JPWO2016104122A1 - 積層体の剥離開始部作成方法、及び剥離開始部作成装置並びに電子デバイスの製造方法 - Google Patents
積層体の剥離開始部作成方法、及び剥離開始部作成装置並びに電子デバイスの製造方法 Download PDFInfo
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Abstract
Description
電子デバイスは、ガラス製、樹脂製、金属製等の基板の表面に電子デバイス用の機能層(LCDであれば、薄膜トランジスタ(TFT)、カラーフィルタ(CF))を形成することにより製造される。
図1は、積層体1の一例を示した要部拡大側面図である。
第1の基板である基板2は、その表面2aに機能層が形成される。基板2としては、ガラス基板、セラミックス基板、樹脂基板、金属基板、半導体基板を例示できる。例示されたこれらの基板のなかでも、ガラス基板は、耐薬品性、耐透湿性に優れ、かつ、線膨張係数が小さいので、電子デバイス用の基板2として好適である。また、線膨張係数が小さくなるに従い、高温下で形成される機能層のパターンが冷却時にずれ難くなる利点もガラス基板にはある。
第2の基板である補強板3としては、ガラス基板、セラミックス基板、樹脂基板、金属基板、半導体基板を例示できる。
吸着層である樹脂層4は、樹脂層4と補強板3との間で剥離するのを防止するため、樹脂層4と補強板3との間の結合力が、樹脂層4と基板2との間の結合力よりも高く設定される。これにより、積層体1を剥離する工程では、樹脂層4と基板2との間で剥離が行われる。
機能層形成工程を経ることにより積層体1の基板2の表面2aには、機能層が形成される。機能層の形成方法としては、CVD(Chemical Vapor Deposition)法、PVD(Physical Vapor Deposition)法等の蒸着法、スパッタ法が用いられる。機能層は、フォトリソグラフィ法、エッチング法によって所定のパターンに形成される。
図3(A)〜(E)は、剥離開始部作成工程にて使用される剥離開始部作成装置10の要部構成を示した説明図であり、図3(A)は、積層体6とナイフ20(剥離刃とも称される)との位置関係を示した説明図、図3(B)は、ナイフ20によって基板2Bと樹脂層4Bとの界面24に剥離開始部26を作成する説明図、図3(C)は、基板2Aと樹脂層4Aとの界面28に剥離開始部30を作成する直前状態を示した説明図、図3(D)は、ナイフ20によって界面28に剥離開始部30を作成する説明図、図3(E)は、剥離開始部26、30が作成された積層体6の説明図である。また、図4は、剥離開始部26、30が作成された積層体6の平面図である。図5は、積層体6にナイフ20を挿入(刺入ともいう)する前の状態を示した平面図である。
剥離開始部作成装置10による剥離開始部作成方法によれば、ナイフ20の挿入位置を、積層体6のコーナーカット部6Aであって、積層体6の厚さ方向において重なる位置に設定し、かつナイフ20の挿入量を、界面24、28ごとに異なるように設定している。
本発明に係る積層体の剥離開始部作成方法、及び剥離開始部作成装置の特徴について説明する。本発明の特徴は、特定の形状を有するナイフ20による剥離開始部作成方法にあり、その点について以下に述べる。
吸着層である樹脂層4A、4Bを削ることができるナイフ20の形状について説明する。図6(A)〜(C)は一実施形態のナイフ20を示している。図6(A)はナイフ20の平面図であり、図6(B)はナイフ20を矢印Dの方向から見た側面図であり、図6(C)は矢印Eの方向から見た正面図である。図6(B)の如く、側面視でナイフ20は、略一定厚さの本体部20bと、この本体部20bと連続して刃先20aに向かって先細りの刃先部20cを備えている。ナイフ20には、本体部20bと刃先部20cの境界である稜線20dが形成されている。稜線20dはナイフ20の幅方向に沿って刃先20aと略平行に延びている。なお、実施形態において、稜線20dを含み、稜線20dから本体部20bの側に5mm、及び稜線20dから刃先部20cの側に刃先部20cの長さの半分の範囲内の領域を稜線部20mと称している。
図14は、実施形態の剥離装置40の構成を示した縦断面図であり、図15は、剥離装置40の剥離ユニット42に対する複数の可動体44の配置位置を模式的に示した剥離ユニット42の平面図である。なお、図14は図15のD−D線に沿う断面図に相当し、また、図15においては積層体6を実線で示している。
図16(A)は、剥離ユニット42の平面図であり、図16(B)は、図16(A)のE−E線に沿う剥離ユニット42の拡大縦断面図である。また、図16(C)は、剥離ユニット42を構成する矩形の板状の可撓性板52に対して、剥離ユニット42を構成する吸着部54が両面接着テープ56を介して着脱自在に備えられたことを示す剥離ユニット42の拡大縦断面図である。
可撓性板52の下面には、図14に示した円盤状の複数の可動体44が、図15の如く碁盤目状に固定される。これらの可動体44は、可撓性板52にボルト等の締結部材によって固定されるが、ボルトに代えて接着固定されてもよい。これらの可動体44は、コントローラ50によって駆動制御された駆動装置48によって、独立して昇降移動される。
1A…第1の積層体
1B…第2の積層体
2,2A,2B…基板(第1の基板)
3,3A,3B…補強板(第2の基板)
4,4A,4B…樹脂層(吸着層)
6…積層体
10…剥離開始部作成装置
12…テーブル(積層体保持手段)
14…ホルダ(ナイフ保持手段)
18…送り装置(移動手段)
20…ナイフ
20b…本体部
20c…刃先部
20d…稜線
20e…貫通孔
20f…バリ
20g…山部
20h…谷部
20k…粒子
20m…稜線部
26…剥離開始部
30…剥離開始部
40…剥離装置
Claims (18)
- 第1の基板と第2の基板とが吸着層を介して剥離可能に貼り付けられた積層体に対して、前記第1の基板と前記吸着層との界面に前記積層体の端面からナイフを所定量挿入して前記界面に剥離開始部を作成する積層体の剥離開始部作成方法において、
前記ナイフは、本体部と、前記本体部と連続して側面視で先細りの刃先部と、前記本体部と前記刃先部との境界である稜線とを含み、
前記稜線を含む稜線部により前記吸着層の少なくとも一部を削る積層体の剥離開始部作成方法。 - 前記稜線部は、前記稜線を横切る位置に複数の貫通孔を有する形状を有する請求項1に記載の積層体の剥離開始部作成方法。
- 前記複数の貫通孔の少なくとも一つは、バリを有する貫通孔である請求項2に記載の積層体の剥離開始部作成方法。
- 前記複数の貫通孔の少なくとも二つは、バリを有する貫通孔であり、二つの前記バリの突出方向は互いに反対方向である請求項2に記載の積層体の剥離開始部作成方法。
- 前記稜線部は、前記ナイフの刃先から見て、山部と谷部とが交互に配置された波状の稜線を有する形状を有する請求項1に記載の積層体の剥離開始部作成方法。
- 前記稜線部は、粒子の配置された形状を有する請求項1に記載の積層体の剥離開始部作成方法。
- 第1の基板と第2の基板とが吸着層を介して剥離可能に貼り付けられた積層体を保持する積層体保持手段と、
ナイフを保持するナイフ保持手段と、
前記積層体保持手段及び前記ナイフ保持手段を相対的に移動させることにより、前記第1の基板と前記吸着層との界面に前記積層体の端面から前記ナイフを所定量挿入させる移動手段と、
を備えた剥離開始部作成装置であって、
前記ナイフは、本体部と、前記本体部と連続し先細りの刃先部と、前記本体部と前記刃先部との境界である稜線とを含み、前記稜線を含む稜線部は前記吸着層の少なくとも一部を削ることができる形状を有する剥離開始部作成装置。 - 前記形状は、前記稜線を横切る位置に設けられた複数の貫通孔である請求項7に記載の剥離開始部作成装置。
- 前記複数の貫通孔の少なくとも一つは、バリを有する貫通孔である請求項8に記載の剥離開始部作成装置。
- 前記複数の貫通孔の少なくとも二つは、バリを有する貫通孔であり、二つの前記バリの突出方向は互いに反対方向である請求項8に記載の剥離開始部作成装置。
- 前記形状は、前記ナイフの刃先から見て、山部と谷部とが交互に配置された波状の稜線を有する形状である請求項7に記載の剥離開始部作成装置。
- 前記形状は、前記稜線部に配置された粒子を有する形状である請求項7に記載の剥離開始部作成装置。
- 第1の基板と第2の基板とが吸着層を介して剥離可能に貼り付けられた積層体における、前記第1の基板の表面に機能層を形成する機能層形成工程と、前記機能層が形成された前記第1の基板を前記第2の基板から剥離する剥離工程とを有する電子デバイスの製造方法において、
前記剥離工程は、前記第1の基板と前記吸着層との界面に前記積層体の端面からナイフを所定量挿入して前記界面に剥離開始部を作成する剥離開始部作成工程と、前記剥離開始部を起点として前記界面を剥離する剥離工程と、を有し、
前記ナイフは、本体部と、前記本体部と連続して側面視で先細りの刃先部と、前記本体部と前記刃先部との境界である稜線とを含み、前記稜線を含む稜線部により前記吸着層の少なくとも一部を削る電子デバイスの製造方法。 - 前記稜線部は、前記稜線を横切る位置に複数の貫通孔を有する形状である請求項13に記載の電子デバイスの製造方法。
- 前記複数の貫通孔の少なくとも一つは、バリを有する貫通孔である請求項14に記載の電子デバイスの製造方法。
- 前記複数の貫通孔の少なくとも二つは、バリを有する貫通孔であり、二つの前記バリの突出方向は互いに反対方向である請求項14に記載の電子デバイスの製造方法。
- 前記稜線部は、前記ナイフの刃先から見て、山部と谷部とが交互に配置された波状の稜線を有する形状である請求項13に記載の電子デバイスの製造方法。
- 前記稜線部は、粒子の配置された形状を有する請求項13に記載の電子デバイスの製造方法。
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