KR20150103655A - Metal plate, metal plate production method, and method for producing vapor deposition mask using metal plate - Google Patents

Abstract

And it is an object of the present invention to provide a metal plate capable of producing a vapor deposition mask with small warpage. When the sample taken out from the metal plate after the annealing process is etched, the curvature (k) of the deflection of the sample after etching is 0.008 mm ^-1 or less.

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a metal plate, a method of manufacturing a metal plate, and a method of manufacturing a deposition mask using a metal plate,

The present invention relates to a metal plate used for manufacturing a deposition mask by forming a plurality of through holes. The present invention also relates to a method of manufacturing a metal plate. The present invention also relates to a method of manufacturing a deposition mask used for deposition in a desired pattern by using a metal plate.

In recent years, it has been required that a display device used in a portable device such as a smart phone or a tablet PC should have a high resolution, for example, a pixel density of 300 ppi or higher. In addition, in a portable device, there is a growing demand for a full high-vision device. In this case, it is required that the pixel density of the display device is, for example, 450 ppi or higher.

An organic EL display device has attracted attention because of its good response and low power consumption. As a method of forming pixels of an organic EL display device, there is known a method of forming pixels in a desired pattern by using a deposition mask including through holes arranged in a desired pattern. Specifically, first, a deposition mask is brought into close contact with a substrate for an organic EL display device, and then a deposition mask and a substrate, which are closely contacted with each other, are all put in a vapor deposition apparatus to deposit an organic material or the like. The deposition mask can be generally manufactured by forming a through hole in a metal plate by etching using a photolithography technique (for example, Patent Document 1).

Japanese Patent Application Laid-Open No. 2004-39319

When the deposition material is deposited on the substrate using a deposition mask, the deposition material adheres to the deposition mask as well as the substrate. For example, some of the evaporation materials are directed toward the substrate along a direction largely inclined with respect to the normal direction of the evaporation mask, and such evaporation material reaches and adheres to the wall surface of the through hole of the evaporation mask before reaching the substrate . In this case, it is difficult for the deposition material to adhere to the region located near the wall surface of the through-hole of the deposition mask in the substrate. As a result, the thickness of the deposition material adhered becomes smaller than the other portions, Or a case where an unintended part occurs. That is, the deposition in the vicinity of the wall surface of the through hole of the deposition mask becomes unstable. Therefore, when a deposition mask is used to form pixels of the organic EL display device, the dimensional accuracy and positional accuracy of the pixel are lowered, and as a result, the luminous efficiency of the organic EL display device is lowered.

In order to solve such a problem, it is conceivable to reduce the thickness of a metal plate used for manufacturing a deposition mask. This is because, by making the thickness of the metal plate small, the height of the wall surface of the through hole of the deposition mask can be made small, so that the rate of deposition on the wall surface of the through hole in the evaporation material can be reduced. However, in order to obtain a metal sheet having a small thickness, it is necessary to increase the rolling rate when rolling the base material to produce a metal sheet. Here, the rolling rate is a value calculated by (the thickness of the base material - the metal plate) / (the thickness of the base material). Even when annealing such as annealing is performed after rolling, the larger the rolling rate is, the larger the stress remaining on the metal plate, that is, the residual stress becomes larger. When the residual stress is large, residual stress is released on the side of the metal plate where etching is performed when the through hole is formed in the metal plate by etching, and as a result, warping occurs in the obtained deposition mask. When the warpage is large, the deposition mask can not be sufficiently adhered to the substrate for the organic EL display device. As a result, the dimensional accuracy and the positional accuracy of the pixel of the obtained organic EL display device are lowered.

It is an object of the present invention to provide a metal plate, a method of manufacturing a metal plate, and a manufacturing method of a deposition mask that can effectively solve such problems.

A first aspect of the present invention is a method of manufacturing a metal plate used for manufacturing a deposition mask by forming a plurality of through holes, wherein the through holes of the deposition mask are formed by etching the metal plate, A rolling step of rolling the base material to obtain the metal plate having a thickness t ₀ and an annealing step of annealing the metal plate to remove an internal stress of the metal plate, wherein the metal plate is orthogonal to the thickness direction (K) of the deflection of the sample after etching is 0.008 mm < ^-1 > or less when the sample taken out from the metal plate after the annealing process is etched with the first and second surfaces opposed to each other, k) was obtained by first taking out the sample having a length of 170 mm and a width of 30 mm from the metal plate after the annealing process, and then, from both ends in the longitudinal direction of the sample Length 150mm, the thickness of the etched region of width 30mm 1/3 × t ₀ or more than the area that is within 10mm also until into a 2/3 × t ₀ within the following range, the etched area from the first face side The etched sample is then loaded on a predetermined stage so that its side faces are horizontally placed, and then the distance between the ends in the longitudinal direction of the etched region of the sample (x) (mm) and the depth (y) (mm) of bending of the etched region of the sample are measured, and then the distance (x)

k = 1 / ρ, ρ = (y / 2) + (x 2 / 8y)

Which is a value obtained by substituting the value obtained by subtracting the value obtained by subtracting the value obtained by substitution.

In the method for manufacturing a metal sheet according to the present invention, the annealing step may be performed while stretching the metal sheet in the longitudinal direction.

In the method for manufacturing a metal plate according to the present invention, the annealing step may be carried out while the metal plate is wound around the core.

In the method for manufacturing a metal plate according to the present invention, preferably, the coefficient of thermal expansion of the metal plate is equal to the coefficient of thermal expansion of the substrate on which an evaporation material is deposited via a deposition mask made of the metal plate.

In the method of manufacturing a metal plate according to the present invention, the metal plate may be made of an invar material.

A second aspect of the present invention is a metal plate used for manufacturing a deposition mask by forming a plurality of through holes, wherein the metal plate has a thickness t ₀ , and the metal plate is arranged so as to be perpendicular to the thickness direction thereof, (K) of the deflection of the sample after etching is not more than 0.008 mm < ^-1 >, and the curvature (k) has a length of 170 mm and a width The thickness of the etched region of 150 mm in length and 30 mm in width excluding the region within 10 mm from both ends in the longitudinal direction of the sample is 1/3 x t ₀ or more and 2/3 Etching the sample from the first surface side over the entire region of the etched region until the side of the etched region becomes within the range of x t ₀ or less, Loading (X) (mm) of the sample in the longitudinal direction of the etched region of the sample and the depth (y) (mm) of the deflection of the etched region of the sample are measured, (X) and the depth (y) are calculated by the following equations

k = 1 / ρ, ρ = (y / 2) + (x 2 / 8y)

Which is a value obtained by substituting the surface roughness of the metal plate.

The thermal expansion coefficient of the metal sheet according to the present invention is preferably equal to the thermal expansion coefficient of the substrate on which the evaporation material is deposited via the deposition mask made of the metal sheet.

The metal plate according to the present invention may be constituted by invar.

A third aspect of the present invention is a method of manufacturing a deposition mask including a plurality of through holes formed therein and a peripheral region located around the effective region, the method comprising: a metal plate having a thickness t ₀ , A step of preparing a metal plate having a first face and a second face opposite to each other, etching the metal plate from the first face side, and forming, in a region of the metal plate constituting the effective region, Wherein a curvature (k) of deflection of the sample after etching is 0.008 mm < ^-1 > or less, and the concavity of the sample The curvature k is obtained by first taking out the sample having a length of 170 mm and a width of 30 mm from the metal plate and then measuring the curvature k of the sample within 10 mm from both ends in the longitudinal direction of the sample Of length 150mm, width 30mm except the station the thickness of the etched region 1/3 × t ₀ or more and until it is within the 2/3 × t ₀ within the following range, from the first surface side in the entire area of the etched areas The etched sample is then placed on a predetermined stage so that its side faces are horizontal, and then the distance (x) between the ends in the longitudinal direction of the etched region of the sample mm and the depth y of the deflection of the etched region of the sample are measured and then the distance x and the depth y are calculated by the following equations

k = 1 / ρ, ρ = (y / 2) + (x 2 / 8y)

Which is a value obtained by substituting the value in the above equation

In the recessed portion forming step of the method for producing a deposition mask according to the present invention, the metal plate may be etched from the first surface side to the entire first surface.

In the concave portion forming step of the method for manufacturing the deposition mask according to the present invention, the metal plate, the thickness is 1/3 × t ₀ or more and 2/3 × t ₀ or less, until the range of the first face side May be etched over the whole area of the first surface.

In the method for manufacturing a deposition mask according to the present invention, preferably, the coefficient of thermal expansion of the metal plate is equal to the coefficient of thermal expansion of the substrate on which an evaporation material is deposited via a deposition mask made of the metal plate.

In the method of manufacturing a deposition mask according to the present invention, the metal plate may be made of Invar.

According to the present invention, a deposition mask having a small warpage can be obtained. As a result, the deposition mask can be closely adhered to the substrate, and as a result, the dimensional accuracy and positional accuracy of the evaporation material adhered on the substrate can be enhanced.

BRIEF DESCRIPTION OF DRAWINGS FIG. 1 is a schematic perspective view showing an example of a deposition mask apparatus including a deposition mask according to one embodiment of the present invention. FIG.
FIG. 2 is a view for explaining a method of depositing using the deposition mask apparatus shown in FIG. 1. FIG.
3 is a partial plan view showing the deposition mask shown in Fig.
4 is a cross-sectional view taken along the line IV-IV in Fig.
5 is a sectional view taken along the line VV in Fig.
6 is a sectional view taken along the line VI-VI in Fig.
7 (a) is a view showing a step of rolling a base material to obtain a metal plate having a desired thickness, and Fig. 7 (b) is a view showing a step of annealing a metal plate obtained by rolling.
8A is a view showing a sample cut out from a metal plate obtained by the process shown in Figs. 7A and 7B, and Fig. 8B is a view showing a sample taken from the sample shown in Fig. 1 is a view showing an etched finished sample obtained by etching the first surface.
9A and 9B are a perspective view and a plan view showing a state in which the etched sample shown in FIG. 8B is loaded on the loading table.
10 is a schematic diagram for explaining an example of a manufacturing method of the deposition mask shown in Fig. 1 as a whole.
FIG. 11 is a view for explaining an example of a method of manufacturing a deposition mask, and shows a long metal plate in a section along the normal direction. FIG.
12 is a view for explaining an example of a method of manufacturing a deposition mask, and is a view showing a long metal plate in a section along the normal direction.
Fig. 13 is a view for explaining an example of a method of manufacturing a deposition mask, and is a view showing a long metal plate in a section along the normal direction. Fig.
14 is a view for explaining an example of a method of manufacturing a deposition mask, and is a view showing a long metal plate in a section along the normal direction.
Fig. 15 is a view for explaining an example of a method of manufacturing a deposition mask, and shows a long metal plate on a cross section along the normal direction. Fig.
FIG. 16 is a view for explaining an example of a method of manufacturing a deposition mask, and shows a long metal plate on a cross section along the normal direction. FIG.
FIG. 17 is a view for explaining an example of a method for manufacturing a deposition mask, and shows a long metal plate on a cross section along the normal direction. FIG.
18 is a view for explaining a modification of the deposition mask and the deposition mask apparatus.
19 (a) to 19 (c) are diagrams for explaining a method of taking out a sample from a metal plate in the embodiment.

Hereinafter, an embodiment of the present invention will be described with reference to the drawings. In addition, in the drawings attached to the present specification, dimensions and aspect ratios are appropriately changed and exaggerated for convenience of illustration and understanding.

1 to 17 are views for explaining an embodiment according to the present invention. In the following embodiments and modifications thereof, a manufacturing method of a deposition mask used for patterning an organic material on a substrate in a desired pattern in manufacturing an organic EL display device will be described as an example. However, the present invention is not limited to such an application, and the present invention can be applied to a manufacturing method of a deposition mask used for various applications.

In the present specification, the terms "plate", "sheet", and "film" are not distinguished from each other only on the basis of the difference in designation. For example, " plate " is a concept including a member that can be called a sheet or film, and therefore, for example, the " metal plate " Can not be distinguished.

The term " plate surface (sheet surface, film surface) " means a plate member (a sheet-like member, a film-like member) to be a target in a case where a plate- In the plan view direction. The normal direction used for the plate-like (sheet-like, film-like) member refers to the normal direction to the plate surface (sheet surface, film surface) of the member.

Also, as used herein, terms such as "parallel", "orthogonal", "same", "equal", and the like, which specify the shape, geometric conditions, and physical characteristics and their degrees, The values of the characteristics and the like are not bound to the strict sense, but are interpreted to include a range in which similar functions can be expected.

(Deposition mask apparatus)

First, an example of a deposition mask apparatus including a deposition mask to be a manufacturing method target will be described mainly with reference to Figs. 1 to 6. Fig. Here, FIG. 1 is a perspective view showing an example of a deposition mask apparatus including a deposition mask, and FIG. 2 is a diagram for explaining a method of using the deposition mask apparatus shown in FIG. Fig. 3 is a plan view showing the deposition mask on the first surface side, and Figs. 4 to 6 are sectional views in each position of Fig.

The deposition mask apparatus 10 shown in Figs. 1 and 2 includes a deposition mask 20 including a metal plate 21 having a rectangular shape and a frame 15 provided at the periphery of the deposition mask 20 . The through hole 25 formed by etching the metal plate 21 having the first surface 21a and the second surface 21b opposite to each other from at least the first surface 21a is formed in the deposition mask 20 . 2, the deposition mask 20 is supported in the deposition apparatus 90 so as to face the lower surface of a substrate, for example, a glass substrate 92, which is an evaporation object , And is used to deposit the evaporation material on the substrate.

In the deposition apparatus 90, the deposition mask 20 and the glass substrate 92 are brought into close contact with each other by a magnetic force from a magnet (not shown). A crucible 94 for accommodating an evaporation material (e.g., an organic light emitting material) 98 and a heater 96 for heating the crucible 94 are provided in the deposition apparatus 90 below the deposition mask apparatus 10, . The evaporation material 98 in the crucible 94 is vaporized or sublimated by heating from the heater 96 and attached to the surface of the glass substrate 92. [ A plurality of through holes 25 are formed in the deposition mask 20 and the deposition material 98 is attached to the glass substrate 92 through the through holes 25. As described above, As a result, the evaporation material 98 is deposited on the surface of the glass substrate 92 in a desired pattern corresponding to the position of the through hole 25 of the deposition mask 20. [

(Deposition mask)

Next, the deposition mask 20 will be described in detail. As shown in Fig. 1, in this embodiment, the deposition mask 20 includes a metal plate 21 and has a substantially rectangular shape in plan view, and more precisely a roughly rectangular shape in plan view . The metal plate 21 of the vapor deposition mask 20 includes the effective area 22 in which the through hole 25 is formed in a regular arrangement and the peripheral area 23 surrounding the effective area 22. The peripheral region 23 is an area for supporting the effective region 22, and is not the region through which the intended deposition material passes through to be deposited on the substrate. For example, in the deposition mask 20 used for the deposition of the organic light emitting material for the organic EL display device, the effective region 22 is a region where the organic light emitting material is deposited to form the pixel )), That is, the region in the deposition mask 20 facing a region above the substrate on which the display surface of the manufactured substrate for the organic EL display device is formed. However, a through hole or a recess may be formed in the peripheral region 23 for various purposes. In the example shown in Fig. 1, each effective region 22 has a substantially rectangular shape in plan view, and more precisely, a substantially rectangular shape in plan view.

In the illustrated example, the plurality of effective regions 22 are arranged at predetermined intervals along one direction parallel to one side of the deposition mask 20, and are arranged at predetermined intervals along another direction orthogonal to the one direction And are spaced apart. In the illustrated example, one effective area 22 corresponds to one organic EL display device. That is, according to the deposition mask apparatus 10 (deposition mask 20) shown in Fig. 1, it is possible to perform multi-surface deposition.

3, in the illustrated example, the plurality of through holes 25 formed in the respective effective regions 22 are formed in the effective region 22 along the two mutually orthogonal directions, Respectively. An example of the through hole 25 formed in the metal plate 21 will be described in more detail with reference mainly to Figs. 3 to 6. Fig.

4 to 6, the plurality of through holes 25 are formed in the order of the first surface 20a which is one side along the normal direction of the deposition mask 20 and the second surface 20b which is one side along the normal direction of the deposition mask 20, And the second surface 20b, which is the other side of the deposition mask 20, and passes through the deposition mask 20. In the illustrated example, a first recess 30 is formed in the metal plate 21 from the first surface 21a side of the metal plate 21, which is one side in the normal direction of the deposition mask, A second concave portion 35 is formed on the metal plate 21 from the second surface 21b side which is the other side in the normal direction of the metal plate 21 and the first concave portion 35 30 and the second recess 35 form a through-hole 25.

As shown in FIGS. 3 to 6, deposition is performed at each position along the normal direction of the deposition mask 20 from the first surface 20a side to the second surface 20b side of the deposition mask 20, The sectional area of each first concave portion 30 in the cross section along the surface of the mask 20 becomes smaller. 3, the wall surface 31 of the first concave portion 30 extends in a direction crossing the normal direction of the deposition mask 20 in the entire region thereof, and the wall surface 31 of the deposition mask 20 And is exposed toward one side along the normal direction. The cross sectional area of each second concave portion 35 in the cross section along the surface of the deposition mask 20 at each position along the normal direction of the deposition mask 20 is larger than the cross sectional area of the second face 20b toward the first surface 20a side. The wall surface 36 of the second concave portion 35 extends in a direction intersecting the normal direction of the deposition mask 20 in the entire region thereof and the other side along the normal direction of the deposition mask 20 .

4 to 6, the wall surface 31 of the first concave portion 30 and the wall surface 36 of the second concave portion 35 are connected to each other through the circumferential connecting portion 41 Respectively. The connecting portion 41 is formed by the wall surface 31 of the first concave portion 30 inclined with respect to the normal direction of the deposition mask and the wall surface 36 of the second concave portion 35 inclined with respect to the normal direction of the deposition mask, Are formed by ridges of protrusions joining together. The connecting portion 41 defines a penetrating portion 42 in which the area of the through hole 25 becomes the smallest in the plane of the deposition mask 20.

4 to 6, the two adjacent through holes 25 on the other side of the deposition mask 20, that is, on the second surface 20b of the deposition mask 20, , And are spaced apart from each other along the surface of the deposition mask. That is, the metal plate 21 is etched from the second surface 21b side of the metal plate 21 corresponding to the second surface 20b of the deposition mask 20, The second surface 21b of the metal plate 21 remains between the adjacent two second recesses 35. In this case,

4 to 6, on one side along the normal direction of the deposition mask, that is, on the first surface 20a side of the deposition mask 20, two adjoining first recesses ( 30 are connected. That is, the metal plate 21 is etched from the first surface 21a side of the metal plate 21 corresponding to the first surface 20a of the deposition mask 20, The first surface 21a of the metal plate 21 does not remain between the two adjacent first recessed portions 30 in the case where the first recessed portion 30 is formed. That is, the first surface 21a of the metal plate 21 is etched over the entire region of the effective region 22. According to the first surface 20a of the deposition mask 20 formed by the first recess 30 as shown in Fig. 2, the first surface 20a of the deposition mask 20 is covered with the deposition material 98, the use efficiency of the evaporation material 98 can be effectively improved when the deposition mask 20 is used.

When the deposition mask apparatus 10 is accommodated in the deposition apparatus 90 as shown in Fig. 2, the first surface 20a of the deposition mask 20 is covered with the deposition material And the second surface 20b of the deposition mask 20 faces the glass substrate 92. The second surface 20b of the deposition mask 20 faces the glass substrate 92, Therefore, the evaporation material 98 is adhered to the glass substrate 92 through the first concave portion 30 gradually becoming smaller in cross-sectional area. The evaporation material 98 not only moves along the normal direction of the glass substrate 92 from the crucible 94 toward the glass substrate 92 as shown by the arrow in Fig. 4, As shown in FIG. At this time, if the thickness of the evaporation mask 20 is large, most of the evaporation material 98 that slantingly moves is a wall surface of the first concave portion 30 before reaching the glass substrate 92 through the through- (31). In addition, in the region facing the through hole 25 on the glass substrate 92, a region where the evaporation material 98 easily reaches and a portion difficult to reach occur. Therefore, in order to save the expensive evaporation material by increasing the utilization efficiency of the evaporation material (the film deposition efficiency: the rate of adhering to the glass substrate 92) and to stably and uniformly perform the film formation using the expensive deposition material in the desired region , It becomes important to configure the deposition mask 20 so as to reach the glass substrate 92 as far as possible. 4 to 6 that are orthogonal to the sheet surface of the deposition mask 20 have a connecting portion 41 which is a portion having the smallest cross sectional area of the through hole 25 and a connecting portion 41 which is a portion of the first concave portion 30 It is advantageous to sufficiently increase the minimum angle? 1 (see FIG. 4) formed by the straight line L1 passing through another arbitrary position of the wall surface 31 with respect to the normal direction of the deposition mask 20.

The thickness of the deposition mask 20 is made small so that the wall surface 31 of the first concave portion 30 and the wall surface 31 of the second concave portion 35 36 can be reduced. That is, as the metal plate 21 for constituting the deposition mask 20, it is preferable to use the metal plate 21 whose thickness is as small as possible within a range in which the strength of the deposition mask 20 can be ensured .

As another method for increasing the angle [theta] 1, it is also conceivable to optimize the outline of the first concave portion 30. [ For example, according to the present embodiment, the wall surfaces 31 of two adjoining first concave portions 30 are merged, so that the concave portions having the wall surface (outline) indicated by the dotted line not joining the other concave portions , And this angle? 1 can be greatly increased. Hereinafter, the reason will be described.

The first concave portion 30 is formed by etching the first surface 21a of the metal plate 21 as described later in detail. The wall surface of the concave portion formed by etching generally has a curved surface shape that is convex toward the erosion direction. Therefore, the wall surface 31 of the concave portion formed by etching is sharply raised in the region to be the start side of the etching, and in the region opposite to the start side of etching, that is, on the deepest side of the concave portion, And the inclination is relatively large with respect to the direction. On the other hand, in the illustrated evaporation mask 20, since the wall surfaces 31 of the two adjacent first recessed portions 30 join at the start side of etching, the wall surfaces of the two first recessed portions 30 The outer contour of the portion 43 where the front end rims 32 of the first and second ribs 31 and 31 join together does not have a steeply raised shape but has a chamfered shape. This makes it possible to effectively tilt the wall surface 31 of the first concave portion 30 constituting the majority of the through holes 25 with respect to the normal direction of the deposition mask. That is, the angle? 1 can be increased.

According to the deposition mask 20 of the present embodiment, the inclination angle [theta] 1 of the wall surface 31 of the first concave portion 30 with respect to the normal direction of the deposition mask is set to be Can be effectively increased. As a result, the deposition efficiency of the evaporation material 98 can be effectively improved, and deposition in a desired pattern can be performed with high accuracy and stability.

The metal plate 21 is etched from the first surface 21a side of the metal plate 21 corresponding to the first surface 20a of the deposition mask 20 to form the first recessed portion 21a The first surface 21a of the metal plate 21 is eroded by etching in the entire region of the metal plate 21 constituting the effective region 22 of the deposition mask 20. [ That is, the maximum thickness Ta in the effective region 22 along the normal direction of the deposition mask is less than 100% of the maximum thickness Tb in the peripheral region 23 along the normal direction of the deposition mask. It is preferable from the viewpoint of improving the use efficiency of the evaporation material that the overall thickness in the effective region 22 is made thin as a whole. On the other hand, from the viewpoint of the strength of the deposition mask, the maximum thickness Ta in the effective region 22 along the normal direction of the vapor deposition mask is 50% of the maximum thickness Tb in the peripheral region 23 along the normal direction of the deposition mask. % Or more. In the case where the maximum thickness Ta in the effective region 22 is 50% or more of the maximum thickness Tb in the peripheral region 23, It is possible to effectively suppress deformation of the deposition mask 20 in the effective region 22, thereby effectively performing deposition in a desired pattern.

However, in order to obtain the metal plate 21 having a small thickness, it is necessary to increase the rolling rate at the time of manufacturing the metal plate 21 by rolling the base metal. However, the larger the rolling rate, the greater the residual stress on the metal plate, i.e., the residual stress. When the residual stress is large, residual stress is released from the side of the metal plate 21 where etching is performed when the deposition mask 20 is fabricated by etching the metal plate 21. As a result, the obtained deposition mask 20 is warped . When the warp is large, the deposition mask 20 can not be sufficiently brought into close contact with the substrate 92, and as a result, the positional accuracy of the deposition is lowered. In the present embodiment, as described above, the deposition mask 20 is manufactured by etching the first surface 21a of the metal plate 21 over the wide area of the effective area 22, for example, over the entire area . Therefore, as compared with the case where the first surface 21a is only locally etched, the degree of residual stress released from the first surface 21a side of the metal plate 21 becomes larger, and as a result, It is getting bigger. Therefore, as will be described later, it becomes important to selectively use the metal plates 21, which are less prone to warpage when they become the deposition masks 20.

As described above, in the present embodiment, the through holes 25 are arranged in the respective effective regions 22 in a predetermined pattern. When the color display is desired, the deposition mask 20 (deposition mask apparatus 10) and the glass substrate 92 are relatively moved relative to each other along the arrangement direction of the through holes 25 (one direction described above) , An organic light emitting material for red, an organic light emitting material for green, and an organic light emitting material for blue may be sequentially deposited.

Further, the frame 15 of the deposition mask apparatus 10 is provided on the periphery of the deposition mask 20 having a rectangular shape. The frame 15 holds the deposition mask 20 so as to prevent the deposition mask 20 from being warped. The deposition mask 20 and the frame 15 are fixed to each other by, for example, spot welding.

The vapor deposition process is performed inside the vapor deposition apparatus 90 which becomes a high-temperature atmosphere. Thus, during the deposition process, the deposition mask 20, the frame 15, and the substrate 92, which are held inside the deposition apparatus 90, are also heated. At this time, the deposition mask, the frame 15, and the substrate 92 exhibit the dimensional change behavior based on the respective thermal expansion coefficients. In this case, when the thermal expansion coefficients of the evaporation mask 20 or the frame 15 and the substrate 92 are greatly different from each other, a positional deviation occurs due to a difference in dimensional change thereof. As a result, The dimensional accuracy and positional accuracy of the evaporation material to be used are lowered. In order to solve such a problem, it is preferable that the thermal expansion coefficient of the evaporation mask 20 and the frame 15 is equal to the thermal expansion coefficient of the substrate 92. [ For example, in the case where the glass substrate 92 is used as the substrate 92, an invar material which is an alloy in which 36% nickel is added to iron can be used as the material of the deposition mask 20 and the frame 15 .

Next, the operation and effect of the present embodiment including this configuration will be described. First, a method of manufacturing a metal plate used for manufacturing a deposition mask will be described. Next, a method of manufacturing a deposition mask using the obtained metal plate will be described. Thereafter, a method of depositing an evaporation material on a substrate using the obtained evaporation mask will be described.

(Manufacturing method of metal plate)

First, a method of manufacturing a metal plate will be described with reference to Figs. 7 (a), 7 (b), 8 (a), 8 (b) and 9 (a) and 9 (b). FIG. 7A is a view showing a step of rolling a base material to obtain a metal plate having a desired thickness, and FIG. 7B is a view showing a step of annealing a metal plate obtained by rolling. 8A is a view showing a sample cut from a metal plate obtained by the process shown in Figs. 7A and 7B, and Fig. 8B is a sectional view taken along the line VIII- Showing the etched sample obtained by etching the first surface of the sample to be exposed. 9 (a) and 9 (b) are a perspective view and a plan view, respectively, showing a state in which a sample cut out from a metal plate is loaded on a loading table.

[Rolling Process]

First, as shown in Fig. 7A, a base material 55 made of Invar is prepared, and the base material 55 is rolled by a rolling device 56 (including a pair of rolling rolls 56a and 56b) ). The base material 55 that has reached between the pair of rolling rolls 56a and 56b is rolled by the pair of rolling rolls 56a and 56b so that the base material 55 is reduced in thickness And extend along the conveying direction. Thereby, a long metal plate 64 having a thickness t ₀ can be obtained. As shown in Fig. 7 (a), the long metal plate 64 may be wound around the core 61 to form the wound body 62. [

[Annealing process]

Thereafter, the long metal plate 64 is annealed by using the annealing device 57 as shown in Fig. 7 (b) in order to remove the residual stress accumulated in the long metal plate 64 by rolling. The annealing process may be performed while stretching the long metal plate 64 in the carrying direction (longitudinal direction) as shown in Fig. 7 (b). As a result, a long metal plate 64 having a thickness t ₀ , from which residual stress is removed to some extent, can be obtained. The long metal plate 64 may be wound around the core 61 to form the winding body 62 as shown in Fig. 7 (b). The thickness t ₀ is usually equal to the maximum thickness Tb in the peripheral region 23 of the deposition mask 20.

The shapes of the rolling process and the annealing process are not particularly limited to those shown in Figs. 7 (a) and 7 (b). For example, the rolling process may be carried out using a plurality of pairs of rolling rolls 56a, 56b. Further, by repeating the rolling process and the annealing process a plurality of times, a long metal plate 64 having a thickness t ₀ may be produced. 7B shows an example in which the annealing process is performed while the long metal plate 64 is stretched in the longitudinal direction. However, the present invention is not limited to this, 61). When the annealing process is carried out while the long metal plate 64 is wound around the core 61, the long metal plate 64 may have a tendency to warp depending on the winding diameter of the winding body 62. [ Therefore, depending on the winding diameter of the winding body 62 and the material constituting the base material 55, it is advantageous to carry out the annealing step while stretching the long metal plate 64 in the longitudinal direction.

[Inspection process]

Thereafter, an inspection process for inspecting the degree of warping of the obtained long metal plate 64 is performed. First, as shown in FIG. 8 (a), a sample 75 having a length (1), a width (w) and a thickness (t ₀ ) is cut out from the long metal plate 64. 8 (a), the first and second surfaces of the sample 75 are indicated by reference numerals 75a and 75b, respectively. The first surface 75a and the second surface 75b are surfaces that are orthogonal to the thickness direction of the sample 75 and also face each other. 8, a pair of side faces located between the first face 75a and the second face 75b and extending in the longitudinal direction of the sample 75 are denoted by reference numerals 75c and 75d, respectively. The length l, the width w and the thickness t ₀ are appropriately determined according to the dimensions of the deposition mask 20 obtained from the long metal plate 64 as described later. For example, when the length l is 170 mm The width w is 30 mm, and the thickness t ₀ is in a range of 0.020 mm or more and 0.100 mm or less.

Subsequently, as shown in FIG. 8 (b), the thickness of the etched region 75f of the sample 75 is increased from the first surface 75a side to the first surface 75a side until the thickness of the etched region 75f becomes t ₁ . The sample 75 is etched all over the etched region 75f. The etched region 75f is an area to be etched in the sample 75. For example, the etched region 75f is a region excluding the region within the distance l ₁ , l ₂ from the both ends 75g1, 75g2 in the longitudinal direction of the sample 75. The regions of the lengths l ₁ and l _{2 in the} vicinity of both ends 75g1 and 75g2 are all unetched regions. This non-etched area helps in securing the stability of the sample 75 when the sample 75 is loaded on the table, as described later.

The length l ₃ of the etched region 75f in the longitudinal direction of the sample 75 is equal to the length l ₁ of the length 75 of the sample 75 as is apparent from Fig. And the length ( ₁₂ ). The lengths l ₁ and l ₂ are appropriately determined so as to secure the stability of the sample 75 when the sample 75 is loaded on the table, but are all 10 mm, for example. In this case, the length 13 of the etched region 75f in the longitudinal direction is 150 mm.

The thickness (t ₁₎ of the sample 75 after the etching is only properly been set according to the degree of etching is carried out to produce a vapor deposition mask 20, for example, the thickness (t ₁₎ is 1/3 × t ₀ or more And is within a range of 2/3 x t ₀ or less. Here, since the residual stress is accumulated in the sample 75 to some extent, the sample 75 is warped by etching the sample 75 from the first surface 75a side. Hereinafter, the process of measuring the curvature of the warp will be described.

As a method for evaluating the warpage of a sample, there is known a method of calculating the warpage curvature of a sample by supporting one end of the sample and suspending the sample in the air. However, in this case, not only the factor due to the release of the residual stress but also the factor due to the weight of the sample is reflected in the curvature measurement result of the warp. Therefore, it is considered that the warping of the sample due to the residual stress can not be accurately evaluated. In this embodiment, as shown in FIG. 9A, in a state in which the sample 75 is placed on a predetermined stage 76 so that the side surface 75c of the sample 75 is horizontal, The curvature of the warp of the sample 75 is calculated. Therefore, according to the present embodiment, the warpage of the sample 75 due to the residual stress can be more accurately evaluated. In addition, the vicinity of both ends (75g1, 75g2) of the sample 75, since the area having the original thickness (t ₀₎ of the left over a length (l _1, l _2), loading the sample (75) to (76 ). In addition, it is easy to grasp both ends 75g1 and 75g2 of the sample 75 by hand. In the case where the operation of taking out the sample 75 includes a step of cutting a part of the metal plate as described later, the influence of the distortion caused by the cutting is absorbed by the region having the original thickness t ₀ , It is possible to prevent or suppress the influence of the distortion caused by the cutting to reach the etched region 75f.

Hereinafter, a specific method for calculating the curvature k of the warp of the sample 75 will be described. 9 (b) is a plan view showing a case where the sample 75 in a warped state in the longitudinal direction is viewed from above. 9 (b), a pair of ends in the longitudinal direction of the etched region 75f of the sample 75 is indicated by 75e. First, the distance (x) (mm) between the end portions in the longitudinal direction of the etched region 75f of the sample 75 and the depth y (mm) of the bending of the etched region 75f of the sample 75 . The depth y of the bend is a distance between a straight line connecting the pair of end portions 75e of the etched region 75f of the sample 75 and the etched region 75f of the sample 75 It refers to the maximum value. Then, the radius of curvature rho corresponding to the warp of the etched region 75f of the sample 75 is calculated based on the following expression.

ρ = (y / 2) + (x ² / 8y)

Then, the curvature k of the flexure of the sample 75 is calculated on the basis of the following equation.

k = 1 / p

In this way, the curvature k (mm ^-1 ) of the flexure of the sample 75 can be obtained.

Thereafter, the long metal plate 64 is selected based on the obtained value of the curvature k. Here, the long metal plate 64 is selected so that only the long metal plate 64 from which the sample 75 whose value of the curvature k is less than or equal to the reference value is used in the manufacturing process of the deposition mask 20 Conduct. The reference value, only been set properly depending on required for the deposition with the deposition mask 20, the position accuracy, for example, long metal sheet, the value of the curvature (k) with a 0.008mm ^-1 or less samples 75 are extracted ( 64) is recognized as a good product. By performing such sorting, even when warpage occurs in the deposition mask 20 due to etching in the manufacturing process of the deposition mask 20, the degree of warpage can be made within the allowable range. Thus, the characteristics of the deposition mask 20 to be manufactured can be improved. In addition, the yield in the manufacturing process of the deposition mask 20 can be improved.

9 (a), a means for facilitating the distance measurement, such as the grid paper 77, may be provided between the loading table and the sample 75. In this case, As a result, it is possible to facilitate the measurement of the distance (x) (mm) and the depth (y) (mm) of deflection of the end portions described above, thereby making it possible to quickly calculate the curvature k.

9 (a), a hollow portion 76b may be formed in the loading table 76 so that the loading surface 76a on which the sample 75 is loaded can be vibrated in the vertical direction. In this case, first, the sample 75 is loaded on the grid paper 76 placed on the rack 76 or on the rack 76, and then the loading surface 76a is tapped so that the loading surface 76a is moved up and down The frictional force that may occur between the sample 75 and the stage 76 or the face paper 77 can be released or reduced. As a result, the influence of the frictional force on the curvature measurement result can be suppressed. For example, the width and length of the stacking belt 76 are all 300 mm, and the thickness of the stacking belt 76 is 50 mm. The width of the stacking belt 76 and the size of the hollow 76b are not particularly limited, . The hollow portion 76b of the loading table 76 is configured such that the thickness of the loading surface 76a and the bottom surface of the loading table 76 are respectively 5 mm, for example. The material constituting the stage 76 is not particularly limited, but for example, the stage 76 is made of acrylic resin.

(Manufacturing Method of Deposition Mask)

Next, a method of manufacturing the deposition mask 20 using the long metal plate 64 selected as described above will be described mainly with reference to FIGS. 10 to 17. FIG. 10, a long metal plate 64 is supplied, a through hole 25 is formed in the long metal plate 64, and a long metal plate 64 is formed on the long metal plate 64. In this way, (64) is cut to obtain a deposition mask (20) including a single sheet metal plate (21).

More specifically, the manufacturing method of the deposition mask 20, the step of supplying the elongated metal plate 64 extending in a strip shape, and the etching using the photolithography technique to the elongated metal plate 64 to form the elongated metal plate 64 Etching the surface of the long metal plate 64 by etching using the photolithography technique to form the first recessed portion 30 from the side of the second surface 64b To form a second concave portion 35 from the side of the second concave portion 35. The first recess 30 and the second recess 35 formed in the long metal plate 64 communicate with each other to form the through hole 25 in the long metal plate 64. [ 10, the step of forming the second recess 35 is performed before the step of forming the first recess 30, and the step of forming the second recess 35 and the step of forming the second recess 35 are performed, A step of sealing the manufactured second concave portion 35 is further provided during the step of forming the first concave portion 30. Hereinafter, the details of each step will be described.

In Fig. 10, a manufacturing apparatus 60 for manufacturing the deposition mask 20 is shown. As shown in Fig. 10, first, a winding body 62 in which a long metal plate 64 is wound around a core 61 is prepared. Then, as the core 61 rotates and the winding body 62 is loosened, a long metal plate 64 extending in a strip shape is supplied as shown in Fig. The long metal plate 64 is formed with a through hole 25 to form the single metal plate 21 and the deposition mask 20.

The supplied long metal plate 64 is conveyed to the etching apparatus (etching means) 70 by the conveying roller 72. The respective processes shown in Figs. 11 to 17 are carried out by the etching means 70. Fig. 11, a resist pattern 65a (simply referred to as resist) is formed on the first surface 64a of the long metal plate 64 and a second surface 65a of the long metal plate 64 A resist pattern (simply referred to as a resist) 65b is formed on the resist patterns 64a and 64b. Specifically, the following is carried out. First, a negative type photosensitive resist material is coated on the first surface 64a of the long metal plate 64 (the lower surface on the paper surface in Fig. 11) and the second surface 64b, Thereby forming a resist film. Next, a glass dry plate is prepared so that light is not transmitted through an area to be removed in the resist film, and a glass dry plate is disposed on the resist film. Thereafter, the resist film is exposed over a glass dry plate, and the resist film is further developed. A resist pattern 65a is formed on the first surface 64a of the long metal plate 64 and the resist pattern 65a is formed on the second surface 64b of the long metal plate 64 (Simply referred to as a resist) 65b can be formed.

As the photosensitive resist material, a positive resist material may be used. In this case, as the exposure mask, an exposure mask is used which allows light to pass through the resist film to be removed.

12, using the resist pattern 65b formed on the long metal plate 64 as a mask and using an etching liquid (for example, a ferric chloride solution), the second And etched at the side of the surface 64b. For example, when the etchant flows from the nozzle disposed on the side facing the second surface 64b of the long metal plate 64 to be transported to the second surface 64b of the long metal plate 64 over the resist pattern 65b Lt; / RTI > As a result, as shown in Fig. 12, in the region of the long metal plate 64 not covered by the resist pattern 65b, erosion by etching liquid proceeds. As described above, a plurality of second recesses 35 are formed in the long metal plate 64 from the second surface 64b side.

Thereafter, as shown in Fig. 13, the second concave portion 35 formed by the resin 69 having resistance to the etching liquid is coated. That is, the second recessed portion 35 is sealed by the resin 69 resistant to the etching solution. In the example shown in Fig. 13, the film of the resin 69 is formed so as to cover not only the second concave portion 35 but also the second surface 64b (the resist pattern 65b).

Then, as shown in Fig. 14, the second etching is performed on the long metal plate 64. Then, as shown in Fig. In the second etching, the long metal plate 64 is etched only from the first surface 64a side, and the formation of the first recessed portion 30 proceeds from the first surface 64a side. This is because the resin 69 having resistance to the etching solution is coated on the second surface 64b side of the long metal plate 64. Therefore, the shape of the second concave portion 35 formed in the desired shape by the first etching is not damaged.

The erosion by the etching is performed at a portion of the long metal plate 64 which is in contact with the etching solution. Therefore, erosion does not proceed only in the normal direction (thickness direction) of the long metal plate 64, but also in the direction along the surface of the long metal plate 64. As a result, as shown in Fig. 15, the first concave portion 30 is not only connected to the second concave portion 35 but also in the direction of the normal line of the long metal plate 64, The two first concave portions 30 formed at the positions facing the two adjacent holes 66a are joined at the other side of the bridge portion 67a located between the two holes 66a.

The etching from the first surface 64a side of the long metal plate 64 proceeds further, as shown in Fig. The confluence portion 43 in which the two adjacent first concave portions 30 are joined is spaced apart from the resist pattern 65a and the confluence portion 43 is formed below the resist pattern 65a, (Thickness direction) of the metal plate 64. In this case, as shown in Fig. As a result, the confluent portion 43, which is pointed toward one side along the normal direction of the deposition mask, is etched from one side along the normal direction of the deposition mask, and is chamfered as shown in Fig. This makes it possible to increase the inclination angle? 1 formed by the wall surface 31 of the first concave portion 30 with respect to the normal direction of the deposition mask.

In this way, the erosion of the first surface 64a of the elongated metal plate 64 by etching proceeds in the entire region that forms the effective region 22 of the elongated metal plate 64. [ The maximum thickness Ta along the normal direction of the long metal plate 64 in the region where the effective region 22 is formed becomes thinner than the maximum thickness Tb of the long metal plate 64 before etching .

As described above, the etching of the long metal plate 64 from the first surface 64a side is advanced by the preset amount, and the second etching for the long metal plate 64 is terminated. The first concave portion 30 extends to a position reaching the second concave portion 35 along the thickness direction of the long metal plate 64 so that the first concave portion 30, The through hole 25 is formed in the long metal plate 64 by the first and second recesses 35,

Thereafter, the resin 69 is removed from the long metal plate 64, as shown in Fig. The resin film 69 can be removed by using, for example, an alkaline removing solution. When an alkaline removing solution is used, the resist patterns 65a and 65b are removed at the same time as the resin 69 as shown in Fig.

The long metal plate 64 formed with the plurality of through holes 25 is cut by the cutting device (cutting means) (not shown) by the conveying rollers 72, 72 rotating while holding the long metal plate 64 73). The feed core 61 described above is rotated through the tension (tension) acting on the long metal plate 64 by the rotation of the conveying rollers 72 and 72 so that the long metal plate 64 Is supplied.

Thereafter, a long metal plate 64 having a plurality of recessed portions 61 is cut to a predetermined length by a cutting device (cutting means) 73 to form a single metal plate 21 having a plurality of through holes 25 ) Is obtained.

As described above, the deposition mask 20 including the metal plate 21 on which the plurality of through holes 25 are formed is obtained. According to the present embodiment, the first surface 21a of the metal plate 21 is etched over the entire region of the effective region 22. [ This reduces the thickness of the effective area 22 of the deposition mask 20 and reduces the thickness of the front end edge 32 of the wall surface 31 of the two first recesses 30 formed on the first surface 21a side Can be formed into a chamfered shape. Therefore, the above-described angle? 1 can be increased, thereby improving the utilization efficiency of the evaporation material and the positional accuracy of the deposition.

The reason for etching the first surface 21a of the metal plate 21 over the entire effective area 22 is that the degree of etching on the first surface 21a side and the degree of etching on the second surface side 21b side . That is, unevenness of the released residual stress between the side of the first surface 21a and the side of the second surface 21b is generated, and furthermore, the warp of the metal plate 21, that is, the deposition mask 20 is generated. According to the present embodiment, as described above, a long metal plate 64 previously selected based on the degree of warpage of the sample 75 is used. Therefore, even when there is a difference in the degree of etching between the first surface 21a side and the second surface 21b side, the degree of warpage generated in the deposition mask 20 can be within the allowable range. Therefore, according to the present embodiment, the thickness of the deposition mask 20 is reduced and the angle of inclination? 1 of the wall surface 31 of the first concave portion 30 of the deposition mask 20 is increased, It is possible to improve utilization efficiency and positional accuracy of deposition, optimize the contour, reduce the warpage of the deposition mask 20, and improve the yield of the deposition mask 20 manufacturing process. Therefore, the deposition mask 20 having excellent characteristics can be stably provided.

(Deposition method)

Next, a method of depositing an evaporation material on the substrate 92 using the obtained evaporation mask 20 will be described. First, as shown in FIG. 2, the deposition mask 20 is brought into close contact with the substrate 92. At this time, by arranging the deposition mask 20 on the frame 15, the surface of the deposition mask 20 is made parallel to the surface of the substrate 92. According to the present embodiment, a long metal plate 64 previously selected based on the degree of warping of the sample 75 is used. As a result, the degree of bending of the deposition mask 20 is uniformly reduced as compared with the case where such selection is not performed. Therefore, by applying appropriate tension to the deposition mask 20, the deposition mask 20 can be kept parallel to the substrate 92. [ That is, it is not necessary to apply a high tensile force to the deposition mask 20 so as to cause wrinkles in the deposition mask 20 in order to correct the warp caused by the release of the internal stress (residual stress). Therefore, the deposition mask 20 can be sufficiently adhered to the substrate 92, whereby the deposition material can be deposited on the substrate 92 with high positional accuracy. Therefore, when pixels of the organic EL display device are formed by vapor deposition, the dimensional accuracy and the positional accuracy of the pixels of the organic EL display device can be increased. This makes it possible to manufacture a highly accurate organic EL display device.

In addition, in the above-described embodiment, the plurality of effective regions 22 of the deposition mask 20 are arranged at predetermined intervals along one direction parallel to one side of the deposition mask 20, Are arranged at predetermined intervals along other directions orthogonal to the longitudinal direction. 18, the deposition mask 20 includes a plurality of effective regions 22 arranged in a row along one direction, and the deposition mask apparatus 10 further includes a plurality of effective regions 22, , And a plurality of deposition masks 20 arranged in the frame 15 in the direction orthogonal to the longitudinal direction (one direction). The method of manufacturing such a deposition mask 20 is not particularly limited. For example, the deposition mask 20 may be manufactured by using a long metal plate 64 having a width corresponding to the deposition mask 20 shown in Fig. 18, that is, a metal plate 21. Fig. Alternatively, after the plurality of effective regions 22 are formed along one direction and the other direction of the long metal plate 64, that is, the metal plate 21, the metal plate 21 is cut along the longitudinal direction thereof, The deposition mask 20 may be manufactured.

Example

Next, the present invention will be described in more detail by way of examples, but the present invention is not limited to the description of the following examples unless they depart from the gist thereof.

(Production of sample)

First, the rolled and annealed processes were performed on the base material composed of Invar ashes to produce a rolled body (first rolled body) in which a long metal plate having a width of 500 mm and a thickness of t ₀ was wound. Thereafter, the first winding body was cut out over a length of 300 mm to obtain a metal plate 63 shown in Fig. 19 (a). In Fig. 19 (a), the arrow D1 corresponds to the conveying direction in the rolling step, that is, the rolling direction, and the arrow D2 corresponds to the width direction in the rolling step.

Next, as shown in Fig. 19 (b), a plurality of samples 75 are taken out of the metal plate 63. Fig. The dimensions of the sample 75 were 170 mm in length x 30 mm in width. The longitudinal direction of the sample 75 is parallel to the arrow D1, and the width direction of the sample 75 is parallel to the arrow D2. The number of samples 75 taken out from one metal plate 63 was 15 sheets. Etching is used as a method of extracting a plurality of samples 75 from the metal plate 63. Specifically, first, a resist pattern is formed on both the first surface side and the second surface side of the metal plate 63 so as to cover the area to be the sample 75 and the outer frame portion 63a of the metal plate 63. [ Subsequently, the metal plate 63 was etched from both the first surface side and the second surface side using the resist pattern as a mask. 19B, between the outer frame portion 63a of the metal plate 63 and the region to be the sample 75 of the metal plate 63, the through holes 63b ). The etching was carried out such that a connection portion 63c for connecting the outer frame portion 63a of the metal plate 63 and the sample 75 was left. The dimension of the connecting portion 63c is about 3 mm in length × 1 mm in width.

Next, as shown in Fig. 19 (c), the thickness of the sample 75 is etched region (75f) of, (1 / 2-8 / 100) × t 0 or more and (1/2 + 8 / 100) × t ₀ until the following range to I of, over the whole of the first surface (75a), the etched region (75f) from the first surface (75a) side of the sample (75) was etched a sample (75) . Thereafter, the connecting portion 63c was cut to remove the 15 samples 75 etched from the metal plate 63. Then, In order to prevent the influence of the distortion caused by the cutting on the etched region 75f, precision scissors may be used as a means for cutting the connection portion 63c.

Further, the metal plate with forming a through-hole (63b) above to 63, the thickness of the sample 75 is etched region (75f) of the (1 / 2-8 / 100) × t 0 or more and (1 / 2 + 8/100) x t ₀ may be performed simultaneously by the same etching process.

(Calculation of curvature of sample)

Subsequently, the curvature k (mm ^-1 ) of warpage in each of the etched samples 75 was obtained in the same manner as in the case of the inspection process described above. More specifically, first, the sample 75 is placed on the loading surface 76a of the loading table 76 on which the hollow portion 76b is formed so that the sample 75 side 75c is horizontal. And loaded. Subsequently, vibration was applied to the mounting surface 76a of the table 76 until the state of warpage of the sample 75 was not changed when viewed from the naked eye. Thereafter, the distance (x) (mm) between the end portions in the longitudinal direction of the etched region 75f and the depth y (mm) of the deflection of the etched region 75f of the sample 75 are determined by the face paper 77 ). Next, the radius of curvature rho corresponding to the deflection of the etched region 75f of the sample 75 was calculated based on the following equation.

ρ = (y / 2) + (x ² / 8y)

Then, the curvature k of the flexure of the sample 75 was calculated based on the following equation.

k = 1 / p

The maximum value of the curvature (k) measurement results of the deflection in the 15 samples 75 from the first winding was 7.6 x 10 ^-3 mm ^-1 .

(Evaluation of primary effect)

Using the above-described method for producing a deposition mask, a deposition mask was manufactured from a long metal plate of the first winding body. The curl of the resulting deposition mask was then measured. Also, curl is the maximum value of the undulation of the deposition mask in the vertical direction, which occurs when the deposition mask is mounted on a horizontal plane. As a result, the curl of the deposition mask obtained from the long metal plate of the first winding body was 0.25 mm.

(Evaluation of secondary effects)

An evaporation material made from a long metal plate of the first winding was used to deposit an evaporation material on a substrate. In addition, the pattern of a plurality of through holes formed in the deposition mask used was a stripe pattern corresponding to a pixel density of 300 ppi. As the evaporation material, an organic light emitting material for green which emits green light was used. Then, the center coordinate position and line width dimension of each of the plurality of green light emitting layers including the organic light emitting material for green deposited on the substrate were measured. In addition, for each of the measured center coordinate position and line width dimension, a shift amount from the design value was calculated. Then, it was judged whether or not the shift amount was less than the allowable value. At this time, the permissible value of the shift amount of the center coordinate position is ± 4 μm and the allowable value of the shift amount of the line width dimension is ± 2 μm. As a result, the shift amount was equal to or smaller than the permissible value for both the center coordinate position and the line width dimension. That is, both the positional accuracy and dimensional accuracy of the evaporation material were OK.

Table 1 shows the results of measurement of the curvature of the sample taken from the first winding body and the evaluation results of the primary effect and the secondary effect concerning the deposition mask made from the long metal plate of the first winding body. Further, in the same manner as in the case of the first winding body, the second winding body to the twentieth winding body were manufactured from the base material composed of invar. Further, in the same manner as in the case of the first winding body, the curvatures of the samples taken from the respective winding bodies for the second winding winding to the twentieth winding winding, and the deposition masks made from the long metal plates of the respective winding bodies The above-described primary effects and secondary effects were evaluated. The results are shown together in Table 1.

As shown in Table 1, the curvatures of the samples taken out from the first to tenth winding bodies were all 0.008 mm ^-1 or less. In addition, the curl of the deposition mask made from the long metal plate of the first to tenth winding was 0.25 mm or less. In the deposition using a deposition mask made of a long metal plate of the first to tenth windings, both the positional accuracy and the dimensional accuracy of the evaporation material were OK.

On the other hand, the curvatures of the samples taken from the 11th to 20th windings exceeded 0.008 mm < ^{-1 &} gt ;. Further, the curl of the deposition mask made from the long metal plate of the 11th to 20th rolls exceeded 0.25 mm. In the deposition using the deposition mask made of the long metal plate of the 11th to 20th windings, part of the positional accuracy of the evaporation material and the dimensional accuracy are both bad (NG), and all of them are bad ). That is, deviation of the positions and dimensions of the evaporated material deposited on the substrate from the design was out of the allowable range.

In this regard, by the curvature of the take-out sample using a 0.008mm ^-1 or lower winding body, it can be said that to obtain a deposition mask having good deposition properties.

20: Deposition mask
20a: a first side of the deposition mask
20b: second side of the deposition mask
21: metal plate
21a: first side of the metal plate
21b: second face of the metal plate
22: Effective area
23: Ambient area
25: Through hole
30: first concave portion
31: Wall
35: second concave portion
36: Wall
55: base metal
56: Rolling device
57: Annealing device
61: Core
62:
64: Long metal plate
64a: first face of the long metal plate
64b: second face of the long metal plate
75: Sample
75a: first side of the sample
75b: second side of the sample
75c, 75d: side
75f: etched area
76: Loading stand
76a:
76b: hollow portion
77: Cardboard

Claims (13)

A manufacturing method of a metal plate used for manufacturing a deposition mask by forming a plurality of through holes,
The through hole of the deposition mask is formed by etching the metal plate,
The method of manufacturing the metal plate may include:
By rolling a base material, and the rolling process to obtain the metal plate having a thickness of t _0,
And an annealing step of annealing the metal plate to remove an internal stress of the metal plate,
The metal plate has a first surface and a second surface which are perpendicular to the thickness direction and face each other,
If the etching of the samples taken out from the metal sheet after the annealing step, the curvature (k) of the warp of the samples after etching and 0.008mm ^-1 or less,
The curvature k was obtained by first taking out the sample having a length of 170 mm and a width of 30 mm from the metal plate after the annealing process and then measuring the curvature k of the sample having a length of 150 mm and a width of 30 mm except for a region within 10 mm from both ends in the longitudinal direction until the thickness of the etched region 1/3 × t ₀ or more and 2/3 × t ₀ within the following range is i, and etching the samples over the whole of the etched area from the first surface side, and thereafter (X) (mm) in the longitudinal direction of the etched region of the sample and a distance between the end of the etched region of the sample and the etched region of the sample The depth (y) (mm) of the deflection of the region is measured, and thereafter the distance (x) and the depth (y)
k = 1 / ρ, ρ = (y / 2) + (x 2 / 8y)
Of the metal plate. The method of manufacturing a metal plate according to claim 1, wherein the annealing process is performed while the metal plate is stretched in the longitudinal direction. The method of manufacturing a metal plate according to claim 1, wherein the annealing process is performed in a state where the metal plate is wound around a core. The method of manufacturing a metal plate according to any one of claims 1 to 3, wherein a coefficient of thermal expansion of the base material is a value equivalent to a thermal expansion coefficient of a substrate on which an evaporation material is deposited via a deposition mask made of the metal plate. The method of manufacturing a metal plate according to claim 1, wherein the base material is an invar material. A metal plate used for manufacturing a deposition mask by forming a plurality of through holes,
The metal plate has a thickness t ₀ and the metal plate has a first surface and a second surface which are orthogonal to the thickness direction and face each other,
If the etching of the samples taken out from the metal sheet, the curvature (k) of the warp of the samples after etching and 0.008mm ^-1 or less,
The curvature k was obtained by first taking out the sample having a length of 170 mm and a width of 30 mm from the metal plate and then measuring the curvature k of the area of the etched area of 150 mm in length and 30 mm in width excluding the area within 10 mm from both ends in the longitudinal direction The sample is etched from the first surface side to the whole area of the area to be etched until the thickness is in a range of not less than 1/3 x t _{0 and not} more than 2/3 x t ₀ , (X) (mm) in the longitudinal direction of the etched region of the sample and the warpage of the etched region of the sample in a direction perpendicular to the longitudinal direction of the sample The depth (y) (mm) is measured, and thereafter the distance (x) and the depth (y)
k = 1 / ρ, ρ = (y / 2) + (x 2 / 8y)
Of the metal plate. The metal plate according to claim 6, wherein the coefficient of thermal expansion of the metal plate is a value equivalent to a coefficient of thermal expansion of the substrate on which an evaporation material is deposited via a deposition mask made of the metal plate. The metal plate according to claim 6, wherein the metal plate is made of Invar. A method for manufacturing a deposition mask having an effective region in which a plurality of through holes are formed and a peripheral region located around the effective region,
Preparing a metal plate having a thickness t ₀ and having a first surface and a second surface perpendicular to the thickness direction and facing each other,
And a recessed portion forming step of etching the metal plate from the first surface side to form a concave portion in the region of the metal plate forming the effective region from the first surface side to form the through hole,
If the etching of the samples taken out from the metal sheet, the curvature (k) of the warp of the samples after etching and 0.008mm ^-1 or less,
The curvature k was obtained by first taking out the sample having a length of 170 mm and a width of 30 mm from the metal plate and then measuring the curvature k of the area of the etched area of 150 mm in length and 30 mm in width excluding the area within 10 mm from both ends in the longitudinal direction The sample is etched from the first surface side to the whole area of the area to be etched until the thickness is in a range of not less than 1/3 x t _{0 and not} more than 2/3 x t ₀ , (X) (mm) in the longitudinal direction of the etched region of the sample and the warpage of the etched region of the sample in a direction perpendicular to the longitudinal direction of the sample The depth (y) (mm) is measured, and thereafter the distance (x) and the depth (y)
k = 1 / ρ, ρ = (y / 2) + (x 2 / 8y)
To the surface of the deposition mask. The method of manufacturing a deposition mask according to claim 9, wherein in the recess forming step, the metal plate is etched from the first surface side to the entire first surface. 11. The method of claim 10, in the concave portion forming step, the metal sheet, the thickness is 1/3 × t ₀ or more and the first from the first surface side until it is within the range of 2/3 × t ₀ less Wherein the mask is etched over the entire surface of the mask. The method of manufacturing a deposition mask according to any one of claims 9 to 11, wherein a coefficient of thermal expansion of the metal plate is a value equivalent to a coefficient of thermal expansion of a substrate on which an evaporation material is deposited via a deposition mask made of the metal plate. The method of manufacturing a deposition mask according to claim 9, wherein the metal plate is made of Invar.

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