Source: http://www.google.com/patents/US7038213?dq=6,360,693
Timestamp: 2015-02-28 14:36:24
Document Index: 316768957

Matched Legal Cases: ['art 13', 'art 13', 'art 13', 'art 13', 'art 13', 'arts 13', 'arts 13', 'arts 13', 'art 13']

Patent US7038213 - Composite active-matrix substrates, methods for manufacturing same, and ... - Google PatentsSearch Images Maps Play YouTube News Gmail Drive More »Sign inAdvanced Patent SearchPatentsA composite active-matrix substrate includes: a plurality of active-matrix substrates which are disposed adjacent to one another; a base substrate which is disposed to oppose a bottom surface of the active-matrix substrates; a sealant which is disposed in the form of a frame between the active-matrix...http://www.google.com/patents/US7038213?utm_source=gb-gplus-sharePatent US7038213 - Composite active-matrix substrates, methods for manufacturing same, and electromagnetic wave capturing devicesAdvanced Patent SearchPublication numberUS7038213 B2Publication typeGrantApplication numberUS 10/850,314Publication dateMay 2, 2006Filing dateMay 19, 2004Priority dateMay 10, 2001Fee statusLapsedAlso published asUS6759660, US20020168793, US20040211910Publication number10850314, 850314, US 7038213 B2, US 7038213B2, US-B2-7038213, US7038213 B2, US7038213B2InventorsYoshihiro Izumi, Osamu TeranumaOriginal AssigneeShimadzu Corporation, Sharp Kabushiki KaishaExport CitationBiBTeX, EndNote, RefManPatent Citations (15), Non-Patent Citations (1), Referenced by (3), Classifications (31), Legal Events (4) External Links: USPTO, USPTO Assignment, EspacenetComposite active-matrix substrates, methods for manufacturing same, and electromagnetic wave capturing devices
US 7038213 B2Abstract
1. A composite active-matrix substrate, comprising:
a plurality of active-matrix substrates, each having a top surface with an active element, which are disposed adjacent to one another so that the top surfaces of the active-matrix substrates make up a substantially level surface;
a base substrate, which is provided so as to oppose a bottom surface of the active-matrix substrates;
a gel sticking material as a first adhesive filler, which is provided to fill substantially a gap extending near a periphery of the active-matrix substrate between the bottom surface of each active-matrix substrate and the base substrate, for combining each active-matrix substrate with the base substrate; and
a second adhesive filler, which fills a gap between edges of the active-matrix substrates which are disposed adjacent to one another.
2. The composite active-matrix substrate as set forth in claim 1, wherein the gel sticking material is a silicon gel.
3. The composite active-matrix substrate as set forth in claim 1, wherein the second adhesive filler is an adhesive resin which is curable in the presence of air.
4. The composite active-matrix substrate as set forth in claim 1, wherein the base substrate has no holes formed therethrough.
5. The composite active-matrix substrate as set forth in claim 1, wherein the second adhesive filler fills the gap between edges of the active-matrix substrates to a level below the surface of the active-matrix substrates.
6. A composite active-matrix substrate, comprising:
a gel sticking material as a first adhesive filler, which is provided between the bottom surface of each active-matrix substrate and the base substrate, for combining each active-matrix substrate with the base substrate;
a second adhesive filler, which fills a gap between edges of the active-matrix substrates which are disposed adjacent to one another; and
a sealant, which is provided so as to surround the gel sticking material.
7. An electromagnetic wave capturing device, comprising:
(I) a composite active-matrix substrate which is provided with:
a second adhesive filler, which fills a gap between edges of the active-matrix substrates which are disposed adjacent to one another;
(II) a conversion layer, provided on the top surface of the active-matrix substrates, for converting an electromagnetic wave into electrical charge; and
(III) a bias applying electrode layer provided on the conversion layer.
8. An electromagnetic wave capturing device, comprising:
(II) a scintillator, provided on the top surface of the active-matrix substrates, for converting an electromagnetic wave into light; and
(III) a photo-electric conversion element, provided on the active-matrix substrates, for converting light into electrical charge.
The present invention is a divisional of, claims priority from, and incorporates by reference the entirety of U.S. patent application Ser. No. 10/143,207 which was filed on May 10, 2002 now U.S. Pat. No. 6,759,660.
As a counter-measure for these problems, there have been proposed methods of forming a composite active-matrix substrate by connecting a plurality of small active-matrix substrates. For example, �Large Area Liquid Crystal Display Realized by Tiling of Four Back Panels (Proceedings of the 15th International Display Research Conference (ASIA DISPLAY '95, pp. 201�204 (1995)))� (reference 1) discloses an arrangement of a composite active-matrix substrate for use in liquid crystal display devices. Further, U.S. Pat. No. 5,827,757 (reference 2), published on Oct. 27, 1998, discloses a method for manufacturing a composite active-matrix substrate and an x-ray capturing device utilizing the composite active-matrix substrate.
The active-matrix substrate described in the above reference 1, as shown in FIGS. 13( a) through 13(c), is fabricated as follows: after four small active-matrix substrates 101, with their element bearing sides 101 a facing down, are aligned on a stage 103 with a vacuum chuck, a back side (upper side in FIG. 13( a)) of the active-matrix substrates 101 is bonded to a base substrate 102 with an adhesive resin 105. Here, the adhesive resin 105 contains a spacer 104. Further, an ultraviolet curable resin is used for the adhesive resin 105.
Meanwhile, the composite active-matrix substrate described in the above reference 2, as shown in FIGS. 14( a) through 14(g), is made up of a plurality of small active-matrix substrates 111 bonded to a base substrate 112. Specifically, this composite active-matrix substrate is fabricated in the following manner: after an edge of the active-matrix substrate 111 whose element bearing side is covered with a protecting film 121 is cut by dicing and polished (see FIGS. 14( a) and 14(b)), the plurality of active-matrix substrates 111, with their element bearing sides facing down, are aligned on a stage 113 and connected to each other with an adhesive resin 141 which fills a gap between the active-matrix substrates 111 (see FIGS. 14( c) and 14(d)). Thereafter, a back side (upper side in FIG. 14( d)) of the plurality of active-matrix substrates 111 is bonded to a base substrate 112 with an adhesive resin 131. Then, after the active-matrix substrates 111 are removed from the stage 113, the protecting film 121 is peeled off from the active-matrix substrates 111 (see FIGS. 14( e) through 14(g)). Here, formation of a large number of orderly openings (holes for releasing an adhesive resin) 112 a prevents air bubbles from being trapped in the adhesive resin 131 which fills a spacing between the active-matrix substrate 111 and the base substrate 112, and helps excess adhesive resin 131 to escape.
FIG. 1( a) is a schematic plan view of a composite active-matrix substrate according to one embodiment of the present invention, and FIG. 1( b) is a cross sectional view of the composite substrate of FIG. 1( a) taken along the line A�A′.
FIG. 2 is a cross sectional view magnifying a juncture of the composite active-matrix substrate of FIG. 1( a) and FIG. 1( b).
FIG. 3( a) through FIG. 3( g) are drawings explaining manufacturing steps of the composite active-matrix substrate shown in FIG. 1( a) and FIG. 1( b).
FIG. 4 is a drawing showing one manufacturing step of the composite active-matrix substrate shown in FIG. 1( a) and FIG. 1( b).
FIG. 5 is a drawing explaining another manufacturing step of the composite active-matrix substrate shown in FIG. 1( a) and FIG. 1( b).
FIG. 6( a) is a schematic plan view of a composite active-matrix substrate according to another embodiment of the present invention, and FIG. 6( b) is a cross sectional view of the composite substrate of FIG. 6( a) taken along the line B�B′.
FIG. 7 is a cross sectional view magnifying a juncture of the composite active-matrix substrate shown in FIG. 6( a) and FIG. 6( b).
FIG. 8( a) through FIG. 8( g) are drawings showing manufacturing steps of the composite active-matrix substrate of FIG. 6( a) and FIG. 6( b).
FIG. 9( a) is a schematic plan view of a composite active-matrix substrate according to yet another embodiment of the present invention, and FIG. 9( b) is a cross sectional view of the composite substrate shown in FIG. 9( a), taken along the line C�C′.
FIG. 10 is a cross sectional view magnifying a juncture of the composite active-matrix substrate of FIG. 9( a) and FIG. 9( b).
FIG. 11( a) through FIG. 11( g) are drawings explaining manufacturing steps of the composite active-matrix substrate of FIG. 9( a) and FIG. 9( b).
FIG. 13( a) through FIG. 13( c) are drawings schematically showing a conventional composite active-matrix substrate.
FIG. 14( a) through FIG. 14( g) are drawings showing manufacturing steps of another conventional composite active-matrix substrate.
As shown in FIG. 1( a) and FIG. 1( b), a composite active-matrix substrate 11 a according to the present invention is composed of a single large-area base substrate 12 and two smaller active-matrix substrates 13, wherein the active-matrix substrates 13 are placed adjacent to each other on the base substrate 12 so that the top surface (active element bearing surface) of one active-matrix substrate 13 is substantially level with that of the other. The top surface of each active-matrix substrates 13 makes up an active-matrix element bearing part 13 a which is provided with various elements such as active elements, scanning signal lines, data signal lines, pixel electrodes, and the like (not shown). The composite active-matrix substrate 11 a is structured such that the other surface (bottom surfaces) of the active-matrix substrates 13 is mated with the base substrate 12 to expose the top surfaces of the active-matrix substrates 13. Note that, as to the structure of the active element bearing part 13 a and a manufacturing method thereof, detailed explanations are omitted here because they are the same as those employed by conventional active-matrix substrates. Further, examples of the active elements include TFT (Thin Film Transistor) elements and MIM (Metal Insulator Metal) elements.
Referring to FIG. 3( a) through FIG. 3( g), and FIG. 4 and FIG. 5, the following describes a manufacturing method of the composite active-matrix substrate 11 a in detail.
First, in step (1), using a process well-known in the field of liquid crystal display, the active element bearing part 13 a including active elements, scanning signal lines, data signal lines, and the like is formed on a surface of an insulating substrate 13 b, so as to make the active-matrix substrate 13 of a small size (FIG. 3( a)). The type of insulating substrate 13 b is not particularly limited as long as it is an active-matrix substrate. For example, the non-alkaline glass #1737 of Corning Inc. can be used. On the insulating substrate 13 b is formed an element structure (shown as active element bearing part 13 a) including: (1) an array of metal wiring (scanning signal lines, data signal lines, etc.), (2) a plurality of active elements made up of thin-film transistor elements (TFT elements) having a semiconductor layer of a-Si (amorphous silicon) or p-Si (polysilicon), or made up of diode elements (MIM elements) of an MIM structure, and (3) a pixel electrode which is provided for each pixel. The result is the active-matrix substrate 13.
Then, a surface protective film 20 is formed on the element bearing surface (top surface) of the active-matrix substrate 13 (FIG. 3( a)). The surface protective film 20 is provided to protect the active-matrix substrate 13 from contamination or damage in the subsequent substrate cutting step (step (2)) or substrate combining steps (step (4) through step (6)). Further, because the surface protective film 20 needs to be completely removed at the end of the substrate combining steps, the surface protective film 20 is required to have such a property that it can be easily removed, while protecting the surface of the active-matrix substrate 13. To this end, the surface protective film 20 is realized by, for example, an IPA (isopropyl alcohol)-soluble temporary protective film chiefly made of acrylic resin, which is applied over the surface of the active-matrix substrate 13 to a thickness of about 3 μm using a spin coater. The property of the surface protective film 20 is such that it is insoluble in water but highly soluble in IPA (surface protective film removing agent). This enables the surface protective film 20 to be easily detached and removed at the end of the fabrication, without being dissolved and detached in the rinsing process which uses water. Note that, the surface protective film 20 is not just limited to the IPA-soluble film whose main component is acrylic resin. Instead, other various temporary protective films which are soluble in alkaline solutions or other organic solvents (surface protective film removing agent) may also be used. Further, instead of spin coating, other techniques, such as dry-film transfer or spraying may be used to form the surface protective film 20.
In subsequent step (2), the active-matrix substrate 13 of a small size is diced to expose the side (edge) which is to be connected to the other active-matrix substrate 13 (FIG. 3( b)). Dicing is accurately made so that the side of the active element bearing part 13 a of one active-matrix substrate 13 matches that of the other. Dicing using a diamond blade is suitable for this purpose. A diamond blade having a particle size of #400 to #800 is particularly preferable. In order to improve processing accuracy, the diced surface may be optionally polished. By polishing, the chipping area on the edge of the diced surface can be leveled to provide a surface (edge) at desirable accuracy.
In step (3), two or four of the active-matrix substrate 13 obtained in step (2) are aligned adjacent to one another so that the edges of the diced surfaces oppose one another and a gap between the edges is no wider than the pixel pitch (FIG. 3( c)). For example, a plurality of active-matrix substrates 13 are aligned on a highly-flat stage 21 equipped with a vacuum chuck (not shown), with their active element bearing parts 13 a (top surfaces) facing the stage 21. The active-matrix substrates 13 so aligned are fixed in position by the vacuum chuck. In this way, the surface flatness of the plurality of active-matrix substrates 13 can be optimized.
In step (4), a sealant (adhesive resin) 14 is applied on one surface of a base substrate 12, for which a glass substrate is used, for example (FIG. 3( d)). The sealant 14 is patterned, for example, along the outer periphery of the bottom surface of the target active-matrix substrate 13. The sealant 14 may be a conventional sealant known in the field of liquid crystal display, for example, such as a heat-curable or light-curable epoxy resin or acryl resin, or a silicon resin which is cured at room temperature. The sealant 14 is applied (drawn) by screen printing or by using a dispenser.
In step (5), the first filler 15 is injected into a gap surrounded by each active-matrix substrate 13, the base substrate 12, and the sealant 14 (FIG. 3( e), FIG. 4). In this step, the first filler 15 is injected into the gap through one of openings (inlet or outlet) 12 b which have been provided through the base substrate 12, for example, as shown in FIG. 4. The openings 12 b open into the gap (spacing A) surrounded by each active-matrix substrate 13, the base substrate 12, and the sealant 14. Two openings 12 b are provided for each spacing A, one of which is used to inject the first filler 15, and the other is used to vent. In this way, the first filler 15 can easily be injected. Note that, the opening used to inject the first filler 15 into the spacing A may be provided through the active-matrix substrates 13 or the sealant 14. Further, the first filler 15 may be injected into the spacing A by a vacuum injection method by evacuating the spacing A.
In step (6), the second filler 16 is injected into a gap 13 c between the edges of the active-matrix substrates 13 (FIG. 3( f), FIG. 5). In this step, for example, using an injector 22, the second filler 16 is injected by capillary action from one end of the gap (spacing) 13 c between the edges of the adjacent active-matrix substrates 13 (FIG. 5). According to this method, the second filler 16 only fills the gap 13 c created between the cut edges of the active-matrix substrates 13 and a gap between the sealants 14 below the gap 13 c. Under usual circumstances, this prevents the second filler 16 from sticking to the surface of the active-matrix substrates 13 (more specifically, surface of the surface protecting film 20), thereby making it easier to inject the second filler 16 while suppressing surface contamination of the active-matrix substrates 13 to minimum.
Though not shown in FIG. 3( a) through FIG. 3( g), and FIG. 4 and FIG. 5, the manufacturing steps of the active-matrix substrates 13 includes a washing step in which water is often used. Here, by ensuring curing of the second filler 16 exposed on the surface, seeping of the organic component and/or organic impurity from the exposed surface can be suppressed to minimum, thereby avoiding surface contamination of the active-matrix substrates 13 without fail.
Finally, in step (7), the surface protecting films 20 on the surface of the active-matrix substrates 13 are detached and removed (FIG. 3( g)). For example, when the surface protecting film 20 is the IPA soluble temporary protecting film whose main component is an acrylic resin, the composite active-matrix substrate 11 with the surface protecting films 20 are dipped in IPA, followed by water, and dried. Note that, it is more preferable to apply an ultrasonic wave in IPA.
As with the composite active-matrix substrate 11 a of the First Embodiment, a composite active-matrix substrate 11 b according to the present embodiment includes a single large-area base substrate 12 and two active-matrix substrates 13, wherein the former is combined with the latter with active element bearing parts 13 a exposed on the surface (FIG. 6( a) and FIG. 6( b), FIG. 7). The difference from the First Embodiment is the method of combining each active-matrix substrate 13 with the base substrate 12, whereby, in the present embodiment, a single-layer gel sticking material (gel sticking material) 25 is used in replacement of the combination of the sealant 14 and the first filler 15.
As shown in FIG. 7, a second filler (adhesive filler B) 16 fills a gap 13 at the juncture of the two active-matrix substrates 13 to bond the edge of one active-matrix substrate 13 with that of the other. Note that, specific examples of the gel sticking material 25 will be given in connection with a manufacturing method of the composite active-matrix substrate 11 b. Referring to FIG. 8( a) through FIG. 8( g), the following describes the manufacturing method of the composite active-matrix substrate 11 b. Note that, steps (1) through (3) shown in FIG. 8( a) through FIG. 8( c) are as already described in the First Embodiment, and no further explanation is given therefor (FIG. 3( a) through FIG. 3( c)).
The plurality of active-matrix substrates 13 with their top surfaces stuck on the stage 21 through steps (1) through (3) are combined with the base substrate 12 in step (4) (FIG. 8( d)). In this step, a layer of gel sticking material 25 is formed substantially entirely over one surface of the base substrate 12, for which a glass substrate is used for example. The plurality of active-matrix substrates 13 and the base substrate 12 are pressed against each other preferably under reduced pressure to combine these substrates. Note that, the gel sticking material 25 is only required to be present between the bottom surfaces of the active-matrix substrates 13 and the top surface of the base substrate 12, and as such, a layer of the gel sticking material 25 may be disposed in some cases in the form of discrete islands only on the corresponding positions on the bottom surface of each active-matrix substrate 13.
In step (5), which is optional, the gel sticking material 25 may be subjected to heat treatment to improve adhesion (stickiness) of the gel sticking material 25 (see FIG. 8( e)). Note that, when the gel sticking material 25 is the gel product of SE1880, it is particularly preferable that the heat treatment be carried out for 30 minutes in the temperature range of from 120� C. to 180� C. Further, in order to prevent the gel sticking material 25 from being exposed, a sealant 26 may be optionally provided around the edges of the composite active-matrix substrate 11 b so as to seal the gel sticking material 25. Note that, the sealant 26 is made of, for example, epoxy resin, and may alternatively be provided so as to surround the gel sticking material 25 between the active-matrix substrates 13 and the base substrate 12. The provision of the sealant 26 prevents outflow of organic materials (contaminants) from the gel sticking material 25 when the composite active-matrix substrate 11 b is washed in post-processes, and thereby prevents surface contamination of the active-matrix substrates 13. Note that, step (5) is not necessarily required and the foregoing processes of step (5) are carried out as required.
In step (6), the second filler (adhesive filler B) 16 is injected between edges of the active-matrix substrates 13 so as to bond the edge of one active-matrix substrate 13 with that of the other (FIG. 8( f)). In step (7), the surface protecting film 20 is detached to obtain the composite active-matrix substrate 11 b. Note that, steps (6) and (7) are essentially the same as the corresponding steps already explained in the First Embodiment and no further explanation is given therefor in the present embodiment.
As with the composite active-matrix substrates 11 a and 11 b of the First and Second Embodiments, a composite active-matrix substrate 11 c according to the present embodiment includes a single large-area base substrate 12 and two active-matrix substrates 13, wherein the former is combined with the latter with active element bearing parts 13 a exposed on the surface (FIG. 9( a) and FIG. 9( b), FIG. 10). The difference from the First and Second Embodiments is the method of combining each active-matrix substrate 13 with the base substrate 12, whereby, in the present embodiment, a double-sided adhesive sheet 35 having a sticking layer on its top surface and bottom surface to combine the substrates is used instead of the combination of the sealant 14 and the first filler 15, or the gel sticking material 25.
Referring to FIG. 11( a) through FIG. 11( g), the following describes the manufacturing method of the composite active-matrix substrate 11 c. Note that, steps (1) through (3) shown in FIG. 11( a) through FIG. 11( c) are as already described in the First Embodiment, and no further explanation is given therefor (FIG. 3( a) through FIG. 3( c)).
The plurality of active-matrix substrates 13 with their top surface stuck on the stage 21 through steps (1) through (3) are combined with the base substrate 12 in step (4) (FIG. 11( d)). In this step, stripes of double-sided adhesive layer 35 are formed substantially entirely over one surface of the base substrate 12, for which a glass substrate is used for example. The plurality of active-matrix substrates 13 and the base substrate 12 are pressed against each other preferably under reduced pressure to combine and integrate these substrates. Note that, the double-sided adhesive sheet 35 may be disposed on the bottom surface of each active-matrix substrate 13, instead of the base substrate 12.
The method of independently providing two or more double-sided adhesive sheets 35 between the active-matrix substrates 13 and the base substrate 12 is not particularly limited. For example, (1) the double-sided adhesive sheet 35 may be provided in stripes, each in the form of a tape extending in one direction, at certain intervals (stripe or lattice pattern) (FIG. 10, FIG. 11( a) through FIG. 11( g)), or (2) the double-sided adhesive sheet 35 may be provided discontinuously in the form of discrete islands. It is particularly preferable that the double-sided adhesive sheet 35 be provided in stripes, each in the form of a tape with a width of 1 cm to 2 cm, at certain intervals.
In step (5), which is optional, in order to prevent the double-sided adhesive sheet 35 from being exposed, a sealant 26 may be optionally provided around the edges of the composite active-matrix substrate 11 c so as to seal the double-sided adhesive sheet 35 (FIG. 11( e)). The provision of the sealant 26 prevents outflow of organic materials (contaminants) from the double-sided adhesive sheet 35 when the composite active-matrix substrate 11 c is washed in post-processes, and thereby prevents surface contamination of the active-matrix substrates 13. Note that, step (5) is not necessarily required and the foregoing processes of step (5) are carried out as required.
In step (6), the second filler (adhesive filler B) 16 is injected between the edges of the active-matrix substrates 13 so as to bond the edge of one active-matrix substrate 13 with that of the other (FIG. 11( f)). In step (7), the surface protecting film 20 is detached to obtain the composite active-matrix substrate 11 c. Note that, steps (6) and (7) are essentially the same as the corresponding steps already explained in the First Embodiment and no further explanation is given therefor in the present embodiment.
As schematically shown in FIG. 12, an X-ray capturing device (electromagnetic wave capturing device) according to the present embodiment includes: one of the composite active-matrix substrates 11 a through 11 c of the First through Third Embodiments (composite active-matrix substrate 11); a photo-electric conversion layer (conversion layer, conversion means) 41 which converts an electromagnetic wave such as X-rays into electrical charge; a bias electrode (bias applying electrode layer) 42 for applying a bias to transfer the generated charge to the composite active-matrix substrate 11; a high voltage power source 43 for the bias electrode 42; and a charge detector 44 for detecting the generated charge of the photo-electric conversion layer 41 from the composite active-matrix substrate 11. The photo-electric conversion layer 41 is provided so as to cover essentially the entire surface (active element bearing part 13 a) of the active-matrix substrates 13, and the bias electrode 42 is stacked on the photo-electric conversion layer 41 so as to cover essentially the entire surface of the photo-electric conversion layer 41.
According to this arrangement, the adhesive filler B can be sufficiently cured even at the seam (edges) of the adjacent active-matrix substrates where the adhesive filler B is exposed (in contact with air), and therefore no tacking remains on the exposed surface of the adhesive filler B. As a result, it is possible to provide a composite active-matrix substrate which can minimize seeping of organic impurity from the exposed surface of the adhesive filler B during washing, and therefore is free from surface contamination of the active-matrix substrates.
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