PROCESS FOR FABRICATING A FLEXIBLE ELECTRONIC DEVICE OF THE SCREEN TYPE, INCLUDING A PLURALITY OF THIN-FILM COMPONENTS

• US 20080309867A1
• Filed: 11/20/2006
• Published: 12/18/2008
• Est. Priority Date: 11/22/2005
• Status: Abandoned Application

• Current Assignee: Vida Kampstra
• Original Assignee: Vida Kampstra
• Inventors: Kampstra, Vida
• Application Number:
  US12/094,521
• Publication Number:
  US 20080309867A1
• Time in Patent Office: Days
• US Class Current: 349/158
• CPC Class Codes: B32B 17/06 comprising glass as the main or only constituent of a layer, next to another layer of a specific material
• CPC Class Codes: B32B 2307/206 Insulating
• CPC Class Codes: B32B 2307/702 Amorphous
• CPC Class Codes: B32B 2457/202 LCD, i.e. liquid crystal displays
• CPC Class Codes: B32B 2457/206 Organic displays, e.g. OLED
• CPC Class Codes: C03C 27/06 Joining glass to glass by processes other than fusing fusing C03B23/20; units for use as elements for closing wall or like openings and comprising two or more parallel glass panes in spaced relationship, the panes being permanently secured together E06B3/66
• CPC Class Codes: G02F 1/133305 Flexible substrates, e.g. plastics, organic film
• CPC Class Codes: H01L 27/1214 comprising a plurality of TFTs formed on a non-semiconducting substrate, e.g. driving circuits for AMLCDs
• CPC Class Codes: H01L 27/1266 the substrate on which the devices are formed not being the final device substrate, e.g. using a temporary substrate
• CPC Class Codes: H01L 29/78603 characterised by the insulating substrate or support H01L29/78657 takes precedence
• CPC Class Codes: H10K 2102/311 Flexible OLED
• CPC Class Codes: H10K 59/12 Active-matrix OLED [AMOLED] displays
• CPC Class Codes: H10K 59/1201 Manufacture or treatment
• CPC Class Codes: H10K 59/17 Passive-matrix OLED displays
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 71/80 using temporary substrates
• CPC Class Codes: H10K 77/111 Flexible substrates
• CPC Class Codes: Y02E 10/549 Organic PV cells

Abstract

In the fabrication of a thin-film flexible electronic device of the screen type that includes a plurality of thin-film components on a glass support a starting support is prepared, including a rigid bulk substrate and a glass sheet fastened to the rigid bulk substrate by reversible direct bonding so as to obtain a removable interface. The plurality of thin-film components are fabricated on the glass sheet. The glass sheet is separated from the rigid bulk substrate by disassembling the interface and, the glass sheet and the plurality of thin-film components are transferred to a final support.

Claims

1. A process for fabricating a flexible electronic device of the screen type, including a plurality of thin layer components on a glass support, the process comprising:

preparing a starting support including a rigid bulk substrate and a glass film attached to the rigid bulk substrate by reversible direct bonding to obtain a debondable interface;

fabricating the plurality of thin layer components on the glass film; and

separating the glass film from the rigid bulk substrate by debonding the interface.

2. The process according to claim 1, further comprising transferring a glass film and the plurality of thin layer components onto a final support.

3. The process according to claim 1, wherein preparing the starting support comprises bonding the glass film to a rigid glass substrate.

4. The process according to claim 1, wherein preparing a starting support further comprises performing a preparation treatment adapted to render surfaces to be bonded hydrophilic prior to the reversible direct bonding.

5. The process according to claim 1, wherein surfaces to be bonded have a roughness less than one nanometer.

6. The process according to claim 5, wherein the roughness of the surfaces to be bonded is less than 0.5 nanometer.

7. The process according to claim 1, wherein preparing the starting support further comprises bonding the rigid bulk support to a glass plate and applying a thinning treatment to the thickness of the glass plate to a required value.

8. The process according to claim 1, wherein the glass film has a thickness at most equal to 100 microns.

9. The process according to claim 8, wherein the glass film has a thickness at most equal to 50 microns.

10. A process according to claim 1, wherein fabricating a plurality of thin layer components comprises a step of fabricating an active matrix of pixels on the glass film and a step of fabricating a display layer on top of the active matrix of pixels, whereby an active matrix screen is obtained after separating the glass film.

11. The process according to claim 10, wherein fabricating the active matrix of pixels comprises forming components in TFT type thin layers.

12. The process according to claim 10, wherein fabricating the display layer comprises forming organic light-emitting components of OLED type.

13. The process according to claim 1, further comprising depositing an electrophoretic layer by a rolling process to obtain an electrophoretic screen.

14. The process according to claim 1, wherein an LCD screen is produced.

15. The process according to claim 1, wherein separating the glass film from the rigid bulk support comprises inserting a blade.

16. The process according to claim 1, further comprising transferring the glass film and the components that are formed thereon to a flexible plastic material film.

17. The process according to claim 1, further comprising transferring the glass film and the components that are formed thereon to a flexible metal film.

25. A starting support for fabricating a thin layer flexible electronic device of the screen type by the process according to claim 1 including a rigid bulk substrate and a glass film fastened to the rigid bulk substrate by direct reversible bonding to obtain a debondable interface.

26. The support according to claim 25, wherein at least the surface of the rigid substrate comprises glass.

18. A flexible electronic device of the screen type comprising a plurality of thin layer electronic components on a support comprising a glass film having a thickness at most equal to 100 microns, such that significant flexibility it is imparted thereto.

19. The device according to claim 18, wherein the glass film has a thickness at most equal to 50 microns.

20. The device according to claim 18, wherein the plurality of components include a layer formed of an active matrix of pixels and a display layer covering the active matrix of pixels.

21. The device according to claim 18, wherein the device comprises an organic light-emitting diode screen.

22. The device according to claim 18, wherein the device comprises an electrophoretic screen.

23. The device according to claim 18, wherein the device comprises an LCD screen.

24. The device according to claim 18, wherein the electronic components emit light through the glass film.