Source: http://www.google.com/patents/US20050003645?dq=5579430
Timestamp: 2017-10-24 08:33:37
Document Index: 288440352

Matched Legal Cases: ['art 35', 'art 34', 'art 34', 'art 34', 'art 34', 'art 34', 'art 34', 'art 34', 'art 34', 'art 34', 'art 34', 'art 34']

Patent US20050003645 - Forming process of thin film pattern and manufacturing process of device ... - Google Patents
The invention provides a forming process of a thin film pattern capable of properly realizing a thin line. The forming process of a thin film pattern of the invention can be a process of forming a thin film pattern by arranging a functional liquid on a substrate P. The process can include a bank forming...http://www.google.com/patents/US20050003645?utm_source=gb-gplus-sharePatent US20050003645 - Forming process of thin film pattern and manufacturing process of device, electro-optical apparatus and electronic apparatus
Publication number US20050003645 A1
Application number US 10/843,426
Also published as CN1575102A, US7326585
Publication number 10843426, 843426, US 2005/0003645 A1, US 2005/003645 A1, US 20050003645 A1, US 20050003645A1, US 2005003645 A1, US 2005003645A1, US-A1-20050003645, US-A1-2005003645, US2005/0003645A1, US2005/003645A1, US20050003645 A1, US20050003645A1, US2005003645 A1, US2005003645A1
Inventors Toshimitsu Hirai
Patent Citations (11), Referenced by (26), Classifications (37), Legal Events (4)
US 20050003645 A1
The invention provides a forming process of a thin film pattern capable of properly realizing a thin line. The forming process of a thin film pattern of the invention can be a process of forming a thin film pattern by arranging a functional liquid on a substrate P. The process can include a bank forming step to set up banks protrudingly on the substrate corresponding to the thin film pattern, a repellent liquefaction step of imparting a liquid repellent property to the bank by CF4 plasma processing, and a material arranging step of arranging the functional liquid between the banks imparted with the liquid repellent property.
1. A forming process of a thin film pattern by placing a functional liquid on a substrate, comprising:
forming a bank to form banks matching the thin-film pattern on the substrate;
arranging a material to place the functional liquid between the banks imparted with the liquid repellent property.
2. The forming process of a thin film pattern according to claim 1,
processing repellent liquefaction including a step of processing plasma by using a fluorocarbon compound as a reaction gas.
3. The forming process of a thin film pattern according to claim 1, the liquid repellent property of the banks being provided higher than a bottom part between the banks.
4. The forming process of a thin film pattern according to claim 1, including lyophilic processing to impart a lyophilic property to a bottom part between the banks.
5. The forming process of a thin film pattern according to claim 1,
arranging a material further including a step of ejecting a liquid droplet of the functional liquid between the banks with the banks having a width smaller than a diameter of the liquid droplet.
6. The forming process of a thin film pattern according to claim 1,
the functional liquid having conductive particulates.
7. The forming process of a thin film pattern according to claim 1,
the functional liquid including a material which manifests conductivity by at least one of heat treatment or optical processing.
8. A manufacturing process of a device including forming a thin film pattern on a substrate,
the thin film pattern being formed on the substrate by the forming process of a thin film pattern according to claim 1.
9. An electro-optical apparatus, comprising:
a device manufactured by using the manufacturing process of a device according to claim 8.
10. An electronic apparatus, comprising the electro-optical apparatus according to claim 9.
Continuing efforts have been made to develop higher and higher density of circuits constituting devices, thereby calling for further thin lines regarding wiring patterns. However, in a case where forming a wiring pattern of a thin line width is attempted based on the process of ejecting liquid droplets, can be difficult to obtain sufficient precision of its wiring line width. It is also extremely difficult to cope with a case where a thinner line width than a diameter of an ejected liquid droplet is required.
Still further, in forming a thin film pattern making up part of a device having a pixel, by setting the width of the groove part between the banks more than {fraction (1/20)} and less than {fraction (1/10)} in a direction of a short side of the pixel, it is possible to form a desired line width of a wiring pattern making up a switching element such as a thin film transistor arranged according to this pixel. At this point, suppose a long side of one pixel formed in a rectangle is approx. 300 μm and a short side thereof is approx. 100 μm, the width of the groove part (the line width of the wiring pattern in its turn) is set at 5-10 μm.
An embodiment of a forming process of a thin film pattern and a manufacturing process of a device of this invention will be described below with reference to drawings. In this embodiment, description will be made by citing an example in which a wiring pattern formed of a conductive film on a substrate is formed as ink for forming (functional liquid) a wiring pattern (thin film pattern) is ejected in liquid droplets from ejection nozzles of an ejection head according to a liquid droplet ejection process.
It is preferable that viscosity of the above-mentioned dispersed liquid is more than 1 mPa·s and less than 50 mPa·s. When ejecting the ink as a liquid droplet by technique of the liquid droplet ejection process, if the viscosity is less than 1 mPa·s, a periphery of the nozzle tends to be soiled by an ink flow, and if the viscosity exceeds 50 mPa·s, a nozzle hole gets clogged with a higher frequency, so that smooth ejection of liquid droplets becomes difficult.
First, prior to coating an organic material, for surface improvement treatment, an HMDS processing is performed to the substrate P. The HMDS processing is a method of vaporizing hexamethyldisilazane ((CH3) 3SiNHSi(CH3)3) into a state of steam for coating. By this means, as shown in FIG. 4(a), an HMDS layer 32 is formed on the substrate P as a closely adhered layer to improve adhesion between the banks and the substrate P.
Subsequently, a mask is provided to fit a bank shape (wiring pattern), and by subjecting the photoresist to exposure and development, the photoresist fitting the bank shape remains. Also, a bank (convex) may be formed with more than two layers having a bottom layer of an inorganic matter and a top layer of an organic matter. By this technique, as shown in FIG. 4(b), banks B and B are protrudingly set up in a manner surrounding the periphery of an area planned for wiring pattern formation. Now, it is desirable for the banks B and B formed in this way to be tapered from a narrow width of a top side to a broad width of a bottom side, so that ink droplets may easily run into the groove part between the banks, as explained in greater detail below.
When the banks B and B are formed on the substrate P, hydrofluoric acid processing is performed. The hydrofluoric acid processing is, for example, a processing to remove the HMDS layer 32 between the banks B and B by etching with a 2.5% hydrofluoric acid water solution. In the hydrofluoric acid processing, the banks B and B function as a mask, and as shown in FIG. 4(c), the HMDS layer 32, an organic matter, which is formed between the banks B and B, on the bottom part 35 of the groove part 34 is removed to expose the substrate P.
The O2 plasma processing irradiates the substrate P with oxygen in plasma state from a plasma discharge electrode. As an example of O2 plasma processing conditions, consider a plasma power of 50-1000 W, an oxygen gas flow rate of 50-100 mL/min, a relative movement rate of a substrate 1 pertaining to a plasma discharge electrode of 0.5-10 mm/sec, and a substrate temperature of 70-90° C.
Next, the repellent liquefaction processing is performed on the banks B to provide the liquid repellent property to their surfaces. For the repellent liquefaction processing, a plasma processing (CF4 plasma processing) using tetrafluoromethan is employed. Conditions of the CF4 plasma processing are, for example, a plasma power of 50-1000 W, a tetrafluoromethane flow rate of 50-100 mL/min, a substrate conveying rate of 0.5-1020 mm/sec, and a substrate temperature of 70-90° C. It is to be noted that the process gas is not limited to tetrafluoromethane, but any other gas of the fluorocarbon type may be used. For CF4 plasma processing, the plasma processing apparatus described by referring to FIG. 6 may be used.
Next, by using the liquid droplet ejection process based on the liquid droplet ejection unit IJ, a liquid droplet of the wiring pattern forming ink is arranged between the banks B and B on the substrate P. It is to be noted that at this point, an organosilver compound is used as a conductive material, and, as a solvent (dispersion medium), ink composed of an organosilver compound using diethyleneglycoldiethylether is ejected. In the material arranging step, as shown in FIG. 5(d), from the liquid droplet ejection head 1, the ink containing the wiring pattern forming material is made into the liquid droplets and ejected. The liquid droplet ejection head 1 ejects the ink droplets towards the groove part 34 therebetween and arranges the ink inside the groove part 34. At this time, since the area planned for wiring pattern formation (that is, the groove part 34) to which the liquid droplets are to be ejected is surrounded by the banks B and B, it is possible for the liquid droplets to spread to outside the prescribed position.
In this embodiment, a width W (at this point, a width of an opening of the groove part 34) of the groove part 34 between the banks B and B is set smaller than the diameter D of the liquid droplet of the ink (functional liquid). It is preferable that the atmosphere in which the droplets are ejected is at a temperature less than 60° C. and a humidity of less than 80%. This allows the ejection nozzles of the liquid droplet ejection head 1 to eject the liquid droplets without clogging and with stability.
As such, liquid droplet is ejected from the liquid droplet ejection head 1 and arranged inside the groove part 34, since the diameter D of the droplet is larger than the width W of the groove part 34, part of it rides on the banks B and B as shown in two-point chain line in FIG. 5(e). However, the surface of the banks B and B are liquid repellent in a tapered shape, so that a liquid droplet portion on the banks B and B is repelled from the banks B and B, and further, due to capillary action, flows into the groove part 34, whereby the liquid droplet enters into the groove part 34 as shown in 2-point chain lines in FIG. 5(e).
Although the heat treatment and/or optical processing is typically carried out in the atmosphere, as necessary, it may be carried out in an inert atmosphere, such as nitrogen, argon, and helium. Processing temperature of heat treatment and/or optical processing is determined by taking into consideration a boiling point of the dispersed medium (steam pressure), type and pressure of an atmosphere gas, dispersibility of particulates and thermal behavior such as oxidizability, existence and quantity of a coating material, heat-resistant temperature of a substrate member, and the like. In this embodiment, a baking step is carried out with respect to the ink of the groove part 34 in a clean oven in atmosphere from 150° C.-200° C. for 10-20 minutes. Further, for example, to remove the organic portion of the organosilver compound, it is necessary to bake at approximately 200° C. Furthermore, when a substrate member, such as plastics is used, it is preferable that baking is carried out at more than room temperature and less than 100° C. By means of the above-mentioned step, a dry film after the ejection step secures electric contact among the particulates and is converted to a conductive film.
FIG. 12(a) is a perspective view of an example of a mobile phone. In FIG. 12(a), 600 shows a mobile phone body, while 601 shows a liquid crystal display part equipped with a liquid crystal display of the above-mentioned embodiment.
FIG. 12(b) is a perspective view showing an example of a mobile type information processing apparatus such as a word processor or a personal computer. In FIG. 12(b), 700 shows an information processing apparatus, 701 shows an input unit such as a keyboard, 703 shows an information processing body, and 702 shows a liquid crystal display part equipped with a liquid crystal display of the above-mentioned embodiment.
FIG. 12(c) is a perspective view showing an example of an electronic apparatus of a wrist watch type. In FIG. 12(c), 800 shows a watch body, and 801 shows a liquid crystal display part of a liquid crystal display of the above-mentioned embodiment.
The electronic apparatus shown in FIG. 12(a)-(c) are equipped with the liquid crystal displays of the above-mentioned embodiment, having a wiring pattern of properly formed thin lines.
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U.S. Classification 438/584, 257/E21.294, 257/E21.174, 438/778, 257/E21.131, 257/E21.114, 257/E21.582, 438/669, 438/781
International Classification H01L21/3205, G02F1/13, H01L21/288, H05K3/12, H01L21/20, G02F1/1333, H01L21/208, B05D3/04, B05D1/26, H01L21/768, H01L21/02
Cooperative Classification H01L21/02422, H05K3/1258, H01L21/288, H01L21/76838, H05K2203/1173, H05K3/125, H05K2201/09909, H01L21/3205, H01L21/02532, H01L21/02639
European Classification H05K3/12C2, H01L21/288, H01L21/20C, H01L21/768C, H01L21/208, H01L21/3205, H05K3/12D
Free format text: ASSIGNMENT OF ASSIGNORS INTEREST;ASSIGNOR:HIRAI, TOSHIMITSU;REEL/FRAME:015137/0068