Peeling method

Patent metadata

Field	Value
Publication number	US-9735398-B2
Application number	US-201414450463-A
Country	US
Kind code	B2
Filing date	Aug 4, 2014
Priority date	Aug 6, 2013
Publication date	Aug 15, 2017
Grant date	Aug 15, 2017

Abstract

To improve the yield in a peeling process and improve the yield in a manufacturing process of a flexible light-emitting device or the like, a peeling method includes a first step of forming a peeling layer over a first substrate, a second step of forming a layer to be peeled including a first layer in contact with the peeling layer over the peeling layer, a third step of curing a bonding layer in an overlapping manner with the peeling layer and the layer to be peeled, a fourth step of removing part of the first layer overlapping with the peeled layer and the bonding layer to form a peeling starting point, and a fifth step of separating the peeling layer and the layer to be peeled. The peeling starting point is preferably formed by laser light irradiation.

First claim

What is claimed is:

1. A manufacturing method comprising:
forming a peeling layer over a first substrate;
forming a first layer over and in contact with the peeling layer;
forming a functional element over the peeling layer;
attaching the first substrate and a second substrate to each other with a bonding layer and a frame-shaped partition surrounding the bonding layer, wherein the second substrate faces the functional element with the bonding layer therebetween;
curing the bonding layer, wherein an end portion of the bonding layer is positioned on an inner side than an end portion of the peeling layer; and
separating the peeling layer and the first layer,
wherein the frame-shaped partition is formed over the second substrate so as to comprise a slit at a corner.

2. The manufacturing method according to claim 1 , further comprising:
forming a peeling starting point by removing part of the first layer by laser light irradiation.

3. The manufacturing method according to claim 2 ,
wherein the frame-shaped partition is in an uncured or semi-cured state in the step of forming the peeling starting point, and
wherein the part of the first layer overlaps with the peeling layer and the bonding layer.

4. The manufacturing method according to claim 2 ,
wherein the frame-shaped partition is in a cured state in the step of forming the peeling starting point, and
wherein the part of the first layer overlaps with the peeling layer and the frame-shaped partition.

5. The manufacturing method according to claim 4 ,
wherein part of the frame-shaped partition exists between the first layer and the second substrate after separating the peeling layer and the first layer.

6. The manufacturing method according to claim 1 ,
wherein the frame-shaped partition is in contact with the bonding layer in the step of curing the bonding layer.

7. The manufacturing method according to claim 1 ,
wherein the frame-shaped partition and the bonding layer are formed over the second substrate before attaching the first substrate and the second substrate to each other.

8. The manufacturing method according to claim 7 ,
wherein the frame-shaped partition is formed before the bonding layer is formed.

9. The manufacturing method according to claim 1 ,
wherein the first layer is an insulating layer, and
wherein the functional element includes any one of a semiconductor element, a light-emitting element, and a display element.

10. A manufacturing method comprising:
forming a first peeling layer over a first substrate;
forming a first layer over the first peeling layer, wherein the first layer includes a second layer which is in contact with the first peeling layer;
forming a second peeling layer over a second substrate;
forming a third layer over the second peeling layer, wherein the third layer includes a fourth layer which is in contact with the second peeling layer;
attaching the first substrate and the second substrate to each other with a first bonding layer and a frame-shaped partition surrounding the first bonding layer, wherein the first layer faces the third layer with the first bonding layer therebetween;
curing the first bonding layer, wherein an end portion of the first bonding layer is positioned on an inner side than an end portion of the first peeling layer;
forming a first peeling starting point by removing part of the second layer;
separating the first peeling layer and the first layer from the first peeling starting point;
attaching the first layer and a third substrate to each other with a second bonding layer and curing the second bonding layer;
forming a second peeling starting point by removing part of the fourth layer; and
separating the second peeling layer and the third layer from the second peeling starting point.

11. The manufacturing method according to claim 10 ,
wherein the first peeling starting point and the second peeling starting point are each fainted by laser light irradiation.

12. The manufacturing method according to claim 10 , wherein an end portion of the second peeling layer is positioned on an inner side than the end portion of the first bonding layer in the step of curing the first bonding layer.

13. The manufacturing method according to claim 10 ,
wherein the first layer includes a light-emitting element, and
wherein the third layer includes a color filter.

14. The manufacturing method according to claim 10 ,
wherein the frame-shaped partition is in a cured state in the step of forming the first peeling starting point, and
wherein the part of the second layer overlaps with the first bonding layer and the frame-shaped partition.

15. The manufacturing method according to claim 14 ,
wherein the first layer includes part of the frame-shaped partition after separating the first peeling layer and the first layer.

16. The manufacturing method according to claim 10 ,
wherein the frame-shaped partition is a first frame-shaped partition, and
wherein a second frame-shaped partition surrounding the second bonding layer is provided before attaching the first layer and the third substrate to each other.

17. The manufacturing method according to claim 16 ,
wherein the second frame-shaped partition is in a cured state in the step of forming the second peeling starting point, and
wherein the part of the fourth layer overlaps with the second bonding layer and the second frame-shaped partition.

18. A manufacturing method comprising:
forming a first peeling layer over a first substrate;
forming a first layer over the first peeling layer, wherein the first layer includes a second layer which is in contact with the first peeling layer;
forming a second peeling layer over a second substrate;
forming a third layer over the second peeling layer, wherein the third layer includes a fourth layer which is in contact with the second peeling layer;
attaching the first substrate and the second substrate to each other with a first bonding layer and a frame-shaped partition surrounding the first bonding layer, wherein the first layer faces the third layer with the first bonding layer therebetween;
curing the first bonding layer, wherein an end portion of the first bonding layer is positioned on an inner side than each end portions of the first peeling layer and the second peeling layer;
forming a first peeling starting point by removing part of the second layer;
separating the first peeling layer and the first layer from the first peeling starting point;
attaching the first layer and a third substrate to each other with a second bonding layer and curing the second bonding layer;
forming a second peeling starting point by removing part of the third substrate, part of the second bonding layer, part of the fourth layer and part of the second peeling layer; and
separating the second peeling layer and the third layer from the second peeling starting point.

19. The manufacturing method according to claim 18 ,
wherein the first peeling starting point is formed by laser light irradiation, and
wherein the second peeling starting point is formed by using a knife.

20. The manufacturing method according to claim 18 ,
wherein the first layer includes a light-emitting element, and
wherein the third layer includes a color filter.

21. A manufacturing method comprising:
forming a first peeling layer over a first substrate;
forming a first layer over and in contact with the first peeling layer;
forming a second peeling layer over a second substrate;

Assignees

• Semiconductor Energy Lab

Inventors

• Aoyama Tomoya
• Chida Akihiro
• Komatsu Ryu

Classifications

• H01L51/56 Primary

  Electricity · mapped topic

• H01L51/524

  Electricity · mapped topic

• H01L51/003

  Electricity · mapped topic

• H01L51/0024

  Electricity · mapped topic

• H10K71/421

  using coherent electromagnetic radiation, e.g. laser annealing · CPC title