Source: https://patents.justia.com/patent/20070111391
Timestamp: 2019-10-20 23:55:59
Document Index: 765972011

Matched Legal Cases: ['art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 102', 'art 221', 'art 221', 'art 221', 'art 251', 'art 251']

US Patent Application for Layer having functionality, method for forming flexible substrate having the same, and method for manufacturing semiconductor device Patent Application (Application #20070111391 issued May 17, 2007) - Justia Patents Search
Justia Patents US Patent Application for Layer having functionality, method for forming flexible substrate having the same, and method for manufacturing semiconductor device Patent Application (Application #20070111391)
Nov 3, 2006 - Semiconductor Energy Laboratory Co., Ltd.
Further, by coating a layer in which oxygen and silicon are combined and an inactive group is combined with the silicon, of which surface energy is low, with a composition by a printing method, unevenness on a side face of the printed composition can be reduced. Furthermore, the width of the composition can be controlled to make the layer thin. Therefore, a layer of which the width and a distance between the adjacent layers are uniform can be formed. Moreover, a layer of which the width is minuter than that of a layer formed by a conventional printing method can be formed.
Further, as particles with a metal element, a compound that contains one or more of elements of In, Ga, Al, Sn, Ge, Sb, Bi, and Zn, or two or more of compound particles is heated and baked, thereby forming a conductive layer having a light transmitting property.
Next, an adhesive 106 is attached to a surface of the insulating layer 104, typically, to part of or to the entire surface of the insulating layer 104; thereafter, the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon is physically divided with the use of the adhesive 106 as shown in FIG. 1B. Typically, the adhesive 106 is pulled up in a direction of an angle of 0 degree with respect to the surface of the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon or the insulating layer 104. The angle of θ degree is other directions than a horizontal direction, specifically, 0°<θ<180°, preferably, 30°≦θ≦160°, more preferably, 60°≦θ≦120°. As a result, the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon is divided, and the functional layer 105 is peeled from the substrate 101 by dividing the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon. At this time, a part 102b of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over the substrate 101, and a part 102a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over a surface of the functional layer 105 having the conductive layer 103. Thus, the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon works as a peeling layer.
Furthermore, in a case where a roller is provided over the adhesive 106 and the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon is physically divided from the substrate by rotation of the roller, the angle of θ degree is 0°≦θ≦90°, preferably, 0°≦θ≦45°. As a result, the functional layer 105 can be peeled from the substrate 101 while a crack is prevented from occurring in the functional layer 105.
Since the combination of the functional group R that is at least one selected form an alkyl group, an aryl group, a fluoroalkyl group, and a fluoroaryl group is partially cut off, a remaining part of the alkyl group, the aryl group, the fluoroalkyl group, and the fluoroaryl group is left over the surface of the substrate. Accordingly, a contact angle is large and the surface energy is relatively small over a surface of the part 102b of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon that is divided. Therefore, a composition having different surface energy from the surface of the part 102b of the layer is easily repelled over the layer, and the composition flows over a surface of a film having small surface energy and stays in a stabilized shape. As a result, the substrate 101 having the part 102b of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon that is divided can be used for forming a functional layer again.
Next, as shown in FIG. 1D, the part 102a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon that remains over a surface of the functional layer 105 having the conductive layer 103 may be removed. The part of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon can be removed by plasma irradiation of hydrogen, a rare gas, nitrogen, or the like, or heating treatment at 400° C. or higher. Through the above step, a functional layer can be easily formed. In addition, a functional layer having a conductive layer in which unevenness on a side face is reduced or a thinned conductive layer can be easily formed.
In this embodiment mode, one mode of a method for easily forming a layer having functionality will be explained with reference to FIGS. 3A to 3E and FIG 4. FIGS. 3A to 3E each show a cross-sectional view of a step for forming a layer having functionality. FIG. 4 shows a cross-sectional view of a liquid crystal display device as a display device in a case where the display device is used as a semiconductor device. A layer having a conductive layer serving as a pixel electrode is used as a layer having functionality to explain this embodiment mode.
Next, as shown in FIG. 3B, an adhesive 106 is attached to a surface of the insulating layer 132, typically, part of or an entire surface of the insulating layer 132 in a similar manner to Embodiment Mode 1, and thereafter, the adhesive 106 is pulled up. As a result, as shown in FIG. 3C, the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon is divided, and the functional layer 133 is peeled from the substrate 101. At this time, a part 102b of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over the substrate 101, and a part 102a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over a surface of the functional layer 133 having the conductive layer 131.
Subsequently, as shown in FIG. 3D, the part 102a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon that remains over a surface of the functional layer 133 having the conductive layer 131 may be removed in a manner similar to that of Embodiment Mode 1. Through the above step, the functional layer 133 can be easily formed.
Next, a flexible substrate 135 having a functional layer is similarly formed. A sealant is applied in a region where the functional layer 133 is not formed over one of the flexible substrates having functionality, and a liquid crystal material is applied inside the sealant. Then, the conductive layer 131 formed over the flexible substrate 134 and a conductive layer 136 formed over the flexible substrate 135 are arranged to be intersected with each other at right angles, and attachment is performed while a pressure is reduced. Please note that the conductive layer 136 serves as an opposite electrode. As a result, a passive matrix liquid crystal display device including a sealant 141 for sealing the flexible substrates 134 and 135, the flexible substrates 134 and 135, and a liquid crystal layer 142 that is formed in a region surrounded by the sealant is manufactured. By the above step, a liquid crystal display device can be manufactured with a high yield. Further, a liquid crystal display device that is. small-sized, thin, and lightweight can be manufactured.
As a result, the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon is divided, and the functional layer 159 is peeled from the substrate 101 as shown in FIG. 5C. At this time, a part 102b of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over the substrate 101, and a part 102a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over a surface of the functional layer 159 having the colored layer.
Subsequently, as shown in FIG. 5D, the part 102a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon that remains over a surface of the functional layer 159 having the colored layer may be removed in a manner similar to that of Embodiment Mode 1.
As a result, as shown in FIG. 6C, the layer 102 in which oxygen and silicon are combined and an inactive group is combined with the silicon is divided, and the functional layer 162 is peeled from the substrate 101. At this time, a part 102b of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over the substrate 101, and a part 102a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over a surface of the functional layer 162 having the colored layer. Thereafter, the part 102a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon that remains over a surface of the functional layer 162 having the colored layer may be removed in a manner similar to that of Embodiment Mode 1.
The average value of the resistance of the conductive layer with respect to the baking temperature at this time and the probability that peeling is possible are shown in Table 1, and graph for showing the relation between a baking temperature and the resistance of the conductive layer is shown in FIG. 8.
Resitance Value [O] Baking Temperature [° C.]
1 36 29 13.9 11.5 8.74 7.8 2 36 28 13.5 10.2 8.75 9.1 3 36 31 14.2 10.8 8.8 8.2 4 35 34 13.9 11 8.46 7.8 5 37 36 14.1 10.5 8.15 7.8 6 38 27 14.6 10.1 8.36 7.9 7 40 29 13.8 11.9 8.8 8.9 8 38 29 12.9 11.5 8.9 8.3 9 37 28 14.5 11.9 9.3 7.8 10 37 30 14.2 11.6 9.8 7.9 Average Value 37 30.1 13.96 11.1 8.806 8.15 Provability for 100 100 100 50 0 0 peeling (%)
According to Table 1, a baking temperature at which peeling is possible was less than 400° C., preferably 350° C. or less. According to FIG. 8, the resistance of the conductive layer serving as an antenna was 30 Ω or less. Thus, in accordance with this embodiment, it was found that the range of a heating temperature at which a functional layer having a conductive layer that serves as an antenna can be peeled was greater than or equal to 200° C. and less than or equal to 350° C., preferably greater than or equal to 200° C. and less than or equal to 300° C.
Then, as shown in FIG. 9D, in order to perform a-subsequent peeling step easily, the insulating layers 203, 205, 207, and 212 are irradiated with laser light 213 to form an opening 214 as shown in FIG. 9E. Subsequently, an adhesive 215 is attached to the insulating layer 212. As the laser light used for forming the opening 214, laser light having a wavelength that is absorbed by the insulating layers 203, 205, 207, and 212 is preferably used. Typically, laser light in a UV region, a visible region, or an infrared region is appropriately selected for irradiation.
As a laser oscillator capable of oscillating such laser light, an oscillator of an excimer laser such as an ArF laser, a KrF laser, or a XeCl laser; a gas laser such as a He laser, a He—Cd laser, an Ar laser, a He—Ne laser, a HF laser, or a C02 laser; a solid laser such as a crystal laser in which a crystal such as YAG, GdVO4, YVO4, YLF, or YAlO3 is doped with Cr, Nd, Er, Ho, Ce, Co, Ti, or Tm, a glass laser, or a ruby laser; or a semiconductor laser such as a GaN laser, a GaAs laser, a GaAlAs laser, or an InGaAsP laser can be used. In the solid laser oscillator, the fundamental wave to the fifth harmonic wave may be appropriately used. As a result, the insulating layers 203, 205, 207, and 212 absorb and melt laser light to form the opening.
Then, as shown in FIG. 10C, the flexible substrate 222 is attached to a UV tape 231 of a dicing frame 232. Since the UV tape 231 has adhessiveness, the flexible substrate 222 is fixed over the UV tape 231. Thereafter, the conductive layer 211 is irradiated with laser light to enhance adhesion between the conductive layer 211 and the conductive layer 208.
Next, as shown in FIG. 11A, the part 221 of the element formation layer is divided into parts. Here, the part 221 of the element formation layer and the flexible substrate 222 are irradiated with laser light 234 to form a groove 241 as shown in FIG. 11A, thereby dividing the part 221 of the element formation layer into a plurality. As for the laser light 234, the laser light that is described for the laser light 231 can be applied by being appropriately selected. Laser light that can be absorbed by the insulating layers 203, 205, 206, and 212 and the flexible substrate 222 is preferably selected. Although the part of the element formation layer is divided into a plurality by using a laser cut method here, a dicing method, a scribing method, or the like can be appropriately used instead of this method. As a result, the divided element formation layer is referred to as thin film integrated circuits 242a and 242b.
Subsequently, a UV sheet of the dicing frame 232 is irradiated with UV light to lower the adhesiveness of the UV sheet, and then, the thin film integrated circuits 242a and 242b are attached to an adhesive sheet 243 of an expander frame 244. At this time, the adhesive sheet 243 is attached to the thin film integrated circuits 242a and 242b while being extended, whereby the width of the groove 241 formed between the thin film integrated circuits 242a and 242b can be expanded. It is to be noted that the expanded groove 246 preferably corresponds to the size of an antenna substrate attached to the thin film integrated circuits 242a and 242b in a subsequent step.
Next, a flexible substrate having a conductive layer serving as an antenna is manufactured. First, as shown in FIG. 12A, a silane coupling agent is applied to a substrate 250, thereby forming a layer 251 in which oxygen and silicon are combined and an inactive group is combined with the silicon. Then, conductive layers 252a and 252b serving as antennas are formed thereover, and an insulating layer 253 for covering the conductive layers 252a and 252b is formed.
Here, a glass substrate is used as the substrate 250, and fluoroalkyl silane is used as for the layer 251 in which oxygen and silicon are combined and an inactive group is combined with the silicon. The substrate 250 is heated for 10 minutes at 170° C. to deposit fluoroalkyl silane onto a surface of the substrate, and then, the surface is cleaned with ethanol and pure water to form a layer in which oxygen and silicon are combined and an inactive group is combined with the silicon with a thickness of several nm to several tens of nm. As the conductive layers 252a and 252b, a composition containing silver particles is applied by a printing method, and the composition is heated for 30 minutes at 300° C. and baked to form a conductive layer with a thickness of 30 μm. As the insulating layer 253, an epoxy resin is applied by a printing method, and the resin is heated for 30 minutes at 160° C. and baked to form the insulating layer 253 with a thickness of 30 μm.
Next, as shown in FIG. 12B, an adhesive 254 is attached to the insulating layer 253, and then, the adhesive 254 is pulled up. As a result, as shown in FIG. 12C, the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon is divided, and the conductive layers 252a and 252b and the insulating layer 253 are peeled from the substrate 250. At this time, a part 251b of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over the substrate 250, and a part 251a of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon remains over a surface of the conductive layers 252a and 252b and the insulating layer 253.
Then, as shown in FIG. 12D, after removing the part of the layer in which oxygen and silicon are combined and an inactive group is combined with the silicon that remains over a surface of the conductive layers 252a and 252b and the insulating layer 253, the conductive layers 252a and 252b and the insulating layer 253 are attached to a flexible substrate 256 where openings 255 are formed. At this time, alignment of the flexible substrate 256 and the conductive layers 252a and 252b is performed so as to expose part of the conductive layers 252a and 252b through the openings 255.
Through the above step, a flexible substrate 257 that has the conductive layers 252a and 252b serving as antennas is formed.
Next, as shown in FIG. 13A, the flexible substrate 257 that has the conductive layers 252a and 252b serving as antennas and the thin film integrated circuits 242a and 242b are attached to each other with the use of anisotropic conductive adhesive agents 255a and 255b. At this time, attachment is performed while aligning so as to connect the conductive layers 252a and 252b serving as antennas to the connection terminal of the thin film integrated circuits 242a and 242b with conductive particles 254a and 254b contained in the anisotropic conductive adhesive agents 255a and 255b.
Here, the conductive layer 252a serving as an antenna and the thin film integrated circuit 242a are connected to each other through the conductive particle 254a in the anisotropic conductive adhesive agent 255a. The conductive layer 252b serving as an antenna and the thin film integrated circuit 242b are connected to each other through the conductive particle 254b in the anisotropic conductive adhesive agent 255b.
Subsequently, as shown in FIG. 13B, the thin film integrated circuit connected to the flexible circuit 257 is divided in a region where the conductive layers 252a and 252b serving as antennas and the thin film integrated circuits 242a and 242b are not formed. Here, division is carried out by a laser cut method in which the insulating layer 253 and the flexible substrate 256 are irradiated with laser light 256.
Through the above step, as shown in FIG. 13C, semiconductor devices 262a and 262b capable of transmitting and receiving data wirelessly can be manufactured.
It is to be noted that the following step may be performed: the flexible substrate 256 that has the conductive layers 252a and 252b serving as antennas and the thin film integrated circuits 242a and 242b are attached to each other with the use of the anisotropic conductive adhesive agents 255a and 255b as shown in FIG. 13A; a flexible substrate is provided to seal the flexible substrate 256 and the thin film integrated circuits 242a and 242b; the region where the conductive layers 252a and 252b serving as antennas and the thin film integrated circuits 242a and 242b are not formed is irradiated with the laser light 261 as shown in FIG. 13B; and a semiconductor device 264 as shown in FIG. 13D is manufactured. In this case, the thin film integrated circuit is sealed by the flexible substrate 256 and a flexible substrate 263 that are divided, whereby deterioration of the thin film integrated circuit can be suppressed.
This application is based on Japanese Patent Application serial no. 2005-327951 filed in Japan Patent Office on November 11 in 2005, the entire contents of which are hereby incorporated by reference.
connecting the conductive layer and a connection terminal of an integrated circuit electrically each other.
39. A method for manufacturing a semiconductor device, comprising the steps of:
forming a first peeling layer comprising a silane coupling agent over a first substrate;
forming a first conductive layer over the first peeling layer;
forming a first insulating layer covering the first conductive layer;
peeling the first conductive layer and the first insulating layer from the first substrate;
attaching a second substrate to the first conductive layer and the first insulating layer;
forming a second peeling layer comprising a silane coupling agent over a third substrate
forming a second conductive layer over the second peeling layer;
forming a second insulating layer covering the second conductive layer;
peeling the second conductive layer and the second insulating layer from the third substrate;
attaching a fourth substrate to the second conductive layer and the second insulating layer;
forming a sealant over the second substrate or the fourth substrate;
attaching the second substrate having the first conductive layer and the first insulating layer and the fourth substrate having the second conductive layer and the second insulating layer with the sealant.
40. A method for manufacturing a semiconductor device, comprising the steps of:
forming a first peeling layer in which oxygen and silicon are combined and an inactive group is combined with the silicon over a first substrate;
peeling the first conductive layer and the first insulating layer from the first substrate at a portion including the first peeling layer or at a boundary between the first peeling layer and the first conductive layer;
forming a second peeling layer in which oxygen and silicon are combined and an inactive group is combined with the silicon over a third substrate;
peeling the second conductive layer and the second insulating layer from the third substrate at a portion including the second peeling layer or at a boundary between the second peeling layer and the second conductive layer;
41. A method for manufacturing a semiconductor device according to claim 39, further comprising:
attaching a first adhesive to the first insulating layer after forming the first insulating layer.
42. A method for manufacturing a semiconductor device according to claim 40, further comprising:
43. A method for manufacturing a semiconductor device according to claim 39, further comprising:
attaching a second adhesive to the second insulating layer after forming the second insulating layer.
44. A method for manufacturing a semiconductor device according to claim 40, further comprising:
45. A method for manufacturing a semiconductor device according to claim 40, further comprising:
removing a remaining peeling layer after peeling the first conductive layer and the first insulating layer.
46. A method for manufacturing a semiconductor device according to claim 39, wherein the first conductive layer is a pixel electrode.
47. A method for manufacturing a semiconductor device according to claim 40, wherein the first conductive layer is a pixel electrode.
48. A method for manufacturing a semiconductor device according to claim 39, wherein the second conductive layer is an opposite electrode.
49. A method for manufacturing a semiconductor device according to claim 40, wherein the second conductive layer is an opposite electrode.
50. A method for manufacturing a semiconductor device according to claim 39, wherein the first peeling layer and the second peeling layer are formed by coating with the silane coupling agent.
51. A method for manufacturing a semiconductor device according to claim 39, wherein each of the first substrate and the third substrate is a substrate selected from the group consisting of a glass substrate, a quartz substrate, a ceramic substrate, a metal substrate and a silicon wafer.
52. A method for manufacturing a semiconductor device according to claim 40, wherein each of the first substrate and the third substrate is a substrate selected from the group consisting of a glass substrate, a quartz substrate, a ceramic substrate, a metal substrate and a silicon wafer.
53. A method for manufacturing a semiconductor device according to claim 39, wherein each of the second substrate and the fourth substrate is a flexible substrate.
54. A method for manufacturing a semiconductor device according to claim 40, wherein each of the second substrate and the fourth substrate is a flexible substrate.
Publication number: 20070111391
Patent Grant number: 7632740
Inventors: Tomoyuki Aoki (Atsugi), Takuya Tsurume (Atsugi)
Application Number: 11/592,249
Current U.S. Class: 438/118.000