Wiping device and stack manufacturing apparatus

An object is to eliminate a harmful effect when a film is bonded by wiping an adhering sealant (30a). Characterized is a wiping device (200) including a stage (230) that supports a sheet-like member (220), a wiping means (210) that wipes an adhering object (30a) adhering on a peripheral portion of the sheet-like member (220), a wiping cloth (241) that is attachably and detachably provided for the wiping means (210), and a solvent (261) that adheres to the wiping cloth (241), in which the wiping means (210) is provided with the wiping cloth (241), makes the solvent (261) adhere to the wiping cloth (241), and wipes the adhering object (30a), or a stack manufacturing apparatus (1000) including such a wiping device (200).

TECHNICAL FIELD

The present invention relates to, for example, a wiping device for wiping an adhering object that adheres in manufacturing a stack for a semiconductor device, a display device, a light-emitting device, a power storage device, a power generating device, and the like, or a stack manufacturing apparatus.

BACKGROUND ART

In recent years, a flexible device in which a functional element such as a semiconductor element, a display element, or a light-emitting element is provided over a substrate having flexibility (hereinafter also referred to as a flexible substrate) has been developed. Typical examples of the flexible device include a lighting device, an image display device, a variety of semiconductor circuits including a semiconductor element such as a transistor, and the like.

As a method for manufacturing a device using a flexible substrate, a technique has been developed in which a functional element such as a thin film transistor or an organic EL element is formed over a substrate such as a glass substrate or a quartz substrate, and then the functional element is transferred to a flexible substrate. This method needs a separation step of separating, from the substrate, a layer to be separated that includes the functional element.

For example, in a separation technique that is disclosed in Patent Document 1 and uses laser ablation, first, a separation layer including a layer containing tungsten, a layer containing tungsten oxide, and the like is provided over a substrate, a layer to be separated that includes a thin film element is provided over the separation layer, and the layer to be separated is made to adhere to a transfer body with the use of an adhesive layer. Then, the separation layer is ablated by laser light irradiation, so that separation is made to occur in the separation layer.

As a method for manufacturing a light-emitting device using a substrate having flexibility, a technique in which a separation layer is formed over a substrate, e.g., a glass substrate or a quartz substrate, a semiconductor element such as a thin film transistor is formed over the separation layer, and then, the semiconductor element is transferred to another substrate (e.g., a substrate having flexibility) has been developed (see Patent Document 1).

PRIOR ART DOCUMENT

Patent Document

SUMMARY OF THE INVENTION

Problems to be Solved by the Invention

Meanwhile, in the case of manufacturing a processed member90shown inFIG. 5(A-1), (A-2) andFIG. 7(A-1), (A-2) described below, the following occurs in some cases: when a first substrate11(e.g., a glass substrate), a first separation layer12existing thereunder and including a layer containing tungsten, a layer containing tungsten oxide, and the like, and a first layer to be separated13existing thereunder and including a thin film element in an upper part are pressure-bonded to a second substrate21(e.g., a glass substrate), a second separation layer22existing thereover and including a layer containing tungsten, a layer containing tungsten oxide, and the like, and a second layer to be separated23existing thereover and including a thin film element in a lower part with a bonding layer30positioned between them, part of a sealant of the bonding layer30flows out and adheres to one or more sides of one to four sides on the peripheral portion of the second substrate21and the second layer to be separated23in the lower part (see a sealant30ain a dashed-line region shown inFIG. 5(A-1)).

In such a case, separation of the first substrate11and the like in the upper part as shown inFIG. 5(C)causes the sealant to remain on one or more sides of the one to four sides on the peripheral portion of the second substrate21and the second layer to be separated23in the lower part.

Therefore, when a first adhesive layer31is formed in the state over the second substrate21, the second separation layer22, and the second layer to be separated23(that correspond to a first remaining portion and a sheet-like member) as shown inFIG. 5(D-1), difference in level is made on one or more sides of the one to four sides on the peripheral portion owing to the remaining sealant30a(for example, see a raised portion31ashown by a dashed line inFIG. 5(D-1)).

Accordingly, when a film-like first support body41is pressure-bonded to a top surface of the first adhesive layer31after that with the use of a roller as shown inFIG. 5(E-1), the roller cannot bond the first support body41uniformly because of the influence of the difference in level.

An object of the present invention is to eliminate a harmful effect when a first support body is pressure-bonded, by wiping a sealant that is an adhering object. An object is to provide a stack manufacturing apparatus with which a stack including a flexible substrate and a component such as a functional element formed over a substrate can be separated and transferred in a short period of time appropriately. Note that the descriptions of these objects do not disturb the existence of other objects.

Means for Solving the Problems

One embodiment of the present invention is a wiping device including a stage that supports a sheet-like member, a wiping means that wipes an adhering object adhering on a peripheral portion of the sheet-like member, a wiping cloth that is attachably and detachably provided for the wiping means, and a solvent that adheres to the wiping cloth, and the wiping means is provided with the wiping cloth, makes the solvent adhere to the wiping cloth, and wipes the adhering object.

Another embodiment of the present invention is a stack manufacturing apparatus including a first feeding unit that feeds a processed member, a support body feeding unit that feeds a first and a second support bodies, a first isolating unit that isolates a first remaining portion by separating one surface of the processed member, a first cleaning device that cleans the first remaining portion, a first bonding unit that bonds the first support body to the first remaining portion with a first adhesive layer, a first unloader unit that unloads a first stack including the first remaining portion and the first support body bonded with the first adhesive layer, a second feeding unit that feeds the first stack, a starting point formation unit that forms a separation starting point in the vicinity of an end portion of the first remaining portion and the first support body, a second isolating unit that isolates a second remaining portion by separating one surface of the first stack, a second bonding unit that bonds the second support body to the second remaining portion with a second adhesive layer, and a second unloader unit that unloads a second stack including the second remaining portion and the second support body bonded with the second adhesive layer. The first cleaning device includes a stage that supports a sheet-like member that is the first remaining portion, a wiping means that wipes an adhering object adhering on a peripheral portion of the sheet-like member, a wiping cloth that is attachably and detachably provided for the wiping means, and a solvent that adheres to the wiping cloth, in which the wiping means is provided with the wiping cloth, makes the solvent adhere to the wiping cloth, and wipes the adhering object.

Furthermore, the stack can be a stack whose upper and lower surfaces are each provided with a flexible substrate.

Effect of the Invention

With one embodiment of the present invention, when a flexible film is transferred to a sheet-like member or a first remaining portion from which a substrate is separated, the flexible film can be bonded approximately uniformly, and a function of the functional element can be prevented from being degraded.

Furthermore, since the wiping is performed using a solvent, a remaining sealant that is an adhering object can be removed easily. Furthermore, since the wiping cloth is replaced when wiping is performed, the remaining sealant can be removed appropriately. Furthermore, the use of a plurality of surfaces of a wiping cloth can reduce the frequency of wiping cloth replacement, and the processing takt can be improved accordingly.

Furthermore, a flexible stack can be manufactured efficiently in a short period of time using a stack manufacturing apparatus made by collecting various steps of isolating, from bonded upper and lower substrates, one of the substrates to form a first remaining portion, bonding a first flexible substrate to the first remaining portion, isolating the other substrate to form a second remaining portion, and bonding a second flexible substrate to the second remaining portion.

MODE FOR CARRYING OUT THE INVENTION

Embodiments will be described in detail with reference to the drawings. Note that the present invention is not limited to the description below, and modes and details thereof can be modified in various ways without departing from the spirit and the scope the present invention. Therefore, the present invention should not be interpreted as being limited to the description of embodiments below. Note that in structures of the invention described below, the same portions or portions having similar functions are denoted by the same reference numerals in different drawings, and description thereof is not repeated in some cases.

In this embodiment, a wiping device of one embodiment of the present invention will be described. One embodiment of the present invention can be used in a step before transferring a component including a functional element and the like formed over a substrate to a flexible substrate. For example, it can be used in a step of cleaning a remaining portion (corresponding to a first remaining portion or a sheet-like member) after separating, from a processed member in which the component is provided between upper and lower substrates, one of the substrates. Although it is preferable to use a rigid substrate such as a glass substrate as the substrate, it is also possible to use a flexible substrate of resin or the like.

FIG. 1is a perspective view illustrating the wiping device of one embodiment of the present invention. (A) is a schematic perspective view of the whole thereof, (B1) is a perspective view of a wiping portion at the tip thereof, and (B2) is a cross-sectional view showing a state where a wiping cloth is attached to or detached from the wiping portion.FIG. 2is a drawing showing a state of attaching a wiping cloth to the wiping portion ((A) to (D)), making a solvent adhere to the wiping cloth ((F)), removing an excess amount of the solvent ((E)), wiping the sealant with the wiping cloth ((G)), and disposing of the wiping cloth ((H)).FIG. 3is a drawing showing various wiping modes of wiping a sealant with the wiping portion ((A1) to (B3)) and various wiping surfaces of the wiping cloth ((C)).

A wiping device200includes a wiping means210, a sheet-like member220, a stage230, a wiping cloth storage container240for storing a wiping cloth241, a wiping cloth disposal container250in which the wiping cloth241is disposed of, a solvent container260for storing a solvent261, and an excess solvent removal container270for removing an excess amount of the solvent261.

The wiping means210is a kind of robot including a plurality of link portions211, a plurality of joint portions212, a power portion213formed of a motor or the like, and a wiping portion215at its tip, and the wiping portion215at its tip is driven in various directions rotatably by a control device not shown.

The wiping portion215at its tip includes a main body portion216and a folded member218. The main body portion216is attached to the tip of the wiping means210and includes open and close nails217on its right and left side surfaces as shown inFIG. 1(B2); tip portions of the open and close nails217are opened and closed in the shape like a Japanese katakana letter “ha” with upper end portions thereof used as pivots. The wiping cloth241is clamped in a close state (seeFIG. 1(B1)), and the wiping cloth is disposed of in an open state (seeFIG. 2(H)). Note that the folded member218is an object folded in two, and it is possible to use fluorine-based rubber, a fluorine-based resin, or the like, specifically a perfluoroelastomer.

The folded member218is attached to the tip of the main body portion216. The attachment is performed in such a manner that upper right and upper left end portions of the folded member218that is folded into a U-like shape are fitted onto step portions216aformed in lower external surfaces of the main body portion216, and portions of contact therebetween are bonded with an adhesive, for example.

As a result, an external surface of the main body portion216and an external surface of the folded member218are made flush with each other. Furthermore, the folded member218takes the shape folded into a U-like shape in its cross section with a hollow portion218aprovided inside. The whole thereof has elasticity; it is deformed by being pressed and returns to its original state, i.e., a state ofFIG. 1(B2) when the pressing is canceled. A state where the wiping cloth241is clamped is shown inFIG. 1(B1).

The sheet-like member220is a rectangular member placed on the stage230. An example of the sheet-like member220is a first remaining portion90a, such as that shown inFIG. 5described below, from which the first substrate11is separated and in which a component including a functional element and the like is stacked on the second substrate21having the sealant30aremaining as an adhering object on its peripheral surface. The sheet-like member220is placed on the stage230with a surface provided with the sealant30aremaining in the vicinity of four sides on the peripheral portion thereof facing upward, and a lower surface thereof is fixed to an upper surface of the stage230by a suction means utilizing vacuum that is provided for the stage230. Note that the sheet-like member220is not limited to the above-described object and may be any as long as an adhering object such as the sealant30aadheres thereon.

The wiping cloth storage container240is a rectangular container whose upper portion is opened, and a plurality of rectangular wiping cloths241made of nonwoven fabric or the like and folded in two are stored inside (seeFIG. 2(A)). Note that the container may have any shape.

The wiping cloth disposal container250is a rectangular container whose upper portion is opened, and the wiping cloth241after being used is disposed of therein (seeFIG. 2(H)). Note that the container may have any shape.

The solvent container260is a circular container whose upper portion is opened, and the solvent261is put therein (seeFIG. 2(F)). Note that the solvent261is, for example, an organic solvent such as acetone and is removed by melting the sealant. Furthermore, the container may have any shape.

The excess solvent removal container270is a circular container whose upper portion is opened, and a wire mesh271is provided horizontally in a portion of the opening. The wiping portion215with the solvent261is struck against the wire mesh271several times to separate and remove an excess amount of the solvent261, and the removed solvent261is stored in the excess solvent removal container270(seeFIG. 2(E)). Note that the container may have any shape.

The procedure of a wiping operation is described with reference toFIG. 2. Prepared is a wiping cloth extraction means280from which a plurality of suction members281utilizing vacuum hang down. The wiping cloth extraction means280is moved to a position above the wiping cloth storage container240, and an uppermost wiping cloth241therein is extracted by being sucked with the suction members281(seeFIG. 2(A)).

Then, the wiping cloth extraction means280is moved to a position above a wiping cloth mount290, and the wiping cloth241is dropped onto a top surface of the wiping cloth mount290by canceling the vacuum in the suction members281. A U-like-shaped opening291is provided in the top surface of the wiping cloth mount290, and the wiping cloth241lies along an upper portion of the U-like-shaped opening291(seeFIG. 2(B)).

Then, the wiping portion215is moved to a position above the wiping cloth mount290and moved downward, whereby the folded member218of the wiping portion215is inserted into the U-like-shaped opening291along with the wiping cloth241. At this time, the open and close nails217are in an open state (seeFIG. 2(C)).

Then, the wiping portion215is completely inserted into the U-like-shaped opening291. This makes the wiping cloth241have a U-like shape along the folded member218, and accordingly, the open and close nails217are closed to clamp end portions of the wiping cloth241. After that, the wiping portion215is moved upward (seeFIG. 2(D)).

Then, the wiping portion215is moved to a position above the solvent container260and moved downward to make the solvent261therein adhere to the wiping cloth241(seeFIG. 2(F)).

Then, the wiping portion215is moved to a position above the excess solvent removal container270and moved downward, and the wiping cloth241with the solvent261is struck against the wire mesh271to remove an excess amount of the solvent261. The amount of solvent necessary for one wiping action, an adhesion amount that adheres in a single adhesion action, and an amount that can be separated with predetermined pressing force applied at a time are obtained in advance. The number of times that the wiping cloth241would strike against the wire mesh271is obtained from the amounts, and striking is repeated the number of times obtained in directions indicated by an arrow shown in the drawing (seeFIG. 2(E)).

Then, the wiping portion215is moved to a position above the sealant30aof the sheet-like member220and moved downward, and wiping is performed with the wiping cloth241in any of the various wiping modes shown inFIG. 3(seeFIG. 2(G)). Note that the wiping is performed with predetermined pressure applied. In this case, the folded member218is slightly deformed owing to its elasticity, and the area of the wiping cloth241contacting the sealant30ais increased accordingly; thus, smooth movement is achieved and a removal effect is improved.

Then, the wiping portion215is moved to a position above the wiping cloth disposal container250, and the wiping cloth241after being used is disposed of in the wiping cloth disposal container250by releasing the open and close nails217(seeFIG. 2(H)).

Note that while these steps are performed, the steps ofFIG. 2(A), (B) in a next process are already performed. After the step ofFIG. 2(H)is finished, the wiping portion215performs the step ofFIG. 2(C), i.e., another wiping cloth241is clamped to wipe the sealant30ain a next wiping region. Accordingly, time for attaching the wiping cloth241can be shortened.

The wiping modes are described usingFIG. 3. The roots of solid arrows shown inFIG. 3(A1) to (B3) are each referred to as a front side, and the directions thereof are each referred to as a front direction. The tips of the solid arrows are each referred to as a back side, and the directions thereof are each referred to as a back direction. The sides shown by a dashed arrow (seeFIG. 3(A1)) substantially orthogonal to the solid arrow are referred to as left and right sides, and the directions thereof are referred to as left and right directions. Note that the wiping cloth241is moved in the front directions from a side a to a side d through a side b and a side c indicated by the solid arrows to wipe the sealant30a.

Furthermore, after the sealant30ain a predetermined region is wiped with a predetermined wiping surface of the wiping cloth241of the wiping portion215, the sealant30ain another region is not wiped by the same wiping surface.

In that case, the predetermined region is determined in advance in accordance with a remaining amount of the sealant30a. When the remaining amount is large, the predetermined region is any one of the sides a, b, c, and d shown inFIG. 3(A1), for example. When the remaining amount is small, the predetermined region is the four sides a to d, the two sides a and b, or the two sides c and d shown inFIG. 3(A1), for example.

(1) Example of One Wiping Action

In this example, after the sealant30ain a predetermined region is wiped with a predetermined wiping surface of the wiping cloth241, the wiping cloth241is disposed of. In the case of this example, as mainly shown inFIG. 3(B1), wiping is performed with the same wiping cloth241located in a lower end region of the wiping portion215with the wiping portion215set substantially orthogonal to and substantially perpendicular to the sealant30a.

Therefore, the width in the left and right directions of the wiping cloth241is substantially half that shown inFIG. 3(C); however, for example, in the case where a region to be wiped with the wiping cloth241is any one of the sides a, b, c, and d, four cloths are necessary and it takes replacement time accordingly. Note that the wiping portion215is rotated 90° every time the wiping of one side is finished, and the same applies to all of the following cases.

(2) Example of Two Wiping Actions

In this example, as shown inFIG. 3(A1), first, the sealant30ain a predetermined region, e.g., on the sides a and b, is wiped with a wiping surface on the left side (shaded region) (corresponding to the same wiping surface) of the wiping cloth241, and then, the wiping portion215is moved to the right side, and after the sealant30ain another predetermined region, e.g., on the sides c and d, is wiped with a wiping surface on the right side (white region) (corresponding to another wiping surface) of the wiping cloth241, the wiping cloth241is disposed of.

Therefore, the width in the left and right directions of the wiping cloth241is substantially twice the case of the above-described one wiping action as that shown inFIG. 3(C); however, the replacement time is reduced half and the processing takt is improved, whereby the productivity is improved. Note that in the case of this example, as mainly shown inFIG. 3(B1), wiping is performed with the wiping cloth241located in the lower end region of the wiping portion215with the wiping portion215set substantially orthogonal to and substantially perpendicular to the sealant30a.

(3) Example of Four Wiping Actions

In this example, as shown inFIG. 3(C), a wiping surface of the wiping cloth241is divided into a front right surface e (corresponding to a surface on the front side and the right side), a front left surface f (corresponding to a surface on the front side and the left side), a back right surface g (corresponding to a surface on the back side and the right side), and a back left surface h (corresponding to a surface on the back side and the left side). The wiping portion215is moved to the front right side, and first, the sealant30ain a predetermined region, e.g., on the side a, is wiped with the front right surface e of the wiping cloth241. The wiping portion215is moved to the front left side, and the sealant30ain another predetermined region, e.g., on the side b, is wiped with the front left surface f of the wiping cloth241. The wiping portion215is moved to the back right side, and the sealant30ain another predetermined region, e.g., on the side c, is wiped with the back right surface g of the wiping cloth241. The wiping portion215is moved to the back left side, and the sealant30ain another predetermined region, e.g., on the side d, is wiped with the back left surface h of the wiping cloth241. After that, the wiping cloth241is disposed of.

Therefore, as compared with the case of the above-described two wiping actions, the replacement time is reduced half, the processing takt is further improved, and the productivity is further improved. Note that in the case of this example, the wiping portion215is used while being inclined to the front as shown inFIG. 3(B2) when the front right surface e and the front left surface f of the wiping cloth241are used, and the wiping portion215is used while being inclined to the back as shown inFIG. 3(B3) when the back right surface g and the back left surface h of the wiping cloth241are used. Furthermore, the movement in the left and right directions is the same as that in the case of the above-described two wiping actions.

(4) Example of a Plurality of Wiping Actions

Although not shown, for example, the case of three wiping actions can be achieved by utilizing the three wiping surfaces of the case of the example of four wiping actions. Furthermore, by providing more than two regions on the left and right, i.e., three or more regions, as regions on the left and right sides of the wiping cloth241, a plurality of wiping actions can be achieved.

(5) Example of Oblique Wiping

In this example, as shown inFIG. 3(A2), a predetermined region is wiped with the wiping cloth241inclined, and then, the wiping cloth241is disposed of Specifically, a wiping surface of the wiping cloth241straddles the sealant30afrom an inside to an outside and is inclined such that an inner side (the shaded region side) precedes an outer side (the white region side).

When the sealant30ais wiped in such a mode, the sealant30aand the like that are wiped off are scraped to the outside, which can reduce a harmful effect of the entry of the sealant30aand the like into the sheet-like member220that would adversely affect the functional element and the like. Note that this example is applicable to any of the above-described examples (1) to (4).

In the case where a flexible film (corresponding to the first support body) is bonded onto a component including a functional element and the like and a substrate with an adhesive layer therebetween, the flexible film can be bonded more uniformly by using the wiping device of one embodiment of the present invention as above.

Note that this embodiment can be combined with the other embodiments in this specification as appropriate.

In this embodiment, a stack manufacturing apparatus including the wiping device described in Embodiment 1 is described. Note that there is no limitation on the usage of the manufacturing apparatus. It is useful to use the manufacturing apparatus in a manufacturing process of, in particular, a semiconductor device, a display device, a light-emitting device, a power storage device, a power generating device, or the like with a flexible substrate.

FIG. 4is a schematic view illustrating a structure of a stack manufacturing apparatus1000of one embodiment of the present invention, and the conveyance path of a processed member and a stack in a process.

FIG. 5andFIG. 6show schematic views illustrating a process for manufacturing a stack with the use of the stack manufacturing apparatus1000of one embodiment of the present invention. Cross-sectional views showing structures of a processed member and a stack are shown inFIG. 5(A-1),FIG. 5(B-1),FIG. 5(C),FIG. 5(D-1),FIG. 5(E-1),FIG. 6(A-1),FIG. 6(B),FIG. 6(C),FIG. 6(D-1),FIG. 6(E-1), and top views corresponding thereto are shown inFIG. 5(A-2),FIG. 5(B-2),FIG. 5(D-2),FIG. 5(E-2),FIG. 6(A-2),FIG. 6(D-2),FIG. 6(E-2) excludingFIG. 5(C),FIG. 6(B), andFIG. 6(C).

The stack manufacturing apparatus1000described in this embodiment includes a first feeding unit100, a first isolating unit300, a first cleaning device350, a first bonding unit400, a support body feeding unit500, a second feeding unit600, a starting point formation unit700, a second isolating unit800, and a second bonding unit900. Note that each unit is named freely, and the name does not limit the function of each unit.

The following describes individual components included in the stack manufacturing apparatus of one embodiment of the present invention.

The first feeding unit100feeds the processed member90(seeFIG. 5(A-1) andFIG. 7(A-1), (A-2)). For example, the first feeding unit100can include a multistage storage capable of storing a plurality of processed members90to allow a conveying means111to convey the processed members90successively.

Furthermore, the first feeding unit100described in this embodiment also serves as a first unloader unit. The first feeding unit100unloads a stack91(corresponding to a first stack) (seeFIG. 5(E-1)) including the first remaining portion90a, the first adhesive layer31, and the first support body41bonded with the first adhesive layer31. For example, the first feeding unit100can include a multistage storage capable of storing a plurality of stacks91to allow the conveying means111to convey the stacks91successively.

The first isolating unit300includes a means of sucking one surface of the processed member90and a means of sucking the other surface facing the one surface. Each of the suction means is pulled away, whereby the one surface of the processed member90is separated to isolate the first remaining portion90a(seeFIG. 4andFIG. 5(A-1) toFIG. 5(C)).

The first cleaning device350removes a sealant remaining on any one or more sides (e.g., two to four sides) of one to four sides on the peripheral portion of the first remaining portion90aby the wiping device described in Embodiment 1. Note that this step corresponds to one embodiment of the present invention. For the detailed description thereon, Embodiment 1 can be referred to.

The first bonding unit400includes a means of forming the first adhesive layer31and a pressure-bonding means of bonding the first remaining portion90aand the first support body41to each other with the use of the first adhesive layer31(seeFIG. 4andFIG. 5(D-1) toFIG. 5(E-2)).

Examples of the means of forming the first adhesive layer31include a dispenser for applying a liquid adhesive and a device feeding an adhesive sheet shaped as a sheet in advance.

Note that the first adhesive layer31may be formed on the first remaining portion90aand/or the first support body41. Specifically, a method of using the first support body41on which the first adhesive layer31is formed in advance may be used. Furthermore, although proper control is made to prevent a material of the first adhesive layer31from being squeezed out and adhering to a peripheral surface of the substrate and the first support body41, in the case where it is squeezed out, it can be wiped using an organic solvent such as acetone, a cloth, or the like.

Examples of the pressure-bonding means of bonding the first remaining portion90ato the first support body include pressure-applying means such as a pair of rollers, a flat plate and a roller, and a pair of facing flat plates that are controlled to provide a constant pressure or a uniform gap.

The support body feeding unit500feeds the first support body41. For example, a film which is fed in a rolled shape is unrolled and cut to a predetermined length, a surface of the film is activated by UV or the like, and the film is fed as the first support body41.

The second feeding unit600can feed the stack91. Note that the second feeding unit600can also serve as a second unloader unit, and the same structure as the first feeding unit can be used for the second feeding unit600. That is, a stack92(corresponding to a second stack) including a second remaining portion91aand a second support body42bonded to each other with a second adhesive layer32is unloaded (seeFIG. 4andFIG. 6(E-1), (E-2)).

The starting point formation unit700forms a separation starting point91sin the vicinity of end portions of the first remaining portion90aand a first support body41bin the stack91(seeFIG. 6(A-1) andFIG. 6(A-2)). A cutting means of cutting the first support body41and the first adhesive layer31and separating part of the second layer to be separated23from the second separation layer22is included, for example.

Specifically, the cutting means includes one or a plurality of blades which have a sharp tip, and relatively moves the blade to the stack91.

The second isolating unit800separates one surface91bof the stack91to isolate the second remaining portion91a(seeFIG. 6(B)). To achieve this, a means of sucking the one surface of the stack91and a means of sucking the other surface facing the one surface are provided. The two suction means are pulled away, whereby the one surface of the stack91is separated to isolate the second remaining portion91a.

The second bonding unit900includes a means of forming the second adhesive layer32and a pressure-bonding means of bonding the second remaining portion91aand the second support body42to each other with the use of the second adhesive layer32. That is, the second support body42is fed, and the second support body42is bonded to the second remaining portion91awith the use of the second adhesive layer32(seeFIG. 6(D-1) toFIG. 6(E-2)).

The means of forming the second adhesive layer32can have a structure similar to that of the first bonding unit400, for example.

Note that the second adhesive layer32may be formed on the second remaining portion91aand/or the second support body42. Specifically, a method of using the second support body42on which the second adhesive layer32is formed in advance may be used.

The pressure-bonding means of bonding the second remaining portion91aand the second support body42to each other can have a structure similar to that of the first bonding unit400, for example.

As described above, the stack manufacturing apparatus includes “the first feeding unit100that feeds the processed member90, unloads the stack91including the first remaining portion90aand the first support body41bonded to each other with the first adhesive layer31, and also serves as an unloader unit”, “the first isolating unit300that isolates the first remaining portion90a”, “the first cleaning device350that wipes the remaining sealant”, “the first bonding unit400that bonds the first support body41to the first remaining portion90a”, “the support body feeding unit500that feeds the first support body41and the second support body42”, “the second feeding unit600that feeds the stack91and unloads the stack92including the second remaining portion91a, the second adhesive layer32, and the second support body42bonded with the second adhesive layer32”, “the starting point formation unit700that forms the separation starting point”, “the second isolating unit800that isolates the second remaining portion91a”, and “the second bonding unit900that bonds the second support body42to the second remaining portion91a”.

With these structures, both of the surfaces of the processed member90can be separated, the second remaining portion91acan be isolated, and the first support body41and the second support body42can be bonded to it. As a result, an apparatus for manufacturing a stack including a support body and a remaining portion of a processed member can be provided.

Furthermore, the stack manufacturing apparatus1000described in this embodiment includes a first storage portion300b, a second storage portion800b, a second cleaning device850, the conveying means111, a conveying means112, and the like.

Furthermore, the first storage portion300bstores one surface90bseparated from the processed member90; the second storage portion800bstores the one surface91bseparated from the stack91; the second cleaning device850cleans the second remaining portion91aisolated from the stack91; the conveying means111conveys the processed member90, the first remaining portion90aisolated from the processed member90, and the stack91; and the conveying means112conveys the stack91, the second remaining portion91aisolated from the stack91, and the stack92. In this manner, the devices are collected, and the processed member and the like are transferred by the two conveying devices, whereby the whole manufacturing apparatus can be downsized, the production time can be shortened, and the production cost can be reduced.

Next, a method for manufacturing the stack92from the processed member90with the use of the stack manufacturing apparatus1000is described below with reference toFIG. 4toFIG. 6.

The processed member90includes the first substrate11that is made of glass or the like; the first separation layer12that is on the first substrate11and includes a layer containing tungsten, a layer containing tungsten oxide, and the like; the first layer to be separated13that includes one surface in contact with the first separation layer12and includes a functional element and the like; the bonding layer30that includes one surface in contact with the other surface of the first layer to be separated13; the second layer to be separated23that includes one surface in contact with the other surface of the bonding layer30and includes a functional element and the like; the second separation layer22that includes one surface in contact with the other surface of the second layer to be separated23and includes a layer containing tungsten, a layer containing tungsten oxide, and the like; and the second substrate21that is on the second separation layer22and made of glass or the like (seeFIG. 5(A-1), (A-2)).

Note that the sealant30ainFIG. 5(A-1) shows a part of the bonding layer30that is squeezed out in pressure-bonding. One embodiment of the present invention wipes the sealant30athat is thus squeezed out and remains on the first remaining portion90a. Furthermore, the raised portion31ashown inFIG. 5(D-1) is a portion that is raised owing to the remaining sealant30awhen the first adhesive layer31is formed over the first remaining portion90a. The raised portion31acan be eliminated by implementing one embodiment of the present invention.

In this embodiment, description is given of the case of using the processed member90in which the separation starting points13sare formed in advance in the vicinity of end portions of the bonding layer30(seeFIG. 5(B-1), (B-2)). Furthermore, a structure of the processed member90is described in detail in Embodiment 3.

The processed member90is loaded into the first feeding unit100. The first feeding unit100feeds the processed member90, and the conveying means111conveys and feeds the processed member90to the first isolating unit300.

The first isolating unit300separates the one surface90bof the processed member90. Specifically, from the separation starting points13sformed in the vicinity of the end portions of the bonding layer30, the first substrate11is isolated from the first layer to be separated13together with the first separation layer12(seeFIG. 5(C)).

Through this step, the first remaining portion90ais obtained from the processed member90. Specifically, the first remaining portion90aincludes the first layer to be separated13; the bonding layer30including one surface in contact with the first layer to be separated13; the second layer to be separated23including one surface in contact with the other surface of the bonding layer30; the second separation layer22one surface in contact with the other surface of the second layer to be separated23; and the second substrate21on the second separation layer22.

Then, the first cleaning device350wipes the sealant30athat is squeezed out and remains on the periphery of the first remaining portion90awith the wiping means of one embodiment of the present invention. As a result, the raised portion31ashown inFIG. 5(D-1) is eliminated.

The conveying means111conveys the first remaining portion90a, and the support body feeding unit500feeds the first support body41.

Then, the first bonding unit400forms the first adhesive layer31on the fed first remaining portion90a(seeFIG. 5(D-1), (D-2)) and bonds the first remaining portion90ato the first support body41with the use of the first adhesive layer31.

Through this step, the stack91is obtained from the first remaining portion90a. Specifically, the stack91includes the first support body41, the first adhesive layer31, the first layer to be separated13, the bonding layer30including one surface in contact with the first layer to be separated13, the second layer to be separated23including one surface in contact with the other surface of the bonding layer30, the second separation layer22including one surface in contact with the other surface of the second layer to be separated23, and the second substrate21on the second separation layer22(seeFIG. 5(E-1), (E-2)).

The conveying means111conveys the stack91, and the stack91is fed to the first feeding unit100also serving as a first unloader unit.

Through this step, the stack91can be unloaded. For example, when it takes time to cure the first adhesive layer31, it is possible to unload the stack91in which the first adhesive layer is not cured yet and cure the first adhesive layer31outside the stack manufacturing apparatus1000. Thus, occupancy time of the apparatus can be reduced.

The stack91is loaded into the second feeding unit600. The second feeding unit600feeds the stack91, and the conveying means112conveys and feeds the stack91to the starting point formation unit700.

The starting point formation unit700forms the second separation starting point91sby separation, from the second separation layer22, part of the second layer to be separated23in the vicinity of the end portions of the first adhesive layer31of the stack91.

For example, the first support body41and the first adhesive layer31are cut from a side where the first support body41is provided, and the second layer to be separated23is partly separated from the second separation layer22.

Specifically, the first adhesive layer31and the first support body41in a region which is over the separation layer22and in which the second layer to be separated23is provided are cut to draw a closed curve with a blade or the like provided with a sharp tip, and along the closed curve, the second layer to be separated23is partly separated from the second separation layer22(seeFIG. 6(A-1), (A-2)).

Through this step, the separation starting point91sis formed in the vicinity of the end portions of the first support body41band the first adhesive layer31that are cut out.

The second isolating unit800separates the second remaining portion91afrom the stack91. Specifically, from the separation starting point formed in the vicinity of the end portions of the bonding layer30, the second substrate21is isolated from the second layer to be separated23together with the second separation layer22(seeFIG. 6(C)).

Through this step, the second remaining portion91ais obtained from the stack91. Specifically, the second remaining portion91aincludes the first support body41b, the first adhesive layer31, the first layer to be separated13, the bonding layer30including one surface in contact with the first layer to be separated13, and the second layer to be separated23including one surface in contact with the other surface of the bonding layer30.

The conveying means112conveys the second remaining portion91a, and turns the second remaining portion91asuch that the second layer to be separated23faces upward. The second cleaning device850cleans the fed second remaining portion91ausing water or the like.

The conveying means112conveys the cleaned second remaining portion91ato the second bonding unit900, and the support body feeding unit500feeds the second support body42. Note that the second remaining portion91amay be directly fed to the second bonding unit900without being fed to the second cleaning device850.

The second bonding unit900forms the second adhesive layer32on the fed second remaining portion91a(seeFIG. 6(D-1), (D-2)) and bonds the second remaining portion91ato the second support body42with the use of the second adhesive layer32(seeFIG. 6(E-1), (E-2)).

Through this step, the stack92is obtained from the second remaining portion91a. Specifically, the stack92includes the first layer to be separated13, the first support body41bbonded to one surface of the first layer to be separated13with the use of the first adhesive layer31, the bonding layer30including one surface in contact with the other surface of the first layer to be separated13, the second layer to be separated23including one surface in contact with the other surface of the bonding layer30, and the second support body42bonded to the other surface of the second layer to be separated23with the use of the second adhesive layer32.

The conveying means112conveys the stack92, and the stack92is fed to the second feeding unit600also serving as a second unloader unit. Through this step, the stack92can be unloaded.

In this embodiment, a structure of a processed member that can be used for the stack manufacturing apparatus of one embodiment of the present invention is described with reference toFIG. 7.

FIG. 7shows schematic views illustrating a structure of a processed member that can be used to form a stack with the use of the stack manufacturing apparatus of one embodiment of the present invention.FIG. 7(A-1) is a cross-sectional view illustrating a structure of the processed member90, andFIG. 7(A-2) is a top view corresponding thereto.

The processed member90includes the first substrate11, the first separation layer12on the first substrate11, the first layer to be separated13including one surface in contact with the first separation layer12, the bonding layer30including one surface in contact with the other surface of the first layer to be separated13, the second layer to be separated23in contact with the other surface of the bonding layer30, the second separation layer22including one surface in contact with the other surface of the second layer to be separated23, and the second substrate21on the second separation layer22(seeFIG. 7(A-1), (A-2)). Note that the separation starting points13smay be provided in the vicinity of the end portions of the bonding layer30.

There is no particular limitation on the first substrate11as long as the first substrate11has heat resistance high enough to withstand a manufacturing process and a thickness and a size which can be used in a manufacturing apparatus. As a material that can be used for the first substrate11, glass, a ceramic, a metal, an inorganic material, resin, or the like can be given, for example.

Specifically, as the glass, non-alkali glass, soda-lime glass, potash glass, crystal glass, or the like can be given. As the metal, SUS, aluminum, and the like can be given.

The first substrate11may have a single-layer structure, a stacked-layer structure, or the like. For example, a structure in which a base and an insulating layer that prevents diffusion of impurities contained in the base are stacked may be employed. Specifically, a structure can be employed in which glass and various base layers that prevent diffusion of impurities contained in the glass, such as a silicon oxide layer, a silicon nitride layer, and a silicon oxynitride layer, are stacked.

There is no particular limitation on the first separation layer12as long as the first separation layer12achieves separation of the first layer to be separated13formed on the first separation layer12and has heat resistance high enough to withstand the manufacturing process. As a material that can be used for the first separation layer12, an inorganic material, an organic resin, or the like can be given.

Specifically, as the inorganic material, a metal containing an element selected from tungsten, molybdenum, titanium, tantalum, niobium, nickel, cobalt, zirconium, zinc, ruthenium, rhodium, palladium, osmium, iridium, and silicon, an alloy containing the element, a compound containing the element, and the like can be given.

Specifically, as the organic resin, polyimide, polyester, polyolefin, polyamide, polycarbonate, an acrylic resin, or the like can be given.

The structure that can be used for the first separation layer12may have a single-layer structure, a stacked-layer structure, or the like. For example, a stacked-layer structure including a layer containing tungsten and a layer containing an oxide of tungsten can be employed.

The layer containing an oxide of tungsten may be a layer formed by a method in which another layer is stacked with a layer containing tungsten; for example, the layer containing an oxide of tungsten may be formed by stacking a film containing oxygen, such as silicon oxide or silicon oxynitride, with a layer containing tungsten.

The layer containing an oxide of tungsten may be formed by performing thermal oxidation treatment, oxygen plasma treatment, nitrous oxide (N2O) plasma treatment, treatment with a solution having strong oxidizing power such as ozone water, or the like on a surface of a layer containing tungsten.

<<First Layer to be Separated>>

There is no particular limitation on the first layer to be separated13as long as the first layer to be separated13can be separated from the first separation layer12and has heat resistance high enough to withstand the manufacturing process.

As a material that can be used for the first layer to be separated13, an inorganic material, an organic resin, or the like can be given.

The first layer to be separated13may have a single-layer structure, a stacked-layer structure, or the like. For example, a structure may be included in which a functional layer overlapping with the first separation layer12and an insulating layer that is provided between the first separation layer12and the functional layer to prevent diffusion of impurities which impair the characteristics of the functional layer are stacked. Specifically, a structure can be employed in which a silicon oxynitride layer, a silicon nitride layer, and the functional layer are sequentially stacked from the first separation layer12side.

As the functional layer that can be used for the first layer to be separated13, a functional circuit, a functional element, an optical element, a functional film, or the like, or a layer including two or more selected from these can be given. Specifically, a pixel circuit of a display device, a driver circuit of a pixel, a display element, a color filter, a moisture-resistant film, or the like that is publicly known, or a layer including two or more selected from these can be given.

There is no particular limitation on the bonding layer30as long as the bonding layer30bonds the first layer to be separated13and the second layer to be separated23to each other. As a material that can be used for the bonding layer30, an inorganic material, an organic resin, or the like can be given.

Specifically, a glass layer with a melting point of 400° C. or lower, preferably 300° C. or lower, an adhesive, or the like can be used.

As the sealant that can be used for the bonding layer30, a photocurable adhesive such as a UV curable adhesive, a reactive curable adhesive, a thermosetting adhesive, an anaerobic adhesive, and the like can be given.

Examples thereof include an epoxy resin, an acrylic resin, a silicone resin, a phenol resin, a polyimide resin, an imide resin, a PVC (polyvinyl chloride) resin, a PVB (polyvinyl butyral) resin, and an EVA (ethylene vinyl acetate) resin.

In the processed member90, the separation starting points13smay be provided in the vicinity of the end portions of the bonding layer30. The separation starting points13shave a structure where part of the first layer to be separated13is separated from the first separation layer12.

The separation starting points13scan be formed by inserting a sharp tip into the first layer to be separated13from the first substrate11side or by separating part of the first layer to be separated13from the first separation layer12by a noncontact method using a laser or the like (e.g., a laser ablation method).

As the second substrate21, the same substrate as the first substrate11can be used. Note that the second substrate21and the first substrate11do not need to have the same structure.

As the second separation layer22, the same layer as the first separation layer12can be used. Note that the second separation layer22and the first separation layer12do not need to have the same structure.

<<Second Layer to be Separated>>

As the second layer to be separated23, the same structure as the first layer to be separated13can be used. Alternatively, the second layer to be separated23can have a structure different from that of the first layer to be separated13. For example, a structure may be employed in which the first layer to be separated13includes a functional circuit and the second layer to be separated23includes a functional layer that prevents diffusion of impurities into the functional circuit.

Specifically, a structure may be employed in which the first layer to be separated13includes a pixel circuit of a display device, a driver circuit of a pixel circuit, and a light-emitting element that is connected to the pixel circuit and emits light to the second layer to be separated23, and the second layer to be separated23includes a color filter and a moisture-resistant film.

REFERENCE NUMERALS