Methods for processing electronic devices
First Claim
1. A method of making an electronic device, comprising:
- obtaining a carrier having a carrier bonding surface;
obtaining a sheet having a sheet bonding surface, the sheet comprising glass;
disposing a surface modification layer on one of the carrier bonding surface and the sheet bonding surface, wherein the surface modification layer comprises one of;
a) a plasma polymerized fluoropolymer; and
b) an aromatic silane;
bonding the carrier bonding surface with the sheet bonding surface with the surface modification layer therebetween to form an article, the surface modification layer being in contact with both the carrier bonding surface and the sheet bonding surface, so that the surface energy bonding the sheet to the carrier is of such a character that after subjecting the article to a temperature cycle by heating in an chamber cycled from room temperature to 600°
C. at a rate of 9.2°
C. per minute, held at a temperature of 600°
C. for 10 minutes, and then cooled at 1°
C. per minute to 300°
C., and then removing the article from the chamber and allowing the article to cool to room temperature, the carrier and sheet do not separate from one another if one is held and the other subjected to the force of gravity, there is no outgassing from the surface modification layer during the temperature cycle, and the sheet may be separated from the carrier without breaking the thinner one of the carrier and the sheet into two or more pieces, wherein the carrier and the sheet have different thicknesses;
disposing an electronic-device component onto the sheet.
1 Assignment
0 Petitions
Accused Products
Abstract
Methods for making electronic devices on thin sheets bonded to carriers. A surface modification layer and associated heat treatments, may be provided on a sheet, a carrier, or both, to control both room-temperature van der Waals (and/or hydrogen) bonding and high temperature covalent bonding between the thin sheet and carrier during the electronic device processing. The room-temperature bonding is controlled so as to be sufficient to hold the thin sheet and carrier together during vacuum processing, wet processing, and/or ultrasonic cleaning processing, during the electronic device processing. And at the same time, the high temperature covalent bonding is controlled so as to prevent a permanent bond between the thin sheet and carrier during high temperature processing, during the electronic device processing, as well as maintain a sufficient bond to prevent delamination during high temperature processing.
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Citations
23 Claims
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1. A method of making an electronic device, comprising:
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obtaining a carrier having a carrier bonding surface; obtaining a sheet having a sheet bonding surface, the sheet comprising glass; disposing a surface modification layer on one of the carrier bonding surface and the sheet bonding surface, wherein the surface modification layer comprises one of; a) a plasma polymerized fluoropolymer; and b) an aromatic silane; bonding the carrier bonding surface with the sheet bonding surface with the surface modification layer therebetween to form an article, the surface modification layer being in contact with both the carrier bonding surface and the sheet bonding surface, so that the surface energy bonding the sheet to the carrier is of such a character that after subjecting the article to a temperature cycle by heating in an chamber cycled from room temperature to 600°
C. at a rate of 9.2°
C. per minute, held at a temperature of 600°
C. for 10 minutes, and then cooled at 1°
C. per minute to 300°
C., and then removing the article from the chamber and allowing the article to cool to room temperature, the carrier and sheet do not separate from one another if one is held and the other subjected to the force of gravity, there is no outgassing from the surface modification layer during the temperature cycle, and the sheet may be separated from the carrier without breaking the thinner one of the carrier and the sheet into two or more pieces, wherein the carrier and the sheet have different thicknesses;disposing an electronic-device component onto the sheet. - View Dependent Claims (2, 3)
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4. A method of making an electronic device, comprising:
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obtaining an article;
the article comprising;a carrier having a carrier bonding surface; a sheet having a sheet bonding surface, the sheet comprising glass; a surface modification layer disposed on one of the carrier bonding surface and the sheet bonding surface;
wherein the surface modification layer comprises one of;a) a plasma polymerized fluoropolymer; and b) an aromatic silane, the carrier bonding surface being bonded with the sheet bonding surface with the surface modification layer therebetween, the surface modification layer being in contact with both the carrier bonding surface and the sheet bonding surface, wherein the surface energy bonding the sheet to the carrier is of such a character that after subjecting the article to a temperature cycle by heating in an chamber cycled from room temperature to 600°
C. at a rate of 9.2°
C. per minute, held at a temperature of 600°
C. for 10 minutes, and then cooled at 1°
C. per minute to 300°
C., and then removing the article from the chamber and allowing the article to cool to room temperature, the carrier and sheet do not separate from one another if one is held and the other subjected to the force of gravity, there is no outgassing from the surface modification layer during the temperature cycle, and the sheet may be separated from the carrier without breaking the thinner one of the carrier and the sheet into two or more pieces, wherein the carrier and the sheet have different thicknesses;disposing an electronic-device component onto the sheet. - View Dependent Claims (5, 6, 7, 8, 9, 10, 11, 12, 13, 14, 15, 16, 17, 18, 19, 20, 21, 22, 23)
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Specification