Patent Application
20170084838
1. Field of the Invention
The present disclosure relates to an electronic device and a method for manufacturing the same and, more particularly, to a method for manufacturing an electronic device with a UV release layer and an electronic device manufactured by the method of the present disclosure.
2. Description of Related Art
As the demand for thin and light electronic devices, conventional glass substrate of the display panel is replaced by flexible substrate which is a thin glass having a thickness between 0.01 mm to 0.3 mm or a plastic substrate.
However, rigidity of the flexible substrate is not high enough for the current used process. Therefore, it is hard to form electronic units thereon through the current used process for manufacturing the electronic device.
In order to obtain the electronic device with the flexible substrate manufactured through the current used process, the flexible substrate is loaded on another carrier to increase the rigidity thereof, and then the flexible substrate is separated from the carrier after finishing electronic unit formation process.
On the other hand, the plastic substrate is also used for preparing a flexible organic light emitting diode (OLED) display device. In the process for manufacturing the OLED display device with the plastic substrate, a sealant layer is formed on a carrier via the conventional thermal release layer, and then transferred onto OLED units. After the sealant layer is cured, a thermal treatment is used to de-bond the carrier from the obtained OLED display device. However, the heat used for curing the sealant layer may cause the thermal release layer degraded, resulting in the OLED unit and/or the sealant layer uneven.
Therefore, it is desirable to provide a novel method for manufacturing an electronic device (including the OLED display device), wherein the carrier can be removed easily without damaging the obtained electronic device.
The object of the present disclosure is to provide a method for manufacturing an electronic device by using a UV release layer comprising a gas-releasing molecule. After UV irradiation, the gas-releasing molecule can be degraded to generate gas; and therefore, the carrier used in the manufacturing process can be easily removed by degrading the UV release layer. In addition, the present disclosure also provides an electronic device obtained by the method of the present disclosure.
To achieve the object, the method for manufacturing an electronic device comprises the following steps: providing a target unit and a carrier with a UV release layer formed thereon, wherein the carrier is adhered to the target unit, the UV release layer is disposed between the target unit and the carrier, the UV release layer comprises a polymer and a gas-releasing molecule, and the target unit comprises an electronic unit layer; and irradiating the UV release layer with UV light to degrade the gas-releasing molecule and separate the target unit from the carrier to obtain an electronic device. Herein, the gas-releasing molecule comprises at least one selected from the group consisting of
wherein each of R1, R1′, R2, R2′ and R9 independently, is C1-10 alkyl;
each of R3 and R3′ independently, is C1-10 alkyl, C2-10 alkenyl, or C3-20 cycloalkyl;
in which each of R4, and
R5 independently, is C1-10 alkyl; R6 is H or C1-10 alkyl; and each of R7 and R8 independently, is C1-10 alkoxy.
After the target unit is separated from the carrier, small molecule residues degraded from the UV release layer may remain on the target unit. Hence, after the method of the present disclosure, and electronic device can be obtained, which comprises: a target unit comprising an electronic unit layer; and small molecule residues adhered on a side of the target unit. Herein, the small molecule residues are at least one selected from the group consisting of
wherein each of R1, R1′, R2, R2′, R4, and R5 independently, is C1-10 alkyl;
each of R3 and R3′ independently, is C1-10 alkyl, C2-10 alkenyl, or C3-20 cycloalkyl;
R6 is H or C1-10 alkyl; and
each of R7 and R8 independently, is C1-10 alkoxy.
In addition, in the method of the present disclosure, preferably, the gas-releasing molecule comprises at least one selected from the group consisting of
wherein each of Rd and Re independently, is C2-6 alkyl;
R9 is C1-5 alkyl;
in which R6 is H or methyl; and each of R7 and R8 independently, is methoxy or ethoxy.
When the gas-releasing molecule comprises the aforementioned preferable molecules, the small molecule residues remained on the electronic device after UV irradiation preferably are at least one selected from the group consisting of
and
wherein each of Ra, Rb and Rc independently, is C2-6 alkyl;
R6 is H or methyl; and
each of R7 and R8 independently, is methoxy or ethoxy.
In the present disclosure, alkyl, alkenyl, cycloalkyl, alkoxy, phenyl present in the small molecule residues and the gas-releasing molecule include both substituted and unsubstituted moieties, unless specified otherwise. Possible substituents on alkyl, alkenyl, cycloalkyl and alkoxy include, but are not limited to, alkyl, halogen, alkoxy, heterocyclic group or aryl; but alkyl cannot be substituted with alkyl.
In the present disclosure, the term “halogen” includes F, Cl, Br and I; and preferably is F, Cl or Br. The term “alkyl” refers to linear and branched alkyl; preferably, includes linear or branched C1-10 alkyl; and more preferably, includes linear or branched C1-6 alkyl. Specific examples of alkyl include, but are not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, tert-butyl, pentyl, neo-pentyl or hexyl. The term “alkenyl” refers to a linear or branched hydrocarbon moiety that contains at least one double bond; preferably, includes a linear or branched hydrocarbon C2-10 moiety containing at least one double bond; and more preferably, includes a linear or branched hydrocarbon C2-6 moiety containing at least one double bond. Specific examples of alkenyl include, but are not limited to, ethenyl, propenyl, allyl, or 1,4-butadienyl. The term “alkoxy” refers to a moiety that the alkyl defined in the present disclosure coupled with an oxygen atom; preferably, includes linear or branched C1-10 alkoxy; and more preferably, includes linear or branched C1-6 alkoxy. Specific examples of alkoxy include, but are not limited to, methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, iso-butoxy, sec-butoxy, tert-butoxy, pentyloxy, neo-pentyloxy or hexyloxy. The term “cycloalkyl” refers to a monovalent saturated hydrocarbon ring system having 3 to 20 carbon atoms; and preferably having 3 to 12 carbon atoms. Specific examples of cycloalkyl include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, and cyclooctyl. The term “heterocyclic group” refers to a 5-8 membered monocyclic, 8-12 membered bicyclic or 11-14 membered tricyclic heteroaryl or heterocycloalkyl having at least one heteroatom which is selected from the group consisting of O, S and N. Specific examples of heterocyclic group include, but are not limited to, pyridyl, pyrimidinyl, furyl, thiazolyl, imidazolyl or thienyl. The term “aryl” refers to a monovalent 6-carbon monocyclic, 10-carbon bicyclic, or 14-carbon tricyclic aromatic ring system. Specific examples of aryl include, but are not limited to, phenyl, naphthyl, pyrenyl, anthracenyl or phenanthryl; and preferably, the aryl is phenyl.
In the method of the present disclosure, the conventional thermal release layer is substituted with a UV release layer, which does not degrade during the curing process of the sealant layer; therefore, the aforementioned problem can be solved. Other objects, advantages, and novel features of the disclosure will become more apparent from the following detailed description when taken in conjunction with the accompanying drawings.
The present disclosure has been described in an illustrative manner, and it is to be understood that the terminology used is intended to be in the nature of description rather than of limitation. Many modifications and variations of the present disclosure are possible in light of the above teachings. Therefore, it is to be understood that within the scope of the appended claims, the disclosure may be practiced otherwise than as specifically described.
In the following embodiments and other embodiments of the present disclosure, alkyl, alkenyl, cycloalkyl, alkoxy, phenyl present in the small molecule residues and the gas-releasing molecule include both substituted and unsubstituted moieties, unless specified otherwise. Possible substituents on alkyl, alkenyl, cycloalkyl and alkoxy include, but are not limited to, alkyl, halogen, alkoxy, heterocyclic group or aryl; but alkyl cannot be substituted with alkyl.
In addition, in the following embodiments and other embodiments of the present disclosure, the term “halogen” includes F, Cl, Br and I; and preferably is F, Cl or Br. The term “alkyl” refers to linear and branched alkyl; preferably, includes linear or branched C1-10 alkyl; and more preferably, includes linear or branched C1-6 alkyl. Specific examples of alkyl include, but are not limited to, methyl, ethyl, n-propyl, iso-propyl, n-butyl, sec-butyl, iso-butyl, tert-butyl, pentyl, neo-pentyl or hexyl. The term “alkenyl” refers to a linear or branched hydrocarbon moiety that contains at least one double bond; preferably, includes a linear or branched hydrocarbon C2-10 moiety containing at least one double bond; and more preferably, includes a linear or branched hydrocarbon C2-6 moiety containing at least one double bond. Specific examples of alkenyl include, but are not limited to, ethenyl, propenyl, allyl, or 1,4-butadienyl. The term “alkoxy” refers to a moiety that the alkyl defined in the present disclosure coupled with an oxygen atom; preferably, includes linear or branched C1-10 alkoxy; and more preferably, includes linear or branched C1-6 alkoxy. Specific examples of alkoxy include, but are not limited to, methoxy, ethoxy, n-propoxy, iso-propoxy, n-butoxy, iso-butoxy, sec-butoxy, tert-butoxy, pentyloxy, neo-pentyloxy or hexyloxy. The term “cycloalkyl” refers to a monovalent saturated hydrocarbon ring system having 3 to 20 carbon atoms; and preferably having 3 to 12 carbon atoms. Specific examples of cycloalkyl include, but are not limited to, cyclopropyl, cyclobutyl, cyclopentyl, cyclohexyl, cycloheptyl, and cyclooctyl. The term “heterocyclic group” refers to a 5-8 membered monocyclic, 8-12 membered bicyclic or 11-14 membered tricyclic heteroaryl or heterocycloalkyl having at least one heteroatom which is selected from the group consisting of O, S and N. Specific examples of heterocyclic group include, but are not limited to, pyridyl, pyrimidinyl, furyl, thiazolyl, imidazolyl or thienyl. The term “aryl” refers to a monovalent 6-carbon monocyclic, 10-carbon bicyclic, or 14-carbon tricyclic aromatic ring system. Specific examples of aryl include, but are not limited to, phenyl, naphthyl, pyrenyl, anthracenyl or phenanthryl; and preferably, the aryl is phenyl.
As shown in
In the present embodiment, the material of the carrier 13 is not particularly limited; as long as the carrier can be applied on the current used machine in the art, for example, a glass carrier, a quartz carrier, or a plastic carrier. Preferably, the carrier 13 has a light transmittance larger than 30%. More preferably, the light transmittance of the carrier is in a range from 80% to 99%. Most preferably, the light transmittance thereof is in a range from 90% to 99%. Specifically, the carrier 13 preferably has a light transmittance larger than 30% under UV irradiation (which has a wavelength of 200-420 nm). More preferably the light transmittance of the carrier 13 is in a range from 80% to 99% under UV irradiation. Most preferably, the light transmittance thereof is in a range from 90% to 99% under UV irradiation.
In the present embodiment, a material of the UV release layer 14 comprises a polymer and a gas-releasing molecule. In addition, a photo initiator is also contained in the material of the UV release layer 14.
Herein, the polymer contained in the UV release layer 14 is preferably has the following properties. The first one is that the polymer can provide enough adhesion for the carrier 13. The second one is that the adhesion thereof is decreased after the UV irradiation; in particular, after the UV irradiation, the polymer is cross-linked, the loss factor (adhesive behavior) tan δ decreases and thus the adhesion thereof is decreased. Wherein the loss factor tan δ=G″/G′, G′ is storage modulus (elastic behavior), and G″ is loss modulus (viscous behavior). In the present embodiment, specific examples of the polymer include, but are not limited to acrylic polymer.
In addition, the gas-releasing molecule contained in the UV release layer 14 of the present embodiment may comprise: at least one selected from the group consisting of
wherein each of R1, R1′, R2, R2′ and R9 independently, is C1-10 alkyl;
each of R3 and R3′ independently, is C1-10 alkyl, C2-10 alkenyl, or C3-20 cycloalkyl;
in which each of R4, and
R5 independently, is C1-10 alkyl; R6 is H or C1-10 alkyl; and each of R7 and R8 independently, is C1-10 alkoxy.
Specific examples of the gas-releasing molecule include, but are not limited to
wherein each of Rd and Re independently, is C2-6 alkyl;
R9 is C1-5 alkyl;
in which R6 is H or methyl; and each of R7 and R8 independently, is methoxy or ethoxy.
The gas-releasing molecules represented by the formulas (I) and (II) can respectively release N2 and CO2 after UV irradiation. Herein, the gas-releasing molecules represented by the formulas (I) and (II) can be used alone or in combination. In addition, the wavelength of the UV light used in the UV irradiation is not particularly limited, and depends upon the substituents present in the formulas (I) and/or (II).
Herein, the thickness of the UV release layer 14 is 10˜100 μm. If the thickness of the UV release layer 14 is too thin, the UV release layer 14 cannot provide enough adhesion for adhering the target unit and the carrier 13. If the thickness thereof is too thick, the polymer contained in the UV release layer 14 may be remain on the obtained electronic device.
In the present embodiment, as shown in
In the present embodiment, the substrate 11 is a plastic substrate such as a poly(ethylene terephthalate) (PET) substrate, a polyethylene naphthalate (PEN) substrate and a cyclic olefin copolymer (COP) substrate, but the present disclosure is not limited thereto. In other embodiment, the substrate 11 is a thin glass substrate. Herein, the OLED unit 12 shown in
After the carrier 13 and the target unit comprising the substrate 11 with the OLED unit 12 formed thereon are provided, the carrier 13 is adhered to the target unit, the UV release layer 14 is disposed between the target unit and the carrier 13, as shown in
Herein, the UV irradiation is provided from the side of the carrier 13. More specifically, the radiation is provided onto the carrier 13 without the UV release layer 14 formed thereon, so that the light can penetrate through the carrier 13 to achieve the UV release layer 14 to perform the photo-reaction (the photo-cleavage, or the photo-degradation). Herein, the wavelength, the light intensity, and the UV irradiation time are not particularly limited, and can be selected according to the gas-releasing molecule, as long as the separation between the target unit and the carrier 13 can be achieved.
After the UV release layer 14 is degraded and the carrier 13 is removed, small molecule residues degraded from the UV release layer 14 may remain on the target unit (especially on the barrier layer 15), which are at least one selected from the group consisting of
wherein each of R1, R1′, R2, R2′, R4, and R5 independently, is C1-10 alkyl;
each of R3 and R3′ independently, is C1-10 alkyl, C2-10 alkenyl, or C3-20 cycloalkyl;
R6 is H or C1-10 alkyl; and
each of R7 and R8 independently, is C1-10 alkoxy.
Herein, specific examples of the small molecule residues include, but are not limited to
and
wherein each of Ra, Rb and Rc independently, is C2-6 alkyl;
R6 is H or methyl; and
each of R7 and R8 independently, is methoxy or ethoxy.
After the aforementioned process, as shown in
Herein, it should be noted that, the UV release layer 14 is almost separated from the target unit (especially, the barrier layer 15 on the OLED unit 12) after the UV irradiation, and only small molecule residues are maintained on the surface of the target unit.
In the present embodiment, as shown in
In the present embodiment, as shown in
As shown in
In the present embodiment, the substrate 21 is a flexible substrate, such as a plastic substrate, a thin glass substrate with a thickness of 0.3 mm or less, a metal substrate, and a stainless steel substrate. The flexible substrate does not have enough rigidity, so the carrier 23 can be used as a support for the sequential process for forming the electronic unit layer 22.
Herein, the carrier 23 and the UV release layer 24 are similar to those illustrated in Embodiment 1, and therefore the descriptions thereof are not repeated.
Then, as shown in
After the UV release layer 24 is degraded and the carrier 23 is removed, small molecule residues degraded from the UV release layer 24 may remain on the target unit (especially on a surface of the substrate 21). Herein, the small molecule residues on the substrate 21 are similar to those illustrated in Embodiment 1, and therefore the descriptions thereof are not repeated.
After the aforementioned process, as shown in
In the present embodiment, as shown in
In the present embodiment, as shown in
In the present test example, the used testing sheet comprises: a substrate 31; a carrier 33; and a UV release layer 34 sandwiched between a carrier 33 and a substrate 31. Herein, the substrate 31 and the carrier 33 are glass substrates; and the UV release layer 34 comprises acrylic acid polymer and methacrylic polymer and a gas-releasing molecule represented by the following formula (I-1):
After UV light having a wavelength of 375 nm is applied onto the UV release layer 34, a photo-degradation process is progressed in the UV release layer 34 to degrade the compound of the formula (I-1); and
and N2 are generated. Bubbles can be observed in the testing sheet (the photo not shown), which are caused by the generated N2.
The testing sheet used in the present test example is similar to that used in Test example 1, except that the gas-releasing molecule used in the present Test example is represented by the following formula (II-1):
After UV light having a wavelength of 365 nm is applied onto the UV release layer 34,
and CO2 degraded from the compound of formula (II-1) are generated. Bubbles can be observed in the testing sheet (the photo not shown), which are caused by the generated CO2.
The results shown in Test examples 1 and 2 indicate that the gas can generate due to the photo-degradation process of the gas-releasing molecule, and the generated gas can expand and open up the adhesion interface between the UV release layer and the substrate.
In the present disclosure, the electronic device obtained in the present embodiment can also be applied to various apparatus, such as cell phones, notebooks, video cameras, cameras, music players, navigation devices, and televisions.
Although the present disclosure has been explained in relation to its preferred embodiment, it is to be understood that many other possible modifications and variations can be made without departing from the spirit and scope of the disclosure as hereinafter claimed.
