Granted Patent B2

US 9,076,822 · App. 13/684,150 · Granted Jul 7, 2015

Inventors: Douglas E Loy (Chandler, AZ); David Morton (Columbia, MO); Emmett Howard (Gilbert, AZ)

Assignee: Arizona Board of Regents, a Body Corporate of the State of Arizona Acting for and on behalf of Arizona State University

H01L29/66765H01L21/6835H01L27/1266H01L29/78603H01L2221/6835H01L2221/68381H01L29/78669H01L27/1218

Abstract

Claims (85)

1. A method of manufacturing, the method comprising:

providing a carrier substrate having a first side and a second side;

bonding a first flexible substrate to the first side of the carrier substrate;

bonding a second flexible substrate to the second side of the carrier substrate;

depositing at least one layer of a first material over the first flexible substrate while the first flexible substrate is bonded to the first side of the carrier substrate to create a portion of at least one first electronic device; and

depositing at least one layer of a second material over the second flexible substrate while the second flexible substrate is bonded to the second side of the carrier substrate to create a portion of at least one second electronic device;

wherein:

bonding the second flexible substrate to the second side of the carrier substrate comprises compensating for a deforming force acting on the carrier substrate by the first flexible substrate resulting from the bonding the first flexible substrate to the first side of the carrier substrate.

2. The method of claim 1 , wherein:

the first flexible substrate comprises a material; and

the second flexible substrate comprises the material.

3. The method of claim 2 , wherein:

the material comprises a thermoplastic polymer; and

the thermoplastic polymer comprises at least one of polyethylene naphthalate, polyethylene terephthalate, polyethersulfone, polyimide, polycarbonate, cyclic olefin copolymer, or liquid crystal polymer.

4. The method of claim 1 further comprising:

depositing at least one first protective layer over the at least one layer of the first material while the first flexible substrate is bonded to the first side of the carrier substrate and before depositing at least a portion of the at least one layer of the second material.

5. The method of claim 4 , further comprising:

depositing at least one second protective layer over the at least one layer of the second material while the second flexible substrate is bonded to the second side of the carrier substrate.

6. The method of claim 1 wherein:

the first electronic device and the second electronic device comprise a same type of electronic device.

7. The method of claim 1 , wherein at least one of:

(a) depositing the at least one layer of the first material over the first flexible substrate comprises:

depositing a first gate metal layer over the first flexible substrate while the first flexible substrate is bonded to the first side of the carrier substrate;

depositing a first silicon comprising layer over the first gate metal layer while the first flexible substrate is bonded to the first side of the carrier substrate;

depositing a first contact element over the first silicon comprising layer while the first flexible substrate is bonded to the first side of the carrier substrate, wherein the first contact element comprises a first diffusion barrier;

depositing a first dielectric material over the first contact element while the first flexible substrate is bonded to the first side of the carrier substrate, wherein the first dielectric material comprises an organic siloxane-based dielectric material;

depositing a second dielectric material over the first dielectric material while the first flexible substrate is bonded to the first side of the carrier substrate, wherein the second dielectric material comprises a silicon nitride material; and

baking the second dielectric material, the first dielectric material, the first contact element, the first silicon comprising layer, the first gate metal layer, the first flexible substrate, and the carrier substrate while the first flexible substrate is bonded to the first side of the carrier substrate;

(b) depositing the at least one layer of the second material over the second flexible substrate comprises:

depositing a second gate metal layer over the second flexible substrate while the second flexible substrate is bonded to the second side of the carrier substrate;

depositing a second silicon comprising layer over the second gate metal layer while the second flexible substrate is bonded to the second side of the carrier substrate;

depositing a second contact element over the second silicon comprising layer while the second flexible substrate is bonded to the second side of the carrier substrate, wherein the second contact element comprises a second diffusion barrier;

depositing a third dielectric material over the second contact element while the second flexible substrate is bonded to the second side of the carrier substrate, wherein the third dielectric material comprises the organic siloxane-based dielectric material;

depositing a fourth dielectric material over the third dielectric material while the second flexible substrate is bonded to the second side of the carrier substrate, wherein the fourth dielectric material comprises the silicon nitride material; and

baking the fourth dielectric material, the third dielectric material, the second contact element, the second silicon comprising layer, the second gate metal layer, the second flexible substrate, and the carrier substrate while the second flexible substrate is bonded to the second side of the carrier substrate;

(c) depositing the at least one layer of the first material over the first flexible substrate further comprises depositing a first base dielectric material, wherein the first base dielectric material comprises a silicon oxide material; or

(d) depositing the at least one layer of the second material over the second flexible substrate further comprises depositing a second base dielectric material, wherein the second base dielectric material comprises the silicon oxide material.

8. The method of claim 1 , wherein at least one of:

(a) at least a portion of depositing the at least one layer of the second material over the second flexible substrate is performed before completely depositing each of the at least one layer of the first material over the first flexible substrate; or

(b) at least a portion of depositing the at least one layer of the first material over the first flexible substrate is performed before completely depositing each of the at least one layer of the second material over the second flexible substrate.

9. The method of claim 1 , wherein:

at least a portion of depositing the at least one layer of the first material over the first flexible substrate is performed concurrently with at least a portion of depositing the at least one layer of the second material over the second flexible substrate.

10. The method of claim 1 , further comprising:

debonding at least one of the first flexible substrate or the second flexible substrate from the carrier substrate.

11. A method comprising:

providing a carrier substrate having a first side and a second side;

bonding a first flexible substrate to the first side of the carrier substrate, at least a portion of an electronic device being located at the second side of the carrier substrate;

depositing a first gate metal layer over the first flexible substrate while the first flexible substrate is bonded to the first side of the carrier substrate;

depositing a first silicon comprising layer over the first gate metal layer while the first flexible substrate is bonded to the first side of the carrier substrate;

forming a first contact element over the first silicon comprising layer while the first flexible substrate is bonded to the first side of the carrier substrate, wherein the first contact element comprises a first diffusion barrier;

depositing a first dielectric material over the first contact element while the first flexible substrate is bonded to the first side of the carrier substrate, wherein the first dielectric material comprises an organic siloxane-based dielectric material;

depositing a second dielectric material over the first dielectric material while the first flexible substrate is bonded to the first side of the carrier substrate, wherein the second dielectric material comprises a silicon nitride material; and

baking the second dielectric material, the first dielectric material, the first contact element, the first silicon comprising layer, the first gate metal layer, the first flexible substrate, and the carrier substrate while the first flexible substrate is bonded to the first side of the carrier substrate;

wherein:

the electronic device comprises a second flexible substrate bonded to the second side of the carrier substrate;

bonding the first flexible substrate to the first side of the carrier substrate comprises compensating for a deforming force acting on the carrier substrate by the second flexible substrate resulting from the second flexible substrate being bonded to the second side of the carrier substrate; and

the at least the portion of the electronic device comprises the first gate metal layer.

12. The method of claim 11 , wherein:

the first flexible substrate comprises a material; and

the second flexible substrate comprises the material.

13. The method of claim 12 , wherein:

the material comprises a thermoplastic polymer; and

the thermoplastic polymer comprises at least one of polyethylene naphthalate, polyethylene terephthalate, polyethersulfone, polyimide, polycarbonate, cyclic olefin copolymer, or liquid crystal polymer.

14. The method of claim 11 wherein:

each of the first flexible substrate and the second flexible substrate comprises a substrate thickness greater than or equal to approximately 3 micrometers and less than or equal to approximately 100 micrometers.

15. The method of claim 11 wherein:

the carrier substrate comprises a carrier material having a glass transition point greater than or equal to approximately 300° C.

16. The method of claim 11 wherein:

the carrier substrate comprises a carrier thickness greater than or equal to approximately 0.5 millimeters and less than or equal to approximately 2.0 millimeters.

17. The method of claim 11 further comprising:

after baking the second dielectric material, the first dielectric material, the first contact element, the first silicon comprising layer, the first gate metal layer, the first flexible substrate, and the carrier substrate, debonding the first flexible substrate from the carrier substrate.

18. The method of claim 11 further comprising:

after baking the second dielectric material, the first dielectric material, the first contact element, the first silicon comprising layer, the first gate metal layer, the first flexible substrate, and the carrier substrate, debonding the second flexible substrate from the carrier substrate.

19. A method of manufacturing electronic devices, the method comprising:

providing a carrier substrate having a first side and a second side;

providing a first flexible substrate;

bonding the first flexible substrate to the first side of the carrier substrate with a first adhesive;

compensating for a deformation of the carrier substrate by coupling a mechanism to the second side of the carrier substrate, the deformation being caused by the bonding the first flexible substrate to the first side of the carrier substrate;

depositing at least one layer of a first material over the first flexible substrate to create a portion of at least one first electronic device while the first flexible substrate is bonded to the first side of the carrier substrate; and

depositing at least one layer of a second material over the second side of the carrier substrate while compensating for the deformation of the carrier substrate.

20. The method of claim 19 further comprising:

providing a second flexible substrate;

wherein:

compensating for the deformation of the carrier substrate by coupling the mechanism to the second side of the carrier substrate comprises bonding the second flexible substrate to the second side of the carrier substrate with a second adhesive; and

the mechanism comprises the second flexible substrate.

Assignments (1)

Continuity (8)