KR102196797B1 - Template for supporting mask and producing methoe thereof and producing method of mask integrated frame - Google Patents

Abstract

The present invention relates to a mask supporting template, a method of manufacturing the same, and a method of manufacturing a frame-integrated mask. The manufacturing method of the mask supporting template according to the present invention is a manufacturing method of a template 50 corresponding to the frame 200 by supporting the mask 100 for forming an OLED pixel. (a) Temporary adhesion 55 Providing a mask 100 including a substrate 60 on which a) portion is formed, and a plurality of mask patterns P adhered to the temporary bonding portion 55, (b) transferring the transfer substrate 65 to the mask 100 Adhering, (c) removing the substrate 60, (d) adhering the template 50 having the temporary bonding portion 55 formed on one surface thereof to the mask 100, and (e) the transfer substrate 65 ) Characterized in that it comprises the step of removing.

Description

A mask supporting template, a manufacturing method thereof, and a manufacturing method of a frame-integrated mask {TEMPLATE FOR SUPPORTING MASK AND PRODUCING METHOE THEREOF AND PRODUCING METHOD OF MASK INTEGRATED FRAME}

The present invention relates to a mask supporting template, a method of manufacturing the same, and a method of manufacturing a frame-integrated mask. More specifically, it is possible to stably support and move without deformation of the mask, and when the mask is integrated with the frame, the adhesion between the mask and the frame can be improved, and alignment between each mask can be made clear. The present invention relates to a mask supporting template, a manufacturing method thereof, and a manufacturing method of a frame-integrated mask.

As a technology for forming pixels in the OLED manufacturing process, the Fine Metal Mask (FMM) method is mainly used in which an organic material is deposited at a desired location by attaching a thin metal mask to a substrate.

In the existing OLED manufacturing process, the mask is manufactured in the form of a stick or plate, and then the mask is welded and fixed to the OLED pixel deposition frame. One mask may include several cells corresponding to one display. In addition, in order to manufacture a large area OLED, several masks can be fixed to the OLED pixel deposition frame. In the process of fixing to the frame, each mask is stretched so that it is flat. It is a very difficult task to adjust the tension so that the entire part of the mask is flat. In particular, in order to align a mask pattern with a size of only a few to tens of μm while making all the cells flat, a high level of work is required to check the alignment in real time while finely adjusting the tension applied to each side of the mask. do.

Nevertheless, in the process of fixing several masks to one frame, there is a problem in that the alignment between the masks and the mask cells is not good. In addition, in the process of welding and fixing the mask to the frame, the thickness of the mask film is too thin and large area, so the mask is struck or distorted by the load, and wrinkles and burrs occur in the welding part during the welding process. There were problems such as misalignment.

In the case of ultra-high-definition OLED, the current QHD quality is 500-600 PPI (pixel per inch), and the pixel size reaches about 30-50 μm, and 4K UHD, 8K UHD high-definition is higher than this -860 PPI, ~1600 PPI Will have a resolution of. In this way, in consideration of the pixel size of the ultra-high-definition OLED, the alignment error between cells should be reduced to about several µm, and the error beyond this leads to product failure, so the yield may be very low. Therefore, there is a need to develop a technique for preventing deformation such as a mask being struck or distorted, a technique for clarifying alignment, a technique for fixing a mask to a frame, and the like.

Accordingly, the present invention was conceived to solve the problems of the prior art as described above, and it is an object of the present invention to provide a mask support template capable of simultaneously responding and attaching a plurality of mask support templates to a frame and a method of manufacturing the same. do.

In addition, an object of the present invention is to provide a mask support template capable of stably supporting and moving a mask without deformation and a method of manufacturing the same.

In addition, an object of the present invention is to provide a method of manufacturing a frame-integrated mask in which a mask and a frame can form an integral structure.

In addition, it is an object of the present invention to provide a method of manufacturing a frame-integrated mask capable of preventing deformation such as being struck or distorted and clarifying alignment.

In addition, an object of the present invention is to provide a method for manufacturing a frame-integrated mask in which the manufacturing time is remarkably reduced and the yield is remarkably increased.

The above object of the present invention is a method of manufacturing a template that supports an OLED pixel forming mask to correspond to a frame, comprising: (a) a substrate having a temporary adhesive portion formed on one surface, and a plurality of mask patterns adhered to the temporary adhesive portion Providing a mask comprising a; (b) adhering the transfer substrate to the mask; (c) removing the substrate; (d) adhering the template with the temporary adhesive portion formed on one surface to the mask; And (e) removing the transfer substrate.

The template and the mask may be adhered to each other in the same area.

The substrate and the transfer substrate may have a larger area than the mask.

The substrate may be made of a glass material, and the transfer substrate may be an invar material sheet or an adhesive sheet capable of being separated by UV irradiation.

When the transfer substrate is an Invar material sheet, a temporary adhesive portion may be formed on one surface to be adhered to the mask.

In step (a), the substrate includes a lower glass substrate and an upper Invar substrate, and in step (c), the glass substrate and the Invar substrate may be removed.

In step (a), the substrate includes a lower glass substrate and an upper Invar substrate, step (b) is performed while the lower glass substrate is separated, and in step (c), the Invar substrate is removed. I can.

Step (a) may include: (a1) bonding a mask metal film on a substrate having a temporary adhesive portion formed on one surface thereof; (a2) forming a patterned insulating portion on the mask metal film; (a3) forming a plurality of mask patterns by etching portions of the mask metal layer exposed between the insulating portions; And (a4) may include the step of removing the insulation.

The temporary bonding unit may be an adhesive or adhesive sheet that can be separated by applying heat, and an adhesive or adhesive sheet that can be separated by UV irradiation.

The temporary adhesive may be a liquid wax or a thermal release tape.

The template may be a transparent material.

The template may include any one material of wafer, glass, silica, heat-resistant glass, quartz, alumina (Al ₂ O ₃ ), borosilicate glass, and zirconia. have.

A through hole through which welding energy passes may be formed in a portion of the template corresponding to the welding portion of the mask.

Further, the above object of the present invention is to provide a template for supporting an OLED pixel forming mask to correspond to a frame, comprising: a template; A temporary adhesive portion formed on the template; And a mask bonded on the template through the temporary bonding portion and formed with a mask pattern, wherein the template and the mask are bonded to each other in the same area.

The thickness of the mask may be 5 μm to 20 μm.

In addition, the above object of the present invention is a method of manufacturing a frame-integrated mask in which a plurality of masks and a frame supporting the mask are integrally formed, comprising: (a) a substrate having a temporary bonding portion formed on one surface, and a plurality of Preparing a mask including a mask pattern; (b) adhering the transfer substrate to the mask; (c) removing the substrate; (d) adhering the template with the temporary adhesive portion formed on one surface to the mask; (e) removing the transfer substrate to prepare a mask support template; (f) preparing a frame including a plurality of mask cell regions; (g) loading the template onto the frame to correspond the mask to the mask cell area of the frame; And (h) irradiating welding energy to the welding portion of the mask to prepare the mask on the frame.

The template and the mask may be adhered to each other in the same area.

The substrate and the transfer substrate may have a larger area than the mask.

The substrate may be made of a glass material, and the transfer substrate may be an invar material sheet or an adhesive sheet capable of being separated by UV irradiation.

The welding energy irradiated from the upper part of the template may pass through the through hole and be irradiated to the welding portion of the mask.

A welding bead is formed in a portion of the welding portion irradiated with welding energy, and the welding bead may be mediated so that the mask and the frame are integrally connected.

In step (g), step (h) may be performed after corresponding a plurality of templates on all mask cell regions of the frame.

A template corresponding to a specific mask cell area and a template corresponding to a neighboring mask cell area may form a predetermined interval.

After step (h), it may further include the step of separating the mask and the template by performing at least one of applying heat, chemical treatment, ultrasonic application, and UV application to the temporary adhesive.

According to the present invention configured as described above, it is possible to simultaneously correspond and attach a plurality of mask support templates to the frame.

In addition, according to the present invention, there is an effect that the mask can be stably supported and moved without deformation.

In addition, according to the present invention, there is an effect that the mask and the frame can form an integral structure.

In addition, according to the present invention, there is an effect of preventing deformation, such as being struck or distorted, of the mask, and enabling clear alignment.

Further, according to the present invention, there is an effect of remarkably reducing the manufacturing time and increasing the yield remarkably.

1 is a schematic diagram showing a conventional OLED pixel deposition mask.
2 is a schematic diagram showing a process of attaching a conventional mask to a frame.
3 is a schematic diagram showing that an alignment error between cells occurs in a process of tensioning a conventional mask.
4 is a front view and a side cross-sectional view showing a frame-integrated mask according to an embodiment of the present invention.
5 is a front view and a side cross-sectional view showing a frame according to an embodiment of the present invention.
6 is a schematic diagram showing a manufacturing process of a frame according to an embodiment of the present invention.
7 is a schematic diagram showing a manufacturing process of a frame according to another embodiment of the present invention.
8 is a schematic diagram showing a mask according to an embodiment of the present invention.
9 to 10 are schematic diagrams illustrating a process of manufacturing a mask supporting template by attaching a mask metal film on a template according to a comparative example and forming a mask.
11 is a schematic diagram illustrating a process of loading a mask supporting template on a frame according to a comparative example.
12 to 13 are schematic diagrams showing a process of manufacturing a mask support template according to an embodiment of the present invention.
14 is an enlarged cross-sectional schematic view showing a temporary bonding unit according to an embodiment of the present invention.
15 is a schematic diagram showing a process of manufacturing a mask supporting template according to another embodiment of the present invention.
16 is a schematic diagram illustrating a process of loading a mask supporting template onto a frame according to an embodiment of the present invention.
17 is a schematic diagram illustrating a state in which a template is loaded onto a frame and a mask is associated with a cell area of the frame according to an embodiment of the present invention.
18 is a schematic diagram illustrating a process of separating a mask from a template after attaching a mask to a frame according to an embodiment of the present invention.
19 is a schematic diagram showing a state in which a mask is attached to a frame according to an embodiment of the present invention.
20 is a schematic diagram showing an OLED pixel deposition apparatus using a frame-integrated mask according to an embodiment of the present invention.

DETAILED DESCRIPTION OF THE INVENTION The detailed description of the present invention to be described later refers to the accompanying drawings, which illustrate specific embodiments in which the present invention may be practiced. These embodiments are described in detail sufficient to enable a person skilled in the art to practice the present invention. It is to be understood that the various embodiments of the present invention are different from each other, but need not be mutually exclusive. For example, specific shapes, structures, and characteristics described herein may be implemented in other embodiments without departing from the spirit and scope of the present invention in relation to one embodiment. In addition, it is to be understood that the location or arrangement of individual components within each disclosed embodiment may be changed without departing from the spirit and scope of the present invention. Accordingly, the detailed description to be described below is not intended to be taken in a limiting sense, and the scope of the present invention, if properly described, is limited only by the appended claims, along with all scopes equivalent to those claimed by the claims. In the drawings, similar reference numerals refer to the same or similar functions over several aspects, and the length, area, thickness, and the like may be exaggerated and expressed for convenience.

Hereinafter, preferred embodiments of the present invention will be described in detail with reference to the accompanying drawings in order to enable those of ordinary skill in the art to easily implement the present invention.

1 is a schematic diagram showing a conventional OLED pixel deposition mask 10.

Referring to FIG. 1, a conventional mask 10 may be manufactured in a stick-type or plate-type. The mask 10 shown in (a) of FIG. 1 is a stick-type mask, and both sides of the stick can be welded and fixed to an OLED pixel deposition frame. The mask 100 shown in (b) of FIG. 1 is a plate-type mask and may be used in a process of forming a pixel having a large area.

A plurality of display cells C are provided on the body of the mask 10 (or the mask layer 11). One cell C corresponds to one display such as a smartphone. A pixel pattern P is formed in the cell C to correspond to each pixel of the display. When the cell C is enlarged, a plurality of pixel patterns P corresponding to R, G, and B appear. For example, a pixel pattern P is formed in the cell C to have a resolution of 70 X 140. That is, a number of pixel patterns P are clustered to form one cell C, and a plurality of cells C may be formed on the mask 10.

2 is a schematic diagram showing a process of attaching the conventional mask 10 to the frame 20. 3 is a schematic diagram showing that an alignment error occurs between cells in a process of stretching the conventional mask 10 (F1 to F2). A stick mask 10 including six cells C: C1 to C6 shown in FIG. 1A will be described as an example.

Referring to FIG. 2A, first, the stick mask 10 must be flattened. The stick mask 10 is unfolded as it is pulled by applying a tensile force F1 to F2 in the long axis direction of the stick mask 10. In that state, the stick mask 10 is loaded on the frame 20 in the form of a square frame. Cells C1 to C6 of the stick mask 10 are located in a blank area inside the frame of the frame 20. The frame 20 may have a size such that cells C1 to C6 of one stick mask 10 are located in an empty area inside the frame, and cells C1 to C6 of a plurality of stick masks 10 are It may be large enough to be located in an internal empty area.

Referring to FIG. 2(b), after aligning while finely adjusting the tensile forces (F1 to F2) applied to each side of the stick mask 10, a part of the side of the stick mask 10 is welded (W). Accordingly, the stick mask 10 and the frame 20 are interconnected. 2C shows a cross-sectional side view of the frame and the stick mask 10 connected to each other.

Referring to FIG. 3, although the tensile forces F1 to F2 applied to each side of the stick mask 10 are finely adjusted, there is a problem in that the mask cells C1 to C3 are not well aligned with each other. For example, the distances D1 to D1" and D2 to D2" between the patterns P of the cells C1 to C3 are different from each other, or the patterns P are skewed. Since the stick mask 10 has a large area including a plurality (for example, 6) of cells C1 to C6 and has a very thin thickness of several tens of µm, it is easily struck or distorted by a load. In addition, it is a very difficult task to check the alignment between each cell (C1 to C6) in real time through a microscope while adjusting the tensile force (F1 to F2) to flatten all of the cells (C1 to C6).

Therefore, a minute error in the tensile force (F1 to F2) may cause an error in the extent to which each of the cells (C1 to C3) of the stick mask 10 is stretched or unfolded, and accordingly, the distance D1 between the mask patterns (P) ~D1", D2 ~ D2") causes a problem that becomes different. Of course, it is difficult to completely align the error to be 0, but in order to prevent the mask pattern (P) having a size of several to tens of µm from adversely affecting the pixel process of ultra-high-definition OLED, the alignment error should not exceed 3 µm It is desirable not to. This alignment error between adjacent cells is referred to as PPA (pixel position accuracy).

In addition, a plurality of stick masks 10 of about 6 to 20 are connected to one frame 20, respectively, between a plurality of stick masks 10, and a plurality of cells C of the stick mask 10 It is also a very difficult task to clarify the alignment state between ~C6), and the process time according to the alignment is inevitably increased, which is a significant reason for reducing productivity.

On the other hand, after the stick mask 10 is connected and fixed to the frame 20, the tensile forces F1 to F2 applied to the stick mask 10 may act in reverse to the frame 20. That is, after the stick mask 10, which was stretched by the tensile force F1 to F2, is connected to the frame 20, a tension may be applied to the frame 20. Usually, this tension is not large and may not have a large effect on the frame 20, but when the size of the frame 20 is reduced in size and the rigidity is lowered, this tension may finely deform the frame 20. As a result, there may be a problem of misalignment between the plurality of cells C to C6.

Accordingly, the present invention proposes a frame 200 and a frame-integrated mask that enables the mask 100 to form an integral structure with the frame 200. The mask 100 integrally formed in the frame 200 is prevented from being struck or warped, and may be clearly aligned with the frame 200. Since no tensile force is applied to the mask 100 when the mask 100 is connected to the frame 200, the frame 200 may not be deformed after the mask 100 is connected to the frame 200. . In addition, the manufacturing time for integrally connecting the mask 100 to the frame 200 can be significantly reduced, and the yield can be remarkably increased.

Figure 4 is a front view [Fig. 4 (a)] and a side cross-sectional view [Fig. 4 (b)] showing a frame-integrated mask according to an embodiment of the present invention, Figure 5 is according to an embodiment of the present invention It is a front view [FIG. 5(a)] and a side cross-sectional view [FIG. 5(b)] showing the frame.

4 and 5, the frame-integrated mask may include a plurality of masks 100 and one frame 200. In other words, a plurality of masks 100 are attached to the frame 200, one by one. Hereinafter, for convenience of explanation, a square-shaped mask 100 will be described as an example, but the mask 100 may be in the form of a stick mask having protrusions clamped on both sides before being attached to the frame 200, and the frame 200 ), the protrusion can be removed after being attached.

A plurality of mask patterns P may be formed on each mask 100, and one cell C may be formed on one mask 100. One mask cell C may correspond to one display such as a smartphone.

Mask 100 may be a coefficient of thermal expansion of about 1.0 X 10 ^-6 / ℃ of invar (invar), about 1.0 X 10 ^-7 / ℃ Super Invar (super invar) material. Since the mask 100 made of this material has a very low coefficient of thermal expansion, it is less likely that the pattern shape of the mask may be deformed by thermal energy, so it can be used as a Fine Metal Mask (FMM) or a shadow mask in high-resolution OLED manufacturing. In addition, considering the recent development of technologies for performing a pixel deposition process in a range where the temperature change value is not large, the mask 100 is made of nickel (Ni) and nickel-cobalt (Ni-Co) having a slightly larger coefficient of thermal expansion than this. ), etc. The mask 100 may be formed of a metal sheet produced by a rolling process or electroforming.

The frame 200 is formed to attach a plurality of masks 100. The frame 200 may include several corners formed in a first direction (eg, horizontal direction) and a second direction (eg, vertical direction) including an outermost edge. These various corners may partition a region on the frame 200 to which the mask 100 is to be attached.

The frame 200 may include a frame portion 210 having a substantially square shape or a square frame shape. The inside of the frame frame 210 may have a hollow shape. That is, the frame frame unit 210 may include a hollow region R. The frame 200 may be made of metal materials such as Invar, Super Invar, aluminum, titanium, etc., and in consideration of thermal deformation, it is composed of materials such as Invar, Super Invar, nickel, nickel-cobalt, etc., which have the same coefficient of thermal expansion as the mask. Preferably, these materials may be applied to both the frame part 210 and the mask cell sheet part 220 which are components of the frame 200.

In addition, the frame 200 may include a plurality of mask cell regions CR, and may include a mask cell sheet part 220 connected to the frame frame part 210. Like the mask 100, the mask cell sheet part 220 may be formed by rolling, or may be formed using another film forming process such as electroplating. In addition, the mask cell sheet part 220 may form a plurality of mask cell regions CR on a planar sheet through laser scribing, etching, or the like, and then connect to the frame frame part 210. Alternatively, the mask cell sheet part 220 may form a plurality of mask cell regions CR through laser scribing, etching, or the like after connecting the planar sheet to the frame frame part 210. In the present specification, it is assumed that a plurality of mask cell regions CR are first formed in the mask cell sheet part 220 and then connected to the frame frame part 210.

The mask cell sheet part 220 may be configured to include at least one of an edge sheet part 221 and first and second grid sheet parts 223 and 225. The frame sheet portion 221 and the first and second grid sheet portions 223 and 225 refer to respective portions partitioned in the same sheet, and they are integrally formed with each other.

The frame sheet part 221 may be substantially connected to the frame frame part 210. Accordingly, the frame sheet part 221 may have a substantially square shape and a square frame shape corresponding to the frame frame part 210.

In addition, the first grid sheet portion 223 may be formed to extend in a first direction (horizontal direction). The first grid sheet portion 223 may be formed in a linear shape so that both ends may be connected to the edge sheet portion 221. When the mask cell sheet portion 220 includes a plurality of first grid sheet portions 223, it is preferable that each of the first grid sheet portions 223 form equal intervals.

Further, in addition to this, the second grid sheet portion 225 may be formed to extend in a second direction (vertical direction). The second grid sheet portion 225 may be formed in a linear shape so that both ends may be connected to the edge sheet portion 221. The first grid sheet portion 223 and the second grid sheet portion 225 may vertically cross each other. When the mask cell sheet portion 220 includes a plurality of second grid sheet portions 225, each of the second grid sheet portions 225 is preferably formed at an equal interval.

Meanwhile, the spacing between the first grid sheet parts 223 and the spacing between the second grid sheet parts 225 may be the same or different according to the size of the mask cell C.

The first grid sheet portion 223 and the second grid sheet portion 225 have a thin thickness in the form of a thin film, but the shape of a cross-section perpendicular to the length direction may be a rectangle, a square shape such as a trapezoid, a triangle shape, etc., Some of the sides and corners may be rounded. The cross-sectional shape can be adjusted in the process of laser scribing and etching.

The thickness of the frame frame part 210 may be thicker than the thickness of the mask cell sheet part 220. Since the frame frame portion 210 is responsible for the overall rigidity of the frame 200, it may be formed to a thickness of several mm to several cm.

In the case of the mask cell sheet part 220, it is difficult to manufacture a substantially thick sheet, and if it is too thick, the organic material source 600 (see FIG. 20) passes through the mask 100 in the OLED pixel deposition process. It can cause clogging problems. Conversely, if the thickness is too thin, it may be difficult to secure enough rigidity to support the mask 100. Accordingly, the mask cell sheet portion 220 is thinner than the thickness of the frame frame portion 210, but is preferably thicker than the mask 100. The thickness of the mask cell sheet part 220 may be about 0.1 mm to 1 mm. In addition, the first and second grid sheet portions 223 and 225 may have a width of about 1 to 5 mm.

A plurality of mask cell areas CR (CR11 to CR56) may be provided except for the area occupied by the edge sheet portion 221 and the first and second grid sheet portions 223 and 225 in a flat sheet. In another aspect, the mask cell area CR is an area occupied by the frame sheet part 221 and the first and second grid sheet parts 223 and 225 in the hollow area R of the frame frame part 210. Except for, it may mean an empty area.

As the cell C of the mask 100 corresponds to the mask cell region CR, it can be used as a passage through which the pixel of the OLED is deposited substantially through the mask pattern P. As described above, one mask cell C corresponds to one display such as a smartphone. Mask patterns P constituting one cell C may be formed on one mask 100. Alternatively, one mask 100 may include a plurality of cells C, and each cell C may correspond to each cell area CR of the frame 200, but clear alignment of the mask 100 is achieved. In order to do so, it is necessary to avoid the large-area mask 100, and a small-area mask 100 having one cell C is preferable. Alternatively, one mask 100 having a plurality of cells C may correspond to one cell area CR of the frame 200. In this case, for clear alignment, it may be considered to correspond to the mask 100 having a small number of cells C of about 2-3.

The frame 200 includes a plurality of mask cell areas CR, and each mask 100 may be attached such that one mask cell C corresponds to the mask cell area CR. Each mask 100 may include a mask cell C having a plurality of mask patterns P formed thereon, and a dummy around the mask cell C (corresponding to a portion of the mask layer 110 excluding the cell C). have. The dummy may include only the mask layer 110 or may include the mask layer 110 in which a predetermined dummy pattern similar to the mask pattern P is formed. The mask cell C corresponds to the mask cell area CR of the frame 200, and a part or all of the dummy may be attached to the frame 200 (mask cell sheet part 220). Accordingly, the mask 100 and the frame 200 can form an integral structure.

Meanwhile, according to another embodiment, the frame is not manufactured by attaching the mask cell sheet part 220 to the frame frame part 210, but the frame frame part 210 is formed in the hollow region R part of the frame frame part 210. ) And an integral grid frame (corresponding to the grid seat portions 223 and 225) may be directly formed. This type of frame also includes at least one mask cell area CR, and a frame-integrated mask can be manufactured by matching the mask 100 to the mask cell area CR.

Hereinafter, a process of manufacturing a frame-integrated mask will be described.

First, the frame 200 described above in FIGS. 4 and 5 may be provided. 6 is a schematic diagram showing a manufacturing process of the frame 200 according to an embodiment of the present invention.

Referring to FIG. 6A, a frame frame part 210 is provided. The frame frame part 210 may have a rectangular frame shape including a hollow region R.

Next, referring to FIG. 6B, a mask cell sheet part 220 is manufactured. The mask cell sheet part 220 is manufactured by manufacturing a flat sheet using rolling, electroplating, or other film forming processes, and then removing the mask cell area CR through laser scribing and etching. can do. In this specification, an example in which a 6 X 5 mask cell region (CR: CR11 to CR56) is formed will be described. Five first grid sheet portions 223 and four second grid sheet portions 225 may be present.

Next, the mask cell sheet part 220 may correspond to the frame frame part 210. In the process of correspondence, all sides of the mask cell sheet part 220 are stretched (F1 to F4) to flatten the mask cell sheet part 220 and the frame sheet part 221 is attached to the frame frame part 210. Can respond. In one side, it is possible to hold the mask cell sheet portion 220 at several points (for example, 1 to 3 points in FIG. 6 (b)) and stretch it. On the other hand, the mask cell sheet portion 220 may be stretched (F1, F2) along some side directions instead of all sides.

Next, when the mask cell sheet part 220 corresponds to the frame frame part 210, the frame sheet part 221 of the mask cell sheet part 220 may be attached by welding (W). It is preferable to weld (W) all sides so that the mask cell sheet part 220 can be firmly attached to the frame part 220. Welding (W) should be performed as close as possible to the edge of the frame frame part 210 to reduce the excitement space between the frame part 210 and the mask cell sheet part 220 and increase adhesion. The welding (W) part may be created in a line or spot shape, and the frame frame part 210 and the mask cell sheet part 220 are integrally made of the same material as the mask cell sheet part 220. It can be a medium to connect with.

7 is a schematic diagram showing a manufacturing process of a frame according to another embodiment of the present invention. In the embodiment of FIG. 6, the mask cell sheet part 220 having the mask cell area CR is first manufactured and attached to the frame frame part 210. However, in the embodiment of FIG. 210), a mask cell region CR is formed.

First, as shown in (a) of FIG. 6, a frame part 210 including a hollow region R is provided.

Next, referring to FIG. 7A, a flat sheet (a flat mask cell sheet 220 ′) may correspond to the frame frame 210. The mask cell sheet part 220 ′ is in a planar state in which the mask cell area CR has not yet been formed. In the matching process, all sides of the mask cell sheet part 220 ′ are stretched (F1 to F4) to correspond to the frame frame part 210 with the mask cell sheet part 220 ′ flattened. One side can also hold the mask cell sheet portion 220 ′ at several points (eg, 1 to 3 points in FIG. 7 (a)) and tension. On the other hand, the mask cell sheet portion 220 ′ may be stretched (F1, F2) along some side directions instead of all sides.

Next, when the mask cell sheet part 220 ′ corresponds to the frame frame part 210, the rim part of the mask cell sheet part 220 ′ may be attached by welding (W). It is preferable to weld (W) all sides so that the mask cell sheet part 220 ′ can be firmly attached to the frame frame part 220. Welding (W) should be performed as close as possible to the edge of the frame frame part 210 to reduce the excitement space between the frame part 210 and the mask cell sheet part 220 ′ and increase adhesion. The welding (W) portion may be generated in a line or spot shape, and has the same material as the mask cell sheet portion 220 ′, and the frame frame portion 210 and the mask cell sheet portion 220 ′ It can be a medium that connects all together.

Next, referring to FIG. 7B, a mask cell region CR is formed on a planar sheet (a planar mask cell sheet portion 220'). The mask cell area CR may be formed by removing the sheet in the mask cell area CR through laser scribing or etching. In this specification, an example in which a 6 X 5 mask cell region (CR: CR11 to CR56) is formed will be described. When the mask cell area CR is formed, the edge frame portion 210 and the welded (W) portion become the edge sheet portion 221, and the five first grid sheet portions 223 and the four second grids A mask cell sheet portion 220 having a sheet portion 225 may be configured.

8 is a schematic diagram showing a mask 100 according to an embodiment of the present invention.

The mask 100 may include a mask cell C on which a plurality of mask patterns P are formed and a dummy DM surrounding the mask cell C. It has been described above that the mask 100 may be manufactured from a metal sheet produced by a rolling process or electroplating, and one cell C may be formed in the mask 100. The dummy DM corresponds to a portion of the mask layer 110 (mask metal layer 110) excluding the cell C, and includes only the mask layer 110, or a predetermined dummy having a shape similar to the mask pattern P A patterned mask layer 110 may be included. In the dummy DM, part or all of the dummy DM may be attached to the frame 200 (mask cell sheet part 220) corresponding to the edge of the mask 100.

The width of the mask pattern P may be less than 40 μm, and the thickness of the mask 100 may be about 5 to 20 μm. Since the frame 200 includes a plurality of mask cell regions CR: CR11 to CR56, the mask 100 having mask cells C: C11 to C56 corresponding to respective mask cell regions CR: CR11 to CR56 ) May also be provided.

Since one surface 101 of the mask 100 is a surface to be attached by contacting the frame 200, it is preferable that it is flat. One surface 101 may be flattened and mirrored in a planarization process to be described later. The other surface 102 of the mask 100 may face one surface of the template 50 to be described later.

Hereinafter, a mask metal layer 110 ′ is manufactured, and the mask 100 is manufactured by supporting it on the template 50, and the template 50 on which the mask 100 is supported is loaded on the frame 200. A series of processes for manufacturing a frame-integrated mask by attaching the mask 100 to the frame 200 will be described. First, after the process according to the comparative example is described in FIGS. 9 to 11, the present invention solving the problem of the comparative example will be described below in FIG. 12.

9 to 10 are schematic diagrams illustrating a process of manufacturing a mask supporting template by attaching a mask metal film on a template according to a comparative example and forming a mask.

First, a mask metal layer 110 ′ may be prepared. As an embodiment, the mask metal layer 110 ′ may be prepared by a rolling method.

The metal sheet manufactured by the rolling process may have a thickness of several tens to several hundred μm in the manufacturing process. For UHD-level high resolution, a thin mask metal layer 110 having a thickness of 20 μm or less must be used to perform fine patterning. For ultra-high resolution above UHD, a thin mask metal layer 110 having a thickness of about 10 μm. ) Should be used. However, since the mask metal layer 110 ′ produced by the rolling process has a thickness of about 25 to 500 μm, it is necessary to have a thinner thickness.

Accordingly, a process of planarizing (PS) one surface of the mask metal layer 110 ′ may be further performed. Here, planarization (PS) refers to reducing the thickness of one surface (upper surface) of the mask metal layer 110 ′ to a thinner surface by removing a part of the upper surface of the mask metal layer 110 ′. Planarization (PS) may be performed by a CMP (Chemical Mechanical Polishing) method, and a known CMP method may be used without limitation. In addition, the thickness of the mask metal layer 110 ′ may be reduced by a chemical wet etching method or a dry etching method. In addition, a process capable of flattening the mask metal layer 110 ′ may be used without limitation.

In the process of performing the planarization (PS), for example, in the CMP process, the surface roughness R _a of the upper surface of the mask metal layer 110 ′ may be controlled. Preferably, mirroring can be performed in which the surface roughness is further reduced. Alternatively, as another example, after performing a chemical wet etching or dry etching process to perform planarization (PS), a polishing process such as a separate CMP process may be added thereafter to reduce the surface roughness R _a .

In this way, the thickness of the mask metal layer 110 ′ can be made thin to about 50 μm or less. Accordingly, it is preferable that the thickness of the mask metal layer 110 is about 2 μm to 50 μm, and more preferably, the thickness may be about 5 μm to 20 μm. However, it is not necessarily limited thereto.

As another embodiment, the mask metal layer 110 may be prepared by electroplating. In order to perform electroforming, the substrate of the electroplated base plate may be a conductive material. The mother plate can be used as a cathode electrode in electroplating.

As a conductive material, in the case of metal, metal oxides may be generated on the surface, impurities may be introduced during the metal manufacturing process, in the case of a polycrystalline silicon substrate, inclusions or grain boundaries may exist, and conductive polymers In the case of the base material, the possibility of containing impurities is high and strength. Acid resistance may be weak. An element that prevents uniform formation of an electric field on the surface of the mother plate (or cathode) such as metal oxide, impurities, inclusions, grain boundaries, etc. is referred to as “defect”. Due to defects, a uniform electric field may not be applied to the cathode body made of the above-described material, so that a part of the plating film 110 (or the mask metal film 110) may be formed unevenly.

In implementing ultra-high definition pixels of the UHD level or higher, non-uniformity of the plating film and the plating film pattern [mask pattern P] may adversely affect the formation of pixels. For example, in the case of current QHD quality, the size of the pixel reaches about 30-50㎛ at 500~600 PPI (pixel per inch), and in the case of 4K UHD and 8K UHD high quality, ~860 PPI and ~1600 PPI are higher. It has the same resolution. Micro-displays directly applied to VR devices, or micro-displays inserted into VR devices, aim for ultra-high quality of about 2,000 PPI or higher, and the size of the pixels reaches about 5 to 10 μm. The pattern width of the FMM and shadow mask applied to this can be formed in a size of several to several tens of µm, preferably smaller than 30 µm, so that even defects of several µm can occupy a large proportion of the pattern size of the mask. to be. In addition, in order to remove defects in the cathode material of the above-described material, an additional process for removing metal oxides and impurities may be performed, and in this process, another defect such as etching of the cathode material may be caused. have.

Accordingly, in the present invention, a single crystal base plate (or a cathode body) may be used. In particular, it is preferably made of single crystal silicon. In order to have conductivity, a high concentration doping of 10 ¹⁹ /cm ³ or more may be performed on the mother plate made of single crystal silicon. Doping may be performed on the entire parent plate, or may be performed only on the surface portion of the parent plate.

Meanwhile, as a single crystal material, metals such as Ti, Cu, and Ag, semiconductors such as GaN, SiC, GaAs, GaP, AlN, InN, InP, Ge, and carbon-based materials such as graphite and graphene _{, CH 3 NH 3 PbCl 3,} CH 3 NH 3 PbBr 3, CH 3 NH 3 PbI 3, SrTiO 3 , etc. page containing the perovskite (perovskite) superconductor single crystalline ceramic, aircraft single crystal second heat-resistant alloy for components for such structures Etc. can be used. Metal and carbon-based materials are basically conductive materials. In the case of a semiconductor material, high concentration doping of 10 ¹⁹ /cm ³ or more may be performed to have conductivity. In the case of other materials, doping may be performed or oxygen vacancy may be formed to form conductivity. Doping may be performed on the entire parent plate, or may be performed only on the surface portion of the parent plate.

Since there are no defects in the case of a single crystal material, there is an advantage in that a uniform plating film 110 can be generated due to the formation of a uniform electric field on all surfaces during electroplating. The frame-integrated masks 100 and 200 manufactured through a uniform plating film can further improve the quality level of OLED pixels. In addition, since there is no need to perform an additional process for removing and eliminating defects, there is an advantage in that process cost is reduced and productivity is improved.

A conductive substrate is used as a mother plate [cathode body, not shown], and an anode body (not shown) is disposed to be spaced apart, and the plating film 110 (or mask metal film 110) is electroplated on the conductive substrate by electroplating. )] can be formed.

Meanwhile, before separating the plating film 110 from the conductive substrate, a heat treatment (H) may be performed. In order to reduce the coefficient of thermal expansion of the mask 100 and prevent deformation of the mask 100 and the mask pattern P by heat, the plated film 110 is removed from the conductive substrate 21 (or the mother plate, the cathode body). Heat treatment (H) may be performed before separation. The heat treatment may be performed at a temperature of 300°C to 800°C.

The thickness of the mask metal layer 110 generated by the electroplating process may be thinner than that of the rolling process. Accordingly, the planarization (PS) process for reducing the thickness may be omitted, but since the etching characteristics may be different depending on the composition of the surface layer of the plating mask metal layer 110 ′ and the crystal structure/fine structure, planarization (PS) is performed. Through the need to control the surface properties and thickness.

Next, referring to FIG. 9A, a template 50' may be provided. The template 50' is a medium that can be moved while the mask 100 is attached and supported on one surface. It is preferable that one surface of the template 50 ′ is flat to support and move the flat mask 100. The central portion 50a may correspond to the mask cell C of the mask metal layer 110, and the edge portion 50b may correspond to the dummy DM of the mask metal layer 110. The size of the template 50 ′ may be a flat plate shape having a larger area than the mask metal layer 110 so that the mask metal layer 110 can be entirely supported.

A temporary adhesive portion 55' may be formed on one surface of the template 50'. In the temporary bonding part 55', the mask 100 (or the mask metal film 110) is temporarily adhered to one surface of the template 50' until the mask 100 is attached to the frame 200, so that the template 50 ') can be supported.

Next, referring to FIG. 9B, a mask metal layer 110 ′ may be adhered on the template 50 ′.

Next, referring to FIG. 9B further, one surface of the mask metal layer 110 ′ may be planarized (PS). As described above, the thickness of the mask metal film 110 ′ manufactured by the rolling process may be reduced (110 ′ -> 110) through a planarization (PS) process. In addition, the mask metal layer 110 manufactured by the electroplating process may also be subjected to a planarization (PS) process to control surface characteristics and thickness.

Accordingly, as shown in (c) of FIG. 9, as the thickness of the mask metal layer 110' is reduced (110' -> 110), the thickness of the mask metal layer 110 becomes about 5 μm to 20 μm. I can.

Next, referring to FIG. 10D, a patterned insulating portion 25 may be formed on the mask metal layer 110. The insulating part 25 may be formed of a photoresist material using a printing method or the like.

Subsequently, the mask metal layer 110 may be etched. A method such as dry etching or wet etching may be used without limitation, and as a result of the etching, a portion of the mask metal layer 110 exposed to the empty space 26 between the insulating portions 25 may be etched. The etched portion of the mask metal layer 110 constitutes the mask pattern P, and the mask 100 having a plurality of mask patterns P formed thereon may be manufactured.

Next, referring to (e) of FIG. 10, the manufacturing of the template 50 supporting the mask 100 may be completed by removing the insulating part 25.

Since the frame 200 includes a plurality of mask cell regions CR: CR11 to CR56, the mask 100 having mask cells C: C11 to C56 corresponding to respective mask cell regions CR: CR11 to CR56 ) May also be provided. In addition, a plurality of templates 50 for supporting each of the plurality of masks 100 may be provided.

11 is a schematic diagram illustrating a process of loading a mask supporting template on a frame according to a comparative example.

Referring to FIG. 11, the template 50 may be transferred by the vacuum chuck 90. The vacuum chuck 90 may adsorb and transport the surface opposite to the surface of the template 50 to which the mask 100 is adhered.

The mask 100 may correspond to one mask cell area CR of the frame 200. By loading the template 50 onto the frame 200 (or the mask cell sheet part 220), the mask 100 may correspond to the mask cell area CR.

Subsequently, the mask 100 may be attached to the frame 200 by irradiating the laser L to the mask 100 by laser welding. A welding bead WB is generated in the welding portion of the laser-welded mask, and the welding bead WB may be integrally connected with the mask 100 / frame 200 and having the same material.

All mask cell areas CR by repeatedly performing the process of attaching the mask 100 to the frame 200 by matching one mask 100 to one mask cell area CR and irradiating the laser L. Each of the masks 100 can be attached to. However, after the mask 100 is attached to the frame 200 by welding, a tensile force may be applied to the mask cell sheet portion 220 around the mask 100. As a result, the mask cell sheet part 220 is slightly deformed, and when the mask 100 in the next order is attempted to be attached, the alignment may be adversely affected.

Therefore, rather than corresponding/attaching the masks 100 one by one to the mask cell area CR, it may be desirable to simultaneously correspond and attach all the masks 100 to all the mask cell areas CR. In this way, in order to simultaneously correspond the mask 100 to the mask cell area CR, a plurality of templates 50 ′ to which the mask 100 is supported and adhered must be loaded on the frame 200. However, as shown in FIG. 11, since the template 50' is formed in a larger area than the mask 100, interference occurs due to an area OR overlapping each other between the adjacent templates 50'. There was this. It is difficult to match the plurality of templates 50 ′ side by side on the frame 200. Since the width of the first and second grid sheet portions 223 and 225 is only about 1 to 5 mm, the difference between the length of one side of the mask 100 and the template 50 ′ is about 0.5 to 2.5 mm. Should be less than It is very difficult to perform the process of manufacturing the mask 100 having the mask pattern P on the template 50 ′ while satisfying the above dimensional difference (see FIGS. 9 to 10 ).

Accordingly, the present invention is characterized in that the template 50 is configured to have the same area as the mask 100. In addition, the process of forming the mask pattern P of the mask metal layer 110 is directly performed on the template 50 to manufacture the mask 100 on the other substrate 60 without manufacturing the mask 100, and then transfer. It is characterized in that the mask 100 is transferred and attached to the template 50 by using the substrate 65 further.

12 to 13 are schematic diagrams showing a process of manufacturing a mask support template according to an embodiment of the present invention.

Referring to FIG. 12A, a mask 100 adhered on the substrate 60 may be provided. A plurality of mask patterns P are formed on the mask 100. 12(a) may correspond to FIG. 10(e). The difference is that the process of forming the mask pattern P for the mask metal layer 110 is not performed on the template 50 ′ (refer to FIG. 10E), but the mask metal layer 110 is applied on the substrate 60. The process of forming the mask pattern P was performed. The substrate 60 is used only for manufacturing the mask 100, and is not used as a means for supporting the mask 100 and loading the frame 200, so the through hole 51' (see Fig. 10(e)) ] Also need not be formed.

The material of the substrate 60 may be glass, and may have a flat plate shape having an area larger than that of the mask 100 so that a process of forming the mask pattern P of the mask metal layer 110 may be performed. That is, it may correspond to the size of the template 50 ′ according to the comparative example of FIGS. 9 to 10.

A first temporary bonding part 55 may be formed on the substrate 60. Hereinafter, depending on the counterpart on which the temporary bonding portion 55 is formed, the first, second, third, and fourth temporary bonding portions 55 are classified and expressed, but these may be of the same material.

The temporary bonding part 55 may use an adhesive or adhesive sheet that can be separated by applying heat, and an adhesive or adhesive sheet that can be separated by UV irradiation.

As an example, the temporary bonding portion 55 may be formed of liquid wax. The liquid wax may be the same as the wax used in the polishing step of a semiconductor wafer, and the like, and the type is not particularly limited. The liquid wax is mainly a resin component for controlling adhesion, impact resistance, and the like with respect to holding power, and may include materials and solvents such as acrylic, vinyl acetate, nylon, and various polymers. As an example, the temporary adhesive part 55 may use SKYLIQUID ABR-4016 including acrylonitrile butadiene rubber (ABR) as a resin component and n-propyl alcohol as a solvent component. The liquid wax may be formed on the temporary bonding portion 55 using spin coating.

The temporary adhesive part 55, which is a liquid wax, has a lower viscosity at a temperature higher than 85°C to 100°C, and becomes more viscous at a temperature lower than 85°C, and may be partially hardened like a solid, so that the two components can be fixedly bonded.

14 is an enlarged cross-sectional schematic view showing a temporary bonding portion 55 according to an embodiment of the present invention. As another example, the temporary adhesive part 55 may use a thermal release tape. In the thermal release tape, a core film 56 such as a PET film is disposed in the center, and thermal release adhesives 57a and 57b are disposed on both sides of the core film 56, and an adhesive layer 57a , 57b) may have a form in which the release film/release film 58a, 58b is disposed. Here, the adhesive layers 57a and 57b disposed on both sides of the core film 56 may have different temperatures at which they are separated from each other.

Meanwhile, a photoresist layer (insulation layer 26) may remain on the mask 100. In FIG. 10D, the insulating layer 26 may be left without removing it. This photoresist layer may be formed in the process of forming the mask pattern P on the mask metal layer 110. In the process of separating and removing the transfer substrate 65 from the mask 100 afterwards (refer to FIGS. 13(f) and (g)), the transfer substrate 65 is not strongly adhered to the mask 100. It can be used as a buffer that can be gently peeled off by keeping it in a state that is not.

Next, referring to FIG. 12B, a transfer substrate 65 may be provided. The transfer substrate 65 may be used to support the mask 100 before transferring the mask 100 to the template 50. The transfer substrate 65 is also preferably formed to have a larger area than the mask 100 so as to easily support the mask 100.

In one embodiment, the transfer substrate 65 may use a sheet made of an Invar material having the same coefficient of thermal expansion as the mask 100. However, it is preferable that the thickness of the mask 100 is thicker than that of the mask 100 so as to have stiffness for easy attachment and detachment. As the Invar sheet is used, the mask 100 can be treated with the same coefficient of thermal expansion, and the mask 100 is easily removed when transferring to the template 50.

A second temporary bonding portion 55 may be formed on one surface of the transfer substrate 65. The transfer substrate 65 may be disposed to face the mask 100. That is, the transfer substrate 65 may be disposed to face the other surface (upper surface) opposite to one surface (lower surface) of the mask 100 adhered to the substrate 60.

In another embodiment, the transfer substrate 65 may be an adhesive sheet (UV rekease tape; URT) that can be separated by UV irradiation. In this case, it is possible to implement adhesive force with the mask 100 without forming the second temporary bonding portion 55.

Next, referring to FIG. 12C, the transfer substrate 65 may be adhered to the mask 100. The lower surface of the mask 100 is bonded to the substrate 60 through the first temporary bonding portion 55, and the upper surface of the mask 100 is bonded to the transfer substrate 65 through the second temporary bonding portion 55. Can be glued.

Next, referring to FIG. 13D, the lower substrate 60 may be separated and removed. Various debonding methods of the temporary bonding unit 55 may be used. The debonding method will be described later in FIG. 18.

When the lower substrate 60 is separated and removed and turned over, the transfer substrate 65 adheres and supports the mask 100 from the lower portion.

Next, referring to FIG. 13E, a template 50 may be provided. The template 50 is a medium that can be moved on the frame 200 while the mask 100 is attached and supported on one surface. It is preferable that one surface of the template 50 is flat so that it can be moved by supporting the flat mask 100. In addition, it is preferable that the template 50 and the mask 100 are adhered to each other in the same area and size so that a plurality of them can be simultaneously disposed on the mask cell area CR of the frame 200.

The template 50 is preferably made of a transparent material to facilitate observation of vision or the like in the process of aligning and attaching the mask 100 to the frame 200. In addition, in the case of a transparent material, the laser may penetrate. As a transparent material, materials such as glass, silica, heat-resistant glass, quartz, alumina (Al ₂ O ₃ ), borosilicate glass, and zirconia can be used. For example, the template 50 may be made of a BOROFLOAT ^® 33 material having excellent heat resistance, chemical durability, mechanical strength, transparency, etc. among borosilicate glass. In addition, BOROFLOAT ^® 33 has a coefficient of thermal expansion of about 3.3, which is advantageous in that it is easy to control the mask 100 because the difference between the coefficient of thermal expansion and the Invar mask 100 is small.

Meanwhile, in the template 50, one surface in contact with the mask 100 may be a mirror surface so that an air gap does not occur between the interface with the mask 100. In consideration of this, the surface roughness Ra of one surface of the template 50 may be 100 nm or less. In order to implement the template 50 having a surface roughness Ra of 100 nm or less, the template 50 may use a wafer. The wafer (wafer) has a surface roughness (Ra) of about 10 nm, there are many commercially available products, and many surface treatment processes are known, and thus can be used as the template 50. Since the surface roughness (Ra) of the template 50 is in nm scale, there is no or almost no air gap, and it is easy to generate the welding bead (WB) by laser welding, which affects the alignment error of the mask pattern (P). I can not give it.

The template 50 includes a laser through hole 51 in the template 50 so that the laser L irradiated from the top of the template 50 can reach the welding portion WP of the mask 100 (a region to be welded). ) Can be formed. The laser through-hole 51 may be formed in the template 50 to correspond to the position and number of the welding portions WP. Since a plurality of welding portions WP are disposed along a predetermined interval in the edge or dummy DM portion of the mask 100 (see FIG. 8), a plurality of laser through holes 51 may be formed along a predetermined interval to correspond thereto. have. As an example, since a plurality of welding parts are disposed along a predetermined distance on both sides (left/right) dummy (DM) parts of the mask 100, the laser through hole 51 is also provided on both sides (left/right). A plurality may be formed along a predetermined interval.

The laser through-hole 51 need not necessarily correspond to the position and number of the welding portions WP. For example, it is also possible to perform welding by irradiating the laser (L) only on a part of the laser through hole 51. In addition, some of the laser through-holes 51 that do not correspond to the welding part WP may be used instead of the alignment mark when aligning the mask 100 and the template 50. If the material of the template 50 is transparent to the laser (L) light, the laser through hole 51 may not be formed.

On the other hand, as long as the laser (L) is applied from the upper part of the template 50 and reaches the welding part (WP) of the mask 100, if it is within the range that can perform welding, another form of energy ("welding energy") Can also be used. In this case, the laser through hole 51 may be referred to as a through hole 51.

A third temporary bonding portion 55 may be formed on one surface of the template 50. The third temporary bonding part 55 may allow the mask 100 to be temporarily adhered to one surface of the template 50 and supported on the template 50 until the mask 100 is adhered to the frame 200. If the temporary adhesive portion 55 remains on the face of the mask 100 opposite to each other, the temporary adhesive portion 55 may not be formed on the template 50.

Next, referring to (f) of FIG. 13, the template 50 may be adhered to the mask 100. The lower surface of the mask 100 is bonded to the transfer substrate 65 through the second temporary bonding portion 55, and the upper surface of the mask 100 is connected to the template 50 through the third temporary bonding portion 55. Can be glued.

For example, after heating the temporary adhesive portion 55 of liquid wax to 85° C. or higher and contacting the mask 100 with the template 50, the mask metal film 100 and the template 50 are passed between rollers to achieve adhesion. Can be done.

Baking is performed on the template 50 at about 120° C. for 60 seconds to evaporate the solvent of the temporary bonding portion 55, and immediately, a mask metal layer lamination process may be performed. Lamination may be performed by loading the mask 100 on the template 50 on which the temporary bonding portion 55 is formed, and passing it between an upper roll of about 100°C and a lower roll of about 0°C. As a result, the mask 100 may be brought into contact with the template 50 through the temporary bonding portion 55.

According to another embodiment, in the case of using the temporary bonding portion 55 which is a thermal peeling tape, the lower surface of the thermal peeling tape (second adhesive layer 57b) in the state where the peeling film/release films 58a and 58b are removed Silver is adhered to the template 50, and the upper surface of the thermal peeling tape (first adhesive layer 57a) may be adhered to the mask 100. Since the first adhesive layer 57a and the second adhesive layer 57b are separated from each other at different temperatures, when separating the template 50 from the mask 100 in FIG. 18 to be described later, the first adhesive layer 57a By applying the heat to be thermally separated, the mask 100 may be separated from the template 50 and the temporary bonding portion 55.

When the template 50 is adhered to the mask 100, the through hole 51 of the template 50 and the welding part WP of the mask 100 may be aligned to be aligned. Since the template 50 has the same area and size as the mask 100, one surface of the mask 100 and one surface of the template 50 may be adhered to each other.

Next, referring to (g) of FIG. 13, the lower transfer substrate 65 may be separated and removed. Various debonding methods of the temporary bonding unit 55 may be used. The debonding method will be described later in FIG. 18.

Accordingly, manufacturing of the mask supporting template having the same area and size as the mask 100 may be completed.

15 is a schematic diagram showing a process of manufacturing a mask supporting template according to another embodiment of the present invention. In FIG. 15, only differences from FIGS. 12 to 13 will be described.

Referring to FIG. 15A, the substrates 60 and 69 may include a lower glass substrate 60 and an upper Invar substrate 69. Temporary adhesive portions 55 may be interposed between each layer. The mask 100 may be adhered to the Invar substrate 69. The Invar substrate 69 may be formed of the same material as the mask 100. The Invar substrate 69 can handle the mask 100 with the same coefficient of thermal expansion, and has an effect of being easily removed when transferring the mask 100 to the template 50.

Next, referring to FIG. 15B, the lower glass substrate 60 may be separated and removed. However, the present invention is not limited thereto, and after attaching the transfer substrate 65 as in steps (c) and (d) of FIG. 15, the glass substrate 60 under the lower portion may be separated and removed.

Next, referring to FIG. 15C, a transfer substrate 65 may be provided.

Next, referring to FIG. 15D, the transfer substrate 65 may be adhered to the mask 100. The lower surface of the mask 100 may be bonded to the Invar substrate 69 through the temporary bonding portion 55, and the upper surface of the mask 100 may be bonded to the transfer substrate 65 through the temporary bonding portion 55. have.

Next, the lower Invar substrate 69 may be separated and removed. Various debonding methods of the temporary bonding unit 55 may be used. The debonding method will be described later in FIG. 18. When the lower Invar substrate 69 is separated and removed and turned over, the transfer substrate 65 adheres and supports the mask 100 from the lower portion. Subsequent steps may be performed in the same manner as in FIGS. 13E to 13G.

16 is a schematic diagram illustrating a process of loading a mask supporting template onto a frame according to an embodiment of the present invention.

Referring to FIG. 16, the template 50 may be transferred by the vacuum chuck 90. The vacuum chuck 90 may adsorb and transport the surface opposite to the surface of the template 50 to which the mask 100 is adhered. The vacuum chuck 90 may be connected to a moving means (not shown) that moves in the x, y, z, and θ axes. In addition, the vacuum chuck 90 may be connected to a flip means (not shown) capable of adsorbing and flipping the template 50. As shown in (b) of FIG. 16, after the vacuum chuck 90 adsorbs and flips the template 50, in the process of transferring the template 50 onto the frame 200, the mask 100 There is no effect on the adhesion and alignment.

17 is a schematic diagram illustrating a state in which a template is loaded onto a frame and a mask is associated with a cell area of the frame according to an embodiment of the present invention.

The present invention is characterized in that the size of the mask 100 and the template 50 are the same, and interference/overlap does not occur between the templates 50 even if the templates 50 are disposed on each mask cell area CR. To do. A plurality of templates 50 for supporting each of the plurality of masks 100 may be provided. In addition, a process of attaching the mask 100 to the frame 200 may be performed by simultaneously matching the plurality of masks 100 to all cell regions CR.

The mask 100 may correspond to one mask cell area CR of the frame 200. By loading the template 50 onto the frame 200 (or the mask cell sheet part 220), the mask 100 may correspond to the mask cell area CR. While controlling the position of the template 50/vacuum chuck 90, it is possible to examine whether the mask 100 corresponds to the mask cell area CR through a microscope. Since the template 50 compresses the mask 100, the mask 100 and the frame 200 can be in close contact with each other.

Sequentially or simultaneously, a plurality of templates 50 may be loaded onto the frame 200 (or the mask cell sheet part 220) so that each mask 100 may correspond to each mask cell area CR. have. Since the template 50 and the mask 100 have the same size, the template 50 corresponding to the specific mask cell area CR11 and the template 50 corresponding to the mask cell areas CR12 and CR21 adjacent thereto Can form a predetermined interval without interfering with each other. This predetermined interval may be less than 1/2 of the width of the first and second grid sheet portions 223 and 225.

Meanwhile, the lower support 70 may be further disposed under the frame 200. The lower support 70 may have a size such that it fits into the hollow region R of the frame rim 210 and may have a flat plate shape. Further, a predetermined support groove (not shown) corresponding to the shape of the mask cell sheet portion 220 may be formed on the upper surface of the lower support body 70. In this case, the edge sheet portion 221 and the first and second grid sheet portions 223 and 225 are fitted into the support grooves, so that the mask cell sheet portion 220 may be better fixed.

The lower support 70 may press the opposite surface of the mask cell area CR to which the mask 100 contacts. That is, the lower support 70 may support the mask cell sheet part 220 in an upward direction to prevent the mask cell sheet part 220 from sagging downward during the attaching process of the mask 100. At the same time, the lower support 70 and the template 50 are pressed against the edge and frame 200 (or mask cell sheet part 220) of the mask 100 in opposite directions, so that the mask 100 Can be maintained without being disturbed.

In this way, just by attaching the mask 100 on the template 50 and loading the template 50 on the frame 200, the mask 100 corresponds to the mask cell area CR of the frame 200. Since the process is completed, no tensile force may be applied to the mask 100 during this process.

Subsequently, after corresponding to the plurality of templates 50 on all the mask cell regions CR, the mask 100 is irradiated with a laser L to attach the mask 100 to the frame 200 by laser welding. I can. Each of the masks 100 may be attached to the frame 200 by irradiating the laser L to the plurality of masks 100 sequentially or simultaneously. A welding bead WB is generated in the welding portion of the laser-welded mask, and the welding bead WB may be integrally connected with the mask 100 / frame 200 and having the same material.

18 is a schematic diagram showing a process of separating the mask 100 and the template 50 after attaching the mask 100 to the frame 200 according to an embodiment of the present invention.

Referring to FIG. 18, after attaching the mask 100 to the frame 200, the mask 100 and the template 50 may be separated (debonded). Separation of the mask 100 and the template 50 can be performed through at least one of heat application (ET), chemical treatment (CM), ultrasonic application (US), and UV application (UV) to the temporary bonding part 55. have. Since the mask 100 remains attached to the frame 200, only the template 50 can be lifted. For example, when heat at a temperature higher than 85°C to 100°C is applied (ET), the viscosity of the temporary bonding portion 55 decreases, and the adhesion between the mask 100 and the template 50 is weakened, and thus the mask 100 ) And the template 50 may be separated. As another example, the mask 100 and the template 50 may be separated by dissolving or removing the temporary bonding portion 55 by immersing (CM) the temporary bonding portion 55 in a chemical substance such as IPA, acetone, and ethanol. have. As another example, when ultrasound is applied (US) or UV is applied (UV), the adhesion between the mask 100 and the template 50 is weakened, so that the mask 100 and the template 50 may be separated.

In more detail, since the temporary bonding portion 55 that mediates the adhesion between the mask 100 and the template 50 is a TBDB adhesive material (temporary bonding&debonding adhesive), various debonding methods can be used.

As an example, a solvent debonding method according to a chemical treatment (CM) may be used. Debonding may be performed as the temporary bonding portion 55 is dissolved by the penetration of the solvent. At this time, since the pattern P is formed on the mask 100, the solvent may penetrate through the mask pattern P and the interface between the mask 100 and the template 50. Solvent debonding has an advantage of being relatively economical compared to other debonding methods because debonding is possible at room temperature and does not require a complex debonding facility designed separately.

As another example, a heat debonding method according to heat application (ET) may be used. When the temporary bonding portion 55 is decomposed using high temperature heat, and the adhesive force between the mask 100 and the template 50 is reduced, debonding may proceed in the vertical direction or the left and right directions.

As another example, a peelable adhesive debonding method based on heat application (ET), UV application (UV), or the like may be used. When the temporary bonding part 55 is a thermal peeling tape, debonding can be performed using a peeling adhesive debonding method, and this method does not require high-temperature heat treatment and expensive heat treatment equipment like the thermal debonding method. It has a relatively simple advantage.

As another example, a room temperature debonding method according to chemical treatment (CM), ultrasonic application (US), and UV application (UV) may be used. When a non-sticky treatment is performed on a part (center) of the mask 100 or the template 50, only the edge portion may be adhered by the temporary bonding portion 55. In addition, during the debonding, the solvent penetrates into the edge portion and the debonding is performed by dissolving the entrance examination bonding portion 55. This method has the advantage of not causing direct loss or defects due to adhesive material residues during debonding, except for the edge area of the mask 100 and the template 50 during bonding and debonding. There is this. In addition, unlike the thermal debonding method, since a high-temperature heat treatment process is not required during debonding, there is an advantage of relatively reducing the process cost.

19 is a schematic diagram showing a state in which the mask 100 is attached to the frame 200 according to an embodiment of the present invention.

Referring to FIG. 19, one mask 100 may be attached on one cell area CR of the frame 200.

Since the mask cell sheet portion 220 of the frame 200 has a thin thickness, when a tensile force is applied to the mask 100 and attached to the mask cell sheet portion 220, the tensile force remaining in the mask 100 is masked. It acts on the cell sheet part 220 and the mask cell area CR, and thus, they may be deformed. Therefore, it is necessary to attach the mask 100 to the mask cell sheet part 220 without applying a tensile force to the mask 100. In the present invention, by attaching the mask 100 on the template 50 and loading the template 50 on the frame 200, the mask 100 corresponds to the mask cell area CR of the frame 200 Since the process is completed, no tensile force may be applied to the mask 100 during this process. Thus, it is possible to prevent deformation of the frame 200 (or the mask cell sheet part 220) by acting as a tension on the frame 200 as opposed to the tensile force applied to the mask 100.

The conventional mask 10 of FIG. 1 has a long length because it includes 6 cells (C1 to C6), whereas the mask 100 of the present invention has a short length including one cell (C). The degree of distortion of the pixel position accuracy (PPA) can be reduced. For example, assuming that the length of the mask 10 including a plurality of cells (C1 to C6, ...) is 1 m and a PPA error of 10 μm occurs in the entire 1 m, the mask 100 of the present invention The above error range can be 1/n according to the reduction in the relative length (corresponding to the reduction in the number of cells C). For example, if the length of the mask 100 of the present invention is 100 mm, since it has a length reduced from 1 m to 1/10 of the conventional mask 10, a PPA error of 1 μm occurs in the entire 100 mm length. , There is an effect that the alignment error is significantly reduced.

On the other hand, if the mask 100 includes a plurality of cells C, and each cell C corresponds to each cell area CR of the frame 200 within a range in which the alignment error is minimized, The mask 100 may correspond to a plurality of mask cell regions CR of the frame 200. Alternatively, the mask 100 having a plurality of cells C may correspond to one mask cell area CR. Even in this case, in consideration of the process time and productivity according to the alignment, the mask 100 is preferably provided with as few cells (C) as possible.

In the case of the present invention, it is only necessary to match one cell (C) of the mask 100 and check the alignment state, so that a plurality of cells (C: C1 to C6) must be matched at the same time and check all alignment states. Compared to the conventional method [see Fig. 2], the manufacturing time can be significantly reduced.

That is, in the method of manufacturing a frame-integrated mask of the present invention, each of the cells C11 to C16 included in the six masks 100 correspond to each of the cell regions CR11 to CR16 and check the alignment state. Through a single process, the time can be much shorter than that of a conventional method in which the six cells C1 to C6 are simultaneously matched and the alignment state of the six cells C1 to C6 is checked at the same time.

In addition, in the method of manufacturing a frame-integrated mask of the present invention, the product yield in the process of 30 times of matching and aligning 30 masks 100 to 30 cell regions (CR: CR11 to CR56), respectively, is 6 cells (C1 The five masks 10 each including ~C6) (see Fig. 2 (a)) may appear much higher than the conventional product yield in the five processes of matching and aligning the frame 20. Since the conventional method of arranging six cells (C1 to C6) in a region corresponding to six cells (C) at a time is much cumbersome and difficult operation, the product yield is low.

Meanwhile, as described above in step (b) of FIG. 9, when the mask metal layer 110 is adhered to the template 50 through a lamination process, a temperature of about 100° C. may be applied to the mask metal layer 110. . Accordingly, the mask metal layer 110 may be adhered to the template 50 in a state where some tensile tension is applied. After that, when the mask 100 is attached to the frame 200 and the template 50 is separated from the mask 100, the mask 100 may contract a predetermined amount.

After the plurality of masks 100 are all attached to the corresponding mask cell area CR, since the plurality of templates 50 and the plurality of masks 100 are separated at the same time, the mask cell sheet part 220 is not deformed. It won't happen. In more detail, since the plurality of masks 100 apply a tension that contracts in opposite directions to each other, the force is canceled so that deformation does not occur in the mask cell sheet part 220. For example, the first grid sheet portion 223 between the mask 100 attached to the CR11 cell area and the mask 100 attached to the CR12 cell area is in the right direction of the mask 100 attached to the CR11 cell area. The applied tension and the tension acting in the left direction of the mask 100 attached to the CR12 cell area may be canceled out. Thus, deformation of the frame 200 (or mask cell sheet part 220) due to tension is minimized, so that an alignment error of the mask 100 (or mask pattern P) can be minimized.

20 is a schematic diagram illustrating an OLED pixel deposition apparatus 1000 using the frame-integrated masks 100 and 200 according to an embodiment of the present invention.

Referring to FIG. 20, the OLED pixel deposition apparatus 1000 includes a magnet plate 300 in which a magnet 310 is accommodated and a cooling water line 350 is disposed, and an organic material source 600 from a lower portion of the magnet plate 300. ) And a deposition source supply unit 500 to supply.

A target substrate 900 such as glass on which the organic material source 600 is deposited may be interposed between the magnet plate 300 and the source deposition unit 500. The frame-integrated masks 100 and 200 (or FMM) that allow the organic material source 600 to be deposited for each pixel may be disposed on the target substrate 900 in close contact or very close to each other. The magnet 310 generates a magnetic field and may be in close contact with the target substrate 900 by the magnetic field.

The deposition source supply unit 500 may reciprocate the left and right path to supply the organic material source 600, and the organic material sources 600 supplied from the deposition source supply unit 500 are pattern P formed on the frame-integrated masks 100 and 200. ) May be deposited on one side of the target substrate 900. The deposited organic material source 600 passing through the pattern P of the frame-integrated masks 100 and 200 may function as the pixel 700 of the OLED.

In order to prevent non-uniform deposition of the pixel 700 due to a shadow effect, the pattern of the frame-integrated masks 100 and 200 may be formed to be inclined (S) (or formed in a tapered shape (S)). . Since the organic material sources 600 passing through the pattern in a diagonal direction along the inclined surface may also contribute to the formation of the pixel 700, the overall thickness of the pixel 700 may be uniformly deposited.

Since the mask 100 is attached and fixed to the frame 200 at a first temperature higher than the pixel deposition process temperature, even if it is raised to the process temperature for pixel deposition, the position of the mask pattern P is hardly affected. The PPA between 100 and the mask 100 adjacent thereto may be maintained not to exceed 3 μm.

Although the present invention has been shown and described with reference to a preferred embodiment as described above, it is not limited to the above embodiment, and within the scope not departing from the spirit of the present invention, various Transformation and change are possible. Such modifications and variations should be viewed as falling within the scope of the present invention and the appended claims.

50: template
51: laser through hole
55: temporary bonding part
60: substrate
65: transfer board
70: lower support
100: mask
110: mask film
200: frame
210: frame frame portion
220: mask cell sheet portion
221: border sheet portion
223: first grid seat portion
225: second grid seat portion
1000: OLED pixel deposition device
C: cell, mask cell
CM: chemical treatment
CR: Mask cell area
DM: dummy, mask dummy
ET: heat application
L: laser
R: hollow area of the frame part
P: mask pattern
US: Ultrasonic approval
UV: UV applied
W: welding
WB: welding bead
WP: weld

Claims (24)

As a manufacturing method of a template corresponding to a frame by supporting an OLED pixel forming mask,
(a) providing a mask including a substrate having a temporary bonding portion formed on one surface thereof and a plurality of mask patterns bonded to the temporary bonding portion;
(b) adhering the transfer substrate to the mask;
(c) removing the substrate;
(d) adhering the template with the temporary adhesive portion formed on one surface to the mask; And
(e) removing the transfer substrate
Containing, the manufacturing method of the mask support template. The method of claim 1,
A method of manufacturing a mask supporting template, wherein the template and the mask are adhered to each other in the same area. delete delete delete The method of claim 1,
In step (a), the substrate includes a lower glass substrate and an upper Invar substrate,
In step (c), removing the glass substrate and the Invar substrate,
Method of manufacturing a mask support template. The method of claim 1,
In step (a), the substrate includes a lower glass substrate and an upper Invar substrate,
Step (b) is performed in a state in which the lower glass substrate is separated,
In step (c), removing the Invar substrate,
Method of manufacturing a mask support template. The method of claim 1,
Step (a),
(a1) adhering a mask metal film onto a substrate having a temporary adhesive portion formed on one surface thereof;
(a2) forming a patterned insulating portion on the mask metal film;
(a3) forming a plurality of mask patterns by etching portions of the mask metal layer exposed between the insulating portions; And
(a4) removing the insulating part
Containing, the manufacturing method of the mask support template. delete delete delete delete The method of claim 1,
A method of manufacturing a mask supporting template, wherein a through hole through which welding energy passes is formed in a portion of the template corresponding to the welding portion of the mask. delete delete A method of manufacturing a frame-integrated mask in which a plurality of masks and a frame supporting the mask are integrally formed,
(a) preparing a mask including a substrate having a temporary bonding portion formed on one surface thereof and a plurality of mask patterns adhered to the temporary bonding portion;
(b) adhering the transfer substrate to the mask;
(c) removing the substrate;
(d) adhering the template with the temporary adhesive portion formed on one surface to the mask;
(e) removing the transfer substrate to prepare a mask support template;
(f) preparing a frame including a plurality of mask cell regions;
(g) loading the template onto the frame to correspond the mask to the mask cell area of the frame; And
(h) attaching the mask to the frame by irradiating welding energy to the welding portion of the mask
Containing, the manufacturing method of the frame-integrated mask. The method of claim 16,
A method of manufacturing a frame-integrated mask in which the template and the mask are adhered to each other in the same area. delete delete delete delete The method of claim 16,
A method of manufacturing a frame-integrated mask, wherein step (h) is performed after matching a plurality of templates on all mask cell regions of the frame in step (g). A method of manufacturing a frame-integrated mask in which a plurality of masks and a frame supporting the mask are integrally formed,
(a) loading a template manufactured by the manufacturing method of claim 1 onto a frame having a plurality of mask cell regions, thereby making the mask correspond to the mask cell region of the frame; And
(b) attaching the mask to the frame
Containing, the manufacturing method of the frame-integrated mask. delete

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