JPWO2017094566A1 - 有機エレクトロニクスデバイスを製造する製造装置の管理方法 - Google Patents
有機エレクトロニクスデバイスを製造する製造装置の管理方法 Download PDFInfo
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Abstract
Description
まず、本発明の一実施形態に係る管理方法の概要について説明する。上記管理方法は、有機エレクトロニクスデバイスを製造する製造装置の管理方法であって、上記製造装置内に基材を配置する配置工程と、上記基材に付着した、上記有機エレクトロニクスデバイスの材料および上記製造装置の材料の少なくとも一方に由来する不純物を検出する検出工程と、を含む。
次に、上記管理方法において管理の対象となる製造装置について説明する。管理の対象となる製造装置は、有機エレクトロニクスデバイスを製造する製造装置であれば、特に限定されない。
上記管理方法は、上記製造装置内に基材を配置する配置工程を含む。それゆえ、有機エレクトロニクスデバイスの材料および製造装置の材料の少なくとも一方に由来する不純物を基材に付着させることができる。そのため、後述する検出工程において、有機エレクトロニクスデバイスの製造工程の任意の段階において基材に付着し得る不純物の種類および/または量を評価することができる。
上記基材は、不純物を検出するために当該不純物を付着させる対象となるものである。上記基材の材質は、特に限定されるものではなく、無機物であってもよく、有機物であってもよく、有機物と無機物との混合物であってもよい。基材の材質は、例えば、有機エレクトロニクス分野で一般的に使用される材質であることが好ましい。
上記基材を配置する場所は、上記製造装置内であれば特に限定されない。基材の配置場所としては、例えば、製造装置のチャンバー内が挙げられる。本明細書において、チャンバーとは、有機エレクトロニクスデバイスが製造される空間を意味し、製造室とも称する。
上記管理方法は、上記基材に付着した、上記有機エレクトロニクスデバイスの材料および上記製造装置の材料の少なくとも一方に由来する不純物を検出する検出工程を含む。これにより、従来知られている真空ポンプの潤滑剤由来の不純物、大気中の有機物、並びに水分および酸素ではなく、有機エレクトロニクスデバイスの材料および上記製造装置の材料に由来する不純物を検出することができ、その結果を製造装置の管理に反映することができる。
上記検出工程において、検出対象となる不純物は、上記有機エレクトロニクスデバイスの材料および上記製造装置の材料の少なくとも一方に由来する不純物である。本明細書において、「上記有機エレクトロニクスデバイスの材料および上記製造装置の材料の少なくとも一方に由来する不純物」とは、真空ポンプの潤滑剤由来の不純物、大気中の有機物、並びに水分および酸素を除く不純物を意味する。
不純物を測定する場合に、不純物を回収するために基材に対して前処理を行ってもよい。不純物を直接測定できる測定方法を用いる場合は、前処理を行わなくてもよい。
不純物の量および有無の測定方法は、基材の形態および測定対象とする不純物の種類に応じて、適宜選択され得る。
上記管理方法は、上記検出工程によって検出された不純物の量が、予め設定された基準量以下であるか否か、または予め設定された基準量以上であるか否かを判定する判定工程を含んでいてもよい。当該判定工程は、検出された不純物の量が基準量より多いか否か、または基準量未満であるか否かを判定する工程であるともいえる。上記判定工程によれば、不純物を除去するために洗浄等の処理が必要であるか否かを決定するための判断材料を得ることができる。
2台の真空蒸着装置内にそれぞれ基材として4インチφのシリコンウェハを配置した。具体的には、真空蒸着装置のチャンバー内の基板ホルダによって基材を保持した。当該基材を30分間静置後および15時間静置後に取り出した。基材の表側(以下では、基材の表側とは、図1の(a)の基材2において成膜材料保持部3と対向する面を意味する)に付着した不純物を、有機溶媒に接触させて回収し、回収液をLC−MSによって測定した。結果を表1に示す。有機エレクトロニクスデバイスの材料に由来する不純物として図3の(a)〜(l)に示す芳香族化合物が検出され、製造装置の材料に由来する不純物として図3の(m)に示すアジピン酸エステルおよび図3の(n)に示すフタル酸エステルが検出された。
図3の(b)に示す化合物:408.1626
図3の(c)に示す化合物:626.3661
図3の(d)に示す化合物:194.0844
図3の(e)に示す化合物:208.1000
図3の(f)に示す化合物:270.1157
図3の(g)に示す化合物:588.2565
図3の(h)に示す化合物:725.2831
図3の(i)に示す化合物:654.2532
図3の(j)に示す化合物:537.2205
図3の(k)に示す化合物:788.2688
図3の(l)に示す化合物:740.2940
図3の(m)に示す化合物:370.3083
図3の(n)に示す化合物:390.2770。
1台の真空蒸着装置内に基材として4インチφのシリコンウェハを配置し、30分静置後および15時間静置後に取り出した。基材の表側に付着した不純物をウェハ加熱脱離ガスクロマトグラフィー質量分析法(WTD−GC−MS)によって測定した。ヘキサデカン標準試料を用いて上記シリコンウェハ1cm2あたりの不純物量を定量した結果を表2に示す。有機エレクトロニクスデバイスの材料に由来する不純物である芳香族化合物(No.1〜4)、製造装置の材料に由来する不純物である添加剤等(No.5〜12)が検出された。
1台の真空蒸着装置内に基材として4インチφのシリコンウェハを配置し、15時間静置後に取り出した。基材の表側に付着した不純物を酸溶媒に接触させて溶解し、溶解液をICP−MSによって測定した。各検出元素の標準試料を用いて上記シリコンウェハ1枚あたりの不純物量を定量した結果を表3に示す。
1台の真空蒸着装置内に基材として4インチφのシリコンウェハを配置し、15時間静置後に取り出し、この基材を装置洗浄前の不純物量測定用サンプルとして評価した。続いて同じ装置にて有機ELデバイスを作成した。装置内を洗浄後、洗浄前と同様に基材として4インチφのシリコンウェハを配置し、15時間静置後に取り出し、この基材を装置洗浄後の不純物量測定用サンプルとして評価した。同じ装置にて再度、有機ELデバイスを作成した。基材の表側に付着した不純物を有機溶媒に接触させて回収し、回収液をLC−MSで測定した。検出された不純物の総量を汚染度として評価した。なお、当該不純物の総量には、真空ポンプの潤滑剤由来の不純物、大気中の有機物、並びに水分および酸素は含まれていない。また、有機ELデバイスの発光寿命LT90(初期輝度1000cd/m2)を評価した。それぞれ装置洗浄前を100%としたときの相対汚染度と相対発光寿命を表4に示す。
真空蒸着装置内に基材として3インチφのSiウェハを配置した。当該真空蒸着装置内を用いて、多層膜としてホール注入層、ホール輸送層、発光層、ホールブロック層および電子輸送層を有する有機ELデバイスを作成した。各層の成膜時間および次の層を形成するまでの待機時間を一定に保ちつつ、発光層成膜前後で次の層の形成を開始するまでに意図的に60分ずつまたは40分ずつの待機時間を設けたデバイスと、待機時間を設けなかったデバイスとを作成し、寿命評価をおこなった。すなわち、待機時間を設けたデバイスでは、ホール輸送層の成膜後から発光層の成膜前までと、発光層の成膜後からホールブロック層の成膜前までとにおいて、それぞれ60分または40分の待機時間を設けた。また、各層の成膜中は基材に成膜材料が付着しないように基材と成膜材料保持部との間にシャッターを配置した。このようにして得られた基材を不純物量測定用サンプルとして評価した。基材の表側に付着した不純物を有機溶媒に接触させて回収し、回収液をLC−MSで測定した。検出された不純物の総量を汚染度として評価した。なお、当該不純物の総量には、真空ポンプの潤滑剤由来の不純物、大気中の有機物、並びに水分および酸素は含まれていない。また、有機ELデバイスは発光寿命LT90(初期輝度1000cd/m2)で評価した。発光層前後で60分ずつ待機した結果を100%としたときの相対汚染度と相対発光寿命を表5に示す。
2 基材
Claims (6)
- 有機エレクトロニクスデバイスを製造する製造装置の管理方法であって、
上記製造装置内に基材を配置する配置工程と、
上記基材に付着した、上記有機エレクトロニクスデバイスの材料および上記製造装置の材料の少なくとも一方に由来する不純物を検出する検出工程と、を含むことを特徴とする管理方法。 - 上記基材は、基板および有機膜の少なくとも一方を含むことを特徴とする請求項1に記載の管理方法。
- 上記基材は、上記有機エレクトロニクスデバイスの材料を含み、かつ上記不純物とは異なる材料からなることを特徴とする請求項1または2に記載の管理方法。
- 上記配置工程は、有機エレクトロニクスデバイスの製造前、製造中および製造後の少なくともいずれか1つの段階で行われることを特徴とする請求項1〜3のいずれか1項に記載の管理方法。
- 上記有機エレクトロニクスデバイスが多層膜を有することを特徴とする請求項4に記載の管理方法。
- 上記製造装置は、蒸着プロセスまたは塗布プロセスによって有機エレクトロニクスデバイスを製造する製造装置であることを特徴とする請求項1〜5のいずれか1項に記載の管理方法。
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