Glass pattern and method for forming the same, sealed body and method for manufacturing the same, and light-emitting device

• US 9,299,943 B2
• Filed: 11/27/2012
• Issued: 03/29/2016
• Est. Priority Date: 11/28/2011
• Status: Expired due to Fees

• Current Assignee: Semiconductor Energy Laboratory Co., Ltd.
• Original Assignee: Semiconductor Energy Laboratory Co., Ltd.
• Inventors: Shimomura, Akihisa, Yoshizumi, Kensuke
• Primary Examiner(s): ARORA, AJAY
• Application Number:
  US13/686,157
• Publication Number:
  US 20130134396A1
• Time in Patent Office: 1,218 Days
• Field of Search: 438/125
• US Class Current: 1/1
• CPC Class Codes: C03B 23/203 Uniting glass sheets C03B23/24 takes precedence
• CPC Class Codes: C03B 23/24 Making hollow glass sheets or bricks
• CPC Class Codes: H10K 50/11 characterised by the electroluminescent [EL] layers
• CPC Class Codes: H10K 50/8426 Peripheral sealing arrangements, e.g. adhesives, sealants
• CPC Class Codes: Y02P 40/57 Improving the yield, e-g- reduction of reject rates
• CPC Class Codes: Y10T 428/1317 Multilayer [continuous layer]
• CPC Class Codes: Y10T 428/197 with noncoplanar reinforcement

Abstract

A glass pattern that can be used for a substrate provided with a material having low heat resistance and has increased productivity is provided. Further, a sealed body having high hermeticity and increased productivity is provided. Furthermore, a light-emitting device with high reliability including such a sealed body is provided. A glass sheet is used for a main portion of a glass pattern such as a straight line portion and a curved portion. In a joint portion of two glass sheets arranged in the corner portion, the straight line portion, or the like of the glass pattern, a frit paste is provided in contact with the glass sheets and is locally heated to remove the binder from the frit paste and to form a glass layer; thus, the glass sheets are fused to each other without any space provided therebetween.

Claims

1. A method for manufacturing a sealed body, comprising the steps of:

providing a first glass sheet and a second glass sheet over a first substrate so that the first glass sheet and the second glass sheet do not overlap with each other;

applying a frit paste including a glass frit and a binder so that a layer of the frit paste is in contact with a first side surface of the first glass sheet and a side surface of the second glass sheet;

forming a glass layer by heating the layer of the frit paste to remove the binder from the layer of the frit paste;

bonding a second substrate and the first substrate in a position in which the second substrate is in contact with a top surface of the first glass sheet, a top surface of the second glass sheet, and a top surface of the glass layer such that the second substrate does not overlap a part of the top surface of the first glass sheet; and

irradiating in the position the first glass sheet, the second glass sheet, and the glass layer with laser light,

wherein irradiating the first glass sheet with the laser light is conducted by oblique irradiation such that a second side surface of the first glass sheet and the part of the top surface of the first glass sheet are irradiated with the laser light.

4. The method for manufacturing a sealed body according to claim 1,

wherein the binder comprises an organic resin.

7. The method for manufacturing a sealed body according to claim 1,

wherein forming the glass layer is performed by providing an electrically conductive material over the fit paste and by induction heating.

10. The method for manufacturing a sealed body according to claim 1,

wherein a thickness of the first glass sheet and a thickness of the second glass sheet are greater than or equal to 3 μ

m and less than or equal to 100 μ

m.

13. The method for manufacturing a sealed body according to claim 1,

wherein a light-emitting element is provided in a closed space -surrounded by the first substrate, the second substrate, the first glass sheet, the second glass sheet.

16. The method for manufacturing a sealed body according to claim 1,

wherein the first glass sheet and the second glass sheet are provided over the first substrate by pulling out a glass sheet wound on a reel and cutting the glass sheet pulled out.

2. A method for manufacturing a sealed body, comprising the steps of:

providing a first glass sheet, a second glass sheet, a third glass sheet, and a fourth glass sheet over a first substrate so that the first glass sheet, the second glass sheet, the third glass sheet, and the fourth glass sheet do not overlap with each other;

applying a frit paste including a glass frit and a binder so that one of layers of the frit paste is in contact with a first side surface of the first glass sheet and a side surface of the second glass sheet; and

forming glass layers by heating the layers of the frit paste to remove the binder from the layers of the frit paste,

bonding a second substrate and the first substrate in a position in which the second substrate is in contact with a top surface of the first glass sheet, a top surface of the second glass sheet, a top surface of the third glass sheet, a top surface of the fourth glass sheet, and top surfaces of the glass layers such that the second substrate does not overlap a part of the top surface of the first glass sheet; and

irradiating in the position the first glass sheet, the second glass sheet, the third glass sheet, the fourth glass sheet, and the glass layers with laser light,

wherein irradiating the first glass sheet with the laser light is conducted by oblique irradiation such that a second side surface of the first glass sheet and the part of the top surface of the first glass sheet are irradiated with the laser light.

5. The method for manufacturing a sealed body according to claim 2,

wherein the binder comprises an organic resin.

8. The method for manufacturing a sealed body according to claim 2,

wherein forming the glass layers is performed by providing an electrically conductive material over the frit paste and by induction heating.

11. The method for manufacturing a sealed body according to claim 2,

wherein thicknesses of each of the first glass sheet, the second glass sheet, the third glass sheet, and the fourth glass sheet are greater than or equal to 3 μ

m and less than or equal to 100 μ

m.

14. The method for manufacturing a sealed body according to claim 2,

wherein a light-emitting element is provided in a closed space surrounded by the first substrate, the second substrate, the first glass sheet, the second glass sheet, the third glass sheet, the fourth glass sheet.

17. The method for manufacturing a sealed body according to claim 2,

wherein the first glass sheet, the second glass sheet, the third glass sheet and the fourth glass sheet are provided over the first substrate by pulling out a glass sheet wound on a reel and cutting the glass sheet pulled out.

3. A method for manufacturing a sealed body, comprising the steps of:

providing a plurality of glass sheets over a first substrate;

applying a frit paste including a glass frit and a binder so that each of a plurality of layers of the frit paste is in contact with side surfaces facing each other of two of the plurality of glass sheets, which are adjacent;

forming a plurality of glass layers by heating the plurality of layers of the frit paste to remove the binder from each of the plurality of layers of the frit paste;

bonding a second substrate and the first substrate in a position in which the second substrate is in contact with top surfaces of the plurality of glass sheets and top surfaces of the plurality of glass layers such that the second substrate does not overlap a part of the top surface of at least one of the plurality of glass sheets; and

irradiating in the position the plurality of glass sheets and the plurality of glass layers with laser light,

wherein irradiating the one of the plurality of glass sheets with the laser light is conducted by oblique irradiation such that another side surface of the one of the plurality of glass sheets and the part of the top surface of one of the plurality of glass sheets are irradiated with the laser light.

6. The method for manufacturing a sealed body according to claim 3,

wherein the binder comprises an organic resin.

9. The method for manufacturing a sealed body according to claim 3,

wherein forming the plurality of glass layers is performed by providing an electrically conductive material over the fit paste and by induction heating.

12. The method for manufacturing a sealed body according to claim 3,

wherein a thickness of the plurality of glass sheets are greater than or equal to 3 μ

m and less than or equal to 100 μ

m.

15. The method for manufacturing a sealed body according to claim 3,

wherein a light-emitting element is provided in a closed space surrounded by the first substrate, the second substrate, the plurality of glass sheets.

18. The method for manufacturing a sealed body according to claim 3,

wherein the plurality of glass sheets are provided over the first substrate by pulling out a glass sheet wound on a reel and cutting the glass sheet pulled out.