TW201107502A - Film forming device, film forming method, and organic el element - Google Patents

Film forming device, film forming method, and organic el element Download PDF

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TW201107502A
TW201107502A TW099109484A TW99109484A TW201107502A TW 201107502 A TW201107502 A TW 201107502A TW 099109484 A TW099109484 A TW 099109484A TW 99109484 A TW99109484 A TW 99109484A TW 201107502 A TW201107502 A TW 201107502A
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Taiwan
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processing container
organic
vapor deposition
film
deposition source
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TW099109484A
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Chinese (zh)
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Tomohiko Edura
Kohei Tsugita
Tomiko Wanifuchi
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Tokyo Electron Ltd
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    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K71/00Manufacture or treatment specially adapted for the organic devices covered by this subclass
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00Electroluminescent light sources
    • H05B33/10Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/06Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
    • C23C14/12Organic material
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24Vacuum evaporation
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24Vacuum evaporation
    • C23C14/243Crucibles for source material
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/24Vacuum evaporation
    • C23C14/246Replenishment of source material
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/56Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/56Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
    • C23C14/562Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks for coating elongated substrates
    • CCHEMISTRY; METALLURGY
    • C23COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
    • C23CCOATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
    • C23C14/00Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
    • C23C14/22Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
    • C23C14/56Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
    • C23C14/568Transferring the substrates through a series of coating stations
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K71/00Manufacture or treatment specially adapted for the organic devices covered by this subclass
    • H10K71/10Deposition of organic active material
    • H10K71/16Deposition of organic active material using physical vapour deposition [PVD], e.g. vacuum deposition or sputtering
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00Organic light-emitting devices
    • H10K50/10OLEDs or polymer light-emitting diodes [PLED]
    • H10K50/17Carrier injection layers
    • H10K50/171Electron injection layers
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00Organic light-emitting devices
    • H10K50/80Constructional details
    • H10K50/805Electrodes
    • H10K50/82Cathodes
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00Organic light-emitting devices
    • H10K50/80Constructional details
    • H10K50/805Electrodes
    • H10K50/82Cathodes
    • H10K50/828Transparent cathodes, e.g. comprising thin metal layers

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  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Materials Engineering (AREA)
  • Mechanical Engineering (AREA)
  • Metallurgy (AREA)
  • Organic Chemistry (AREA)
  • Manufacturing & Machinery (AREA)
  • Electroluminescent Light Sources (AREA)
  • Physical Vapour Deposition (AREA)

Abstract

In order to prevent the deterioration of a metallic layer that forms the electron-injecting layer of an organic EL element, a film forming device (PM1) is equipped with a processing container (100) that carries out desired processes upon a substrate there within; a vapor deposition source (200) (a first vapor deposition source) that stores organic materials, and that heats and vaporizes the stored organic materials; first spray mechanisms (120a-120f) that are contained within the processing container (100) and connected to the vapor deposition source (200), and that sprays the organic materials vaporized in the vapor deposition source (200) towards the substrate (G) in the processing container; a vaporizer (300) (a second vapor deposition source) that stores an alkali metal such as lithium, and that heats and vaporizes the stored alkali metal; and a second spray mechanism (130) that is contained within the processing container (100) and connected to the vaporizer (300), and that sprays the alkali metal vaporized in the vaporizing device (300) towards the substrate (G) in the processing container.

Description

201107502 、發明說明: 【發明所屬之技術領域】 本發明係關於一種成膜裝置,更詳細說明,係關於 一種包含有機EL元件的膜結構及形成該膜結構用的成 膜裝置與成膜方法。 【先前技術】 〇 〇 近年’利用了一種使用有機化合物來發光之有機 EL(0rganic Electroluminescence)元件的有機 顯示器 係受到注目。該有機EL元件具有自體發光、反應速度 决/肖耗電力低等特徵。因此’相較於液晶顯示器不僅 是影像會變得更美,且無需背光源,而可薄型化,特別 是被期待能應用在攜帶型機器的顯示部等。 有機EL元件係形成於玻璃基板上,而為具有由陽 極層(anode)及陰極層(cath〇de)來夾設有機層的夾層結 構。從外部將數V之電壓施加給該有機EL元件而流通 電流時,電子會從陰極侧注人有機層,電_從陽極側 注入有機層。藉由注人電子與電洞會讓有機材料蒸氣带 成激發狀態,而當電子與電洞再次結合,讓受激^之^ 機,料洛氣回復至基底狀態時,便會以光的形式釋 其多餘能量。 陰極機層時,如能降低電子注入能障而從 有效率地將電子注人有機層,便可製造 的有機el元件。因此,一般係在有機層與陰極之= 201107502 交界面處,形成由功函數(work function)較低之驗金屬 等材料所組成的電子注入層(例如,參考非專利文獻: "Bright organic electroluminescent devices having a metal-dopedelectron-injecting layer” 1998 American Institute of Physics, Applied Physics Letters, VOLUME 73, NUMBER 1998) 〇 非專利文獻揭露了一種於各陰極與發光體層之間 形成摻雜有金屬的有機層之方法。作為摻 如,可舉出雖i)或離)蝴Sm)等範例。仝屬 鹼主屬由於功函數較小,故適合作為形成電子注/ 吉:是’另一方面’由於鹼金屬為高活性體 水八,、空i“的處理室内,仍容易與殘留於加 表面存在有前述不純物的狀態二 處’鋰等金屬與幾 膜的劣4 η 乳化鐘(U2〇)絕緣物等,而造; 、 。因此,考慮到鋰等金屬合棘$ =r’已知-種形成非常 疋,即使如此,形成非常 羯的方法η 勻性劣化,而造成有機肛-杜時仍會有膜之面内; 於是,為了解?前ΐ:性能的 止形成電子注入層之金二層發明係提供—種可ρ 子注入致率的成膜裳置膜二、:,提高該金屬層之1 置成膜方法及有機EL元件。 201107502 【發明内容】 即,為了解決前述問題,依本發明之一樣態係提供 一種成膜裝置,具備有:處理容器,係在其内部於被處 理體上施以所期望的處理;第1蒸鍍源,係收納有機材 料,將所收納之有機材料加熱以氣化;第1喷出機構, 係内藏於該處理容器並連結至該第1蒸鍍源,將於該第 1蒸鍍源處所氣化之有機材料朝向該處理容器内的被處 理體喷出;第2蒸鍍源,係收納鹼金屬材料,將所收納 Ο 之驗金屬材料加熱以氣化;以及第2喷出機構,係内藏 於該處理容器並連結至該第2蒸鍍源,將於該第2蒸鍍 源處所氣化之鹼金屬材料朝向該處理容器内的被處理 體喷出。 藉此,具有能將於第1蒸鍍源處所氣化之有機材料 朝向處理容器内的被處理體喷出之第1喷出機構、以及 能將於該第2蒸鍍源處所氣化之鹼金屬材料朝向處理 容器内的被處理體喷出之第2喷出機構。藉此,可於一 〇 個處理容器内設置有將有機材料之材料蒸氣喷出的第1BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a film forming apparatus, and more particularly to a film structure including an organic EL element and a film forming apparatus and a film forming method for forming the film structure. [Prior Art] 〇 〇 In recent years, an organic display using an organic EL (Organic Electroluminescence) element that emits light using an organic compound has been attracting attention. This organic EL device has characteristics such as self-luminous emission, low reaction rate, and low power consumption. Therefore, compared with the liquid crystal display, not only the image is more beautiful, but also a backlight is not required, and the thickness can be reduced, and it is expected to be applied to a display portion of a portable device. The organic EL element is formed on a glass substrate, and has an interlayer structure in which an organic layer is sandwiched between an anode layer and a cathode layer. When a voltage of a number V is externally applied to the organic EL element to flow a current, electrons are injected from the cathode side into the organic layer, and the electrons are injected from the anode side into the organic layer. By injecting electrons and holes, the organic material vapor is brought into an excited state, and when the electrons and the holes are combined again, the excited machine is returned to the substrate state, and the light is in the form of light. Explain its excess energy. In the case of a cathode layer, an organic EL element can be manufactured by efficiently injecting an organic layer into an electron if the electron injection energy barrier can be reduced. Therefore, generally, at the interface between the organic layer and the cathode = 201107502, an electron injecting layer composed of a material such as a metal having a lower work function is formed (for example, refer to the non-patent literature: "Bright organic electroluminescent Apparatus having a metal-dopedelectron-injecting layer" 1998 American Institute of Physics, Applied Physics Letters, VOLUME 73, NUMBER 1998) 〇 Non-patent literature discloses the formation of an organic layer doped with a metal between each cathode and the illuminant layer. As an example of the blending, there may be mentioned examples such as i) or from Sm). The main genus of the same base is suitable for forming an electron injection because of a small work function: it is 'another side' due to an alkali metal In the treatment chamber where the high-activity body water is eight or empty, it is still easy to exist in the state where the above-mentioned impurities are present on the surface to be added, and the metal such as lithium and the inferior 4 η emulsification clock (U2〇) insulation of several films are required. And made; Therefore, considering that the metal or the like of lithium is known to be abruptly formed, the seed formation is very flawless. Even so, the method of forming a very flawed η is degraded, and the organic anus-du is still in the surface of the film; In order to understand the front ΐ: the performance of the formation of the electron injection layer of the gold two-layer invention system provides a ρ sub-injection rate of the film formation of the film 2,: improve the metal layer of the film formation method and Organic EL element. According to the present invention, in order to solve the above problems, a film forming apparatus is provided, comprising: a processing container in which a desired treatment is applied to the object to be processed; and the first steaming The plating source is an organic material, and the stored organic material is heated to be vaporized; the first discharge mechanism is built in the processing container and connected to the first vapor deposition source, and the first vapor deposition source is The organic material vaporized in the space is ejected toward the object to be processed in the processing container; the second vapor deposition source is an alkali metal material, and the metal material to be stored is heated to vaporize; and the second ejecting mechanism is The inside of the processing container is connected to the second vapor deposition source, and the alkali metal material vaporized at the second vapor deposition source is discharged toward the object to be processed in the processing container. Thereby, the first discharge means capable of ejecting the organic material vaporized in the first vapor deposition source toward the object to be processed in the processing container, and the alkali which can be vaporized at the second vapor deposition source are provided. The second discharge mechanism that ejects the metal material toward the object to be processed in the processing container. Thereby, the first step of ejecting the vapor of the material of the organic material can be provided in one processing container.

喷出機構、以及將鹼金屬之氣化原子喷出的第2喷出機 構。藉此,於形成有機層後,無需將被處理體搬送至其 他處理裝置,可於同一個處理室内形成鹼金屬層。藉 此,可避免水分、氮、氧等不純物附著於有機層表面。 藉此,可防止鹼金屬層與附著於有機層表面的不純物相 互反應而受到氧化,並形成絕緣物等而使膜劣化。其結 果,可提高電子注入效率,可製造出高性能的有機EL 201107502 元件。 又,由於可如前述般地防止驗金屬層的劣化,故相 較於習知技術,可形成更厚的膜。例如,可形成厚度 0.5nm〜100nm的鹼金屬層。藉由形成相當厚度的驗金 屬層,可抑制有機EL元件之性能的不均勻。又,藉由 設置相當厚度之驗金屬層,不但能讓驗金屬層具有作為 電子注入層之功能,亦可具有作為有機EL元件之陰極 的功能。 但是,為了防止具有活性之鹼金屬層與處理容器内 之殘留水分、氮、氧等進行反應,於形成鹼金屬層後, 必須立即以金屬或樹脂或SiN等矽氮氧化膜等保護膜 來保護驗金屬層。 此時,成膜裝置亦可更具備有:第3蒸鍍源,係收 納保護膜用材料,將所收納之保護膜用材料加熱以氣 化;以及第3噴出機構,係内藏於該處理容器並連結至 該第3蒸鍍源,將於該第3蒸鍍源處所氣化之保護膜用 材料朝向該處理容器内的被處理體噴出。 亦可更具備有濺鍍裝置,係内藏於該處理容器,對 保護膜用材料所組成的濺鍍靶進行濺鍍。 亦可具備有載置搬送至該處理容器之被處理體的 載置台,且該載置台能將朝上方或朝下方或朝縱向地載 置之被處理體從該第1喷出機構朝向該第2喷出機構侧 進行滑移。 於該處理容器兩端可具備有滾筒,能藉由捲動該兩 201107502 端之滾筒,使得捲附於該兩端之滾筒的膜從該第1喷出 機構朝向該第2喷出機構侧進行移動。 該處理容器可至少於該第1喷出機構側設置有排 氣裝置。於該第1喷出機構與該第2喷出機構之間亦可 設置有分隔壁。 該第1蒸鍍源可由收納複數種有機材料之複數個 坩堝所形成,該第1喷出機構可由連結至複數個坩堝之 複數個喷出部所形成,將於該複數個坩堝處所氣化之複 〇 數種有機材料,各自從該第1喷出機構所設置之複數個 喷出部處喷出,藉以於被處理體上層積複數種有機材料 以進行有機層之連續成膜。 該驗金屬材料可為鐘、絶、納、钾及伽中任一者。 又,為了解決前述問題,依本發明之其他樣態係提 供一種成膜方法,係將收納於第1蒸鍍源之有機材料加 熱以氣化,將於該第1蒸鍍源處所氣化之有機材料從連 接至該第1蒸鍍源的第1喷出機構噴出至處理容器内, 〇 藉由所喷出之有機材料而於該處理容器内在被處理體 處形成有機層,將收納於第2蒸鍍源之鹼金屬加熱以氣 化,將於該第2蒸鍍源處所氣化之鹼金屬從連接至該第 2蒸鍍源的第2喷出機構喷出至處理容器内,藉由所喷 出之鹼金屬而於該處理容器内在被處理體之有機層上 立即形成金屬層。 此時,該金屬層亦可形成0.5nm〜100nm的厚度。 藉此,該金屬層可發揮作為電子注入層及電極的功能。 7 201107502 氣化3蒸_之保護朗材料加熱以 接至今m减源處所减之保護膜用材料從連 f 4减源的第3喷出機構噴出至處理容哭 =由:噴出之保護膜用材料,於該處理容器内在被處理 體之金屬層上立即形成保護膜。 亦可藉由内$於該處理容器之賤鑛褒置來 斤組成的賤鍍嫌賤鍍,藉由受濺鑛之保護 該處理容器内在被處理體之金屬層上立^ 該金置於該處理容器外之靖置來钱刻 來對保雙膜用好姐精由设置於該處理容器外之崎裝置 鍍之保】膜用材:所:成♦之錢鍍靶進行濺鍍,藉由受機 層上立即形=膜於該處理容器外在被處理體之金屬 該金設置於該處理容器外之1 虫刻裝置來姓刻 來由容器外™置 :於物容器外在被處;體二== 供4有述::有依:發明之其他樣態係提 理體之τ 係3有.有機層,係形成於被處 〜度S金=係:該有機層上形成一 作為電子注入声及中任一者’藉以發揮 曰及免極的功能;保護膜,係形成於該金 201107502 屬層上。 依此,藉由在處理容器内之相同空間連續地形成有 機層與驗金屬層,可防止於驗金屬層與有機層之邊界 處,鹼金屬與處理容器内之殘留水分、氮、氧等進行反 應而劣化。藉此,可製造出能維持較高之電子注入效率 的高性能有機EL元件。 為了解決前述問題,依本發明之其他樣態係提供一 種成膜裝置,具備有:處理容器,係在其内部於被處理 〇 體上施以所期望的處理;第1蒸鍍源,係收納有機材 料,將所收納之有機材料加熱以氣化;第1喷出機構, 係内藏於該處理容器並連結至該第1蒸鍍源,將於該第 1蒸鍍源處所氣化之有機材料朝向該處理容器内的被處 理體喷出;第1濺鍍裝置,係内藏於該處理容器,對鹼 金屬材料所組成的濺鍍靶進行濺鍍;以及第2濺鍍裝 置,係内藏於該處理容器,對保護膜用材料所組成的濺 鑛輕進行滅鍵。 Ο 該處理容器可至少於該第1喷出機構側設置有排 氣裝置。 於該第1喷出機構與該第2喷出機構之間可設置有 分隔壁。 如以上說明,依本發明可防止形成電子注入層之金 屬層的劣化,且可提高該金屬層之電子注入效率。 【實施方式】 201107502 以下,參考添附圖式來詳細說明本發明之各實施形 態。另外,以下說明及添附圖式中,對於具有相同結構 及功能的構成要件係賦予相同符號,並省略重複說明。 又,以下依序進行說明。 〔1〕第1實施形態 〔1-1〕基板處理系統之整體結構 〔1-2〕成膜裝置之内部結構 〔1-3〕第1實施形態之變形例 〔2〕第2實施形態 〔2-1〕成膜裝置之内部結構 〔3〕第3實施形態 〔3-1〕成膜裝置之内部結構 〔3-2〕第3實施形態之變形例 〔4〕第4實施形態 〔1〕第1實施形態 〔1-1〕基板處理系統之整體結構。 首先,參考圖1來說明包含有第1實施形態之成膜 裝置的基板處理系統之整體結構。有機EL元件係於例 如圖1所示之叢集型(cluster)基板處理系統Sys内所製 造。 基板處理系統S y s係將複數個處理容器連結至叢集 側。實際上,基板處理系統Sys具有:加載互鎖裝置 LLM(Load Lock Module)、搬送裝置 TM(Transfer 201107502The discharge mechanism and the second discharge mechanism that ejects the vaporized atoms of the alkali metal. Thereby, after the organic layer is formed, it is not necessary to transport the object to be processed to another processing apparatus, and an alkali metal layer can be formed in the same processing chamber. Thereby, impurities such as moisture, nitrogen, and oxygen can be prevented from adhering to the surface of the organic layer. Thereby, it is possible to prevent the alkali metal layer from reacting with the impurities adhering to the surface of the organic layer to be oxidized, and to form an insulator or the like to deteriorate the film. As a result, the electron injection efficiency can be improved, and a high-performance organic EL 201107502 component can be manufactured. Further, since the deterioration of the metal layer can be prevented as described above, a thicker film can be formed as compared with the prior art. For example, an alkali metal layer having a thickness of 0.5 nm to 100 nm can be formed. By forming a metallographic layer of a considerable thickness, unevenness in performance of the organic EL element can be suppressed. Further, by providing a metal layer having a relatively large thickness, the metal layer can function not only as an electron injecting layer but also as a cathode of the organic EL element. However, in order to prevent the active alkali metal layer from reacting with residual moisture, nitrogen, oxygen, and the like in the processing container, it is necessary to protect the alkali metal layer immediately after the formation of the alkali metal layer with a protective film such as a metal oxide or a NiN oxide film such as SiN. Check the metal layer. In this case, the film forming apparatus may further include: a third vapor deposition source for storing a protective film material, heating the material for the protective film to be vaporized; and a third discharge mechanism built in the treatment The container is connected to the third vapor deposition source, and the material for the protective film vaporized at the third vapor deposition source is discharged toward the object to be processed in the processing container. Further, a sputtering apparatus may be further provided in the processing container to perform sputtering on a sputtering target composed of a material for a protective film. A mounting table that carries the object to be processed that is transported to the processing container may be provided, and the object to be processed that can be placed upward or downward or in the longitudinal direction may be directed from the first discharge mechanism toward the first 2 The side of the discharge mechanism is slipped. A roller may be provided at both ends of the processing container, and the rollers of the two rollers of the 201107502 end may be rolled so that the film of the roller attached to the both ends is directed from the first ejection mechanism toward the second ejection mechanism side. mobile. The processing container may be provided with an exhaust device at least on the side of the first discharge mechanism. A partition wall may be provided between the first discharge mechanism and the second discharge mechanism. The first vapor deposition source may be formed by a plurality of crucibles accommodating a plurality of organic materials, and the first ejecting mechanism may be formed by a plurality of ejecting portions connected to a plurality of crucibles, and vaporized in the plurality of crucible spaces. A plurality of organic materials are rewound, and each of the plurality of organic materials is ejected from the plurality of ejecting portions provided in the first ejecting mechanism, whereby a plurality of organic materials are stacked on the object to be processed to form a continuous film of the organic layer. The metal test material can be any of a clock, a nano, a nano, a potassium, and a gamma. Further, in order to solve the above problems, according to another aspect of the present invention, a film forming method is provided in which an organic material accommodated in a first vapor deposition source is heated to be vaporized, and is vaporized at the first vapor deposition source. The organic material is ejected from the first ejecting mechanism connected to the first vapor deposition source into the processing container, and an organic layer is formed in the processing container in the processing container by the organic material to be ejected, and is stored in the first layer. (2) the alkali metal of the vapor deposition source is heated to be vaporized, and the alkali metal vaporized at the second vapor deposition source is ejected from the second ejection mechanism connected to the second vapor deposition source into the processing container. The alkali metal to be sprayed forms a metal layer on the organic layer of the object to be treated in the processing container immediately. At this time, the metal layer may also have a thickness of 0.5 nm to 100 nm. Thereby, the metal layer functions as an electron injection layer and an electrode. 7 201107502 Gasification 3 steaming _ protection lang material heating to remove the protective film material from the source of the m reduction source so far from the third discharge mechanism of the f 4 reduction source to the treatment capacity cry = by: sprayed protective film The material immediately forms a protective film on the metal layer of the object to be treated in the processing container. The ruthenium plating plate may be formed by the inner 于 于 于 该 该 该 , , , , , , , 该 该 该 该 该 该 该 该 该 该 该 该 该 该 该 该 该 该 该 该 该The processing of the outside of the container of the Jingdian money to engrave the use of the double-film is used by the Suzuki device outside the processing container. The film material: the: ♦ money plating target for sputtering, by accepting Immediately on the machine layer = the film is outside the processing container in the metal of the object to be treated. The gold is placed outside the processing container. The insect is engraved by the outside of the container: it is placed outside the container; Two == For the description of 4:: There are other aspects of the invention: the τ system of the analytic body 3 has an organic layer, which is formed at the location of the degree S gold = system: the organic layer forms an electron Injecting sound and either of them 'acts to play the role of 曰 and exemption; protective film, formed on the layer of the 201107502 genus. Accordingly, by continuously forming the organic layer and the metal layer in the same space in the processing container, it is possible to prevent residual moisture, nitrogen, oxygen, etc. in the alkali metal and the processing container at the boundary between the metal layer and the organic layer. Deteriorated by the reaction. Thereby, a high-performance organic EL device capable of maintaining high electron injection efficiency can be manufactured. In order to solve the above problems, according to another aspect of the present invention, there is provided a film forming apparatus comprising: a processing container in which a desired treatment is applied to a treated body; and a first vapor deposition source is stored The organic material is heated to vaporize the stored organic material, and the first discharge mechanism is embedded in the processing container and connected to the first vapor deposition source, and is organicated at the first vapor deposition source. The material is ejected toward the object to be processed in the processing container; the first sputtering device is embedded in the processing container, and is sputtered with a sputtering target composed of an alkali metal material; and the second sputtering device is internally It is hidden in the processing container, and the splashing of the material for the protective film is lightly extinguished. Ο The processing container may be provided with an exhaust device at least on the side of the first discharge mechanism. A partition wall may be provided between the first discharge mechanism and the second discharge mechanism. As described above, according to the present invention, deterioration of the metal layer forming the electron injecting layer can be prevented, and electron injection efficiency of the metal layer can be improved. [Embodiment] Hereinafter, various embodiments of the present invention will be described in detail with reference to the accompanying drawings. In the following description and the appended drawings, the same reference numerals are given to the constituent elements having the same structures and functions, and the repeated description is omitted. In addition, the following description will be made in order. [1] The first embodiment [1-1] The overall structure of the substrate processing system [1-2] The internal structure of the film forming apparatus [1-3] The modification of the first embodiment [2] The second embodiment [2] -1] Internal structure of film forming apparatus [3] Third embodiment [3-1] Internal structure of film forming apparatus [3-2] Modification of third embodiment [4] Fourth embodiment [1] 1 Embodiment [1-1] Overall structure of a substrate processing system. First, the overall configuration of a substrate processing system including the film forming apparatus of the first embodiment will be described with reference to Fig. 1 . The organic EL device was fabricated in a cluster substrate processing system Sys as shown in Fig. 1. The substrate processing system S y s connects a plurality of processing containers to the cluster side. In fact, the substrate processing system Sys has: load lock device LLM (Load Lock Module), transport device TM (Transfer 201107502

Module)、清潔裝置(前處理室)CM(Cleaning Module)、 成膜裝置PMl(Process Module)、餘刻裝置PM2、 CVD(Chemical Vapor Deposition :化學蒸鍍薄膜成膜法) 裝置PM3及濺鍍裝置PM4。成膜裝置PM1相當於可在 同一個處理容器内連續形成有機層與鹼金屬層的成膜 裝置。 Ο Ο 加載互鎖裝置LLM係可將内部保持於減壓狀態的 真空搬送室,以將從大氣側搬送而來之玻璃基板G(以 下稱作基板G)搬送至減壓狀態之搬送装置TM。搬送裝 置TM於約略中央處設置有能進行屈伸及旋轉的多關節 ,搬送手臂初’使用搬送手臂Απη來將基板〇 從加载互鎖裝置LLM搬送至清潔裝置CM。於基板G 形成作為陽極層的IT0(Indium Tin 〇xide),以清潔裝置 CM來去除附著於其表面的污染物(主要為有機物)、。 圖2係顯示有機EL元件的製程。如圖2⑻所示, 张清潔完畢的基板G搬人_«置PM卜如圖2(b) c成膜裳置藉由蒸錢於基板之ιτο表面連 膜‘置2之有機層2〇。形成有機層後,於同-個成 全2 Ρ 圖2⑷所示,立即藉由紐來形成 層3〇 =金屬層3〇之成膜係使用氣化器。形成金屬 鉋、抵 力函數較低_金屬為佳,特別是鐘、 活性體且:ί铷中任一者為佳。考慮到該等鹼金屬為高 性體且不穩定,特別是在薄臈 均勻性的現象,於太㈣㈣庙兄下難以達成面内 見冢於本實施形態便於成膜裝置pM1 11 201107502 一空間内連續地形成有機層2〇及金 本實施形態會舉出使用鋰作為鹼金屬二、。關於此, 詳述如後。 月况的範例,並 其次,基板G會被支撐於搬送 Arm,並搬送錄崎置刚2。# ^ TM之手臂 所示,會對金屬層30表面進行軟細置如圖2(d) 屬層30表面的不純物去除。然後,義而將附著於金 搬送裝置TM之手臂八加,並搬送至會被支撑於 鍍裝置屬會對銘或銀等保護膜用^置PM4。濺 乾進行雜,讓飛散出的保護膜用=組成的濺鍍 屬層30上。藉此,如圖 <原子層積於金 成有保護膜40。 _2_^心屬層3〇上便形 要讓光從層積膜上部透出产 读+屬层m mu_逯出之匱况’則必須要讓光能 透過屬層因此金屬層3〇需形成薄膜。此時,由 於金屬層30是薄膜,故有時盔 二M此蚪由 軟姓刻。因此,可於金屬/3〇,、身 =^如圖2(d)所示之 屬層表面形成IT0膜般的透 明氧化物膜,便無需進行軟蝕刻。 保龍4G之賴亦可制㈣裝置ρΜ3以取代 賤鑛裝置ΡΜ4。此時,亦可如圖2⑷所示,首先,將金 屬層30表面進行軟蝕刻,以去除附著於金屬層3〇表面 的不純物。然後,將基板G搬送至CVD裝置pm3(jCvd 裝置PM3會由保護臈用材料氣體來激發電衆,藉由所 激發出的電漿於基板G之金屬層上形成保護膜4〇。藉 此,亦可如圖2(e)所示,於金屬層3〇上形成有保護膜 12 201107502 40°另外,只要是將氣體激發以產生電漿,並使用所產 生之電漿對基板G進行成膜的裝置,CVD裝置PM3亦 可為電容耦合型(平行平板)電漿處理裝置、感應耦合塑 (ICP : inductively Coupled Plasma)電漿處理裝置、 ECR(Electron Cyclotron Resonance)、微波電漿處理裝置 等任一者。 (控制器) 控制器 50 具有 ROM50a、RAM50b、CPU50c 及輸 出入I/F(使用者介面)5〇d°R〇M50a、RAM50b收納有 資料或控制程式(例如’用以控制有機層2〇於成膜時之 有機材料的蒸發速度,抑或控制金屬層30於成膜時之 驗金屬的蒸發速度等)。 基板處理系統Sys之各裝置係由控制器5〇加以控 制。具體說明,CPU50C會使用收納於R〇M5〇a、RAM5〇b 的為料或控制程式,而產生用以控制基板處理系統Sys 内之搬送或製程的驅動訊號。輸出入I /F50d會將由 CPU5〇C所產生之驅動訊號輸出給基板處理系統Sys, 亚接收相對應地從基板處理系統Sys所輸出的響應訊號 而傳送給CPU50c。 〔1_2〕成膜裝置之内部結構 其次,參考圖3來詳細說明成膜裝置pM1之 結構。圖3係本實施形態之成膜|置pM1的概略㈣ 13 201107502 面圖。成膜裝置PM1具有處理容器1〇0、作為第i暮梦 源的蒸鍍源200、以及作為第2蒸鍍源的氡化哭3〇^广 處理容器100為直方體,並内藏有可滑動的載置二 110、6個第i喷出機構12Ga〜而、i個第2噴出^ 130、以及分隔壁140與分隔壁150。處理容器 側壁設置有可藉由開啟/關閉來讓基板〇枷 閘閥H祕。 詉入、搬出的 載置台110係猎由從圖中未顯示之高曾柯& Λ ΛΛ上门罨壓電源所施 加的咼電壓,將從閘閥160a搬入之基板Γτ輕& ^ 土丨久VJ静電吸著。 載置台110可在如前述般朝向下方而載置有基板G的狀 態下’於設置於頂面的導軌110a上,從第^喷出機構 120a側朝向第2喷出機構130側滑動。藉此,某板G 便會依第 1 喷出機構 120a、120b、120c、、 120f至第2噴出機構130的順序,貼進且於各噴出口上 空平行移動。 ' 第1喷出機構120a〜120f之形狀及結構完全相 同’且相互平行呈等間隔設置。第【喷出機構12〇a〜12〇f 之内部形成有中空(緩衝空間S)之矩形形狀,而可從其 上部中央所設置的開口將有機材料蒸氣噴出。第1喷出 機構120a〜120f下部經由貫穿處理容器1〇〇底壁的第j 氣體供給管170a〜170f而連接至蒸鍍源2〇〇。 於處理容器100之同一空間中,稍微遠離第丨喷出 機構120f而設置有第2噴出機構13〇。第2噴出機構 130下部經由貫穿處理容器1〇〇底壁之第2氣體供給管 201107502 =連至氣化器則1氣體供給管170a〜17〇f 及供給管18〇各自設置有控制朝處理容哭側搬 达之有機材料或驗金屬材料的供給/切 量的閥V卜V2。 ㈣U及控制抓 ^喷出機構驗〜120f及第2噴出機構13〇的 兩側則設置有區分各噴出機構的分隔壁14〇、15〇。藉 此,可防止從相鄰接之第1噴出機構l2〇a〜120f以^Module), cleaning device (pretreatment chamber) CM (Cleaning Module), film forming device PM1 (Process Module), residual device PM2, CVD (Chemical Vapor Deposition) device PM3 and sputtering device PM4. The film forming apparatus PM1 corresponds to a film forming apparatus which can continuously form an organic layer and an alkali metal layer in the same processing container.加载 加载 The load lock device LLM can transport the glass substrate G (hereinafter referred to as the substrate G) conveyed from the atmosphere side to the transfer device TM in a reduced pressure state by holding the inside of the vacuum transfer chamber in a reduced pressure state. The transporting device TM is provided with a plurality of joints capable of flexing and stretching and rotating at the approximate center, and the transfer arm is initially transported by the transport arm Απη to transport the substrate 〇 from the load interlock device LLM to the cleaning device CM. An IT0 (Indium Tin 〇xide) as an anode layer is formed on the substrate G to clean the device CM to remove contaminants (mainly organic matter) attached to the surface thereof. Fig. 2 is a view showing the process of an organic EL element. As shown in Fig. 2 (8), the cleaned substrate G is moved to a state where the film is placed as shown in Fig. 2(b), and the organic layer 2 is placed on the surface of the substrate by evaporation of money. After the formation of the organic layer, the film formation system of the layer 3 〇 = metal layer 3 立即 is formed by the formation of the same layer as shown in Fig. 2 (4). Forming a metal planer, the resistance function is lower _ metal is preferred, especially the clock, the active body and: ί铷 is preferred. Considering that these alkali metals are highly acidic and unstable, especially in the phenomenon of uniformity of thin enamel, it is difficult to achieve in-plane view under the Tai (4) (4) temple brother. This embodiment facilitates the film forming apparatus pM1 11 201107502 in a space. The organic layer 2 and the gold are continuously formed. This embodiment exemplifies the use of lithium as the alkali metal. In this regard, the details are as follows. An example of the monthly situation, and secondly, the substrate G will be supported by the transport arm and will be transported to the record. As shown in the #^TM arm, the surface of the metal layer 30 is softly placed as shown in Fig. 2(d). Then, the arm attached to the gold transfer device TM is added and transported to the protective device for holding the PM4. The sputter is dried and mixed, and the flying protective film is deposited on the sputtered layer 30 of =. Thereby, as shown in the figure, the atomic layer is laminated on the gold to form the protective film 40. _2_^Heart layer 3 便 便 要 要 要 要 要 要 要 要 要 要 要 要 便 便 便 便 便 便 便 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心 心film. At this time, since the metal layer 30 is a film, sometimes the helmet is inscribed by a soft surname. Therefore, an IOT film-like transparent oxide film can be formed on the surface of the metal layer as shown in Fig. 2(d), and it is not necessary to perform soft etching. The 4G of Baolong can also make (4) the device ρΜ3 to replace the 贱4. At this time, as shown in Fig. 2 (4), first, the surface of the metal layer 30 is soft-etched to remove impurities attached to the surface of the metal layer 3. Then, the substrate G is transported to the CVD apparatus pm3 (the jCvd apparatus PM3 excites the electric power by the protective material gas, and the protective film 4 is formed on the metal layer of the substrate G by the excited plasma. Alternatively, as shown in FIG. 2(e), a protective film 12 may be formed on the metal layer 3, 201107502 40°. Further, as long as the gas is excited to generate a plasma, the substrate G is formed using the generated plasma. The device CVD device PM3 can also be a capacitive coupling type (parallel plate) plasma processing device, an inductively coupled plasma (ICP) plasma processing device, an ECR (Electron Cyclotron Resonance), a microwave plasma processing device, and the like. (Controller) The controller 50 has a ROM 50a, a RAM 50b, a CPU 50c, and an input/output I/F (user interface) 5〇d°R〇M50a, and the RAM 50b stores data or a control program (for example, 'to control the organic layer 2, the evaporation rate of the organic material at the time of film formation, or the evaporation rate of the metal of the metal layer 30 at the time of film formation, etc.) The devices of the substrate processing system Sys are controlled by the controller 5〇. CPU50C will The drive signal for controlling the transfer or process in the substrate processing system Sys is generated by the material or control program stored in the R〇M5〇a, RAM5〇b. The input/output I/F50d will be generated by the CPU5〇C. The driving signal is output to the substrate processing system Sys, and the sub-receiving is transmitted to the CPU 50c correspondingly from the response signal output from the substrate processing system Sys. [1_2] Internal structure of the film forming apparatus Next, the film forming apparatus pM1 will be described in detail with reference to FIG. Fig. 3 is a plan view of the present embodiment. (4) 13 201107502. The film forming apparatus PM1 has a processing container 1〇0, a vapor deposition source 200 as an i-then source, and a second The vaporization source of the vaporization source is a rectangular parallelepiped, and has a slidable mounting member 110, six i-th ejecting mechanisms 12Ga~, i second ejecting units 130, and The partition wall 140 and the partition wall 150. The side wall of the processing container is provided with a substrate gate valve H by opening/closing. The loading and unloading stage 110 is hung by Gao Zengke & not shown in the figure. Λ ΛΛ ΛΛ ΛΛ 罨 罨 电源 电源 电源 电源 电源 电源 电源 电源 电源 电源The substrate Γτ light-loaded by the gate valve 160a is light-sucking. The mounting stage 110 can be placed on the guide rail 110a provided on the top surface in a state where the substrate G is placed downward as described above. The second discharge mechanism 120a side slides toward the second discharge mechanism 130. Thereby, a certain plate G is attached in the order of the first discharge mechanisms 120a, 120b, 120c, and 120f to the second discharge mechanism 130. And moving in parallel above the jet outlets. The first ejection mechanisms 120a to 120f have the same shape and structure, and are disposed at equal intervals in parallel with each other. The inside of the ejection mechanism 12〇a to 12〇f has a rectangular shape in which a hollow (buffer space S) is formed, and the organic material vapor can be ejected from an opening provided at the center of the upper portion thereof. The lower portions of the first discharge mechanisms 120a to 120f are connected to the vapor deposition source 2A via the jth gas supply pipes 170a to 170f penetrating the bottom wall of the processing vessel 1 . In the same space of the processing container 100, the second ejection mechanism 13A is provided slightly away from the second ejection mechanism 120f. The lower portion of the second discharge mechanism 130 is connected to the second gas supply pipe 201107502 through the bottom wall of the processing container 1 = the gas supply pipe 170a to 17〇f and the supply pipe 18 are connected to the gasifier. The valve V V2 of the supply/cutting amount of the organic material or the metal material of the metal material. (4) U and control grips The discharge walls 14 120 and the second discharge mechanism 13 are provided with partition walls 14 〇 and 15 区分 for distinguishing the respective discharge mechanisms. By this, it is possible to prevent the first ejection mechanism l2a to 120f from being adjacent to each other.

St?構130之喷出口所喷出的各種有機材料及鹼 金屬材料相互混合。 處理容器於第i喷出機構咖側設置有排氣 口 i9〇a。驅動連接至排氣口 190a的排氣裝置195a 第1噴出機構12〇a〜12〇f所噴出之有機材料的 歹欠召物從排氣口 19〇a排出至處理容器外。又,户 ❹ 器1〇〇於第2嘴出機構130侧設置有排氣口 動連接至排氣口 DOb的排氣裝置195b時,便可將第2 喷出機構13G所喷出之驗金屬材料蒸氣的殘留原子從 排氣口 190b排出至處理容器外。特別是,藉由蒸鍍所 進行的成财’氣輯子會飛至處理容^ 到達基板賴。喊是㈣著於基= 體原子、亦可成會從基板G脫離而再次飛至處理容丄 内。如前述,藉由蒸鍍所進行之成膜中,氣化原子會有 於處理容器内擴散至相當廣範圍的傾向。 因此,藉由從第1喷出機構120a側將殘留之有機 材料蒸氣排出,可抑制有機材料蒸氣飛至第2喷出機構 15 201107502The various organic materials and alkali metal materials ejected from the discharge port of the St. structure 130 are mixed with each other. The processing container is provided with an exhaust port i9〇a on the side of the i-th discharge mechanism. The exhaust device 195a that is connected to the exhaust port 190a is driven to discharge from the exhaust port 19〇a to the outside of the processing container by the first discharge mechanism 12〇a to 12〇f. Further, when the household appliance 1 is provided with the exhaust device 195b whose exhaust port is movably connected to the exhaust port DOb on the side of the second nozzle opening mechanism 130, the metal sprayed from the second discharge mechanism 13G can be detected. The residual atoms of the material vapor are discharged from the exhaust port 190b to the outside of the processing vessel. In particular, the Chengcai's gas piece by vapor deposition will fly to the processing capacity to reach the substrate. Shouting is that (4) at the base = body atom, it can also be detached from the substrate G and fly again into the processing volume. As described above, in the film formation by vapor deposition, the vaporized atoms tend to diffuse into a wide range in the processing container. Therefore, by discharging the residual organic material vapor from the first discharge mechanism 120a side, it is possible to suppress the organic material vapor from flying to the second discharge mechanism 15 201107502

130側而混入金屬層3〇的可能。又,藉 機構W侧將殘留之轉出,可抑制鐘飛至第= 構120a〜120f側而混人有機層2()的可能。有機層^ 之成膜中,僅驅動排氣裝置195a,以使得殘留有機 蒸氣不會飛至第2嘴出機構請側,而於金屬層3〇之 成膜中,則伽動排氣裝置195b,以使得殘留鐘不合 飛至第i喷出機構丨施叫避側。成膜中,藉由驅ς 各排氣裝置195a、195b來讓處理容維持在ι〇2 〜l(T3Pa左右的減壓狀態。 蒸鍍源200内藏有形狀及結構皆相同的6個掛禍 2H)a〜冨。各㈣驗〜麗各自於内部收納有相異 的有機材料A〜F。各自收納著有機材料A〜F之容器 底面則各自埋設有加熱器2施〜22Qf。各自將加熱器It is possible to mix the metal layer 3〇 on the 130 side. Further, by transferring the remaining portion by the W side of the mechanism, it is possible to suppress the possibility that the organic layer 2 () is mixed with the side of the first structure 120a to 120f. In the film formation of the organic layer, only the exhaust device 195a is driven so that the residual organic vapor does not fly to the request side of the second nozzle-out mechanism, but in the film formation of the metal layer 3, the exhaust device 195b is spurred. So that the residual clock does not fly to the i-th discharge mechanism. In the film formation, the discharge capacity is maintained at ι〇2 to 1 (the pressure reduction state of about T3Pa by driving each of the exhaust devices 195a and 195b. The vapor deposition source 200 has six hooks having the same shape and structure. Disaster 2H) a ~ 冨. Each (four) inspection ~ Li each contains different organic materials A ~ F inside. The bottoms of the containers in which the organic materials A to F are accommodated are each embedded with a heater 2 to 22Qf. Each heater

22〇a〜22Gf加熱’使得㈣21Ga〜21Gf達到2GG〜50(TC 左右的高溫’藉以控制有機材料A〜F的氣化速度。另 外,所謂之氣化並不只是指液體變成氣體的現象,亦包22〇a~22Gf heating 'make (4) 21Ga~21Gf reach 2GG~50 (high temperature around TC' to control the gasification speed of organic materials A~F. In addition, the so-called gasification does not only mean the phenomenon that liquid becomes gas, but also package

含有固體不經由液體狀態而直接變成氣體的現象(即, 昇華)。 坩堝210a〜21〇f設置有供給氬氣Ar的氣體管線。 從氣體管線供給至㈣而内的氬氣能將於各掛塌 21〇a〜21〇f處所氣化之有機材料蒸氣Λ〜F經由第1氣 體供給官170a〜17〇f而搬送至第1喷出機構12〇a〜 12〇f’再從第1嘴出機構120a〜120f之喷出口喷出至處 理容器1〇0内部。蒸鍍源200設置有排氣口 230。藉由 16 201107502 内部維持於所期望之 驅動排氣裝置240可讓處理容器 真空度。 流通有氬氣及有機材料蒸氣之第 170a〜l70f亦與坩堝相同地被調節至i、、、、e管 度。藉此’藉由氬氣來搬送有機材料蒸氣時,可 液化而附著於第丨氣體供给管ma〜⑽等處止其 可提南有機層20成膜時的材料效率。 精此,A phenomenon in which a solid directly becomes a gas without passing through a liquid state (ie, sublimation).坩埚210a to 21〇f are provided with a gas line for supplying argon Ar. The organic material vapor Λ~F which is supplied from the gas line to the (4) and can be vaporized at each of the collapses 21〇a to 21〇f is transported to the first through the first gas supply officers 170a to 17〇f. The discharge mechanisms 12A1 to 12〇f' are ejected from the discharge ports of the first nozzles 120a to 120f to the inside of the processing container 1A. The vapor deposition source 200 is provided with an exhaust port 230. The container can be vacuumed by 16 201107502 internally maintained at the desired drive vent 240. The 170a to l70f in which the argon gas and the organic material vapor are circulated are also adjusted to the i, , and e tubes in the same manner as the crucible. When the organic material vapor is transported by argon gas, it can be liquefied and adhered to the second gas supply tubes ma to (10) or the like to prevent the material efficiency of the organic layer 20 from forming. Fine,

處理容1 100夕卜部設置有將鐘加熱 裔300。氣化器㈣設置討收納 發容器如。蒸發容器Dsl連接有電源Ds2。電 會根據從控㈣50所輸出的_訊號來施加所期 ,壓’讓特定電流流通至蒸發容器Ds卜藉此,蒸發容 器Dsl會文加熱而保持於所期望的溫度。如此,便 整收納於蒸發容器Dsl之_蒸發量。另外,收納於^ 發谷器Dsl的材料只要是功函數較低之驗金屬材料,亦 可為链、納、卸、錄j、絶等任一者。 氣化器300係經由可調整開啟程度之閥V3而連結 至^空泵31G。根據從控制器5G所輸出之驅動訊號來 凋節閥V3的開啟程度,藉以將氣化器3〇〇内部控制於 所期望的真空壓力。 又,氣化器300係經由調整氣體流量之質量流量控 制器MFC及閥V4而連結至氬氣供給源320。根據從控 制器50所輸出之驅動訊號來控制質量流量控制器MFC 及閥V4,藉以調節氬氣之供給/切斷、以及流量。 17 201107502 藉此’於氣化器3〇〇内所蒸發之鐘會以供給至氣化 器3〇〇内部之較量的氬氣料健氣體,通過第 體供給管⑽而搬送至第2噴出機構m,並從喷出口 喷出至處理容器内。另夕卜,作為從第2噴出機構130噴 出驗金屬的機器,並不限於前述之氣化器·,亦可使 用將鹼金屬單體直接蒸發而噴出的機構。The handling capacity 1 100 is set to have a bell heating 300. The gasifier (4) is set up to store the container. The evaporation container Ds1 is connected to the power source Ds2. The electricity is applied according to the _ signal output from the control (4) 50, and the voltage is caused to flow to the evaporation container Ds, whereby the evaporation container Ds1 is heated to maintain the desired temperature. Thus, the amount of evaporation stored in the evaporation container Ds1 is completed. Further, the material accommodated in the swarf device Ds1 may be any one of a metallurgical material having a low work function, and may be a chain, a nano, a unloading, a recording j, or a singular. The gasifier 300 is coupled to the air pump 31G via a valve V3 whose opening degree can be adjusted. The inside of the gasifier 3 is controlled to a desired vacuum pressure based on the degree of opening of the purge valve V3 based on the drive signal output from the controller 5G. Further, the vaporizer 300 is coupled to the argon supply source 320 via a mass flow controller MFC and a valve V4 that adjust the gas flow rate. The mass flow controller MFC and the valve V4 are controlled based on the drive signal output from the controller 50 to adjust the supply/disconnection of argon gas and the flow rate. 17 201107502 The clock that is evaporated in the gasifier 3 is transported to the second discharge mechanism through the first supply pipe (10) by the amount of argon gas supplied to the inside of the gasifier 3〇〇. m, and ejected from the discharge port into the processing container. Further, the apparatus for ejecting the metal from the second ejecting mechanism 130 is not limited to the above-described vaporizer, and a mechanism for evaporating the alkali metal monomer and ejecting it may be used.

將抓通有氬氣及鐘的第2氣體供給管18〇及氣 300調節至細。C以上的溫度。藉此,可控義之蒸發 速度,同時能防止在藉由氬氣來搬送經時,液化而附著 於第2氣體供給管⑽等處。藉此,可提高金屬層30 成膜時的材料效率。 另外’為了形成金屬層3〇,亦可使用為了形成有 機層20所使用的掛堝之相同結構的蒸鑛源以取代氣化 器300,亦可為電阻加熱板等加熱器。 依以上說明之成膜裝置PM1,、:r藉由從第丨喷出機 構120a〜120f所育出之有機材料蒸氣來形成有機層The second gas supply pipe 18 and the gas 300 having the argon gas and the bell are grasped to be fine. Temperature above C. Thereby, the evaporating speed can be controlled, and at the same time, it is prevented from being liquefied and adhered to the second gas supply pipe (10) or the like when it is transported by argon gas. Thereby, the material efficiency at the time of film formation of the metal layer 30 can be improved. Further, in order to form the metal layer 3, a vapor source of the same structure for forming the hook layer used in the organic layer 20 may be used instead of the vaporizer 300, or a heater such as a resistance heating plate may be used. The film forming apparatus PM1,, r, as described above, forms an organic layer by the organic material vapor bred from the second squirting mechanisms 120a to 120f.

20 ’然後,藉由從第2噴出機構13〇所喷出之鐘來連續 地形成金屬層30。 具體說明’從第1嘴出機構12〇a〜丽所喷出之 有機材料蒸氣中’首先,從第1噴出機構⑽所喷出 之有機材料蒸氣會畴在於噴出機構〗施上方以固定 速度前進的基板G上之ITO(陽極),如圖4所示,藉由 將從第1喷出機構120a所噴出之有機材料蒸氣A堆積 於基板G’以於基板上形成第丨層之電職人層。接著, 18 201107502 當基板G依序從第1喷出機構12〇b移動至第i喷出機 構120f時,從第1噴出機構12〇b〜12〇f所喷出之有機 材料蒸氣B〜F會各自堆積於基板G,藉此依序形成有 機層(第2層〜第6層)。最後,藉由將從第2喷出機構 130所喷出之鋰堆積於基板G,便會形成金屬層3〇。 如此,藉由於同一個處理裝置内連續地形成有機層 20及金屬層30,便可防止有機層2〇及金屬層3〇的劣 化。關於此點具體進行說明。由於鋰或鉋等鹼金屬之功 函數較小,故適合作為形成有機£[元件之電子注入層 的材料。但是,另一方面,由於鹼金屬為高活性體,即 使在高真空狀態之處理室内亦容易會與殘留於室内的 水分、氮、氧專相互反應。因此,當作為金屬層3〇之 基底層的有機層20表面存在有前述不純物之狀態下, 而於其上方形成金屬層30時,於有機層2〇與金屬層 30之邊界處所形成之鹼金屬會與附著於有機層的不純 物相互反應,而形成例如氧化鋰(Li 〇)^緣物等 金屬層30產生劣化。因此,習知技上二二 鹼金屬會變化成絕緣物,而採用了形成非常薄之鋰膜的 方法。但是,即便如此,形成非常薄之鐘膜時,仍會留 下膜之面内均勻性惡化、有機EL元件之性能不均^等 問題。 、 對此,本實施形態之成膜裝置PM1中,於有機層 20之成膜後m在金屬層3G之成膜前將基板搬^ 至其他處理室。因此,不純物附著於有機層上的機率會 19 201107502 义的非¥低。因此’在同_個處理容器内,於有機層上 立即形成之金屬層3〇 ’於有機層2()之邊面處與不純物 相„而形成絕緣物的機率亦變的非常低。其結果, :提同金屬層30之電子注人效率,可提高有機層2〇之 光電轉換效率。 又’依本實施形態之成膜裝置PM1,如前述般,由 於金屬層30於有機層2G之邊界處與不純物相互反應而 形成絕緣物的機率非常低,故不會使電子注人效率降低 ,可形成U知技術更厚的驗金屬膜。因此,依本成膜 哀置PM1 ’可形成例如〇 5nm〜i〇〇nm厚度的金屬層 t而達到成膜製程所能進行管理賴厚。藉由形成相 當厚度的金屬層3G,能改善金屬層3G之面内均勻性, 可抑制有機EL元件之性能的不均勻。 再者,藉由形成相當厚度的金屬層3〇,可達成習 知技術中因膜厚過薄而不可能達成之電子注入層的電 極化。即,依本實施形態之成膜裝置,藉由形成例如 5〇mn〜l〇〇nm左右厚度之金屬層3〇,能讓金屬層刈發 揮作為電子注入層及電極(陰極)的功能。又,藉由形成 相當厚度之金屬層30,對於後工程之保護膜濺鍍,能 以金屬層30來吸收其損傷,可減低因濺鍍對有機層2〇 造成的損傷。 於金屬層30成膜後,將基板G搬送至圖1之钱刻 裝置PM2 ’對容易反應之鋰金屬層30進行軟蚀刻以清 潔其表面(參考圖2(d))。然後’立即搬送至賤鑛裝置 20 201107502 PM4 ’讓氬氣離子掊 材,以撞出騎原^至由㉟A1或銀Ag所形成之濺鑛 於金屬層30 ~。撞出後的麟原子Ag會堆積20' Then, the metal layer 30 is continuously formed by the clock ejected from the second ejection mechanism 13A. Specifically, 'from the organic material vapor ejected from the first nozzle-out mechanism 12〇a to 丽', first, the organic material vapor ejected from the first ejecting mechanism (10) will advance at a fixed speed above the ejection mechanism. As shown in FIG. 4, the ITO (anode) on the substrate G is deposited on the substrate G' by the organic material vapor A discharged from the first discharge mechanism 120a to form a second layer of the electric layer. . Next, 18 201107502 When the substrate G is sequentially moved from the first discharge mechanism 12〇b to the i-th discharge mechanism 120f, the organic material vapors B to F discharged from the first discharge mechanisms 12〇b to 12〇f Each of them is deposited on the substrate G, whereby an organic layer (the second layer to the sixth layer) is sequentially formed. Finally, by depositing lithium ejected from the second ejecting mechanism 130 on the substrate G, the metal layer 3 is formed. Thus, deterioration of the organic layer 2 and the metal layer 3 can be prevented by continuously forming the organic layer 20 and the metal layer 30 in the same processing apparatus. This point will be specifically described. Since an alkali metal such as lithium or a planer has a small work function, it is suitable as a material for forming an organic injection layer of an element. On the other hand, on the other hand, since the alkali metal is a highly active substance, it is easy to react with moisture, nitrogen, and oxygen remaining in the room even in a treatment chamber in a high vacuum state. Therefore, when the metal layer 30 is formed on the surface of the organic layer 20 which is the base layer of the metal layer 3, and the metal layer 30 is formed thereon, the alkali metal formed at the boundary between the organic layer 2 and the metal layer 30 is formed. The metal layer 30 such as lithium oxide (Li 〇) is formed to be deteriorated by reacting with the impurities adhering to the organic layer. Therefore, it is conventionally known that the alkali metal changes into an insulator, and a method of forming a very thin lithium film is employed. However, even when a very thin film is formed, the in-plane uniformity of the film is deteriorated, and the performance of the organic EL element is uneven. On the other hand, in the film forming apparatus PM1 of the present embodiment, after the film formation of the organic layer 20, the substrate is transferred to the other processing chamber before the formation of the metal layer 3G. Therefore, the probability of impure attachment to the organic layer will be lower than that of 2011-07502. Therefore, in the same processing container, the probability of forming an insulator with the metal layer 3〇 immediately formed on the organic layer at the edge of the organic layer 2() becomes very low. , the electron injection efficiency of the metal layer 30 can be improved, and the photoelectric conversion efficiency of the organic layer can be improved. Further, the film formation apparatus PM1 according to the embodiment has the metal layer 30 at the boundary of the organic layer 2G as described above. The probability of reacting with impurities to form an insulator is very low, so that the efficiency of electron injection is not lowered, and a metal film having a thicker U-known technique can be formed. Therefore, depending on the film formation, PM1' can be formed, for example, The metal layer t having a thickness of 5 nm to ii nm can be managed to a thickness of the film formation process. By forming a metal layer 3G having a considerable thickness, the in-plane uniformity of the metal layer 3G can be improved, and the organic EL element can be suppressed. Further, by forming a metal layer 3 of a considerable thickness, it is possible to achieve electrodeposition of an electron injecting layer which is impossible to achieve due to an excessively thin film thickness in the prior art. Membrane device, by formation For example, a metal layer having a thickness of about 5 〇 mn to about 1 〇〇 nm allows the metal layer to function as an electron injection layer and an electrode (cathode). Further, by forming a metal layer 30 of a considerable thickness, for post engineering The protective film is sputtered, and the damage can be absorbed by the metal layer 30, and the damage caused by the sputtering on the organic layer 2 can be reduced. After the metal layer 30 is formed, the substrate G is transferred to the PM2 of FIG. 'The easy-to-react lithium metal layer 30 is soft etched to clean its surface (refer to Figure 2(d)). Then 'immediately transferred to the antimony device 20 201107502 PM4 'Let the argon ion coffin to knock out the rider ^ The splash formed by 35A1 or silver Ag is deposited on the metal layer 30 ~. After the collision, the argon atom Ag will accumulate.

40。保護膜40可^^ ’會如圖咖所示般形成保護膜 要讓光從層積活性化體之金屬層3G的氧化° 透過金屬層30,部透出之情況’則必須要讓光能 於金屬層30是薄腺此金屬層30需形成薄膜。此時,由 蝕刻。因此,可於么’有時無法進行如圖2(d)所示之軟 氧化物膜,便無^屬層3G表面形成IT〇膜般的透明 -订軟姓刻。40. The protective film 40 can form a protective film as shown in Fig. 3, so that light can be transmitted from the oxidized metal layer 3G of the laminated active material through the metal layer 30, and the portion must be allowed to pass light. The metal layer 30 is a thin gland. The metal layer 30 needs to form a thin film. At this time, it is etched. Therefore, it is possible to perform a soft oxide film as shown in Fig. 2(d), and it is possible to form an IT film like a transparent film on the surface of the layer 3G.

另外’保護膜40 Q 之金屬層30的材是能保魏金屬(高活性化體) 但是,將樹脂應用於侔^使用銀或㈣外的樹脂等。 点胺:ft成膜的方法’故需使用藉由蒸鍍或CVD來 攻媒的方法。 只2 ΙΤ^]放出光之有機EL元件的情況,則使用光 、率較高之銀或!s來作為保護膜4()者較佳。又,保 膜4〇過薄則會使光透過,故為了從ITCM則放出光, 呆遵膜40需具有相當厚度。又,此時,保護膜4〇無法 使用不會反射光的樹脂。 另一方面,從ITO側之相反側(保護膜侧)讓光透出 之有機EL元件的情況,為使光能輕易穿透,使用銀或 鋁之薄膜來作為保護膜40者較佳。又,此時,只要是 不易吸收光’且能㈣讓光穿透的樹脂,亦可適用於保 護膜40。 21 201107502 再者,藉由讓鋰等金屬層30與鋁或銀等保護膜4〇 之間的厚度比例達最佳化,可相對於金屬層3〇及保護 膜40而讓光的穿透率或光之反射率達最佳化。 如以上說明,依本實施形態之成膜裝置pM1,藉由 將從第1噴出機構120a〜120f所噴出之有機材料的材 料蒸氣堆積於基板G以形成有機層20,隨後立即於同 一空間内,藉由將從第2喷出機構13〇所喷出之鹼金屬 氣化原子堆積於基板G以形成金屬層3〇。藉此,於有 機層20成膜後,無需將基板G搬送至其他處理裝置,❹ 便可於同一個處理室内形成金屬層3〇。藉此,可避免 有機層20表面吸附水分、氮、氧等不純物,故可防止 金屬層30與附著於有機層20表面之不純物相互反應而 氧化、絕緣物化而造成膜的劣化。其結果,可製造出電 子注入效率較高、具高性能的有機EL元件。 又,由於可如前述般地防止金屬層3〇之劣化,故 相較於習知技術’可形成較厚之金屬層3〇。例如,可 形成0.5nm〜l〇〇nm厚度的金屬層30。藉由設置具相當 ◎ 厚度之金屬層30 ’可讓金屬層30不只具有作為電子注 入層的功能’亦具有作為有機EL元件之陰極的功能。 又,可抑制有機EL元件之性能的不均勻。 〔1-3〕第1實施形態之變形例 參考圖5來說明第1實施形態之成膜裝置PM1的 變形例。第1實施形態之成膜裝置PM1係將基板G朝 22 201107502 向下方的方式進行成膜。 相對於此,第1實施形態之變形例之成膜裝置卩]^! 中,載置台110係如圖5所示地設置於處理容器1〇〇底 面。載置台110會以朝向上方之狀態來載置從閘閥160a 所搬入的基板G。另外,只要可進行氣體輸送成膜,成 膜基材不只是可朝向上方(face up),亦可朝向下方(face down)或為縱向(side)。載置台n〇可於設置於處理容器 底面的導執11〇a上,從第1喷出機構120a側朝向第2 喷出機構130侧滑動。藉此,基板G便會依第丨喷出機 構 120a、120b、120c、120d、120e、120f 至第 2 噴出機 構130的順序,貼進且於各喷出口下方平行移動。其結 果,與第1實施形態相同,可於同一個處理容器1〇〇内 部連續形成有機層20及金屬層30。 依此,能在朝向上方而載置有基板G的狀態下進行 成膜處理。藉此,即使於大型基板之情況,亦不會讓基 板G產生翹曲而可輕易進行搬送。又,可提高基板上所 〇 形成之膜的面内均勻性。 〔2〕苐2實施形態 其次,參考圖6來說明第2實施形態之成膜裝置。 另外,第2實施形態之基板處理系統Sys與第丨實施形 態相同,有機EL元件係於圖丨所示叢集型基板處理系 統Sys内所製造。 23 201107502 〔2-1〕成膜裝置之内部結構 本實施形態之成膜裝置PM1係於處理容器1〇〇内 部連續地進行有機層20之蒸鍍、金屬層30之蒸鍍、以 及保護膜40之成膜等處理。因此,本實施形態之成膜 裝置PM1中’除了第1實施形態之成膜裝置pMi之中, 用以蒸鍍有機層20而設置的蒸鍍源2〇〇(第1蒸鍍源) 及第1喷出機構120a〜120f、用以蒸鍍金屬層30而設 置的氣化器300(第2蒸鍍源)及第2喷出機構130之外, 如以下說明般而於處理容器内部亦設置有濺鍍裝置❹ 400。 * 濺鍍裝置400係於處理容器100内部鄰近第2喷出 機構130而設置。如同在第1喷出機構12〇a〜12〇f與 第2喷出機構130之間設置有分隔壁140、150,同樣 地於第2噴出機構13〇與濺鍍裝置4〇〇之間亦設置有分 隔壁410。 濺鍍裝置400能將氬氣激發以產生電漿,藉由氬離 子來對銀之濺鍍靶進行濺鍍以將銀原子撞出。撞出後的 銀會堆積於基板上,藉以形成保護膜40。 具體說明,濺鍍裝置400具有濺鍍靶材42〇a與 42〇b、背板(Backing Piate)43〇a與4通、濺鍍靶保持^ 440a與440b、磁場產生機構45〇a與45%、以及氣 氣頭460。 & 一成對之濺鍍靶材420a、42〇b係平行於濺鍍面般 地對向設置。賤鑛乾材42〇a、4篇係用作保護膜用 24 201107502 料=電阻較低、光反射率較高的銀祕者為佳 形悲中,濺鍍靶材420a、420b係銀所形成。 只也 一成對之濺鍍靶材420a、420b係經由背板43如、 43〇b而_於_⑽持台44()a、暢。磁場^ 構條、450b於本實施形態中為磁石,於各賤鑛^ 420a、42Gb背面處,濺鍍乾材伽設置s極磁石 鍍4鳥則设置n極磁石。藉此,於錢鍵乾材dFurther, the material of the metal layer 30 of the protective film 40 Q is a fermentable metal (highly activated body). However, the resin is applied to a resin other than silver or (iv). Point amine: ft film formation method] Therefore, a method of attacking by vapor deposition or CVD is required. In the case where only the organic EL element of the light is emitted, it is preferable to use silver or ?s having a high light transmittance as the protective film 4 (). Further, since the film is too thin to transmit light, in order to emit light from the ITCM, the film 40 needs to have a considerable thickness. Further, at this time, the protective film 4 〇 cannot use a resin that does not reflect light. On the other hand, in the case of the organic EL element which allows light to pass through from the opposite side (protective film side) of the ITO side, it is preferable to use a film of silver or aluminum as the protective film 40 in order to easily penetrate light. Further, in this case, it is also applicable to the protective film 40 as long as it is a resin which does not easily absorb light 'and can (4) penetrate light. 21 201107502 Further, by optimizing the thickness ratio between the metal layer 30 such as lithium and the protective film 4 such as aluminum or silver, the light transmittance can be made with respect to the metal layer 3 and the protective film 40. Or the reflectance of light is optimized. As described above, in the film forming apparatus pM1 of the present embodiment, the material vapor of the organic material discharged from the first discharge mechanisms 120a to 120f is deposited on the substrate G to form the organic layer 20, and then immediately in the same space. The metal layer 3 is formed by depositing alkali metal vaporized atoms ejected from the second discharge mechanism 13A on the substrate G. Thereby, after the organic layer 20 is formed, it is not necessary to transport the substrate G to another processing apparatus, so that the metal layer 3 can be formed in the same processing chamber. Thereby, impurities such as moisture, nitrogen, and oxygen can be prevented from adsorbing on the surface of the organic layer 20, so that the metal layer 30 and the impurities adhering to the surface of the organic layer 20 can be prevented from reacting with each other to be oxidized or insulative to cause deterioration of the film. As a result, an organic EL device having high electron injection efficiency and high performance can be manufactured. Further, since the deterioration of the metal layer 3 can be prevented as described above, a thick metal layer 3 can be formed as compared with the prior art. For example, the metal layer 30 having a thickness of 0.5 nm to 1 〇〇 nm can be formed. By providing the metal layer 30' having a thickness of ◎, the metal layer 30 can have a function not only as an electron injecting layer but also as a cathode of the organic EL element. Further, unevenness in performance of the organic EL element can be suppressed. [1-3] Modification of the first embodiment A modification of the film formation apparatus PM1 of the first embodiment will be described with reference to Fig. 5 . In the film forming apparatus PM1 of the first embodiment, the substrate G is formed to face the film 22 201107502 downward. On the other hand, in the film forming apparatus according to the modification of the first embodiment, the mounting table 110 is provided on the bottom surface of the processing container 1 as shown in Fig. 5 . The mounting table 110 places the substrate G carried in from the gate valve 160a in a state of being placed upward. Further, as long as gas transport can be formed into a film, the film formation substrate can be faced not only face up but also face down or side. The mounting table n is slidable from the first discharge mechanism 120a side toward the second discharge mechanism 130 side on the guide 11A provided on the bottom surface of the processing container. Thereby, the substrate G is attached in the order of the second ejection mechanism 120a, 120b, 120c, 120d, 120e, and 120f to the second ejection mechanism 130, and is moved in parallel below each ejection outlet. As a result, in the same manner as in the first embodiment, the organic layer 20 and the metal layer 30 can be continuously formed inside the same processing vessel 1 . According to this, the film formation process can be performed in a state where the substrate G is placed on the upper side. Thereby, even in the case of a large substrate, the substrate G is not warped and can be easily transported. Further, the in-plane uniformity of the film formed on the substrate can be improved. [2] 苐 2 Embodiment Next, a film formation apparatus according to a second embodiment will be described with reference to Fig. 6 . Further, the substrate processing system Sys of the second embodiment is the same as the third embodiment, and the organic EL element is manufactured in the cluster substrate processing system Sys shown in Fig. 。. 23 201107502 [2-1] Internal structure of film forming apparatus The film forming apparatus PM1 of the present embodiment continuously vapor-deposits the organic layer 20, vapor-deposits the metal layer 30, and the protective film 40 in the inside of the processing container 1A. Processing such as film formation. Therefore, in the film forming apparatus PM1 of the present embodiment, in addition to the film forming apparatus pMi of the first embodiment, a vapor deposition source 2 (first vapor deposition source) and a vapor deposition source provided in the organic layer 20 are deposited. The discharge means 120a to 120f, the vaporizer 300 (second vapor deposition source) and the second discharge mechanism 130 which are provided by vapor-depositing the metal layer 30 are provided in the processing container as described below. There is a sputtering device ❹ 400. * The sputtering apparatus 400 is disposed inside the processing container 100 adjacent to the second ejection mechanism 130. The partition walls 140 and 150 are provided between the first discharge mechanisms 12a and 12f and the second discharge mechanism 130, and similarly between the second discharge mechanism 13A and the sputtering device 4〇〇. A partition wall 410 is provided. The sputtering apparatus 400 is capable of exciting argon gas to generate a plasma, and sputtering a silver sputtering target by argon ions to knock out silver atoms. The silver that has been knocked out is deposited on the substrate to form the protective film 40. Specifically, the sputtering apparatus 400 has sputtering targets 42A and 42B, backing electrodes 43A and 4, sputtering target holders 440a and 440b, and magnetic field generating mechanisms 45A and 45. %, and the gas head 460. & A pair of sputter targets 420a, 42〇b are disposed opposite each other in parallel with the sputter surface. 42〇a and 4 parts of dry ore are used as protective film. 24 201107502 Material=Silver secrets with low resistance and high light reflectivity are good shape, and sputtering targets 420a and 420b are formed by silver. . Only a pair of sputtering targets 420a, 420b are via the backing plate 43, for example, 43〇b, and the _(10) holding table 44()a is smooth. The magnetic field ^ slab, 450b is a magnet in this embodiment, and is placed on the back surface of each bismuth ore 420a, 42Gb, and sputter dry material is provided to form an s-pole magnet. 4 birds are provided with an n-pole magnet. In this way, Yu Qianjian dry material d

Ο Πί對向空間中,會包圍該空間般地產生與各濺錄 乾材420a、420b垂直的磁場。 從氬氣供給源320所輸出的氬氣會從淋氣頭46〇供 給至處理容㈣。氬氣之供給/切斷、以及流量係根據 從控制H 50所輪出的轉訊號,藉由控㈣量流量押 制器MFC及閥V5之方式來加以調節。 卫 直流電源470係以各濺鍍靶材42〇a、42〇b作為陰 極且以者板430b作為陽極,根據從圖1所示之^制 器50所輸出的驅動訊號來施加所期望的直流電壓(ο。 定額電功率)。藉此,於濺鍍靶材420a、420b之對向空 間處形成電漿。電功率的種類不限定為DC定額電功 率’亦可為AC電功率、rf電功率、娜電功率、脈衝 DC電功率等,亦可為改等之重疊電功率。另外,直流 電源470為供給所期望能量至處理容器1〇〇内部的能量 源的一範例。 濺鑛裝置400附近設置有連接至排氣口 48〇及排氣 480的排氣裝置490,藉由驅動排氣裝置49〇 ,將處 25 201107502 理谷之濺職原子排出至 此處,說明有關處理容器⑽ 器100之内部壓力會對各 内二^力。處理容 如,有機層2〇及金屬層大的影響。例 :嬌:的膜’成膜時之環境會對膜“:二:二層: 如,在處理容器内壓力較高而於處理In the opposite space, a magnetic field perpendicular to each of the splattered dry materials 420a, 420b is generated so as to surround the space. The argon gas output from the argon supply source 320 is supplied from the air shower head 46 to the processing volume (4). The supply/disconnection of argon gas and the flow rate are adjusted by controlling the (four) flow rate damper MFC and the valve V5 based on the number of the relay that is rotated from the control H 50 . The DC power source 470 applies the sputtering target 42a, 42b as the cathode and the board 430b as the anode, and applies the desired DC according to the driving signal outputted from the controller 50 shown in FIG. Voltage (ο. rated electric power). Thereby, plasma is formed at the opposing spaces of the sputtering targets 420a, 420b. The type of electric power is not limited to the DC rated electric power ‘, and may be AC electric power, rf electric power, nava electric power, pulsed DC electric power, etc., and may be a superimposed electric power. In addition, the DC power source 470 is an example of supplying the desired energy to the energy source inside the processing container 1〇〇. An exhaust device 490 connected to the exhaust port 48A and the exhaust gas 480 is disposed in the vicinity of the sputtering device 400, and by driving the exhaust device 49〇, the atomic atom of the 25 201107502 The internal pressure of the vessel (10) 100 will force each. The handling capacity is such that the organic layer 2 has a large influence on the metal layer. Example: Jiao: The film's environment at the time of film formation will be "film:" two: two layers: eg, the pressure in the processing container is higher and the treatment

不純物的狀態下,有機層2G膜會與水分等相互反應了 而於膜中產生暗點(dark SPGt)等造成光電轉換效^亞 化,或使得有機EL元件之壽命劣化。又,由於金屬^ 30使用了鐘等高活性金屬,在處理容器内之壓力較^ 而存在有許多不純物的狀態下,金屬層3〇會與氧等相 互反應而變成絕緣物,造成電子注入效率惡9化^因此, 在將處理容器内壓力維持於較l〇-2Pa更低之真空度的 狀態下進行有機層20及金屬層30之蒸鍍者並非良策。In the state of the impurity, the organic layer 2G film reacts with moisture or the like, and dark spots (dark SPGt) or the like are generated in the film to cause photoelectric conversion effect, or the life of the organic EL element is deteriorated. Further, since the metal ^ 30 uses a highly active metal such as a bell, in the state where the pressure in the processing container is relatively high and there are many impurities, the metal layer 3 相互 reacts with oxygen and the like to become an insulator, resulting in electron injection efficiency. Therefore, it is not a good idea to carry out vapor deposition of the organic layer 20 and the metal layer 30 while maintaining the pressure in the processing vessel at a vacuum lower than l〇-2Pa.

本實施形態中,藉由將處理容器内壓力維持於1〇_2 〜10-3Pa左右,可實現於同一個容器内連續進行有機層 20之蒸鑛、金屬層30之療·鍵、保護膜4〇之賤鍵等處 理的成膜裝置。 X 依本實施形態之成膜裝置PM1,可防止有機材料及 鹼金屬材料之氧化或氮化’同時形成優質的有機層2〇 及金屬層30。同時,於同一個處理室内所設置之濺铲 裝置400處對氛氣進行電紧點火(piasma ignitiQn彡,_ 26 201107502 由氬氣離子來將濺鍍原子Ag撞出,藉此,可如圖2(e) 所示般地於同一個處理室内形成保護膜4〇。 依此,於金屬層30成膜後,無須將基板G搬送至 處理容器100外部。其結果,可避免於金屬層3〇表面 附著水分、氮、氧等不純物,在將保護膜4〇形成於金 屬層30上之前’可防止金屬層3〇與處理容器内之不純 物相互反應而氧化、絕緣物化來造成膜之劣化。如此, 藉由在高活性化體之金屬層30受氧化之前於同一個處 理室内形成保護膜40,可製造出電子注入效率較高、 具高性能之有機EL元件。 又,本實施形態中,無須進行在第1實施形態中作 為濺鍍之前處理的軟蝕刻製程(圖2(d))。藉此,可提高 產能、生產性。 再者,依本實施形態,可於較習知技術更低之1〇-2 〜10 3Pa左右真空下實施濺鍍。因此,可提高排氣效率, 縮短基板G之搬送及處理所需時間(相較於習知技術)。 藉此,可提高產能、生產性。 〔3〕第3實施形態 其次,參考圖7來說明第3實施形態之成膜裝置。 另外,第3貫施开>‘%之基板處理系統gys與第1實施形 態相同,有機EL元件係於圖丨所示叢集型基板處理系 統Sys内所製造。 27 201107502 〔3-1〕成膜裝置之内部結構 ύ 本實施形態之成膜裝置PM1中,可於處理容器ι〇〇 内部連續進行有機層20之蒸鍍、金屬層30之蒸錢、以 及保護膜40之蒸鍍等處理。因此,本實施形態之成膜 裝置PM1中’除了第2實施形態之成膜裝置pMi之中, 用以蒸鑛有機層20而設置的蒸鑛源2〇〇(第1蒸鑛源) 及第1喷出機構120a〜120f、用以蒸鍍金屬層3〇而設 置的氣化器300(第2蒸鍍源)及第2噴出機構13〇之夕!^ 如以下說明般地於處理容器内部亦設置有氣化哭 500(相當於第3蒸鍍源)及第3嘴出機構51〇。” 益 處理容器⑽外部除了用以加熱鐘以 器300之外,核置有將銀或料化的氣化器·Ί 化器500係經由可調整開啟程度的閥V6而連結 : 泵520。根據從控制器50所輸出之驅 :至真空 V6的開啟程度’藉以將氣化器5。。内部控:二;= 的真空壓力。 刊%所期望 ❹ 又,氣化器500係經由調整氣體流量之所旦*曰 :;器爾及閥V?而連結至氮氣供給源32^ 制器所輸出之驅動訊號來控織量流量控控 及閥V7’藉以調節氬氣之供給/切斷、以及、☆旦°严 器測與第3噴出機構51〇係藉由第3氣體;氣匕 相互連結。第3氣體供給管530係設置有_ v°,吕 制朝處理容H側搬送之保護制材料的供給/以^ 及流量。 辦以 28 201107502 藉此,於氣化器500内所蒸發之鋁或銀會以供給至 氣化器500内部之特定量的氬氣作為載體氣體,通過第 3氣體供給管520内部的通路而搬送至處理容器内。 第2喷出機構130與第3噴出機構510之間設置有 分隔壁540。又,處理容器1〇〇之第3喷出機構51〇側 設置有排氣〇 550。排氣口 550連接至排氣裝置569。 驅動排氣裝置560時,便可將第3喷出機構51〇所喷出 之銀的殘留原子從排氣口 550排出至處理容器外。 另外,為了形成保護膜4〇,亦可使用為了形成有 機層20所使用的坩堝之相同結構的蒸鍍源以取代氣化 器500。但是,由於保護膜用材料氣體為金屬材料,需 注意不可使用會成為合金等。 +依以上說明之連續成膜裝置,當基板G依序通過第 1賀出機構120a〜120f下方時,可藉由將第丨噴出機構 120a〜l20f所噴出之有機材料蒸氣A〜F各自堆積至基 板G,來依序形成有機層(第i層〜第6層)。其次,藉 由將第2噴出機構130所噴出之鋰堆積至基板G,來形 成金屬層3G。最後,藉由將第3喷出機構51()所喷出 之銀堆積至基板G,來形成保護膜4〇。 依此,可防止有機材料及鹼金屬材料之氧化或氮 化,同時能形成優質之有機層2〇及金屬層3〇。此外, 本貝施形悲、之成膜襄置PMi,藉由於同—個處理室内 所設置的第3噴出機構51〇所喷出的銀,可於金屬層 30上立即形成保護膜40。 29 201107502 依此,於金屬層3〇成膜後,無需將基 處理容器100外部。其結果,可避免金屬層撖达至 附水分、氮、氧等不純物,在將保護膜40形表面吸 層30上之前,可防止金屬層30與處理、容器^戍於金屬 相互反應而氧化、絕緣物化來造成臈之劣化。之不純物 由在高活性化體之金屬層3〇受氧化之前,、如此,藉 理室内形成保護膜4〇,可製造出電子=入=同〜個處 具高性能之有機EL元件。 '夕、率較高、 又’無須進行在第1實施形態中作為濺鍍 的軟蝕刻製程(圖2(d))。藉此,可提高則處理 门座犯、生產性。 〔3-2〕第3實施形態之變形例 以上各實施形態中,將基板G載置於載置a 執,來讓載置台11G進行滑行移動口,藉此 於基板G連_成各層。相對於此,第3實施形能之變 形例中’如圖8所示’係於處理容器兩端設置滾筒_、 ㈣,藉㈣端之滾筒61〇、62()的捲繞來讓捲附於兩端 之滾筒610、620的膜Fhn從第丨噴出機構i2〇a〜i2〇f 側、里由第2噴出機構130 ’朝向第3嘴出機構510捲動 的方式,來取代將基板G載置於載置台11〇的方式。其 』從第1噴出機構120a〜120f、第2噴出機構13〇、 2 3噴出機構51〇各自喷出的有機材料Α〜ρ、鋰、銀, 會依序蒸鍍於膜Flm上。藉此,於處理容器内之同一空 間中便可於膜Flm上連續形成有機層2〇、金屬層3〇, 201107502 保護膜40。藉此,可防止對於成膜時的環境氣體相當 敏感的有機層20及金屬層30於成膜中產生劣化。藉 此’可於膜Flm上製造出光電轉換效率及電子注入效^ 維持較高’且長壽命的有機EL元件,同時,藉由使用 膜Flm作為被處理體以取代基板G,可降低製造成本。 另外,作為膜Flm可使用PET(聚對苯二甲酸二乙醋: Polyethylene Terephthalate)或 PPE(聚笨趟: Polyphenylene Ether) ° 〇 〔4〕第4實施形態 其次,參考圖9來說明第4實施形態之成膜裝置的 内部結構。本實施形態之成膜裝置pM1係於有機層2〇 蒸鍍後,接著於同一個處理容器1〇〇内使用2個相異之 濺鍵祀來連續進行2個相異之賤鍍處理。 具體說明處理方式。首先,蒸鍍有機層20時,於 蒸鑛源200處所氣化的有機材料蒸氣會從第!喷出機構 G 12Ga〜12〇f各自朝向基板嘴出,藉以進行有機層2〇之 6層連續成膜。 處理容器100於第1嘴出機構120f旁邊,内藏有 形成金屬層30用的賤鍍裝置40卜再者,濺鍍裝置4〇1 旁邊,内藏有軸賴膜4〇用的雜裝 置402。丨賤鍍 裝置401及減鑛裝置402之主要内部結構與第2實施形 態所述的麟裝置_相同,故此處省略說明。另外, 濺鍍裝置401相當於第1濺鍍裝置,濺鍍裝置402則相 31 201107502 當於第2濺鍍裝置。 於有機層20成膜後,基板會移動至濺鍍裝置4〇ι 下方,於該處形成功函數較高的金屬層3〇。濺鍍裝置 401係例如對鎂Mg所組成的濺鍍靶進行濺鍍,將所撞 出的鎂Mg層積於基板上,以形成金屬層3〇。 於金屬層30成膜後,基板會移動至濺鍍裝置4犯 下方,以形成具陰極功能的保護膜4〇。濺鍍裴置4〇2 係例如對銀Ag所組成的濺鍍靶進行濺鍍’將所撞出的 銀Ag原子層積於基板上,以形成保護膜仞。保護膜仞❹ 亦可使用IS A1。又’亦可使祕金屬滴塗器㈣沾酬w dispenser)來取代濺鍍裝置4〇1、4〇2。 另外’保護膜40上形成有氧化石夕膜Si〇2或氮化石夕 膜SiN等所組成的密封膜(圖中未顯示),藉此,可製造 成有機EL元件。 、有機材料减之蒸鍍中,有機材料蒸氣會邊擴散邊 基板# 原子則能以較直線之路徑到 ❹ 此’相較於舰原子,有機材料蒸氣較容易 友痤#本。因此,於有機成膜側至少設置1個以上之排 軋較仫,以防止有機材料蒸氣飛至濺鍍裝置處, 之成膜造成不良影響。本實施:態中, ’y k貝出機構12〇f側設置有排氣裝置195b,主要 ::第光1:出機構120a〜120fm喷出的有機材料蒸氣 +山德:防止有機材料蒸氣飛至濺鍍襄置401處。第 育出機構120f與濺鍍裝置4〇1之間的分隔壁41〇同樣 32 201107502 可防止有機材料蒸氣飛至濺鍍裝置4〇1處。當然,該等 結構亦可防止濺鍍原子飛至有機成膜側。 、依本實卿態,亦可在防止有機材料及驗金屬材料 荨之氧化或氮化的同時形成有機層2〇、金屬層及保 護臈40。本實施形態中,可於同—個處理容器内連續 地進行有機層20之瘵鍍、金屬層3〇及保護膜4〇的形 成,故可提高生產性,並達成製造時的成本降低。特別 〇 是,藉由橫向並排設置濺鍍裝置401、402,可以相異 之成膜條件、相異之裝置結構來連續進行相異之材料的 贿成膜,而於同-個處理容器中具有功能分離及時間 縮短的效果。 另外,本實施形態中,雖排列有2個濺鍍裝置,但 亦可排列有3個以上的賤鍍裝置。 如以上說明,依各實施形態,可讓易活性化的鹼金 屬不受到氧化等’而穩定地製造出具高性能之有機扯 元件。 〇 前述實施形'態中’各部動作係相互關連,可考慮其 相互關連,而置換—連串的動作。然後,藉由這樣的置 換’可將用以製造前迷有機EL元件的成膜裝置之實施 形態成為用以製造前述有機EL元件的成膜方法之實施 形態以及使用前述成骐裝置所製造出的有機EL元件之 實施形態。 以上’已參考添附圖式說明本發明之較佳實施形 態,但本發明當然並非限定於該等範例。該行業者自可 33 201107502 於申請專利範圍所記載的範_ 正例,該等當然、亦屬於 ^丨各種變更例或修 例如’本發明雖係將驗金屬氣::圍。 ,,融點低’故亦能以液體方’但由於驗 刖述十月況,取代前述氣化哭 連、,供給。藉此, 液體狀態來連續供給驗以?有使用專用容器而以 面’前述氣化器中,材料之連續2膜的特徵。另-方 為了讓氣化器能連續供給材料,則。因此, 化器而將各氣化器切換使用等。、兩費工準備複數個氣In the present embodiment, by maintaining the pressure in the processing chamber at about 1 〇 2 to 10 -3 Pa, it is possible to continuously perform the vapor deposition of the organic layer 20, the treatment key of the metal layer 30, and the protective film in the same container. A film forming apparatus such as a 4-inch button. X According to the film forming apparatus PM1 of the present embodiment, oxidation or nitridation of the organic material and the alkali metal material can be prevented, and the high-quality organic layer 2 and the metal layer 30 can be simultaneously formed. At the same time, the atmosphere is electrically ignited at the splash shovel device 400 provided in the same processing chamber (piasma ignitiQn彡, _ 26 201107502 by argon ions to knock out the sputter atom Ag, thereby, as shown in Fig. 2 (e) The protective film 4 is formed in the same processing chamber as shown in the drawing. Accordingly, after the metal layer 30 is formed, it is not necessary to transport the substrate G to the outside of the processing container 100. As a result, the metal layer 3 can be avoided. The surface adheres to impurities such as moisture, nitrogen, and oxygen, and prevents the metal layer 3〇 from reacting with the impurities in the processing container to oxidize and insulate the film to cause deterioration of the film before the protective film 4 is formed on the metal layer 30. By forming the protective film 40 in the same processing chamber before the metal layer 30 of the highly activated body is oxidized, an organic EL element having high electron injection efficiency and high performance can be manufactured. In this embodiment, it is not necessary. In the first embodiment, a soft etching process (Fig. 2(d)) is performed as a process before sputtering, whereby productivity and productivity can be improved. Further, according to the present embodiment, it is possible to use a lower technique than the prior art. 1〇-2 ~1 Sputtering is performed under a vacuum of about 0 Pa. Therefore, the exhaust efficiency can be improved, and the time required for the transfer and processing of the substrate G can be shortened (compared to the conventional technique). Thereby, productivity and productivity can be improved. Third Embodiment Next, a film forming apparatus according to a third embodiment will be described with reference to Fig. 7. The third processing unit gys of the substrate processing system gys is the same as that of the first embodiment, and the organic EL element is in the figure. Manufactured in the cluster-type substrate processing system Sys. 27 201107502 [3-1] Internal structure of film forming apparatus PM In the film forming apparatus PM1 of the present embodiment, steaming of the organic layer 20 can be continuously performed inside the processing vessel ι In the film forming apparatus PM1 of the present embodiment, in the film forming apparatus PM1 of the second embodiment, the organic layer is used for the vapor deposition of the organic layer in the film forming apparatus PM1 of the second embodiment. a vapor source 2 (a first steam source) and a first discharge mechanism 120a to 120f, and a vaporizer 300 (second vapor deposition source) for vapor-depositing the metal layer 3 and The second discharge mechanism 13 is on the eve of the day! ^ As in the following description, the inside of the processing container is also There is a vaporized crying 500 (corresponding to the third vapor deposition source) and a third nozzle discharging mechanism 51." The outer portion of the processing container (10) is provided with silver or a material for the purpose of heating the bell jar 300. The gasifier/deuterator 500 is connected via a valve V6 whose opening degree can be adjusted: the pump 520. The gasifier 5 is controlled according to the degree of opening of the vacuum output V6 from the output of the controller 50. The vacuum pressure of the second; = is expected. In addition, the gasifier 500 is connected to the output of the nitrogen supply source 32 by adjusting the flow rate of the gas flow and the valve V? The driving signal controls the amount of flow control and the valve V7' to adjust the supply/disconnection of the argon gas, and the third discharge device 51 is connected to the third gas by the third gas; The third gas supply pipe 530 is provided with _v°, and the supply/suction and flow rate of the protective material conveyed toward the processing capacity H side. 28 201107502 Thereby, aluminum or silver evaporated in the vaporizer 500 is transported through a passage inside the third gas supply pipe 520 by using a specific amount of argon gas supplied to the inside of the vaporizer 500 as a carrier gas. To the inside of the processing container. A partition wall 540 is provided between the second discharge mechanism 130 and the third discharge mechanism 510. Further, an exhaust port 550 is provided on the side of the third discharge mechanism 51 of the processing container 1A. Exhaust port 550 is coupled to exhaust 569. When the exhaust unit 560 is driven, the residual atoms of the silver ejected from the third discharge unit 51 can be discharged from the exhaust port 550 to the outside of the processing container. Further, in order to form the protective film 4, a vapor deposition source having the same structure for forming the crucible used for the organic layer 20 may be used instead of the vaporizer 500. However, since the material gas for the protective film is a metal material, care must be taken not to use it as an alloy. According to the continuous film forming apparatus described above, when the substrate G sequentially passes under the first exhalation mechanisms 120a to 120f, the organic material vapors A to F discharged from the second ejection mechanisms 120a to 120f can be stacked to each other. The substrate G is sequentially formed with an organic layer (i-th layer to sixth layer). Next, the metal layer 3G is formed by depositing lithium discharged from the second discharge mechanism 130 onto the substrate G. Finally, the protective film 4 is formed by depositing silver ejected from the third ejecting mechanism 51 () onto the substrate G. Accordingly, oxidation or nitridation of the organic material and the alkali metal material can be prevented, and at the same time, a high-quality organic layer 2 and a metal layer 3 can be formed. Further, in the case of the Bebe, the film formation is placed on the PMi, and the protective film 40 can be formed on the metal layer 30 immediately by the silver ejected from the third discharge mechanism 51 provided in the same processing chamber. 29 201107502 Accordingly, after the metal layer 3 is formed into a film, it is not necessary to externally the base processing container 100. As a result, the metal layer can be prevented from reaching impurities such as moisture, nitrogen, oxygen, etc., and before the protective film 40 is formed on the surface suction layer 30, the metal layer 30 can be prevented from reacting with the metal in the treatment, the container, and the metal. Insulation is used to cause deterioration of defects. The impurity is formed by the formation of the protective film 4 in the metal layer 3 of the highly activated body. Thus, the organic EL element having high performance in the electron = input = the same can be produced. The eve rate is high, and it is not necessary to perform a soft etching process as a sputtering in the first embodiment (Fig. 2(d)). In this way, it is possible to improve the handling of the door and the productivity. [3-2] Modification of the third embodiment In the above embodiments, the substrate G is placed on the mounting a, and the mounting table 11G is slidably moved to form the respective layers on the substrate G. On the other hand, in the modification of the third embodiment, as shown in Fig. 8, the drums _, (4) are provided at both ends of the processing container, and the windings of the rollers 61 〇, 62 () at the ends of the four ends are attached. The film Fhn of the rollers 610 and 620 at both ends is replaced by the second discharge mechanism 130' toward the third nozzle mechanism 510 from the second discharge mechanism i2a to i2〇f side instead of the substrate G. The method of placing on the mounting table 11〇. The organic materials Α to ρ, lithium, and silver which are ejected from the first discharge mechanisms 120a to 120f, the second discharge mechanism 13A, and the second discharge mechanism 51 are sequentially vapor-deposited on the film Flm. Thereby, the organic layer 2, the metal layer 3, and the 201107502 protective film 40 can be continuously formed on the film Flm in the same space in the processing container. Thereby, deterioration of the organic layer 20 and the metal layer 30 which are relatively sensitive to the environmental gas at the time of film formation can be prevented from being formed in the film formation. In this way, an organic EL element having a high photoelectric conversion efficiency and an electron injection efficiency can be produced on the film Flm while maintaining a high lifetime and a long life, and the manufacturing cost can be reduced by using the film Flm as a processed object instead of the substrate G. . Further, as the film Flm, PET (polyethylene terephthalate) or PPE (polyphenylene Ether) can be used. Fourth embodiment, the fourth embodiment will be described with reference to FIG. The internal structure of the film forming apparatus of the form. The film forming apparatus pM1 of the present embodiment is subjected to vapor deposition after the organic layer 2, and then two different sputtering electrodes are continuously used in the same processing container 1 to perform two different ruthenium plating processes. Specifically explain the processing method. First, when the organic layer 20 is vapor-deposited, the vapor of the organic material vaporized at the vapor source 200 will be from the first! Each of the discharge mechanisms G 12Ga to 12〇f is directed toward the substrate nozzle, whereby six layers of the organic layer 2 are continuously formed. The processing container 100 is provided with a ruthenium plating apparatus 40 for forming the metal layer 30, and a side of the sputtering apparatus 4〇1, and a miscellaneous apparatus 402 for the lining film 4 is placed beside the first nozzle opening mechanism 120f. . The main internal structure of the ruthenium plating apparatus 401 and the metal concentrating apparatus 402 is the same as that of the lining apparatus _ described in the second embodiment, and thus the description thereof is omitted. Further, the sputtering apparatus 401 corresponds to the first sputtering apparatus, and the sputtering apparatus 402 has the phase 31 201107502 as the second sputtering apparatus. After the organic layer 20 is formed, the substrate is moved below the sputtering apparatus 4〇, where the metal layer 3' with a higher success function is formed. The sputtering apparatus 401 is, for example, sputtered a sputtering target composed of magnesium Mg, and laminates the knocked magnesium Mg on the substrate to form a metal layer 3〇. After the metal layer 30 is formed, the substrate is moved to the lower side of the sputtering apparatus 4 to form a protective film 4 having a cathode function. The sputtering apparatus 4 is for example sputtering a sputtering target composed of silver Ag. The silver Ag atoms which are knocked out are laminated on the substrate to form a protective film. Protective film IS IS A1 can also be used. In addition, the secret metal dripper (4) can be used instead of the sputtering apparatus 4〇1, 4〇2. Further, a sealing film (not shown) composed of osmium oxide film Si〇2 or nitriding film SiN or the like is formed on the protective film 40, whereby an organic EL device can be produced. In the evaporation of organic materials, the organic material vapor will diffuse while the substrate # atom can be in a relatively straight path to ❹. Compared with the ship atom, the organic material vapor is easier to use. Therefore, at least one or more of the rows of the organic film forming side are arranged to prevent the organic material vapor from flying to the sputtering apparatus, and the film formation adversely affects the film formation. In the present embodiment, the yk shelling mechanism 12 〇 f side is provided with an exhaust device 195b, mainly:: the first light: the organic material vapor ejected by the outlet mechanisms 120a to 120fm + Sander: preventing the organic material vapor from flying to The sputtering device is placed at 401. The partition wall 41〇 between the first growing mechanism 120f and the sputtering device 4〇1 is the same 32 201107502 to prevent the organic material vapor from flying to the sputtering device 4〇1. Of course, these structures also prevent the sputtered atoms from flying to the organic film forming side. According to the actual state, it is also possible to form an organic layer 2, a metal layer and a protective layer 40 while preventing oxidation or nitridation of the organic material and the metal material. In the present embodiment, the bismuth plating of the organic layer 20, the formation of the metal layer 3 and the protective film 4A can be continuously performed in the same processing container, so that productivity can be improved and cost reduction at the time of production can be achieved. In particular, by providing the sputtering devices 401 and 402 side by side in the lateral direction, different film forming conditions and different device structures can be used to continuously perform brique film formation of different materials, and have the same processing container. Functional separation and time reduction. Further, in the present embodiment, although two sputtering apparatuses are arranged, three or more ruthenium plating apparatuses may be arranged. As described above, according to the respective embodiments, the alkali metal which is easily activated can be stably produced without being oxidized or the like.各 The actions in the above-mentioned implementations are related to each other, and they can be considered to be related to each other, and the replacement-series actions. Then, the embodiment of the film forming apparatus for manufacturing the organic EL element can be used as an embodiment of a film forming method for producing the organic EL element, and the use of the above-described enthalpy device can be used. An embodiment of an organic EL element. The preferred embodiments of the present invention have been described above with reference to the accompanying drawings, but the invention is of course not limited to the examples. Those skilled in the art can cite the patents described in the scope of the patent application, which are, of course, also belong to various variations or modifications. For example, the present invention is a metal gas::. ,, if the melting point is low, it can also be used as a liquid side, but it is replaced by the gasification and crying, and supply. By this, the liquid state is continuously supplied for inspection? There is a feature of using a dedicated container to face the continuous film of the material in the gasifier described above. In addition, in order to allow the gasifier to continuously supply materials, then. Therefore, each gasifier is switched to use or the like. Two laborers are preparing for multiple gas

又,本發明所用的鹼金屬材料 化合物。但是,使聽合物之情=體,亦可使用 材料混入膜中。 奴金屬蒸氣以外的 本實施形態巾’成縣置之處理容器⑽與蒸鍵源 200係各別設置,但亦可於—個處理容器内内藏有各有 機材料之蒸艘源。Further, the alkali metal material compound used in the present invention. However, it is also possible to mix the materials into the film by using the material. In addition to the slave metal vapor, the processing container (10) and the steam source 200 of the present invention are separately provided, but a steam source of each organic material may be contained in a processing container.

又’被處理體可為730mmx920mm以上的基板,亦 可為200mm或300mm以上的石夕晶圓。 又’有機層與功函數蒸鍍層(金屬層)可於使材料蒸 氣相互混合之狀態下進行成膜。例如,使得來自第1喷 出機構120a側的殘留有機材料蒸氣飛至第2喷出機構 130側而混入金屬層30。又,使得鋰飛至第丨喷出機構 120a〜120f側而混入有機層2〇。 34 201107502 【圖式簡單說明】 圖1係第1〜第4實施形態及其變形例之基板處理 系統的概略構成圖。 圖2係本發明一實施形態之有機EL元件的製程之 一範例圖。 圖3係第1實施形態之成膜裝置PM1的縱剖面圖。 圖4係顯示藉由第1〜第4實施形態之6層連續成 膜處理所形成的有機EL元件之圖式。 Ο 圖5係第1實施形態之變形例之成膜裝置PM1的 縱剖面圖。 圖6係第2實施形態之成膜裝置PM1的縱剖面圖。 圖7係第3實施形態之成膜裝置PM1的縱剖面圖。 圖8係第3實施形態之變形例之成膜裝置PM1的 縱剖面圖。 圖9係第4實施形態之成膜裝置PM1的縱剖面圖。Further, the object to be processed may be a substrate of 730 mm x 920 mm or more, or may be a silicon wafer of 200 mm or more. Further, the organic layer and the work function vapor deposition layer (metal layer) can be formed in a state in which the material vapors are mixed with each other. For example, the residual organic material vapor from the first discharge mechanism 120a side is caused to fly to the second discharge mechanism 130 side to be mixed into the metal layer 30. Further, lithium is caused to fly to the side of the second discharge means 120a to 120f to be mixed into the organic layer 2''. [Brief Description of the Drawings] Fig. 1 is a schematic configuration diagram of a substrate processing system according to the first to fourth embodiments and their modifications. Fig. 2 is a view showing an example of a process of an organic EL device according to an embodiment of the present invention. Fig. 3 is a longitudinal sectional view showing a film forming apparatus PM1 of the first embodiment. Fig. 4 is a view showing an organic EL device formed by the six-layer continuous film formation process of the first to fourth embodiments. Fig. 5 is a longitudinal sectional view showing a film forming apparatus PM1 according to a modification of the first embodiment. Fig. 6 is a longitudinal sectional view showing a film forming apparatus PM1 of the second embodiment. Fig. 7 is a longitudinal sectional view showing a film forming apparatus PM1 according to a third embodiment. Fig. 8 is a longitudinal sectional view showing a film forming apparatus PM1 according to a modification of the third embodiment. Fig. 9 is a longitudinal sectional view showing a film forming apparatus PM1 of the fourth embodiment.

【主要元件符號說明】 10 ITO 20 有機層 30 金屬層 40 保護膜 50 控制器 50a ROM 50b RAM 50c CPU 50d 輸出入1/F 100 處理容器 110 載置台 110a 導軌 130 第2喷出機構 140、 150 分隔壁 35 201107502 160a、160b 閘閥 180 120a、120b、120c、120d、120e、120f 170a、170b、170c、170d、170e、170f 210a、210b、210c、210d、210e、210f 氣體供給管 第1嘴出機構 第1氣體供給管 坩堝 220a、220b、220c、220d、220e、220f 加熱器 195a、195b排氣袭置 190a 、190b排氣口 200 蒸鍵源 240 排氣裝置 310 真空泵 400、 401、402濺鍍裝置 420a 、420b賤鍍乾材 440a 、440b濺鍍乾保持台 460 淋氣頭 480 排氣口 500 氣化器 520 真空泵 540 分隔壁 560 排氣裝置 CM 清潔裝置 Ds2 電源 LLM 加載互鎖裝置 PM2 蝕刻裝置 PM4 濺鍍裝置 Sys 基板處理系統 230 排氣口 300 氣化器 320 氬氣供給源 410 分隔壁 430a 、430b背板 450a、450b磁場產生機構 470 電源 490 排氣裝置 510 第3噴出機構 530 第3氣體供給管 550 排氣口 610、 620 滾筒 Dsl 蒸發容器 G 基板 PM1 成膜裝置 PM3 CVD襞置 S 緩衝空間 TM 搬送裝置[Main component symbol description] 10 ITO 20 organic layer 30 metal layer 40 protective film 50 controller 50a ROM 50b RAM 50c CPU 50d output 1/F 100 processing container 110 mounting table 110a rail 130 second ejection mechanism 140, 150 points Partition wall 35 201107502 160a, 160b Gate valves 180 120a, 120b, 120c, 120d, 120e, 120f 170a, 170b, 170c, 170d, 170e, 170f 210a, 210b, 210c, 210d, 210e, 210f Gas supply pipe first nozzle mechanism 1 gas supply pipe 坩埚 220a, 220b, 220c, 220d, 220e, 220f heater 195a, 195b exhaust 190a, 190b exhaust port 200 steam source 240 exhaust device 310 vacuum pump 400, 401, 402 sputtering device 420a 420b贱plated dry material 440a, 440b sputter dry holding station 460 air head 480 exhaust port 500 gasifier 520 vacuum pump 540 partition wall 560 exhaust CM cleaning device Ds2 power LLM load interlock device PM2 etching device PM4 splash Plating device Sys substrate processing system 230 exhaust port 300 gasifier 320 argon gas supply source 410 partition wall 430a, 430b back plate 450a, 450b magnetic field generating mechanism 470 Discharge means 510 of the third exhaust means 530 of the source 490 gas supply pipe 3 550 610 an exhaust port, the drum 620 Dsl evaporation vessel G substrate PM1 PM3 CVD film-forming apparatus folds the buffer space S facing the transport means TM

36 201107502 V 卜 V2、V3、V4、V5、V6、V7、V8、V10、V15 閥 A、B、C、D、E、F 有機材料36 201107502 V Bu V2, V3, V4, V5, V6, V7, V8, V10, V15 valves A, B, C, D, E, F organic materials

3737

Claims (1)

201107502 七、申請專利範圍: 1. 一種成膜裝置,具備有: 處理容器,係在其内部於被處理體上施以所期望的 處理; 第1蒸鍍源,係收納有機材料,將所收納之有機材 料加熱以氣化; 第1喷出機構,係内藏於該處理容器並連結至該第 1蒸鍍源,將於該第1蒸鍍源處所氣化之有機材料 朝向該處理容器内的被處理體喷出; 第2蒸鑛源,係收納驗金屬材料,將所收納之驗金 屬材料加熱以氣化;以及 第2喷出機構,係内藏於該處理容器並連結至該第 2蒸鍍源,將於該第2蒸鍍源處所氣化之鹼金屬材 料朝向該處理容器内的被處理體喷出。 2. 如申請專利範圍第1項之成膜裝置,其更具備有: 第3蒸鍍源,係收納保護膜用材料,將所收納之保 護膜用材料加熱以氣化,以及 第3喷出機構,係内藏於該處理容器並連結至該第 3蒸鍍源,將於該第3蒸鍍源處所氣化之保護膜用 材料朝向該處理容器内的被處理體喷出。 3. 如申請專利範圍第1項之成膜裝置,其更具備有濺 鍍裝置,係内藏於該處理容器,對保護膜用材料所 組成的藏鑛把進行濺鑛。 4. 如申請專利範圍第1項之成膜裝置,其具備有載置 38 201107502 5. Ο 6. 〇 台,係載置搬送至該處理容器之被處理體; 該载置台能將朝上方或朝下方或朝縱向地載置之 破處理體從該第丨仙機構朝向該第2喷出機構侧 進行滑移。 ^申請專利範圍第1項之錢裝置,其中於該處理 容器兩端具備有滚筒; 藉由捲動該兩端之滾筒,使得捲附於該兩端之滾筒 的獏從該第丨喷出機構朝向該第2喷出機構側=行 移動。 =申請專利範圍第1項之成膜裝置,其中該處理容 器係至少於該第1喷出機構側設置有排氣裂置。 如申請專利範圍第1項之成膜裝置,其中於該第丄 噴出機構與該第2喷出機構之間設置有分隔=。 如申請專利範圍第1項之成膜裝置,其中該同第丨。蒗 鍍源係由收納複數種有機材料之複數個坩堝所= 成; y 該第1噴出機構係由連結至複數個坩堝之複 噴出部所形成; 將於該複數個坩堝處所氣化之複數種有機 自從該第1噴出機構所設置之複數個噴出邻声 出’精以於被處理體上層積複數 7 有機層之賴成膜。 ’賤材枓以進行 如尹請專利_第〗項之成職置, 材料為鋰、铯、鈉、鉀及铷中任—者、中錢金屬 39 9. 201107502 ίο. —種成膜裝置,具備有: 處理容器,係在其内部於被處理體上施以所期望的 處理; 第1蒸鍍源,係收納有機材料,將所收納之有機材 料加熱以氣化, 第1喷出機構,係内藏於該處理容器並連結至該第 1蒸鍍源,將於該第1蒸鍍源處所氣化之有機材料 朝向該處理容器内的被處理體喷出; 第1濺鍍裝置,係内藏於該處理容器,對鹼金屬材 料所組成的濺鍍靶進行濺鍍;以及 第2濺鍍裝置,係内藏於該處理容器,對保護膜用 材料所組成的藏鑛粗進行減:鑛。 11. 如申請專利範圍第10項之成膜裝置,其中該處理 容器係至少於該第1喷出機構側設置有排氣裝置。 12. 如申請專利範圍第10項之成膜裝置,其中於該第 1喷出機構與該第2喷出機構之間設置有分隔壁。 40201107502 VII. Patent application scope: 1. A film forming apparatus comprising: a processing container in which a desired treatment is applied to the object to be processed; and a first vapor deposition source for storing the organic material and storing the material The organic material is heated to be vaporized; the first discharge mechanism is built in the processing container and connected to the first vapor deposition source, and the organic material vaporized at the first vapor deposition source faces the processing container The second vapor source is stored in the metal material, and the stored metal material is heated to be vaporized; and the second discharge mechanism is housed in the processing container and connected to the first (2) The vapor deposition source ejects the alkali metal material vaporized at the second vapor deposition source toward the object to be processed in the processing container. 2. The film forming apparatus of the first aspect of the invention, further comprising: a third vapor deposition source for storing a protective film material, heating the material for the protective film to be vaporized, and discharging the third discharge The mechanism is built in the processing container and connected to the third vapor deposition source, and the material for the protective film vaporized at the third vapor deposition source is discharged toward the object to be processed in the processing container. 3. The film forming apparatus of claim 1 is further provided with a sputtering apparatus which is housed in the processing container and splashes the ore deposit composed of the material for the protective film. 4. The film forming apparatus of claim 1 which is provided with a mounting surface 38 201107502 5. Ο 6. A truss, which is a workpiece to be transported to the processing container; the mounting table can be turned upward or The ruptured body placed downward or in the longitudinal direction is slid from the third slanting mechanism toward the second ejector. The invention provides the money device of claim 1, wherein a drum is provided at both ends of the processing container; and by rolling the rollers at the both ends, the cymbal of the roller attached to the both ends is ejected from the cymbal Moving toward the second discharge mechanism side = row. The film forming apparatus of claim 1, wherein the processing container is provided with an exhaust crack at least on the side of the first discharge mechanism. The film forming apparatus of claim 1, wherein a separation is provided between the third discharge mechanism and the second discharge mechanism. For example, the film forming apparatus of claim 1 is the same as the third. The ruthenium plating source is formed by a plurality of enthalpy materials containing a plurality of organic materials; y the first discharge mechanism is formed by a plurality of squirting portions connected to a plurality of sputum; a plurality of species that will be vaporized in the plurality of sputum spaces The organic film is formed by laminating a plurality of adjacent layers of the organic layer from the first discharge mechanism. 'Coffin 枓 进行 进行 尹 尹 尹 尹 尹 尹 专利 专利 专利 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹 尹The processing container is configured to perform a desired treatment on the object to be processed; the first vapor deposition source stores the organic material, and heats the stored organic material to vaporize, and the first discharge mechanism And being stored in the processing container and connected to the first vapor deposition source, and the organic material vaporized at the first vapor deposition source is discharged toward the object to be processed in the processing container; the first sputtering device is The sputtering container is embedded in the processing container, and the sputtering target composed of an alkali metal material is sputtered; and the second sputtering device is embedded in the processing container, and the thickness of the protective film is reduced: mine. 11. The film forming apparatus of claim 10, wherein the processing container is provided with an exhausting device at least on the side of the first ejection mechanism. 12. The film forming apparatus of claim 10, wherein a partition wall is provided between the first discharge mechanism and the second discharge mechanism. 40
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US9249503B2 (en) 2011-07-29 2016-02-02 Nitto Denko Corporation Method for double-side vacuum film formation and laminate obtainable by the method
US9297066B2 (en) 2011-07-29 2016-03-29 Nitto Denko Corporation Method for double-side vacuum film formation and laminate obtainable by the method

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US9249503B2 (en) 2011-07-29 2016-02-02 Nitto Denko Corporation Method for double-side vacuum film formation and laminate obtainable by the method
US9297066B2 (en) 2011-07-29 2016-03-29 Nitto Denko Corporation Method for double-side vacuum film formation and laminate obtainable by the method

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