the disclosure,FIG. 12Bis a cross-sectional view along line E-E ofFIG. 12A, andFIG. 12Cis a cross-sectional view along line F-F ofFIG. 12A. Referring toFIG. 12AtoFIG. 12C, a processing step is performed to cut the flexible substrate410along the periphery of the release layer10so as to form a circular cut opening V as shown inFIG. 12A, and the cut opening V exposes the release layer10, or the cut opening V passes through the flexible substrate410and the release layer10at the same time and exposes the carrier20(FIG. 12B). Here, the flexible substrate410is cut into two portions separate from each other, one of the portions is a flexible substrate410B to be removed and the other portion is the portion410A in contact with the carrier20. Moreover, in the present embodiment, the elements120are all fabricated on the flexible substrate410B to form a flexible device400.

In the present embodiment, the elements120include a rigid element122and a functional element124, wherein the stiffness of the rigid element122may be greater than that of the functional element124and also greater than that of the flexible substrate410B. Therefore, the flexible device400may have a first area402and a second area404, and the rigid element122is located in the first area402such that the stiffness of the first area402is greater than that of the second area404.

FIG. 13Ais a top view of a step of a fabrication method of a flexible device of the fourth embodiment of the disclosure,FIG. 13Bis a cross-sectional view along line E-E ofFIG. 13A, andFIG. 13Cis a cross-sectional view along line F-F ofFIG. 13A. Referring toFIG. 13AtoFIG. 13C, the flexible device400is removed from the carrier20, such as irradiating from one side of the carrier20toward the release layer10located in the first area402via a laser beam L so as to form a release layer10A in the first area402. In the present embodiment, since the edge of the flexible substrate410B is exposed by the cut opening V, the irradiation path of the laser beam L starts from the first side S1of the flexible substrate410and travels toward the second side S2of the flexible substrate410, and the first side S1and the second side S2are opposite sides. Moreover, the peeling direction of the removal of the flexible device400from the carrier20may be the same asFIG. 13Cin that peel force is applied from a third side S3of the flexible substrate410B toward a fourth side S4of the flexible substrate410B, or the peel force is applied from the fourth side S4of the flexible substrate410B toward the third side S3of the flexible substrate410B. Here, the third side S3is farther from the rigid element122and the fourth side S4is closer to the rigid element122. Therefore, when peeling the flexible device400from the carrier20via the method ofFIG. 13C, the peeling step and the laser irradiation step may be performed at the same time, but the disclosure is not limited thereto. In other embodiments, the laser irradiation step may be before the peeling step. Moreover, similar to the above embodiments, in the laser irradiation step, a coarse structure414A is formed on the second surface414of the flexible substrate410B, and the laser irradiation step is only performed in the first area402, and therefore the coarse structure414A is also only located in the first area402.

In the above embodiments, the irradiation of the laser beam may decompose or modify the release layer material and thereby reduce the adhesion of the release layer in the irradiated area. However, heat accumulation phenomenon may occur to the periphery of the area irradiated by the laser beam. The heat accumulation phenomenon may cause the adhesion of the release layer material to increase and is not good for the peeling step. Therefore, the irradiation method of a laser beam may be adjusted accordingly.

The irradiation method of a laser beam is described in the following based on the step ofFIG. 2A.

FIG. 14is an embodiment of an irradiation method of a laser beam in the step ofFIG. 2A. Referring toFIG. 14A, the members in the present figure are all as described forFIG. 2Aand are not repeated herein. When the laser irradiation step is performed via a dot laser beam LB, the irradiation point LB of the laser beam travels, for instance, along a trajectory P1. Moreover, the area of each irradiation point LB of the laser beam partially overlaps the area of the previous irradiation point LB. The irradiation points LB of the laser beam cover the entire first area102, and therefore the coarse structure generated based on laser irradiation in the above embodiments also covers the entire first area102.

FIG. 15shows a schematic of a laser irradiation point and a heat-affected zone under an irradiation method ofFIG. 14. Referring to bothFIG. 14andFIG. 15, the irradiation point LB of each laser beam corresponds to a heat-affected zone HB, and the area of the heat-affected zone HB is greater than the area of the irradiation point LB. When two overlapping irradiation points LB, such as irradiation points LB1and LB2are irradiated in a consecutive manner, the heat-affecting effect of the corresponding heat-affected zones HB1and HB2may be increased. Therefore, the overlapping portion of the heat-affected zones HB1and HB2, such as a heat-affected zone HBS, has the most heat-affecting effect. In other words, the adhesion of the release layer material in the heat-affected zone HBS may be more increased. Therefore, when the flexible substrate110is to be peeled from the carrier20along the peeling direction DP, the heat-affected zone HBS is preferably not densely arranged in a direction R perpendicular to the peeling direction DP, which causes difficult peeling. In the present embodiment, since the irradiation point LB of the laser beam travels along the trajectory P1, the heat-affected zone HBS is arranged to be substantially parallel to the peeling direction DP, so as to prevent difficulty in peeling.

FIG. 16andFIG. 17are two other embodiments of the irradiation method of a laser beam in the step ofFIG. 2A. InFIG. 16, the irradiation point LB of a laser beam travels, for instance, along a trajectory P2, and overlapping does not occur between irradiation points LB, wherein the trajectory P2is substantially formed by the connection of a plurality of V-type paths. At this point, the irradiation points LB are distributed in a partial area of the first area102, and therefore the coarse structure generated based on laser irradiation in the above embodiments is also distributed in a partial area of the first area102. Moreover, inFIG. 17, overlapping may also not occur between the irradiation points LB, and the irradiation points LB of the laser beam travel along a trajectory P3, wherein the trajectory P3may be similar to the trajectory P1ofFIG. 14in that both are winding trajectories, but the trajectory P3is more sparsely distributed and the trajectory P1is more densely distributed.

In addition to controlling the travel trajectory of the irradiation points, a negative effect to the peeling step by a heat-affected zone may also be reduced via the incident angle of the laser beam. For instance,FIG. 18andFIG. 19are schematics of different embodiments of the laser irradiation step. InFIG. 18andFIG. 19, the irradiation direction of the laser beam L may be not perpendicular to the flexible substrate110, and irradiation may be performed in the irradiation direction of an angle of θ1, θ2, or θ3. Therefore, the release layer10A irradiated by laser may have a trapezoidal (FIG. 18) or approximate parallelogram (FIG. 19) cross-sectional profile. By controlling the irradiation location of the laser beam, the heat-affected zone HB may be located at the edge of the rigid element122and inclined at an angle. In this way, the flexible substrate110is separated from the carrier20along separating interfaces Z1and Z2when removed from the carrier20. In other words, in the area not irradiated by the laser beam, the separating interface Z1is located between the release layer10and the flexible substrate110, and in the area irradiated by the laser, since a portion of the material of the release layer10A is decomposed, the separating interface Z2is located between the release layer10A and the carrier20. InFIG. 18, the orthographic projections of the separating interface Z1and the separating interface Z2on the flexible substrate110are overlapped with each other and continuously cover the entire area of the flexible substrate110, and therefore the flexible substrate110may be readily peeled from the carrier20. The embodiment ofFIG. 19is no different.

FIG. 20is a schematic top view of an electronic device structure according to an embodiment of the present disclosure.FIG. 21is a schematic cross-sectional view of the electronic device structure taken along line I-I depicted inFIG. 20andFIG. 22is a schematic cross-sectional view of the electronic device structure taken along II-II depicted inFIG. 20. Referring toFIGS. 20, 21 and 22, in the present embodiment, an electronic device structure500A includes a wire layer510, a plurality of rigid elements520, and a molding layer530may be sequentially disposed on one side of a carrier540with a releasing layer550thereon. The releasing layer550is formed on the carrier540prior to the wire layer510, the releasing layer550is sandwiched between the carrier540and the wire layer510. The wire layer510has a first surface S1and a second surface S2opposite to the first surface S1. The rigid elements520may be disposed on the first surface S1of the wire layer510and are separated from each other by a distance. The molding layer530may be disposed on the first surface S1of the wire layer510, and the molding layer530may cover and encapsulate the rigid elements520having the wire layer510. In one instance, a material of the carrier540includes glass, or the like.

FIG. 20shows the molding layer530and the outlines of the rigid elements520arranged in an array for illustrating the disposition locations of the rigid elements520, and other components in the electronic device structure500A are shown inFIG. 21andFIG. 22. In addition, the rigid elements520shown inFIG. 20respectively have a rectangle shape for illustration purpose. In an alternative embodiment, the shape of the rigid element520can be a square, a hexagon, or other geometric shapes.

The wire layer510may include a dielectric matrix512and a plurality of wiring units514. In one instance, the material of the dielectric matrix512of the wire layer510includes polyimide, PBO, SiNx, SiOx, SiON, or other insulation material. The wiring units514are respectively connected to the rigid elements520. In other words, each rigid element520is disposed correspondingly on one wiring unit514. Each of the wiring layers510may include a plurality of wirings WR distributed in the dielectric matrix512and the wirings WR may be made of metal material having conductivity to transmit electric signal. In some embodiments, the material of wirings WR may be copper.

In an embodiment, the rigid elements520can be a plurality of semiconductor devices, such as chips or dies. The wirings WR in each wiring unit514are electrically connected to one rigid element520to define the electric transmission path of the rigid element520based on the needed layout design. Therefore, in some embodiments, the wire layer510can be considered as a redistribution layer (RDL) which helps to fan-out or fan-in the electric connection path of a semiconductor device.

For electric connecting the rigid element520and redistributing the electric connection path of the rigid element520, at least one of the wiring WR includes a fan-out portion WR1and a conductive via WR2. The fan-out portion WR1may be disposed on the first surface S1of the wire layer510to be electrically connected to the rigid element520thereon, and the conductive via WR2is connected to the fan-out portion WR1and passes through the dielectric matrix512to extend to the elevation of the second surface S2of the wire layer510.

The molding layer530covering the rigid elements520may be made of epoxy compound or the like capable of protecting the rigid elements520and electrically insulating the rigid elements520from each other. In the present embodiment, the electronic device structure500A may include a plurality of semiconductor devices encapsulated on the carrier540by the molding layer530. In an alternative embodiment, the molding layer530may not continuously cover the rigid elements520and may include a plurality of independent mold patterns respective covering the rigid elements520.

The rigid elements520are independent devices and the rigid elements520are predetermined to be connected to an external device through the wire layer510. The carrier540may be removed from the wire layer510to expose the second surface S2of the wire layer510.

In the present embodiment, the releasing layer550is selectively to have a temporary attachment effect to the wire layer510so that the wire layer510can be separated from the carrier540through the releasing layer550as desired. In one instance, the releasing force of the releasing layer550with respect to the wire layer510is less than or equal to 30 gf/cm so as to provide a temporary attachment effect. The releasing force of the releasing layer550with respect to the wire layer510may be consider as the intensity of the releasing layer550attaching to the dielectric matrix512of the wire layer510. The material of the releasing layer550can be organic material or inorganic material, for example. In some embodiment, the organic material for fabricating the releasing layer550includes polysiloxane, polysiloxane hybridize materials, cyclic olefin copolymers (COC), poly(methyl methacrylate) (PMMA), polyimide (PI), or the like and the inorganic material for fabricating the releasing layer550includes SiOx, SiNx, SiON, or the like.

In the present embodiment, the electronic device structure500A may be fabricated by forming the releasing layer550on the carrier540, forming the wire layer510on the releasing layer550, bonding the rigid elements520on the wire layer510, and encapsulating the rigid elements520by the molding layer530. In an example, the rigid element520can be bonded on the wire layer510by a flip chip process, a wiring process or a combination thereof.

FIG. 23is a schematic top view of an electronic device structure according to an embodiment of the present disclosure.FIG. 24is a schematic cross-sectional view of the electronic device structure taken along line I-I depicted inFIG. 23andFIG. 25is schematic cross-sectional view of the electronic device structure taken along II-II depicted inFIG. 23. Referring toFIGS. 23, 24 and 25, in the embodiment, the electronic device structure500B is similar to the electronic device structure500A depicted inFIG. 20,FIG. 21andFIG. 22. The electronic device structure500B is formed by applying an energy beam to the releasing layer550of the electronic device structure500B. The same or similar symbols in the two embodiments can represent the components having the same or similar functions, structure and dispositions. In other words, the electronic device structure500B may include a wire layer510A, a plurality of rigid elements520, and a molding layer530disposed on a carrier540with a releasing layer550A thereon, in which the structure, the disposition and the function of the rigid elements520, the molding layer530and the carrier540can refer to the foregoing descriptions accompanying withFIG. 20,FIG. 21andFIG. 22.

In the present embodiment, the energy beam is applied to a portion552A of the releasing layer550A along a predetermined path LRP1while the other portion554A of the releasing layer550A does not subject to the energy beam. The predetermined path LRP1includes a plurality of predetermined spot areas LB1respectively overlapping the edges E1of the rigid elements520. In one instance, the energy beam applied to the releasing layer550A includes a laser irradiation. The power and the frequency of the laser irradiation can be adjusted based on the material of the releasing layer550A. Owing to the energy beam applied to the portion552A of the releasing layer550A may have a structure different from the other portion554A of the releasing layer550A. For example, the portion552A of the releasing layer550A may have higher porosity than the other portion554A of the releasing layer550A. The density of the portion552A of the releasing layer550A may be smaller than the other portion554A of the releasing layer550A.

After subjecting to the energy beam, a coarse structure516A may be formed at the second surface S2of the wire layer510A, and for instance may be formed in the dielectric matrix512of the wire layer510A. In the present embodiment, the coarse structure516A is distributed along with the predetermined path LRP1. As shown inFIG. 23, one predetermined spot area LB1of the predetermined path LRP1overlaps with an edge E1of one rigid element520and the coarse structure516A also overlaps with the edge E1of each rigid element520.

FIG. 26schematically illustrates a process of removing the carrier depicted inFIGS. 23 to 25according to an embodiment. Referring toFIG. 26, the carrier540is removed from the wire layer510A via the releasing layer550A subjected to the energy beam. In the present embodiment, referring toFIG. 23andFIG. 26simultaneously, the wire layer510A is separated from the carrier540in a direction DS that the edge E1of each rigid element520subjected to a separating force earlier than the other portion of the rigid element520. In other words, for the rigid element520, the separating force is applied to where overlaps with the predetermined spot area LB1of the predetermined path LRP1prior to where not overlaps with the predetermined spot area LB1of the predetermined path LRP1. As such, the rigid elements520would not be damaged by the separating force and the separating process may be performed in a higher yield rate. In addition, a peeling effect at the interface between the wire layer510A and the rigid element520due to the separating force may be avoided.

In the case of removing the carrier540from the wire layer510of the electronic device structure500A shown inFIGS. 21 and 22, the separating force applied to where the rigid elements520are located shall be increased because the stiffness of the rigid element520is greater than the wire layer510. Comparably, as shown inFIGS. 24 and 25, the process of applying the energy beam to the releasing layer550A may cause the wire layer510A to be separated from the carrier540at the position where the energy beam is applied. The portion of the wire layer510A with the rigid elements520thereon may be easily separated from the carrier540and the separating force applied to such portion of the wire layer510A with the rigid elements520thereon may be relatively reduced or need not be increased overly. Owing that the separating force applied to the rigid elements520need not be overly increased, the rigid elements520may not be damage during the separating process, which improves the yield rate of the fabrication.

FIG. 27schematically illustrates an array of electronic device packages obtained by finishing the process depicted inFIG. 26according to an embodiment. Referring toFIG. 27, an array600of electronic device packages may include the wire layer510A, the rigid elements520, the molding layer530and the conductive bumps560. The wire layer510A may include the dielectric matrix512and the wiring units514, the dielectric matrix512may be made of a polymer, which may be a photo-sensitive material such as polybenzoxazole (PBO), polyimide, benzocyclobutene (BCB), or the like, and the wirings WR may be made of metal material such as such as copper, aluminum, tungsten, or the like. The wire layer510A has a first surface S1and a second surface S2opposite to each other, and the second surface S2has a plurality of coarse structures516A. The portion of the second surface S2having the coarse structures516A has a greater roughness than another portion of the second surface S2. Each of the rigid elements520is disposed on the first surface S1. In the present embodiment, the rigid elements520may be semiconductor devices, such as chips or dies, and the wire layer510A may be a redistribution layer. A stiffness of the rigid elements520can be greater than a stiffness of the wire layer510A. In addition, a projection area of the coarse structures512A on the first surface S1of the wire layer510A overlaps a projection area of the rigid elements520on the first surface S1of the wire layer510A.

In the present embodiment, the array600of electronic device packages is obtained by removing the carrier540from the electronic device structure500B depicted inFIG. 25andFIG. 26, so that the wirings WR of the wiring units514are exposed at the second surface S2. It is selectively to form a plurality of conductive bumps560on the second surface S2and the conductive bumps560may be respectively connected to the wirings WR exposed at the second surface S2. For instance, each conductive bump560can physically contact and electrically connect with one wiring WR at the second surface S2.

In addition, the rigid elements520are encapsulated by the molding layer530. In the present embodiment, a singulation process may be performed to divide the array600of electronic device packages into a plurality of electronic device packages600A as shown inFIG. 28. In the present embodiment, the singulation process may include cutting the array600of electronic device packages along the cutting path CTP shown inFIG. 27. In an example, before the cutting step, a laser mark can be formed on the molding layer530, the cutting path CTP can be controlled to conform to the laser mark.

FIG. 28schematically illustrates a cross-sectional view of an electronic device package according to an embodiment of the present disclosure. As shown inFIG. 28, the electronic device package600A may include a wire layer610, a rigid element520, the molding layer630, and a plurality of conductive bumps560. In the present embodiment, the rigid element520and the conductive bumps560may refer to the previous descriptions. The wire layer610has a first surface S1and a second surface S2opposite to the first surface S1. The rigid element520is disposed on the first surface S1. A coarse structure516A is formed on a portion of the second surface S2. The portion of the second surface S2having the coarse structure516A has a greater roughness than another portion of the second surface S2. In addition, a stiffness of the rigid element520is greater than a stiffness of the wire layer610and a projection area of the coarse structure516A on the first surface S1of the wire layer610overlaps an edge E1of the rigid element520.

The wire layer610is formed from the wire layer510A inFIG. 27, the wire layer610may include a dielectric matrix512and a plurality of wirings WR distributed in the dielectric matrix512. The rigid element520is electrically connected to the wirings WR. Simultaneously, the coarse structure516A may be formed on the dielectric matrix512. In the present embodiment, at least one of the wirings WR may include a fan-out portion WR1and a conductive via WR2. The fan-out portion WR1is disposed on the first surface S1to be electrically connected to the rigid element520, and the conductive via WR2is connected to the fan-out portion WR1and passes through the dielectric matrix512. The conductive via WR2is connected to one of the conductive bumps560for electrically connecting to an external device through the conductive bumps560.

FIG. 29schematically illustrates an electronic device package according to another embodiment. InFIG. 29, the electronic device package600B may include the wire layer610, the rigid element520, the molding layer630and the conductive bumps560as depicted inFIG. 28, and further include an optional passivation structure670disposed on the second surface S2of the wire layer610. In the present embodiment, the passivation structure670has a plurality of opening670A and the conductive bumps560are respectively located at the openings570A. Each of the openings670A exposes a terminal of the conductive via WR2of one wiring WR at the second surface S2and accommodates one conductive bump560. In one instance, the conductive bump560can be a solder bump made of solder material including Sn or the like and the passivation structure670with the openings670A can be used for restricting the disposition location of the conductive bump560or facilitating the conductive bump560to have a ball-like shape. The material of the passivation structure670may include a solder resist material such as epoxy, epoxy-acrylate resin, etc. Alternately, the material of the passivation structure670may be inorganic material or organic material which is capable of electrically insulting the conductive bumps560from each other. In an example, the rigid element520can have a plurality of pads522exposed at the first surface S1, and a wire or a conductive connector524can be formed between the pads522and the wirings WR of the wiring unit514. The design of the pads522and the conductive connector524of the rigid element520can be utilized in the embodiment depicted inFIGS. 20 to 28.

FIG. 30is a schematic top view of an electronic device structure according to another embodiment of the present disclosure.FIG. 31is a schematic cross-sectional view of the electronic device structure taken along line III-III depicted inFIG. 30andFIG. 32is a schematic cross-sectional view of the electronic device structure taken along IV-IV depicted inFIG. 30. Referring toFIGS. 30 to 32, in the present embodiment, the electronic device structure700, similar to the electronic device structure500B depicted inFIGS. 23 to 25, may include a wire layer710A, a plurality of rigid elements520, and a molding layer530disposed on a carrier540with a releasing layer750A thereon. The releasing layer750A is formed on the carrier540prior to the wire layer710A, the releasing layer750A is sandwiched between the carrier540and the wire layer710A. The wire layer710A may include the dielectric matrix712and the wirings WR. The rigid elements520are disposed on the wire layer710A, arranged in an array, and separated from each other by a distance. The molding layer530covers and encapsulates the rigid elements520. In brief, the releasing layer750depicted inFIGS. 30 to 32subjected to an energy beam, such as laser irradiation, irradiating along a predetermined path LRP2while the predetermined path LRP2includes a plurality of predetermined stripe areas LB2, and the predetermined stripe areas LB2respectively pass through the rigid elements520arranged in one column. In the present embodiment, as shown inFIG. 31andFIG. 32, the releasing layer750A includes a portion752A subjected to the energy beam and the other portion754A not subjected to the energy beam. In addition, the wire layer710A can have the coarse structures716A corresponding to the portion752A of the releasing layer750A. In the present embodiment, at least one through hole THO may be formed to pass through the molding layer630and the wire layer710A prior to applying the energy beam to the releasing layer750A and the predetermined path LRP of the energy beam overlaps with the through hole THO, such that the gas generated by applying the energy beam onto the releasing layer750A may leak from the through hole THO, which avoids to a stress concentration effect.

In the present embodiment, a separating process can be performed to remove the carrier540. Under the configuration of the predetermined path LRP2having parallel predetermined stripe areas LB2, the separating force for removing the carrier540may be applied in a direction DS parallel to or substantially parallel to the predetermined stripe areas LB2. The portion752A of the releasing layer750A may be treated by the energy beam irradiation, the corresponding portion of the wire layer710A having the coarse structure716A can be separated from the carrier540before subjecting to the separating force for removing the carrier540. The separating force for removing the carrier540can be reduced, which helps to prevent from the damage of the rigid element520caused by the separating force.

In the present embodiment, a singulation process can be performed after the carrier540is removed and the singulation process includes cutting the molding layer530and the wire layer710A along the cutting path CTP shown inFIGS. 30 to 32. Accordingly, an electronic device package800shown inFIG. 33andFIG. 34is formed. InFIG. 33andFIG. 34, a single electronic device package800can be similar to electronic device package600A depicted inFIG. 28, and include a wire layer810, a rigid element520, the molding layer630and a plurality of conductive bumps560. The wire layer810has a first surface S1and a second surface S2opposite to the first surface S1. The rigid element520is disposed on the first surface S1and the conductive bumps560are disposed on the second surface S2. In addition, the wirings WR of the wire layer810are exposed at the second surface S2for in contact with the conductive bumps560. In the present embodiment, the projection area of the coarse structure716A on the first surface S1of the wire layer810overlaps with the whole of the projection area of the rigid element520on the first surface S1of the wire layer810. Furthermore, at the second surface S2, a portion of the dielectric matrix712having the coarse structure716A has a surface roughness greater than the other portion of the dielectric matrix712. According to the present embodiment and the embodiment shown inFIG. 28, the distribution of the projection area of the coarse structure516A or716A on the first surface S1of the wire layer510or810may be determined by the predetermined path LRP1or LRP2and overlap with the projection area of the rigid element520on the first surface S1of the wire layer510or810. Therefore, the following embodiments are taken as alternative examples for illustrating different predetermined paths of the energy beam.

FIG. 35toFIG. 39are schematic top views of electronic device structures according to numerous embodiments of the present disclosure.FIG. 35toFIG. 39are utilized to show the electronic device structures901to909having the rigid elements520arranged in an array and the molding layer530encapsulating the rigid elements520.FIG. 35schematically illustrates the electronic device structure901formed by applying an energy beam along the predetermined path LRP3onto the electronic device structure500A depicted inFIG. 20. InFIG. 35, the predetermined path LRP3includes a plurality of predetermined stripe areas LB3, the predetermined stripe areas LB3pass through the edges E1of respective rigid elements520. In the present embodiment, each predetermined stripe area LB3is extended in the row direction of the array of the rigid elements520and thus one predetermined stripe area LB3passes through the edges E1of the rigid elements520arranged in one row. In addition, each rigid element520can have a portion not overlapping with the predetermined path LRP3. In other words, the predetermined path LRP3may skip over a portion of the projection area of the rigid element520. The step of removing the carrier as depicted inFIG. 26may be adopted in the present embodiment by applying the separating force in the direction DS, the portion of each rigid element520adjacent to the edges E1may subject to the separating force prior to the other portion of the said rigid element520.

FIG. 36schematically illustrates the electronic device structure903formed by applying an energy beam along the predetermined path LRP4onto the electronic device structure500A depicted inFIG. 20. In the present embodiment, the predetermined path LRP4includes a plurality of predetermined spot areas LB4A, LB4B and LB4C. The predetermined spot areas LB4A respectively overlap with the rigid elements520at one edge EA, the predetermined spot areas LB4B respectively overlap with the rigid elements520at an edge EB that is opposite to the edge EA correspondingly overlapped with the predetermined spot area LB4A, and the predetermined spot areas LB4C respectively overlap with the rigid element520at a middle portion MP between the edge EA and the opposite edge EB. Accordingly, a plurality of coarse structures may be formed at where the predetermined path LRP4is the projection areas of the coarse structures may overlap with the projection areas of the middle portion MP, the edge EA and the opposite edge EB of the rigid element520. In the present embodiment, either the edge EA or the edge EB can be an edge predetermined to subject the separating force prior to the other portion of the rigid element520. The step of removing the carrier as depicted inFIG. 26may be adopted in the present embodiment by applying the separating force in the direction DS or DS′, the portion of each rigid element520adjacent to the edge (EA or EB) may subject to the separating force prior to the other portion of the said rigid element520.

FIG. 37schematically illustrates the electronic device structure905formed by applying an energy beam along the predetermined path LRP5onto the electronic device structure500A depicted inFIG. 20. The present embodiment is similar to the embodiment depicted inFIG. 36. The predetermined path LRP5in the present embodiment includes a plurality of predetermined stripe areas LB5A, LB4B and LB5C. In other words, the path of applying an energy beam onto the electronic device structure905is linearly extended. The predetermined stripe areas LB5A respectively overlap with the rigid elements520at the edges EA, the predetermined stripe areas LB5B respectively overlap with the rigid elements520at the edge EB that is opposite to the edge EA correspondingly overlapped with the predetermined stripe area LB5A, and the predetermined stripe areas LB5C respectively overlap with the rigid element520at a middle portion MP between the edge EA and the opposite edge EB. Similar to the embodiment ofFIG. 36, either the edge EA or the edge EB can be the edge subjecting to the separating force prior to the other portion of the rigid element520in the step of removing the carrier540.

FIG. 38schematically illustrates the electronic device structure907having a plurality of sub regions907A, each sub region907A may be similar to the electronic device structure901and is subjected to the application of an energy beam along the predetermined path LRP3. In addition, the predetermined path LRP3in one sub region907A is not continuous to the predetermined path LRP3in an adjacent sub region907A.FIG. 39schematically illustrates the electronic device structure909having a plurality of sub regions909A, each sub region909A may be similar to the electronic device structure905and is subjected to the application of an energy beam along the predetermined stripe areas LB5A, LB5B and LB5C of the predetermined path LRP5. In addition, the predetermined path LRP5in one sub region909A is not continuous to the predetermined path LRP5in an adjacent sub region909A.

In the fabrication method of an electronic device structure of the embodiments of the disclosure, before the electronic device package is removed from the carrier, an energy beam application such as a laser irradiation step . . . etc. is first performed on the area having greater stiffness to reduce the separating force needed for this area. The fabrication method of an electronic device package may have a desirable yield. Moreover, the embodiments of the disclosure do not readily damage rigid element on the electronic device package, and the rigid element of the embodiments of the disclosure may have a desirable quality.

It will be clear that various modifications and variations may be made to the disclosed methods and materials. It is intended that the specification and examples be considered as exemplary only, with a true scope of the disclosure being indicated by the following claims and their equivalents.