TWI578015B - Flexible substrate and manufacturing method thereof and manufacturing method of package of environmental sensitive electronic element - Google Patents
Flexible substrate and manufacturing method thereof and manufacturing method of package of environmental sensitive electronic element Download PDFInfo
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本發明是有關於一種基板及其製作方法以及封裝體的製作方法,且特別是有關於一種可撓性基板及其製作方法與環境敏感電子元件之封裝體的製作方法。The present invention relates to a substrate, a method for fabricating the same, and a method for fabricating the package, and more particularly to a method for fabricating a flexible substrate, a method for fabricating the same, and a package for environmentally sensitive electronic components.
有機電激發光二極體是一種可將電能轉換成光能的半導體元件,其具有高轉換效率、自發光、結構超薄、高亮度、高發光效率、高對比、響應時間(response time)短(可到達數微秒之內)、超廣視角、低功率消耗、可操作溫度範圍大,以及面板可撓曲(flexible)等優點,因此經常被應用於許多的電子產品上。The organic electroluminescent diode is a semiconductor component that converts electrical energy into light energy, which has high conversion efficiency, self-luminescence, ultra-thin structure, high brightness, high luminous efficiency, high contrast, and short response time ( It can be used in many electronic products because it can reach a few microseconds, has a wide viewing angle, low power consumption, a large operating temperature range, and flexible panels.
為了增加有機電激發光二極體的出光效率,最簡易的方式是透過改變承載基板的結構設計來達成。一般來說,承載基板可透過外貼一具有結構性表面之膠層,亦或是,透過微影蝕刻的方式製作光子晶體或奈米結構來達到所需之光散射的效果。然而,若採用外貼的方式,則承載基板與外貼之膠層之間的黏附力易受到外力而產生脫落,而導致結構可靠度不佳的問題產生。若採用微影蝕刻的方式,則在製作光子晶體或奈米結構的過程中,所需的製程步驟及製程設備也較多,因而無法降低製作成本。In order to increase the light extraction efficiency of the organic electroluminescent diode, the easiest way is to change the structural design of the carrier substrate. Generally, the carrier substrate can be adhered to a layer having a structural surface, or a photonic crystal or a nanostructure can be formed by photolithography to achieve the desired light scattering effect. However, if the external bonding method is adopted, the adhesion between the carrier substrate and the externally applied adhesive layer is liable to be detached by an external force, resulting in a problem of poor structural reliability. If the lithography method is used, in the process of fabricating a photonic crystal or a nanostructure, more processing steps and process equipment are required, and thus the manufacturing cost cannot be reduced.
本發明提供一種可撓性基板的製作方法,以製作出同時具有較佳的結構可靠度及可提高發光元件之光取出效率的可撓性基板。The present invention provides a method of fabricating a flexible substrate, which is capable of producing a flexible substrate having better structural reliability and improved light extraction efficiency of the light-emitting element.
本發明提供一種環境敏感電子元件之封裝體的製作方法,以製作出具有較佳光取出效率之環境敏感電子元件之封裝體。The present invention provides a method of fabricating a package of environmentally sensitive electronic components to produce a package of environmentally sensitive electronic components having better light extraction efficiency.
本發明提供一種可撓性基板,其具有較佳的結構可靠度,且於後續產品應用中,可提高發光元件之光取出效率。The invention provides a flexible substrate which has better structural reliability and can improve the light extraction efficiency of the light-emitting element in subsequent product applications.
本發明提出一種可撓性基板的製作方法,其包括下述步驟。提供一承載器。承載器上已形成有一材料層,其中材料層具有彼此相對的一上表面與一下表面以及多個凹陷部,而下表面與承載器接觸,且凹陷部由材料層之上表面朝向下表面延伸。形成一離型層於材料層的上表面上,其中離型層與材料層共形。塗佈一混合聚合物層(hybrid polymer layer)於離型層上,其中混合聚合物層中具有多個散射粒子。進行一沈降步驟,以使混合聚合物層中的散射粒子沈降至混合聚合物層之底部,以與離型層直接接觸。以使混合聚合物層與承載器分離,而形成一具有多個突出部且部分散射粒子暴露於突出部之外的可撓性基板。The present invention provides a method of fabricating a flexible substrate comprising the following steps. A carrier is provided. A material layer has been formed on the carrier, wherein the material layer has an upper surface and a lower surface opposite to each other and a plurality of recesses, and the lower surface is in contact with the carrier, and the recess extends from the upper surface of the material layer toward the lower surface. A release layer is formed on the upper surface of the material layer, wherein the release layer is conformal to the material layer. A hybrid polymer layer is applied to the release layer, wherein the mixed polymer layer has a plurality of scattering particles. A settling step is performed to cause the scattering particles in the mixed polymer layer to settle to the bottom of the mixed polymer layer to be in direct contact with the release layer. The mixed polymer layer is separated from the carrier to form a flexible substrate having a plurality of protrusions and partially scattering particles exposed outside the protrusions.
本發明還提出一種環境敏感電子元件之封裝體的製作方法,其包括下述步驟。提供一承載器。承載器上已形成有一材料層,其中材料層具有彼此相對的一上表面與一下表面以及多個凹陷部,而下表面與承載器接觸,且凹陷部由材料層之上表面朝向下表面延伸。形成一離型層於材料層的上表面上,其中離型層與材料層共形。塗佈一混合聚合物層於離型層上,其中混合聚合物層中具有多個散射粒子。進行一沈降步驟,以使混合聚合物層中的散射粒子沈降至混合聚合物層之底部,以與離型層直接接觸。形成一環境敏感電子元件於混合聚合物層上。使混合聚合物層及其上之環境敏感電子元件與承載器分離,而形成一具有多個突出部且部分散射粒子暴露於突出部之外的環境敏感電子元件之封裝體。The present invention also provides a method of fabricating a package of environmentally sensitive electronic components, which includes the following steps. A carrier is provided. A material layer has been formed on the carrier, wherein the material layer has an upper surface and a lower surface opposite to each other and a plurality of recesses, and the lower surface is in contact with the carrier, and the recess extends from the upper surface of the material layer toward the lower surface. A release layer is formed on the upper surface of the material layer, wherein the release layer is conformal to the material layer. A mixed polymer layer is applied to the release layer with a plurality of scattering particles in the mixed polymer layer. A settling step is performed to cause the scattering particles in the mixed polymer layer to settle to the bottom of the mixed polymer layer to be in direct contact with the release layer. An environmentally sensitive electronic component is formed on the mixed polymer layer. The mixed polymer layer and the environmentally sensitive electronic components thereon are separated from the carrier to form a package having a plurality of protrusions and partially scattering the particles exposed to environmentally sensitive electronic components outside the protrusions.
本發明還提出一種可撓性基板的製作方法,其包括下述步驟。提供一承載器。承載器具有彼此相對的一第一表面與一第二表面以及多個凹陷部,其中凹陷部由第一表面朝向第二表面延伸。形成一離型層於承載器的第一表面上,其中離型層與承載器共形。塗佈一混合聚合物層於離型層上,其中混合聚合物層中具有多個散射粒子。進行一沈降步驟,以使混合聚合物層中的散射粒子沈降至混合聚合物層之底部,以與離型層直接接觸。使混合聚合物層與承載器分離,而形成一具有多個突出部且部分散射粒子暴露於突出部之外的可撓性基板。The present invention also provides a method of fabricating a flexible substrate comprising the following steps. A carrier is provided. The carrier has a first surface and a second surface opposite to each other and a plurality of recesses, wherein the recess extends from the first surface toward the second surface. A release layer is formed on the first surface of the carrier, wherein the release layer is conformal to the carrier. A mixed polymer layer is applied to the release layer with a plurality of scattering particles in the mixed polymer layer. A settling step is performed to cause the scattering particles in the mixed polymer layer to settle to the bottom of the mixed polymer layer to be in direct contact with the release layer. The mixed polymer layer is separated from the carrier to form a flexible substrate having a plurality of protrusions and partially scattering particles exposed outside the protrusions.
本發明另提出一種可撓性基板,其包括一基材以及多個散射粒子。基材具有彼此相對的之一第一表面與一第二表面以及多個位於第二表面上的突出部。散射粒子分布於基材中,且位於突出部,其中部分散射粒子暴露於突出部之外,且每一散射粒子之折射率與基材之折射率之差值的絕對值除以每一散射粒子的折射率的比值大於等於25%。The invention further provides a flexible substrate comprising a substrate and a plurality of scattering particles. The substrate has one of a first surface and a second surface opposite each other and a plurality of protrusions on the second surface. The scattering particles are distributed in the substrate and are located at the protrusions, wherein the partially scattering particles are exposed outside the protrusions, and the absolute value of the difference between the refractive index of each scattering particle and the refractive index of the substrate is divided by each scattering particle The ratio of the refractive index is greater than or equal to 25%.
基於上述,由於本發明是透過沈降步驟使混合聚合物層中的散射粒子沈降至混合聚合物層的底部以與離型層直接接觸,因此當進行掀離步驟而使混合聚合物層與離型層分離時,具有突出部且部分散射粒子暴露於突出部之外的可撓性基板即可形成。換言之,本發明可製作出同時具有較佳的結構可靠度及可提高發光元件之光取出效率的可撓性基板。Based on the above, since the present invention passes the scattering particles in the mixed polymer layer to the bottom of the mixed polymer layer to directly contact the release layer through the sedimentation step, the mixed polymer layer and the release layer are subjected to the separation step. When the layer is separated, a flexible substrate having a protruding portion and partially scattering particles exposed to the protruding portion can be formed. In other words, the present invention can produce a flexible substrate which has both good structural reliability and improved light extraction efficiency of the light-emitting element.
為讓本發明之上述特徵和優點能更明顯易懂,下文特舉實施例,並配合所附圖式作詳細說明如下。The above described features and advantages of the present invention will be more apparent from the following description.
圖1A至圖1F為本發明之一實施例之一種可撓性基板的製作方法的剖面示意圖。請先參考圖1A,關於本實施例之可撓曲基板的製造方法,首先,提供一承載器10,其中承載器10上已形成有一材料層20,而材料層20具有彼此相對的一上表面21與一下表面23以及多個凹陷部22,而下表面23與承載器10接觸,且凹陷部22由上表面21朝向下表面23延伸。在本實施例中,承載器10的材質例如是一玻璃基板,而材料層20的材質例如是高分子材料,例如是光阻材料。當然,材料層20的材質亦可為金屬(例如是鈦或鉬)、金屬氧化物(例如是氧化鋁)、非金屬氧化物(例如是氧化矽、氧化鈦)、非金屬氮化物(例如是氮化矽)、非金屬氮氧化物(例如是氮氧化矽)、陶瓷材料或上述材料所組成的複合材料。需說明的是,本實施例之材料層20可為一連續膜層,而凹陷部22可為各自獨立的凹陷部22,或者是,材料層20為一非連續膜層,即材料層20可由多個各自獨立的圓柱(未繪示)所組成,而相鄰兩圓柱之間構成凹陷部22,於此並不加以限制材料層20及凹陷部22的型態。此外,如圖1A所示,本實施例之凹陷部22會從上表面21延伸至下表面23且暴露出部分承載器10,但於其他未繪示的實施例中,凹陷部22亦可不暴露出承載器10。1A to 1F are schematic cross-sectional views showing a method of fabricating a flexible substrate according to an embodiment of the present invention. Referring first to FIG. 1A, with respect to the method of manufacturing the flexible substrate of the present embodiment, first, a carrier 10 is provided in which a material layer 20 has been formed on the carrier 10, and the material layer 20 has an upper surface opposite to each other. 21 and the lower surface 23 and the plurality of recesses 22, while the lower surface 23 is in contact with the carrier 10, and the recess 22 extends from the upper surface 21 toward the lower surface 23. In the present embodiment, the material of the carrier 10 is, for example, a glass substrate, and the material of the material layer 20 is, for example, a polymer material, such as a photoresist material. Of course, the material layer 20 may also be made of a metal (for example, titanium or molybdenum), a metal oxide (for example, alumina), a non-metal oxide (for example, cerium oxide, titanium oxide), or a non-metal nitride (for example, A tantalum nitride), a non-metal oxynitride (for example, bismuth oxynitride), a ceramic material, or a composite material composed of the above materials. It should be noted that the material layer 20 of the embodiment may be a continuous film layer, and the recesses 22 may be independent recesses 22, or the material layer 20 may be a discontinuous film layer, that is, the material layer 20 may be A plurality of independent cylinders (not shown) are formed, and the recesses 22 are formed between the adjacent two cylinders, and the shapes of the material layer 20 and the recesses 22 are not limited thereto. In addition, as shown in FIG. 1A, the recessed portion 22 of the embodiment may extend from the upper surface 21 to the lower surface 23 and expose a portion of the carrier 10. However, in other embodiments not shown, the recess 22 may not be exposed. Out of the carrier 10.
接著,請參考圖1B,形成一離型層30於材料層20的上表面21上,其中離型層30與材料層20共形。意即,離型層30亦具有多個凹陷部32。於此,離型層30的材質例如是聚對二甲苯(Poly-para-xylylene,parylene),但並不以此為限。Next, referring to FIG. 1B, a release layer 30 is formed on the upper surface 21 of the material layer 20, wherein the release layer 30 is conformal to the material layer 20. That is, the release layer 30 also has a plurality of recesses 32. Here, the material of the release layer 30 is, for example, poly-para-xylylene (parylene), but is not limited thereto.
接著,請參考圖1C,塗佈一混合聚合物層110於離型層30上,其中混合聚合物層110中具有多個散射粒子112。在本實施例中,混合聚合物層110的材質例如是聚亞醯胺(PI)。Next, referring to FIG. 1C, a mixed polymer layer 110 is coated on the release layer 30, wherein the mixed polymer layer 110 has a plurality of scattering particles 112 therein. In the present embodiment, the material of the mixed polymer layer 110 is, for example, polyamidamine (PI).
接著,請參考圖1D,進行一沈降步驟,例如:重力沉降、離心沉降或靜電吸附沉降,以使混合聚合物層110中的散射粒子112沈降至混合聚合物層110之底部,以與離型層30直接接觸。也就是說,混合聚合物層110中的散射粒子112沈降至離型層30的凹陷部32中,且至少部分散射粒子112與離型層30直接接觸。Next, referring to FIG. 1D, a sedimentation step, such as gravity sedimentation, centrifugal sedimentation or electrostatic adsorption sedimentation, is performed to cause the scattering particles 112 in the mixed polymer layer 110 to settle to the bottom of the mixed polymer layer 110 to be separated from the release layer. Layer 30 is in direct contact. That is, the scattering particles 112 in the mixed polymer layer 110 settle into the recesses 32 of the release layer 30, and at least a portion of the scattering particles 112 are in direct contact with the release layer 30.
之後,請參考圖1E,使混合聚合物層110與承載器10分離,而形成一具有多個突出部114且部分散射粒子112的表面暴露於突出部114之外的可撓性基板100。詳細來說,進行一掀離步驟,以使混合聚合物層110與離型層30分離,而形成具有突出部114且部分散射粒子112暴露於突出部114之外的可撓性基板100。至此,已完成可撓性基板100的製作。Thereafter, referring to FIG. 1E, the mixed polymer layer 110 is separated from the carrier 10 to form a flexible substrate 100 having a plurality of protrusions 114 and a surface of the partially scattering particles 112 exposed to the outside of the protrusions 114. In detail, a lift-off step is performed to separate the mixed polymer layer 110 from the release layer 30 to form the flexible substrate 100 having the protrusions 114 and the partial scattering particles 112 exposed to the outside of the protrusions 114. So far, the fabrication of the flexible substrate 100 has been completed.
由於本實施例是以材料層20為模型,依序形成離型層30與混合聚合物層110於其上,並透過沈降步驟使混合聚合物層110中的散射粒子112沈降至混合聚合物層110之底部以與離型層30直接接觸。因此,當進行掀離步驟而使混合聚合物層110與離型層30分離時,具有突出部114且部分散射粒子112暴露於突出部114之外的可撓性基板100即可形成。相較於習知形成具有散射表面之可撓性基板的方法而言,本實施例之可撓性基板100的製作方法除了具有製成簡單及可降低製作成本等優勢外,亦可製作出同時具有較佳結構可靠度及可提高發光元件之光取出效率的可撓性基板100。Since the present embodiment is based on the material layer 20, the release layer 30 and the mixed polymer layer 110 are sequentially formed thereon, and the scattering particles 112 in the mixed polymer layer 110 are sedimented to the mixed polymer layer through the sedimentation step. The bottom of the 110 is in direct contact with the release layer 30. Therefore, when the separation step is performed to separate the mixed polymer layer 110 from the release layer 30, the flexible substrate 100 having the protruding portion 114 and partially scattering the particles 112 exposed to the outside of the protruding portion 114 can be formed. Compared with the conventional method for forming a flexible substrate having a scattering surface, the manufacturing method of the flexible substrate 100 of the present embodiment can be simultaneously manufactured, and the manufacturing cost can be reduced. The flexible substrate 100 has better structural reliability and improved light extraction efficiency of the light-emitting element.
值得一提的是,為了增加可撓性基板100對一發光元件(未繪示)的光取出效率,亦可於圖1E之步驟後,即於進行掀離步驟之後,請參考圖1F,更包括進行一表面處理步驟,以增加部分散射粒子112暴露於突出部114之外的面積,而完成可撓性基板100a的製作。再者,本實施例並不限制使混合聚合物層110與承載器10分離的步驟。於其他未繪示的實施例中,亦可進行一掀離步驟,使離型層30及其上之混合聚合物層110與材料層20分離。之後,再對離型層30進行一表面處理步驟(例如是蝕刻程序),以暴露出混合聚合物層110中的部分散射粒子112,而形成具有突出部114且部分散射粒子112暴露於突出部114之外的可撓性基板100。上述之製作步驟仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。It is to be noted that, in order to increase the light extraction efficiency of the flexible substrate 100 to a light-emitting element (not shown), after the step of FIG. 1E, that is, after the step of separating, please refer to FIG. 1F, The surface of the flexible substrate 100a is completed by performing a surface treatment step to increase the area of the portion of the scattering particles 112 exposed to the protrusions 114. Moreover, this embodiment does not limit the step of separating the mixed polymer layer 110 from the carrier 10. In other embodiments not shown, a lift-off step can also be performed to separate the release layer 30 and the mixed polymer layer 110 thereon from the material layer 20. Thereafter, a surface treatment step (for example, an etching process) is performed on the release layer 30 to expose a portion of the scattering particles 112 in the mixed polymer layer 110 to form a protrusion 114 and a portion of the scattering particles 112 are exposed to the protrusion. The flexible substrate 100 other than 114. The above-described manufacturing steps are still within the scope of the present invention, and do not depart from the scope of the present invention.
此外,需說明的是,本發明並不限定材料層20之凹陷部22的形狀,雖然此處所提及的凹陷部22的形狀具體化為半圓形。但於其他未繪示的實施例中,凹陷部22的形狀亦可為矩形、三角形、梯形或其他多邊形,仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。Further, it should be noted that the present invention does not limit the shape of the depressed portion 22 of the material layer 20, although the shape of the depressed portion 22 referred to herein is embodied as a semicircular shape. However, in other embodiments not shown, the shape of the recess 22 may be a rectangle, a triangle, a trapezoid or other polygons, and still belong to the technical solution that can be adopted by the present invention without departing from the scope of the present invention.
在結構上,請再參考圖1F,在本實施例中,可撓性基板100a包括混合聚合物層110以及散射粒子112,其中混合聚合物110可視為一基材,且具有彼此相對的之一第一表面111與一第二表面113以及位於第二表面113上的突出部114。散射粒子112分布於混合聚合物110中,且位於突出部114,其中部分散射粒子112暴露於突出部114之外。特別是,每一散射粒子112的折射率為n1,而混合聚合物110之折射率為n2,且∣n1-n2∣/n1≧25%。意即,每一散射粒子112之折射率n1與基材110之折射率n2之差值的絕對值除以每一散射粒子112的折射率n1的比值大於等於25%。簡言之,本實施例之可撓性基板100a除了具有較佳的結構可靠度之外,於後續產品應用中,亦可有效提高發光元件(未繪示)之光取出效率。Structurally, referring again to FIG. 1F, in the present embodiment, the flexible substrate 100a includes a mixed polymer layer 110 and scattering particles 112, wherein the mixed polymer 110 can be regarded as a substrate and has one opposite to each other. The first surface 111 and a second surface 113 and a protrusion 114 on the second surface 113. The scattering particles 112 are distributed in the hybrid polymer 110 and are located at the protrusions 114 with portions of the scattering particles 112 exposed outside of the protrusions 114. In particular, each of the scattering particles 112 has a refractive index of n1, and the mixed polymer 110 has a refractive index of n2, and ∣n1-n2∣/n1≧25%. That is, the absolute value of the difference between the refractive index n1 of each scattering particle 112 and the refractive index n2 of the substrate 110 divided by the refractive index n1 of each scattering particle 112 is greater than or equal to 25%. In short, in addition to having better structural reliability, the flexible substrate 100a of the present embodiment can effectively improve the light extraction efficiency of the light-emitting element (not shown) in subsequent product applications.
在此必須說明的是,下述實施例沿用前述實施例的元件標號與部分內容,其中採用相同的標號來表示相同或近似的元件,並且省略了相同技術內容的說明。關於省略部分的說明可參考前述實施例,下述實施例不再重複贅述。It is to be noted that the following embodiments use the same reference numerals and parts of the above-mentioned embodiments, and the same reference numerals are used to refer to the same or similar elements, and the description of the same technical content is omitted. For the description of the omitted portions, reference may be made to the foregoing embodiments, and the following embodiments are not repeated.
圖2A至圖2B為本發明之另一實施例之一種可撓性基板的製作方法之局部步驟的剖面示意圖。請先參考圖2B,本實施例之可撓性基板100b與圖1F之可撓性基板100a相似,惟二者主要差異之處在於:本實施例之可撓性基板100b更包括一阻氣層120,其中阻氣層120配置於混合聚合物層110上,而阻氣層120是由至少一有機材料層122(圖2B中僅示意地繪示兩層)與至少一無機材料層124(圖2B中僅示意地繪示兩層)相互交替堆疊所構成,且有機材料層122的折射率不同於無機材料層124的折射率。於其他未繪示的實施例中,阻氣層亦可是由至少二無機材料層相互堆疊所構成,其中無機材料層的折射率彼此不同;或者是,阻氣層亦可為單層具適當阻氣性的有機材料層、單層具適當阻氣性的無機材料層或單層具適當阻氣性的有機-無機混合之複合材料層,此仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。2A-2B are cross-sectional views showing a partial step of a method of fabricating a flexible substrate according to another embodiment of the present invention. Referring to FIG. 2B, the flexible substrate 100b of the present embodiment is similar to the flexible substrate 100a of FIG. 1F, but the main difference is that the flexible substrate 100b of the embodiment further includes a gas barrier layer. 120, wherein the gas barrier layer 120 is disposed on the mixed polymer layer 110, and the gas barrier layer 120 is composed of at least one organic material layer 122 (only two layers are schematically shown in FIG. 2B) and at least one inorganic material layer 124 (Fig. 2) 2B is only schematically shown in two layers) alternately stacked, and the refractive index of the organic material layer 122 is different from the refractive index of the inorganic material layer 124. In other embodiments not shown, the gas barrier layer may be formed by stacking at least two inorganic material layers, wherein the inorganic material layers have different refractive indices from each other; or the gas barrier layer may be a single layer with appropriate resistance a layer of a gas-like organic material, a single layer of an inorganic material layer having a suitable gas barrier property, or a single layer of an organic-inorganic hybrid composite material layer having a suitable gas barrier property, which still belongs to the technical solution applicable to the present invention, without departing from the present invention. The scope of the invention to be protected.
在製程上,本實施例的可撓性基板100b可以採用與前述實施例之可撓性基板100a大致相同的製作方式,並且在圖1D之步驟後,即進行完沈降步驟之後以及進行掀離步驟之前,請參考圖2A,形成阻氣層120於混合聚合物層110的第一表面111上,其中阻氣層120是透過沈積的方式由有機材料層122與無機材料層124相互交替堆疊所構成,且有機材料層122的折射率不同於無機材料層124的折射率。接著,再進行圖1E,即可完成圖2B之可撓性基板100b的製作。之後,亦可選擇性的進行圖1F的步驟,即進行表面處理步驟,以達成所需之技術效果。In the process, the flexible substrate 100b of the present embodiment can be fabricated in substantially the same manner as the flexible substrate 100a of the previous embodiment, and after the step of FIG. 1D, that is, after the sedimentation step is performed and the separation step is performed. Previously, referring to FIG. 2A, a gas barrier layer 120 is formed on the first surface 111 of the mixed polymer layer 110, wherein the gas barrier layer 120 is formed by alternately stacking the organic material layer 122 and the inorganic material layer 124 in a manner of deposition. And the refractive index of the organic material layer 122 is different from the refractive index of the inorganic material layer 124. Next, referring to FIG. 1E, the fabrication of the flexible substrate 100b of FIG. 2B can be completed. Thereafter, the step of FIG. 1F can also be selectively performed, that is, a surface treatment step is performed to achieve the desired technical effect.
由於本實施例之可撓性基板100b的相對兩表面上分別具有阻氣層120以及散射結構(即突出部114且部分散射粒子112暴露於突出部114之外)的設計,因此於後續應用中,將一發光元件(未繪示)配置於可撓性基板100b之阻氣層120上時,發光元件所發出的光可先透過阻氣層120產生折射的效果,之後,再經由突出部114及散射粒子112的散射,而達到提高發光元件之光取出效率的效果。Since the opposite surfaces of the flexible substrate 100b of the present embodiment have a gas barrier layer 120 and a scattering structure (ie, the protrusions 114 and the partial scattering particles 112 are exposed to the protrusions 114), respectively, in subsequent applications. When a light-emitting element (not shown) is disposed on the gas barrier layer 120 of the flexible substrate 100b, the light emitted by the light-emitting element may first pass through the gas barrier layer 120 to produce a refractive effect, and then pass through the protruding portion 114. The scattering of the scattering particles 112 achieves an effect of improving the light extraction efficiency of the light-emitting element.
圖3A至圖3C為本發明之一實施例之一種環境敏感電子元件之封裝體的製作方法之局部步驟的剖面示意圖。本實施例的環境敏感電子元件之封裝體的製作,可於前述製作可撓性基板100(或100a)之圖1D之步驟後,即進行完沈降步驟之後以及進行掀離步驟之前,請參考圖3A,形成一環境敏感電子元件210於混合聚合物層110上。之後,請同時參考圖3B與圖3C,進行一掀離步驟,以使混合聚合物層110及其上之環境敏感電子元件210與離型層30分離,而形成一環境敏感電子元件之封裝體200。於此,環境敏感電子元件之封裝體200是由可撓性基板100以及環境敏感電子元件210所組成,其中可撓性基板100的第一表面111上配置環境敏感電子元件210,而可撓性基板100的第二表面113上具有突出部114且部分散射粒子112暴露於突出部114。3A-3C are cross-sectional views showing a partial step of a method of fabricating a package of environmentally sensitive electronic components according to an embodiment of the invention. The package of the environmentally sensitive electronic component of the present embodiment can be fabricated after the step of forming the flexible substrate 100 (or 100a) in FIG. 1D, that is, after the sedimentation step and before the separation step, please refer to the figure. 3A, an environmentally sensitive electronic component 210 is formed on the hybrid polymer layer 110. Thereafter, referring to FIG. 3B and FIG. 3C, a step of separating is performed to separate the mixed polymer layer 110 and the environmentally sensitive electronic component 210 thereon from the release layer 30 to form an environmentally sensitive electronic component package. 200. Here, the environmentally sensitive electronic component package 200 is composed of a flexible substrate 100 and an environmentally sensitive electronic component 210. The first surface 111 of the flexible substrate 100 is provided with an environmentally sensitive electronic component 210, and the flexibility is provided. The second surface 113 of the substrate 100 has a protrusion 114 thereon and a portion of the scattering particles 112 are exposed to the protrusion 114.
當然,為了增加可撓性基板100對環境敏感電子元件210的光取出效率,亦可於圖3B之步驟後,即於進行掀離步驟之後,請參考圖3C,更包括進行一表面處理步驟,以增加部分散射粒子112暴露於突出部114之外的面積,而完成環境敏感電子元件之封裝體200a的製作。值得一提的是,本實施例並不限制使混合聚合物層110及其上之環境敏感電子元件210與承載器10分離的步驟。於其他未繪示的實施例中,亦可進行一掀離步驟,使離型層30及其上之混合聚合物層110及環境敏感電子元件210與材料層20分離。之後,再對離型層30進行一表面處理步驟(例如是蝕刻程序),以暴露出混合聚合物層110中的部分散射粒子112,而形成具有突出部114且部分散射粒子112暴露於突出部114之外的可撓性基板100。上述之製作步驟仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。Of course, in order to increase the light extraction efficiency of the environmentally sensitive electronic component 210 of the flexible substrate 100, after the step of FIG. 3B, that is, after the step of separating, please refer to FIG. 3C, and further including performing a surface treatment step. The fabrication of the package 200a of environmentally sensitive electronic components is accomplished by increasing the area of the portion of the scattering particles 112 that is exposed outside of the protrusions 114. It is worth mentioning that this embodiment does not limit the step of separating the hybrid polymer layer 110 and the environmentally sensitive electronic component 210 thereon from the carrier 10. In other embodiments not shown, a lift-off step can be performed to separate the release layer 30 and the mixed polymer layer 110 and the environmentally sensitive electronic component 210 from the material layer 20 thereon. Thereafter, a surface treatment step (for example, an etching process) is performed on the release layer 30 to expose a portion of the scattering particles 112 in the mixed polymer layer 110 to form a protrusion 114 and a portion of the scattering particles 112 are exposed to the protrusion. The flexible substrate 100 other than 114. The above-described manufacturing steps are still within the scope of the present invention, and do not depart from the scope of the present invention.
由於本實施例之環境敏感電子元件之封裝體200(或200a)的製作可將可撓性基板100(或100a)與環境敏感電子元件210的製程整合在一起。也就是說,可撓性基板100(或100a)與環境敏感電子元件210可以在同一腔體中完成製作。因此,本實施例之環境敏感電子元件之封裝體200(或200a)的製作方法具有製程步驟簡單且可降低購買製程設備之成本的優勢。再者,本實施例之環境敏感電子元件210所發出的光可透過其下方之突出部114及散射粒子112的散射,而達到提高環境敏感電子元件210之光取出效率的效果。也就是說,本實施例之環境敏感電子元件之封裝體200(或200a)具有較佳光取出效率。The fabrication of the package 200 (or 200a) of the environmentally sensitive electronic component of the present embodiment can integrate the flexible substrate 100 (or 100a) with the process of the environmentally sensitive electronic component 210. That is, the flexible substrate 100 (or 100a) and the environmentally sensitive electronic component 210 can be fabricated in the same cavity. Therefore, the manufacturing method of the package 200 (or 200a) of the environmentally sensitive electronic component of the present embodiment has the advantages that the process steps are simple and the cost of purchasing the process equipment can be reduced. Furthermore, the light emitted by the environmentally sensitive electronic component 210 of the present embodiment can pass through the scattering of the protruding portion 114 and the scattering particles 112 underneath, thereby achieving the effect of improving the light extraction efficiency of the environmentally sensitive electronic component 210. That is, the package 200 (or 200a) of the environmentally sensitive electronic component of the present embodiment has better light extraction efficiency.
圖4A至圖4C為本發明之另一實施例之一種環境敏感電子元件之封裝體的製作方法之局部步驟的剖面示意圖。本實施例的環境敏感電子元件之封裝體的製作,可於前述製作可撓性基板100b之圖2A之步驟後,即形成阻氣層120之後,請參考圖4A,形成一環境敏感電子元件210於阻氣層120上。之後,請同時參考圖4B與圖4C,進行一掀離步驟,以使混合聚合物層110及其上之阻氣層120及環境敏感電子元件210與離型層30分離,而形成一環境敏感電子元件之封裝體200b。於此,環境敏感電子元件之封裝體200b是由可撓性基板100b’以及環境敏感電子元件210所組成。4A-4C are cross-sectional views showing a partial step of a method of fabricating a package of environmentally sensitive electronic components according to another embodiment of the present invention. The environment-sensitive electronic component package of the present embodiment can be formed after the step of forming the flexible substrate 100b in FIG. 2A, that is, after the gas barrier layer 120 is formed. Referring to FIG. 4A, an environmentally sensitive electronic component 210 is formed. On the gas barrier layer 120. Thereafter, please refer to FIG. 4B and FIG. 4C simultaneously, and perform a separation step to separate the mixed polymer layer 110 and the gas barrier layer 120 and the environmentally sensitive electronic component 210 from the release layer 30 to form an environmentally sensitive layer. The package 200b of the electronic component. Here, the package 200b of the environmentally sensitive electronic component is composed of the flexible substrate 100b' and the environmentally sensitive electronic component 210.
當然,為了增加可撓性基板100b’對環境敏感電子元件210的光取出效率,亦可於圖4B之步驟後,即於進行掀離步驟之後,請參考圖4C,更包括進行一表面處理步驟,以增加部分散射粒子112暴露於突出部114之外的面積,即形成可撓性基板100b,而完成環境敏感電子元件之封裝體200c的製作。Of course, in order to increase the light extraction efficiency of the environmentally sensitive electronic component 210 of the flexible substrate 100b', after the step of FIG. 4B, that is, after the step of separating, please refer to FIG. 4C, and further includes performing a surface treatment step. In order to increase the area in which the partial scattering particles 112 are exposed outside the protruding portion 114, that is, the flexible substrate 100b is formed, the fabrication of the package 200c of the environmentally sensitive electronic component is completed.
由於本實施例之環境敏感電子元件之封裝體200b(或200c)的製作可將可撓性基板100b與環境敏感電子元件210的製程整合在一起。也就是說,可撓性基板100b與環境敏感電子元件210可以在同一腔體中完成製作。因此,本實施例之環境敏感電子元件之封裝體200b(或200c)的製作方法具有製程步驟簡單且可降低購買製程設備之成本的優勢。再者,本實施例之環境敏感電子元件210所發出的光可先透過阻氣層120產生折射的效果,之後,再經由突出部114及散射粒子112的散射,而達到提高環境敏感電子元件210之光取出效率的效果。也就是說,本實施例之環境敏感電子元件之封裝體200b(或200c)具有較佳光取出效率。The fabrication of the package 200b (or 200c) of the environmentally sensitive electronic component of the present embodiment integrates the process of the flexible substrate 100b with the environmentally sensitive electronic component 210. That is, the flexible substrate 100b and the environmentally sensitive electronic component 210 can be fabricated in the same cavity. Therefore, the manufacturing method of the package 200b (or 200c) of the environmentally sensitive electronic component of the present embodiment has the advantages that the process steps are simple and the cost of purchasing the process equipment can be reduced. Furthermore, the light emitted by the environmentally sensitive electronic component 210 of the present embodiment may first be refracted by the gas barrier layer 120, and then the scattering of the protruding portion 114 and the scattering particles 112 may be used to improve the environmentally sensitive electronic component 210. The effect of light extraction efficiency. That is, the package 200b (or 200c) of the environmentally sensitive electronic component of the present embodiment has better light extraction efficiency.
值得一提的是,本發明並不限定承載器10與材料層20的搭配形態,雖然此處所提及的承載器10的表面為一平面,而材料層20配置於承載器10的表面上且具有凹陷部22。但於其他實施例中,請參考圖5,本實施例之承載器10a具有彼此相對的一第一表面12a與一第二表面14a以及多個凹陷部16a,其中凹陷部16a由第一表面12a朝向第二表面14a延伸。上述之方式亦能達到使後續完成之可撓性基板具有突出部且部分散射粒子暴露於突出部之外的結構設計,仍屬於本發明可採用的技術方案,不脫離本發明所欲保護的範圍。因此,於其他未繪示的實施例中,亦可選用於如上述實施例所提及之具有凹陷部16a之承載器10a,本領域的技術人員當可參照前述實施例的說明,即於承載器10a上依序形成離型層、塗佈混合聚合物層、對散射粒子進行一沈降步驟以及使混合聚合物層與承載器分離等步驟,而完成可撓性基板的製作。It is worth mentioning that the present invention does not limit the matching form of the carrier 10 and the material layer 20, although the surface of the carrier 10 mentioned here is a plane, and the material layer 20 is disposed on the surface of the carrier 10. And having a recess 22 . In other embodiments, referring to FIG. 5, the carrier 10a of the present embodiment has a first surface 12a and a second surface 14a and a plurality of recesses 16a opposite to each other, wherein the recess 16a is formed by the first surface 12a. Extending toward the second surface 14a. The above-mentioned manner can also achieve the structural design that the subsequently completed flexible substrate has the protruding portion and the partially scattering particles are exposed outside the protruding portion, and still belongs to the technical solution that can be adopted by the present invention without departing from the scope of the present invention. . Therefore, in other embodiments not shown, the carrier 10a having the recess 16a as mentioned in the above embodiment may also be selected, and those skilled in the art may refer to the description of the foregoing embodiment, that is, on the bearer. The step of forming a release layer, applying a mixed polymer layer, performing a sedimentation step on the scattering particles, and separating the mixed polymer layer from the carrier are sequentially performed on the device 10a to complete the fabrication of the flexible substrate.
綜上所述,由於本發明是透過沈降步驟使混合聚合物層中的散射粒子沈降至混合聚合物層之底部,以與離型層直接接觸,因此當進行掀離步驟而使混合聚合物層與離型層分離時,具有突出部且部分散射粒子暴露於突出部之外的可撓性基板即可形成。換言之,本發明可製作出同時具有較佳的結構可靠度以及能夠提高發光元件之光取出效率的可撓性基板。再者,本發明之環境敏感電子元件之封裝體的製作方法可將可撓性基板與環境敏感電子元件的製程整合在一起,可減少製程步驟且可降低購買製程設備之成本。In summary, since the present invention separates the scattering particles in the mixed polymer layer to the bottom of the mixed polymer layer through the sedimentation step to directly contact the release layer, the mixed polymer layer is subjected to the separation step. When separated from the release layer, a flexible substrate having protrusions and partially scattering particles exposed to the protrusions can be formed. In other words, the present invention can produce a flexible substrate which has both good structural reliability and improved light extraction efficiency of the light-emitting element. Furthermore, the method for fabricating the package of environmentally sensitive electronic components of the present invention can integrate the process of the flexible substrate and the environmentally sensitive electronic component, thereby reducing the number of manufacturing steps and reducing the cost of purchasing the process equipment.
雖然本發明已以實施例揭露如上,然其並非用以限定本發明,任何所屬技術領域中具有通常知識者,在不脫離本發明之精神和範圍內,當可作些許之更動與潤飾,故本發明之保護範圍當視後附之申請專利範圍所界定者為準。Although the present invention has been disclosed in the above embodiments, it is not intended to limit the invention, and any one of ordinary skill in the art can make some modifications and refinements without departing from the spirit and scope of the invention. The scope of the invention is defined by the scope of the appended claims.
10、10a...承載器10, 10a. . . Carrier
12a...第一表面12a. . . First surface
14a...第二表面14a. . . Second surface
16a、22、32...凹陷部16a, 22, 32. . . Depression
20...材料層20. . . Material layer
21...上表面twenty one. . . Upper surface
23...下表面twenty three. . . lower surface
30...離型層30. . . Release layer
100、100a、100b、100b’...可撓性基板100, 100a, 100b, 100b’. . . Flexible substrate
110...混合聚合物層110. . . Mixed polymer layer
111...第一表面111. . . First surface
112...散射粒子112. . . Scattering particle
113...第二表面113. . . Second surface
114...突出部114. . . Protruding
120...阻氣層120. . . Gas barrier
122...有機材料層122. . . Organic material layer
124...無機材料層124. . . Inorganic material layer
200、200a、200b、200c...環境敏感電子元件之封裝體200, 200a, 200b, 200c. . . Environmentally sensitive electronic component package
210...環境敏感電子元件210. . . Environmentally sensitive electronic components
圖1A至圖1F為本發明之一實施例之一種可撓性基板的製作方法的剖面示意圖。1A to 1F are schematic cross-sectional views showing a method of fabricating a flexible substrate according to an embodiment of the present invention.
圖2A至圖2B為本發明之另一實施例之一種可撓性基板的製作方法之局部步驟的剖面示意圖。2A-2B are cross-sectional views showing a partial step of a method of fabricating a flexible substrate according to another embodiment of the present invention.
圖3A至圖3C為本發明之一實施例之一種環境敏感電子元件之封裝體的製作方法之局部步驟的剖面示意圖。3A-3C are cross-sectional views showing a partial step of a method of fabricating a package of environmentally sensitive electronic components according to an embodiment of the invention.
圖4A至圖4C為本發明之另一實施例之一種環境敏感電子元件之封裝體的製作方法之局部步驟的剖面示意圖。4A-4C are cross-sectional views showing a partial step of a method of fabricating a package of environmentally sensitive electronic components according to another embodiment of the present invention.
圖5為本發明之一實施例之一種承載器的剖面示意圖。FIG. 5 is a cross-sectional view of a carrier according to an embodiment of the present invention.
100a...可撓性基板100a. . . Flexible substrate
110...混合聚合物層110. . . Mixed polymer layer
111...第一表面111. . . First surface
112...散射粒子112. . . Scattering particle
113...第二表面113. . . Second surface
114...突出部114. . . Protruding
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