TW201835173A - Film formation method, film formation apparatus, method of manufacturing element structure, and element structure manufacturing apparatus - Google Patents

Film formation method, film formation apparatus, method of manufacturing element structure, and element structure manufacturing apparatus Download PDF

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Publication number
TW201835173A
TW201835173A TW107105823A TW107105823A TW201835173A TW 201835173 A TW201835173 A TW 201835173A TW 107105823 A TW107105823 A TW 107105823A TW 107105823 A TW107105823 A TW 107105823A TW 201835173 A TW201835173 A TW 201835173A
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Taiwan
Prior art keywords
resin material
film
layer
resin
substrate
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TW107105823A
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Chinese (zh)
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TWI696650B (en
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清健介
青代信
高橋明久
矢島貴浩
加藤裕子
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日商愛發科股份有限公司
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    • 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
    • C23C14/54Controlling or regulating the coating process
    • C23C14/542Controlling the film thickness or evaporation rate
    • 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
    • C23C14/58After-treatment
    • C23C14/5873Removal of 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
    • C23C28/00Coating for obtaining at least two superposed coatings either by methods not provided for in a single one of groups C23C2/00 - C23C26/00 or by combinations of methods provided for in subclasses C23C and C25C or C25D
    • 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
    • H05B33/02Details
    • H05B33/04Sealing arrangements, e.g. against humidity
    • 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

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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)
  • Laminated Bodies (AREA)

Abstract

The present invention provides a film formation method of spraying a liquid resin material into a heater causing the liquid resin material to vaporize, supplying the vapor to a substrate to form a resin material film. In the film formation method, conditions for film formation are controlled so as to compensate a vaporization rate of the resin material decreasing in accordance with vaporization integrated quantity representing a total amount of supplying the resin material to the heater.

Description

成膜方法、成膜裝置、元件結構體之製造方法及元件結構體之製造裝置Film forming method, film forming device, device structure manufacturing method, and device structure manufacturing device

本發明係關於一種成膜方法、成膜裝置、元件結構體之製造方法及元件結構體之製造裝置,尤其是關於一種用於製造具有保護器件等免受氧、水分等影響之積層結構之元件結構體之較佳技術。The present invention relates to a film forming method, a film forming device, a method for manufacturing a component structure, and a device for manufacturing a component structure, and more particularly, to a component for manufacturing a laminated structure having a protection device and the like from being affected by oxygen and moisture Better technology for structures.

作為包含具有容易因水分或氧等而劣化之性質之化合物之元件,已知有例如有機EL(Electro Luminescence,電致發光)元件等。關於此種元件,曾嘗試藉由形成由包含化合物之層、及被覆該層之保護層積層而成之積層結構,來抑制水分等向元件內侵入。例如,於日本專利特開2013-73880號公報中,記載有一種於上部電極層之上具有由無機膜與有機膜之積層膜構成之保護膜之發光元件。 作為上述有機膜,可使用丙烯酸樹脂等。作為有機膜之成膜方法而正研究如下方法,即:將樹脂材料以氣化形式供給,且使樹脂材料於基板上液化,藉由對樹脂材料照射UV(ultraviolet,紫外)光而使樹脂材料聚合,從而成膜樹脂膜。但於使樹脂材料氣化時存在如下情況,即,樹脂材料並未於氣化器中完全蒸發而是樹脂材料液殘留於加熱部,或因加熱而產生樹脂材料之固化。因此,有如下問題,即:氣化效率經時變差,即便向氣化器供給之樹脂材料之供給量固定,自氣化器供給至成膜室之蒸氣供給量仍慢慢減少,從而堆積速率(成膜率)慢慢惡化。尤其存在如下問題,即:若處理時間變長,則因氣化效率降低而成膜狀態不穩定。 又,有如下可能性,即:由於未向成膜裝置供給充分之樹脂材料蒸氣而導致無法充分進行成膜。於該情形時,存在如下問題,即:於在具有器件層之基板表面形成有凹凸之情形等時,無法將該凹凸充分被覆,例如有於凹凸之邊界部產生被覆不良之可能性。一旦產生此種無機膜之被覆不良,便無法阻止水分自產生了被覆不良之部位侵入,故而難以確保充分之阻隔性。As an element including a compound having a property that is easily deteriorated by moisture, oxygen, or the like, an organic EL (Electro Luminescence) element or the like is known. With regard to such a device, attempts have been made to suppress the intrusion of moisture and the like into the device by forming a laminated structure composed of a layer containing a compound and a protective layer covering the layer. For example, Japanese Patent Laid-Open No. 2013-73880 discloses a light-emitting element having a protective film composed of a laminated film of an inorganic film and an organic film on an upper electrode layer. As the organic film, an acrylic resin or the like can be used. As a method for forming an organic film, a method is being studied in which a resin material is supplied in a vaporized form, the resin material is liquefied on a substrate, and the resin material is irradiated with UV (ultraviolet) light to the resin material. Polymerize to form a resin film. However, when the resin material is vaporized, there is a case where the resin material does not completely evaporate in the vaporizer but the resin material liquid remains in the heating portion, or the resin material solidifies due to heating. Therefore, there is a problem that the gasification efficiency deteriorates with time, and even if the amount of the resin material supplied to the gasifier is fixed, the amount of vapor supplied from the gasifier to the film forming chamber gradually decreases, thereby accumulating The rate (film formation rate) gradually deteriorates. In particular, there is a problem that if the processing time becomes longer, the film state becomes unstable due to the decrease in gasification efficiency. In addition, there is a possibility that a sufficient film formation cannot be performed because a sufficient resin material vapor is not supplied to the film forming apparatus. In this case, there is a problem that when unevenness is formed on the surface of the substrate having the device layer, the unevenness cannot be sufficiently covered, for example, there is a possibility that a defective coating may occur at a boundary portion of the unevenness. Once the coating failure of such an inorganic film occurs, it is impossible to prevent moisture from penetrating from the place where the coating failure occurs, and it is difficult to ensure sufficient barrier properties.

本發明係鑒於上述狀況而完成者,其欲達成以下目的中之至少一者。 1.實現樹脂材料蒸氣之供給狀態之改善。 2.防止供給量降低引起之成膜不良。 3.實現成膜速率之穩定化。 4.實現阻隔性之確保。 本發明之第1態樣之成膜方法係將液狀之樹脂材料以霧狀噴出至加熱部而使之氣化,且將氣化之蒸氣供給至基板上而成膜樹脂材料膜者;且以補償對應於將上述樹脂材料供給至上述加熱部之量之合計即氣化累計量而減少的上述樹脂材料之氣化率之方式控制成膜條件。 於本發明之第1態樣之成膜方法中,亦可為上述成膜條件包括對每一片上述基板成膜上述樹脂材料膜之成膜時間、或對上述加熱部以霧狀噴出液狀之樹脂材料之每單位時間之供給量的至少任一者。 於本發明之第1態樣之成膜方法中,亦可為上述加熱部具有傾斜面。 於本發明之第1態樣之成膜方法中,亦可為上述樹脂材料係紫外線硬化型丙烯酸樹脂之材料。 本發明之第2態樣之成膜裝置係將液狀之樹脂材料以霧狀噴出至加熱部而使之氣化,且將氣化之蒸氣供給至基板上而成膜樹脂材料膜者;且具有:記錄部,其記錄包含將樹脂材料供給至上述加熱部之累計量之氣化運轉資料;及控制部,其參照上述氣化運轉資料,決定將成膜時間延長之時間、或使對上述加熱部以霧狀噴出上述液狀之樹脂材料之每單位時間之供給量增加之增加量的至少任一者。 本發明之第3態樣之元件結構體之製造方法包括:第1步驟(步驟A),其係形成第一層,該第一層被覆配置於基板一面之功能層,並且具有局部性之凸部,包含無機材料;第2步驟(步驟B),其係以被覆覆蓋上述基板之一面側(一主面側)之上述第一層之方式,將液狀之樹脂材料以氣化形式供給而形成包含上述樹脂材料之樹脂材料膜;第3步驟(步驟C),其係自側剖面觀察上述第一層,使位於包含上述凸部之外側面與上述基板之一面之邊界部之位置的上述樹脂材料膜之一部分殘存,而將位於與殘存上述樹脂材料膜之位置不同之位置的該樹脂材料膜去除;及第4步驟(步驟D),其係以被覆上述所殘存之樹脂材料膜之一部分、及藉由上述樹脂材料膜之去除而露出之上述第一層之方式形成包含無機材料之第二層;且於上述第2步驟中,以補償對應於氣化之上述樹脂材料之氣化持續時間而減少之上述樹脂材料之方式控制供給狀態。 於本發明之第3態樣之元件結構體之製造方法中,亦可為於上述第2步驟中,對應於與氣化之上述樹脂材料之供給時間對應的上述樹脂材料之供給量,而延長上述樹脂材料膜之成膜時間。 於本發明之第3態樣之元件結構體之製造方法中,亦可為於上述第2步驟中之上述樹脂材料膜之成膜處理時,將氣化之上述樹脂材料供給至成膜室之內部,並且於上述樹脂材料膜之非成膜處理時,將氣化之上述樹脂材料送出至上述成膜室之外部;且獲得將上述樹脂材料之供給量作為上述樹脂材料之氣化量進行累計所得之累計量,根據上述累計量而控制上述樹脂材料膜之成膜時間。 於本發明之第3態樣之元件結構體之製造方法中,亦可為上述第3步驟係自側剖面觀察上述第一層,以上述凸部之外側面中之包含頂部之區域露出之方式將上述樹脂材料膜去除。 於本發明之第3態樣之元件結構體之製造方法中,亦可為上述第3步驟使用乾式蝕刻法作為將上述樹脂材料膜去除之方法。 亦可為上述第3步驟檢測對上述樹脂材料膜進行蝕刻處理之條件中之特定條件之變化,且將所檢測出之檢測結果用作該蝕刻處理之終點。 本發明之第4態樣之元件結構體之製造裝置具有:第一層形成部,其形成第一層,該第一層被覆配置於基板一面側之功能層,並且具有局部性之凸部,包含無機材料;樹脂成膜部,其能自對液狀之樹脂材料進行加熱而使之氣化之氣化器供給氣化之上述樹脂材料,形成被覆上述第一層且包含上述樹脂材料之樹脂材料膜;定域化處理部,其係自側剖面觀察上述第一層,使位於包含上述凸部之外側面與上述基板之一面之邊界部之位置的上述樹脂材料膜之一部分殘存,而將位於與殘存上述樹脂材料膜之位置不同之位置的該樹脂材料膜去除;及第二層形成部,其以被覆位於上述基板之一面側之上述凸部、上述所殘存之樹脂材料膜之一部分、及藉由上述去除而露出之上述第一層之方式形成包含無機材料之第二層;並且具備:供給管,其連接於上述氣化器所具備之氣化槽,於成膜時將氣化之上述樹脂材料供給至上述樹脂成膜部;外部管,其連接於上述氣化槽,於非成膜處理時將氣化之上述樹脂材料送出至上述樹脂成膜部之外部;及切換閥,其對上述供給管與上述外部管進行切換;且具有控制部,該控制部以補償對應於氣化持續時間而減少之上述樹脂材料之方式,控制對上述樹脂成膜部供給樹脂材料之供給時間。 根據本發明之第1態樣之成膜方法,能補償對應於氣化之上述樹脂材料之氣化持續時間而減少之上述樹脂材料,能以不管成膜時間如何經過均能使樹脂材料之供給量穩定之方式進行補償,而使存在對應於氣化累計量而減少之情形的成膜速率固定,從而能使膜厚之均勻性等成膜特性成為所期望之狀態。 於本發明之第1態樣之成膜方法中,上述成膜條件包括對每一片上述基板成膜上述樹脂材料膜之成膜時間、或對加熱部以霧狀噴出液狀之樹脂材料之每單位時間之供給量的至少任一者。因此,藉由將成膜時間延長、或將對加熱部以霧狀噴出液狀之樹脂材料之每單位時間之供給量逐漸地增加,能實現成膜速率之均勻化。 於本發明之第1態樣之成膜方法中,上述加熱部具有傾斜面,藉此能減小樹脂材料之供給量對應於氣化累計量而減少之比率。 於本發明之第1態樣之成膜方法中,上述樹脂材料可為紫外線硬化型丙烯酸樹脂之材料。 根據本發明之第2態樣之成膜裝置,可具有:記錄部,其記錄包含將樹脂材料供給至上述加熱部之累計量之氣化運轉資料;及控制部,其參照氣化運轉資料,決定將成膜時間延長之時間、或使對上述加熱部以霧狀噴出上述液狀之樹脂材料之每單位時間之供給量增加之增加量的至少任一者。 根據本發明之第3態樣之元件結構體之製造方法,於上述第2步驟中,以補償對應於氣化之上述樹脂材料之氣化持續時間而減少之上述樹脂材料之方式控制供給狀態,藉此能使樹脂材料之供給量不管成膜時間如何經過而均穩定,並且即便於對複數個基板依序進行成膜之情形時,亦能使樹脂材料之供給量不管成膜順序及成膜時間而均穩定,從而可防止成膜速率產生變動。又,能使成膜速率穩定而形成具有所期望之膜特性之樹脂材料膜,並且藉此能利用定域化之樹脂材料膜(樹脂材),確實地對包含第一層及第二層之功能層進行密封,從而能製造出阻隔特性較高之元件結構體。 於本發明之第3態樣之元件結構體之製造方法中,在上述第2步驟中,根據與氣化之上述樹脂材料之供給時間對應的上述樹脂材料之供給量,而延長上述樹脂材料膜之成膜時間,藉此能容易地補償對應於處理時間而減少之上述樹脂材料,從而實現成膜速率之穩定化,防止膜特性變動。 於本發明之第3態樣之元件結構體之製造方法中,於上述第2步驟中之上述樹脂材料膜之成膜處理時,供給氣化之上述樹脂材料,並且於非成膜處理時,將氣化之上述樹脂材料送出至上述成膜室外部。獲得將上述樹脂材料之供給量作為上述樹脂材料之氣化量進行累計所得之累計量,根據該累計量控制上述樹脂材料膜之成膜時間,藉此於進行複數片之成膜之情形時,能無關於成膜順序及成膜時間之經過而控制成膜厚度。 又,於本發明之第3態樣之元件結構體之製造方法中,上述第3步驟係自側剖面觀察上述第一層,以上述凸部之外側面中之包含頂部之區域露出之方式將上述樹脂材料膜去除。藉此,能容易地利用經定域化之樹脂材料膜(樹脂材),確實地對包含第一層及第二層之功能層進行密封,從而不對第一層造成不必要之損傷即可將樹脂材料膜(樹脂材)之非必要部分去除,僅使需密封之部分定域化。藉此,能製造出阻隔特性較高之元件結構體。 於本發明之第3態樣之元件結構體之製造方法中,上述第3步驟使用乾式蝕刻法作為將上述樹脂材料膜去除之方法,藉此不對第一層造成不必要之損傷即可將樹脂材料膜之非必要部分去除,而僅使需密封之部分定域化。 又,於上述第3步驟中,檢測對上述樹脂材料膜進行蝕刻處理之條件中之特定條件之變化,而將其用作該蝕刻處理之終點,藉此能將樹脂材料膜確實地去除,並且能降低對第一層造成之不必要之損傷。 根據本發明之第4態樣之元件結構體之製造裝置,能使樹脂材料之供給量不管成膜時間如何經過而均穩定,並且即便於對複數個基板依序進行成膜之情形時,亦能使樹脂材料之供給量不管成膜順序及成膜時間而均穩定,從而防止成膜速率產生變動。又,能使成膜速率穩定而形成具有所期望之膜特性之樹脂材料膜,並且藉此能利用定域化之樹脂材料膜,確實地對包含第一層及第二層之功能層進行密封,從而能製造出阻隔特性較高之元件結構體。 發明之效果 根據本發明之態樣,能實現如下效果,即:實現樹脂材料供給狀態之穩定化,防止供給量變動引起之成膜不良,實現成膜速率之穩定化,從而能穩定地成膜樹脂材料膜。The present invention has been made in view of the above circumstances, and it is intended to achieve at least one of the following objects. 1. To improve the supply state of resin material vapor. 2. Prevent film formation failure caused by lower supply. 3. Realize the stabilization of film formation rate. 4. To ensure the barrier properties. The film forming method according to the first aspect of the present invention is a method in which a liquid resin material is sprayed into a heating portion in a mist state to vaporize, and a vaporized vapor is supplied to a substrate to form a resin material film; and The film forming conditions are controlled so as to compensate for a decrease in the vaporization rate of the resin material corresponding to the total amount of the resin material supplied to the heating section, that is, the cumulative amount of vaporization. In the film-forming method of the first aspect of the present invention, the film-forming conditions may include a film-forming time for filming the resin material film on each of the substrates, or spraying liquid in a mist state to the heating portion. At least any one of the supply amount of the resin material per unit time. In the film formation method according to the first aspect of the present invention, the heating section may have an inclined surface. In the film forming method according to the first aspect of the present invention, the resin material may be a material of a UV-curable acrylic resin. The film forming apparatus of the second aspect of the present invention is a person who sprays a liquid resin material in a mist state to a heating portion to vaporize it, and supplies the vaporized vapor to a substrate to form a resin material film; and It has a recording unit that records gasification operation data including a cumulative amount of the resin material supplied to the heating unit, and a control unit that refers to the gasification operation data to determine a time for extending the film formation time, or The heating portion sprays at least any one of the increase amount of the supply amount of the liquid resin material per unit time in a mist state. The manufacturing method of the third aspect of the present invention includes a first step (step A), which is to form a first layer, the first layer covers a functional layer disposed on one side of the substrate, and has a local convexity. The second step (step B) is to supply the liquid resin material in a vaporized form so as to cover the first layer on one side (one main side) of the substrate. Forming a resin material film containing the resin material; and the third step (step C) is to observe the first layer from a side section so that the above-mentioned portion is located at a position including a boundary portion between the outer surface of the convex portion and one surface of the substrate A part of the resin material film remains, and the resin material film is removed at a position different from the position where the resin material film remains; and the fourth step (step D) is to cover a part of the remaining resin material film And forming the second layer containing the inorganic material by the above-mentioned first layer exposed by the removal of the resin material film; and in the above-mentioned second step, the gas corresponding to the gasification of the resin material is compensated The resin material of the embodiment to reduce the duration of the supply state control. In the manufacturing method of the element structure of the third aspect of the present invention, the supply amount of the resin material corresponding to the supply time of the gasified resin material in the second step may be extended, Film formation time of the resin material film. In the manufacturing method of the element structure of the third aspect of the present invention, during the film forming treatment of the resin material film in the second step, the vaporized resin material is supplied to the film forming chamber. Inside, and during the non-film forming treatment of the resin material film, the vaporized resin material is sent to the outside of the film forming chamber; and the supply amount of the resin material is obtained as the gasification amount of the resin material to be accumulated The obtained cumulative amount controls the film forming time of the resin material film according to the cumulative amount. In the manufacturing method of the element structure of the third aspect of the present invention, the third step may be a method in which the first layer is viewed from a side section, and a region including the top portion on the outer side surface of the convex portion is exposed. The resin material film is removed. In the manufacturing method of the element structure of the third aspect of the present invention, a dry etching method may be used as the method for removing the resin material film in the third step. It is also possible to detect a change in a specific condition among the conditions for performing the etching treatment on the resin material film for the third step, and use the detected detection result as an end point of the etching treatment. The device manufacturing device of the fourth aspect of the present invention includes a first layer forming portion that forms a first layer, the first layer covering a functional layer disposed on one surface side of the substrate and having a local convex portion, Contains inorganic materials; a resin film-forming portion that can supply the vaporized resin material from a vaporizer that heats the liquid resin material to vaporize, and forms a resin that covers the first layer and includes the resin material Material film; a localization treatment section, which observes the first layer from a side cross section, leaving a part of the resin material film at a position including a boundary portion between the outer surface of the convex portion and one surface of the substrate, and Removing the resin material film at a position different from the position where the resin material film remains; and a second layer forming portion that covers the convex portion located on one side of the substrate, a portion of the remaining resin material film, And forming the second layer containing an inorganic material by the above-mentioned first layer exposed by the removal; and provided with: a supply pipe connected to the above-mentioned gasifier The gasification tank supplies the gasified resin material to the resin film forming part during film formation; the outer tube is connected to the gasification tank, and sends the gasified resin material to the above during non-film-forming treatment. The outside of the resin film forming section; and a switching valve that switches the supply pipe and the external pipe; and has a control section that controls the control of the resin material in a manner that compensates for the reduction of the resin material corresponding to the duration of vaporization. The supply time of the resin film forming part to supply the resin material. According to the film forming method of the first aspect of the present invention, the resin material can be compensated for the reduction of the gasification duration of the resin material vaporized, and the resin material can be supplied regardless of the film formation time. The amount is stabilized to compensate, and the film formation rate is fixed corresponding to the case where the amount of gasification is reduced, so that film formation characteristics such as uniformity of film thickness can be brought into a desired state. In the film-forming method of the first aspect of the present invention, the film-forming conditions include a film-forming time for filming the resin material film on each of the substrates, or spraying a liquid resin material as a mist on the heating portion. At least any one of the supply amount per unit time. Therefore, by extending the film formation time or gradually increasing the supply amount per unit time of the resin material sprayed in a liquid state to the heating portion in a mist form, uniformization of the film formation rate can be achieved. In the film-forming method according to the first aspect of the present invention, the heating section has an inclined surface, thereby reducing the ratio of the supply amount of the resin material corresponding to the cumulative amount of vaporization. In the film-forming method according to the first aspect of the present invention, the resin material may be a material of an ultraviolet curing acrylic resin. According to a second aspect of the present invention, the film forming apparatus may include a recording unit that records gasification operation data including a cumulative amount of the resin material supplied to the heating unit, and a control unit that references the gasification operation data, It is determined at least any one of a time for extending the film formation time or an increase in the amount of supply per unit time of spraying the liquid resin material to the heating portion in a mist form. According to the manufacturing method of the element structure of the third aspect of the present invention, in the above-mentioned second step, the supply state is controlled in such a manner as to compensate the resin material that is reduced corresponding to the gasification duration of the resin material that is vaporized, With this, the supply amount of the resin material can be stabilized regardless of the film formation time, and even when a plurality of substrates are sequentially formed into a film, the supply amount of the resin material can be made regardless of the film formation order and film formation. It is stable over time, which prevents variations in the film formation rate. In addition, it is possible to stabilize the film formation rate to form a resin material film having desired film characteristics, and by using the localized resin material film (resin material), it is possible to reliably use the localized resin material film (resin material). The functional layer is sealed, so that a device structure with high barrier properties can be manufactured. In the manufacturing method of the element structure of the third aspect of the present invention, in the second step, the resin material film is extended according to the supply amount of the resin material corresponding to the supply time of the vaporized resin material. The film forming time can be easily compensated for the above-mentioned resin material which is reduced in accordance with the processing time, thereby achieving stabilization of the film forming rate and preventing changes in film characteristics. In the manufacturing method of the element structure of the third aspect of the present invention, during the film forming process of the resin material film in the second step, the vaporized resin material is supplied, and during the non-film forming process, The vaporized resin material is sent to the outside of the film forming chamber. A cumulative amount obtained by accumulating the supply amount of the resin material as the vaporization amount of the resin material, and controlling the film forming time of the resin material film according to the cumulative amount, thereby performing the film formation of a plurality of sheets, The film thickness can be controlled regardless of the film formation sequence and the elapse of the film formation time. In the third aspect of the method for manufacturing an element structure of the present invention, the third step is to observe the first layer from a side cross-section, and to expose a region including a top portion on an outer side surface of the convex portion. The resin material film is removed. Thereby, the localized resin material film (resin material) can be easily used to surely seal the functional layer including the first layer and the second layer, so that the first layer can be sealed without unnecessary damage. The unnecessary part of the resin material film (resin material) is removed, and only the part to be sealed is localized. Thereby, a device structure having a high barrier property can be manufactured. In the manufacturing method of the element structure of the third aspect of the present invention, the third step uses the dry etching method as a method for removing the resin material film, so that the resin can be removed without causing unnecessary damage to the first layer. The unnecessary part of the material film is removed, and only the part to be sealed is localized. In the third step, a change in a specific condition among the conditions for performing the etching treatment on the resin material film is detected and used as an end point of the etching treatment, so that the resin material film can be reliably removed, and Can reduce unnecessary damage to the first layer. According to the manufacturing apparatus of the element structure of the fourth aspect of the present invention, the supply amount of the resin material can be stabilized regardless of the film formation time, and even when a plurality of substrates are sequentially film-formed, The supply amount of the resin material can be stabilized regardless of the film formation sequence and film formation time, thereby preventing a change in the film formation rate. In addition, the film formation rate can be stabilized to form a resin material film having desired film characteristics, and the localized resin material film can be used to reliably seal the functional layer including the first layer and the second layer. Therefore, a device structure with higher barrier properties can be manufactured. Effects of the Invention According to aspects of the present invention, the following effects can be achieved: stabilization of the supply state of the resin material, prevention of film formation failure caused by fluctuations in the supply amount, stabilization of the film formation rate, and stable film formation Resin material film.

以下,基於圖式對本發明之第1實施形態之成膜方法、成膜裝置、元件結構體之製造方法及元件結構體之製造裝置進行說明。 圖1係表示本實施形態之元件結構體之製造裝置(成膜裝置)之概略模式圖。圖2係表示本實施形態之元件結構體之製造裝置之概略模式圖。圖3係表示本實施形態之元件結構體之製造方法之流程圖,於圖1中,符號1000係元件結構體之製造裝置。 如下所述,本實施形態之元件結構體之製造裝置1000進行有機EL元件等元件結構體之製造。如圖1所示,製造裝置1000具有第一層形成部201、樹脂成膜部100、定域化處理部202、第二層形成部203、形成成為有機EL層之功能層之功能層形成部204、核心室200、及連接於外部之加載互鎖真空室210。核心室200連結於第一層形成部201、樹脂成膜部100、定域化處理部202、第二層形成部203、功能層形成部204及加載互鎖真空室210。 加載互鎖真空室210之內部係供插入自其他裝置等搬送至元件結構體之製造裝置1000之基板。於核心室200,例如配置有未圖示之基板搬送機器人。藉此,能於核心室200與第一層形成部201、樹脂成膜部100、定域化處理部202、第二層形成部203、功能層形成部204、加載互鎖真空室210各者之間進行基板之搬送。能經由該加載互鎖真空室210將基板向元件結構體之製造裝置1000之外側搬送。核心室200、各成膜室100、201、202、203、204、加載互鎖真空室210分別構成與未圖示之真空排氣系統連接之真空腔室。 藉由使用具有上述構成之元件結構體之製造裝置1000進行元件結構體10之製造,能使各製造步驟自動化,並且能同時使用複數個成膜室高效地進行製造,從而能提高生產性。 第一層形成部201形成下述元件結構體10中之第一層41,該第一層41被覆配置於基板2之一面側2a之功能層3,並且具有局部性之凸部,包含氮化矽(SiNx )等無機材料。第一層形成部201係藉由例如CVD(Chemical Vapor Deposition,化學氣相沈積)法、濺鍍法、或ALD(Atomic Layer Deposition,原子層沈積)法等成膜第一層41之成膜室。 功能層形成部204形成下述元件結構體10中之功能層3。再者,功能層形成部204亦可設置於加載互鎖真空室210之外側。 第二層形成部203係以將第一層41及樹脂材51被覆之方式形成下述元件結構體10中之第二層42之成膜室,該第二層42係與第一層41同樣地包含無機材料。再者,於第二層42與第一層41係包含相同材料之情形時,亦可將第二層形成部203與第一層形成部201設定為相同之構成,或使用一個成膜室(共用之成膜室)形成第二層42與第一層41。 進而,於第二層形成部203與第一層形成部201之任一者、或共用之成膜室係由電漿CVD裝置所構成之情形時,該形成部201、203或成膜室不僅具有上述功能,亦可兼具下述定域化處理部202之功能。例如,將形成有樹脂膜之基板搬入至電漿CVD裝置,並導入氧化性氣體使產生電漿,藉此能對樹脂膜進行蝕刻,使樹脂膜定域化而形成樹脂材。其後,亦能直接於電漿CVD裝置內形成第二層42。 樹脂成膜部100係成膜室,即,將氣化之樹脂材料供給至樹脂成膜部100之內部,於第一層41上形成包含樹脂材料之樹脂材料膜,且使樹脂材料膜硬化而形成樹脂膜。 如圖2所示,樹脂成膜部100具有內部空間能減壓之腔室110、將氣化之樹脂材料供給至腔室110(處理室)之氣化器300、及控制部400。 如下所述,腔室110之內部空間由上部空間107及下部空間108構成。 於腔室110,連接有未圖示之真空排氣裝置(真空排氣設備、真空泵等),真空排氣裝置係以能將內部空間之氣體排出以使腔室110之內部空間成為真空環境之方式構成。 如圖2所示,於腔室110之內部空間配置有簇射板105,腔室110內較簇射板105更靠上側之空間構成上部空間107。於腔室110之最上部設置有包含石英等能透過紫外光之構件之頂板120,於頂板120之上側配置有紫外光之照射裝置122(UV照射裝置)。 此處,簇射板105亦係由能透過紫外光之構件所形成,藉此自照射裝置122通過頂板120導入至上部空間107之紫外光能進而通過簇射板105,向位於簇射板105下側之下部空間108行進。藉此,能於成膜後對下述形成於基板S上之丙烯酸材料膜(樹脂材料膜)照射紫外光,使丙烯酸材料膜硬化而形成丙烯酸樹脂膜(樹脂膜)。 於腔室110配置有未圖示之加熱裝置。構成上部空間107及下部空間108之腔室110之內壁面之溫度能以成為樹脂材料之氣化溫度以上、較佳成為40~250℃左右之方式設定,其係由加熱裝置控制。 於在腔室110內位於較簇射板105更靠下側之下部空間108,配置有載置基板S之載台102(基板保持部)。 於載台102,於表面預先設定有應配置基板之位置。載台102係以使該表面露出之狀態配置於腔室110內。符號S表示配置於基板載台102之表面之特定位置之基板。於載台102設置有冷卻基板S之基板冷卻裝置102a。 基板冷卻裝置102a係對載台102內部供給冷媒而將載台102上表面之基板S冷卻。具體而言,基板S之溫度由內置於載置基板S之載台102(基板保持部)之冷卻裝置102a控制,被控制於樹脂材料之氣化溫度以下、較佳為零度(0℃)以下、例如-30℃~0℃左右。 於載台102之上側位置,與載台102之整個表面對向而設置有簇射板105。簇射板105係由設置有多個貫通孔之板狀構件所構成,該板狀構件包含石英等紫外線透過材料,上述簇射板105將腔室110之內部空間分割為上空間與下空間。 於下部空間108設置有未圖示之遮罩,該遮罩之位置於成膜時可被設定為特定位置。於基板移動時,遮罩能以自基板退避之方式移動。 腔室110之上部空間107經由配管112(樹脂材料供給管)及閥112V與氣化器300連通。能經由該樹脂材料供給管112對腔室110之上部空間107供給氣化之樹脂材料。 於樹脂材料供給管112(第一配管)之較閥112V靠氣化器300更近之位置,連接有具有閥113V之樹脂材料迂迴管113之一端。樹脂材料迂迴管113(第二配管)之另一端經由排氣管114連接於外部,氣體能通過樹脂材料迂迴管113排出。排氣管114連接於液化回收裝置,能使樹脂材料液化後加以回收。 閥112V及閥113V之開閉驅動由控制部400控制。控制部400係以能於成膜狀態與非成膜狀態之間切換之方式進行控制,上述成膜狀態係指將來自氣化器300之氣化之樹脂材料供給至腔室110內;上述非成膜狀態係指向外部進行來自氣化器300之氣化之樹脂材料之排氣,而不將其供給至腔室110內。 閥112V、閥113V及控制部400構成切換部,該切換部具有通過樹脂材料供給管112對腔室110之內部供給樹脂材料、或通過樹脂材料迂迴管113向腔室110之外部進行樹脂材料排氣之選擇功能。 氣化器300能對腔室110供給氣化之樹脂材料。如圖2所示,氣化器300具有氣化槽130、噴出部132及樹脂材料原料容器150。 如圖2所示,氣化槽130具備用以使液狀之樹脂材料氣化之內部空間,於內部空間之上方,配置有以霧狀噴出液狀之樹脂材料之噴出部132。氣化槽130形成為大致圓筒狀,但亦可設定為其他剖面形狀。氣化槽130之內表面例如可包含SUS、Al等。 於噴出部132連接有與樹脂材料原料容器150經由閥140V而連接之樹脂材料液供給管140之一端、及供給氮氣等載氣之載氣供給管130G。樹脂材料液供給管140之另一端連接於樹脂材料原料容器150,並且位於樹脂材料原料容器150內所貯存之液狀之樹脂材料之內部。 於樹脂材料原料容器150,連接有氮氣等材料液供給用之加壓氣體供給管150G,能向樹脂材料液供給管140輸送使樹脂材料原料容器150之內壓上升而得以加壓之液狀之樹脂材料。 噴出部132係以將自樹脂材料液供給管140供給之液狀之樹脂材料以霧狀連同載氣一併向氣化槽130之內部空間噴出之方式構成。噴出部132設置於氣化槽130之頂部大致中央位置。 亦可於氣化槽130之內部空間設置具有斜面之加溫部135,而對加熱構件以霧狀噴出樹脂材料。 於氣化槽130設置有真空計PG,從而能測定內部之壓力。 又,於氣化槽130之側壁,設置有對與內部空間相接之面之溫度進行控制之溫度控制裝置,具體而言,設置有對氣化槽130之側壁進行加溫之加熱器。 在連接於氣化槽130之樹脂材料供給管112(第一配管),亦設置有加熱器作為相同之溫度調整裝置。該加熱器捲繞於樹脂材料供給管(第一配管),使氣化之樹脂材料不會於壁面凝縮。 再者,亦可於樹脂材料迂迴管113設置加熱器作為相同之溫度調整裝置。 該等加熱器能將露出於氣化之樹脂材料之表面之溫度設定為高於樹脂材料之氣化溫度之狀態,從而防止樹脂材料液化。同時,以儘量降低樹脂材料之加熱固化之方式進行溫度設定。 於氣化器300使樹脂材料氣化時,設為藉由加熱器將氣化槽130及樹脂材料供給管112(第一配管)加溫之狀態。 同時,藉由控制部400使閥112V成為關閉狀態而形成氣體無法流入至樹脂材料供給管112之狀態,並且使閥113V成為打開狀態而形成氣體能流入至樹脂材料迂迴管113之狀態。 於該狀態下,使樹脂材料原料容器150之內壓上升,將自樹脂材料液供給管140供給之液狀之樹脂材料以霧狀連同載氣一併自噴出部132向氣化槽130之內部空間噴出。此時,亦可對供給至噴出部132之樹脂材料及載氣進而進行加溫。 自噴出部132以霧狀連同載氣一併向氣化槽130之內部空間噴出之樹脂材料於加溫後之氣化槽130內部氣化。 再者,於本實施形態中,有使用紫外線硬化樹脂材料作為樹脂材料之情形時。紫外線硬化樹脂材料有因加熱等而一部分聚合、變質之情形時。如此變化後之樹脂有如下可能性,即:蒸發溫度上升,該樹脂不蒸發而殘存於加溫部135或氣化槽130表面,從而蒸發量變動。 於樹脂材料之氣化穩定地進行之期間,藉由控制部400使閥112V成為打開狀態,而形成氣體能流入至樹脂材料供給管112之狀態,並且使閥113V成為關閉狀態,而形成氣體無法流入至樹脂材料迂迴管113之狀態。藉此,能對腔室110供給氣化之樹脂材料而進行成膜處理。 藉由切換部之驅動,即,僅藉由利用控制部400對閥112V及閥113V之開閉狀態進行切換,便能選擇對樹脂材料供給管112(第一配管)供給樹脂材料與對樹脂材料迂迴管113(第二配管)供給樹脂材料。因此,能使供給至腔室110之氣化之樹脂材料之供給量穩定化,故而能使成膜開始時之成膜速率穩定。 樹脂成膜部100例如係以能於同一腔室110內進行成膜及紫外線照射之方式構成,上述成膜係以40~250℃左右之氣化溫度,對紫外線硬化型丙烯酸樹脂材料進行之成膜;上述紫外線照射係用以使成膜後之樹脂材料硬化。藉此,能以相同之裝置構成進行任一處理步驟,從而能提高生產性。 於樹脂成膜部100中,作為本實施形態之元件結構體之製造方法(成膜方法)中之步驟B,於成膜下述液狀之樹脂材料膜5a時,控制樹脂材料之供給。如圖3所示,步驟B具有檢量線獲取步驟S01、補償時間設定步驟S02、外部排氣切換步驟S03、氣化開始步驟S04、氣化持續時間計測步驟S05、膜厚設定步驟S06、供給時間設定步驟S07、基板搬入步驟S08、供給開始步驟S09、供給時間計測步驟S10、供給停止步驟S11、基板搬出步驟S12及氣化停止步驟S13。 於圖3所示之檢量線獲取步驟S01中,相對於來自氣化器300之氣化之樹脂材料供給量,如圖15所示般使每1片基板之成膜時間固定而測定膜厚。 此時,於使來自樹脂材料原料容器150之樹脂材料供給量固定而穩定地進行供給之狀態下,對複數片基板S以成為相同之成膜處理時間之方式依序進行成膜,測定各次之膜厚之減少部分(減少量)作為檢量線。 如圖15所示,相對於向氣化器300之累計供給量(氣化器累計樹脂材料供給量(g)),即隨著氣化持續時間之經過,每一片基板之膜厚(=成膜速率)減少。針對該減少,在圖中畫出直線作為檢量線。 於圖3所示之補償時間設定步驟S02中,相對於在檢量線獲取步驟S01中獲取到之檢量線,以補償相對於最初所設定之成膜處理時間之減少部分之方式,對應於累計樹脂材料供給量而設定增加每1片之成膜處理時間之補償時間。該補償時間係以相對於所要成膜之目標膜厚而補償成膜速率之減少之方式設定。補償時間或成膜速率之變化傾向記憶於控制部。 繼而,於圖3所示之外部排氣切換步驟S03中,藉由控制部400對閥112V及閥113V之開閉狀態進行切換,而自氣化器300對樹脂材料迂迴管113(第二配管)供給樹脂材料。 於圖3所示之氣化開始步驟S04中,在該狀態下,如上所述,於氣化器300開始樹脂材料之氣化。 同時,作為圖3所示之氣化持續時間計測步驟S05,開始成為計算出補償時間之基準之氣化持續時間之計測。 繼而,於圖3所示之膜厚設定步驟S06與供給時間設定步驟S07中,預先根據目標膜厚、及成膜開始時之氣化持續時間而計算出補償時間。 具體而言,以與氣化之樹脂材料之氣化持續時間對應地,延長每1次之成膜時間即供給時間之方式進行設定。 繼而,於圖3所示之基板搬入步驟S08中,向樹脂成膜部100搬入基板S。 繼而,於圖3所示之供給開始步驟S09中,藉由控制部400對閥112V及閥113V之開閉狀態進行切換,而自氣化器300對樹脂材料供給管112(第一配管)供給樹脂材料開始成膜。 同時,作為圖3所示之供給時間計測步驟S10,開始被換算為成膜之膜厚之樹脂材料供給量之計測。 繼而,於圖3所示之供給停止步驟S11中,按照在供給時間設定步驟S07中設定之供給時間,藉由控制部400對閥112V及閥113V之開閉狀態進行切換,自氣化器300對樹脂材料迂迴管113(第二配管)供給樹脂材料,獲得目標膜厚而結束成膜。 繼而,作為圖3所示之基板搬出步驟S12,將已成膜之基板S自樹脂成膜部100搬出。 必要時,將自膜厚設定步驟S06至基板搬出步驟S12重複執行複數次。此時,將氣化持續時間計測步驟S05中計測之氣化持續時間累計,根據該值,每次於供給時間設定步驟S07重新計算出補償時間而控制供給停止步驟S11中之切換時間。 具體而言,根據氣化器300中之樹脂材料之氣化持續時間之增加,為了補償因加熱固化之產生等而減少之樹脂材料量,而以補償供給時間來延長成膜時間即供給時間之方式進行設定。 繼而,作為圖3所示之氣化停止步驟S13,將氣化器300中之氣化停止,結束氣化持續時間之計測。再者,膜厚設定步驟S06及供給時間設定步驟S07只要處於在基板搬入步驟S08以後執行之步驟、即實際進行成膜之步驟之前即可,其實施時期、順序不限於上述步驟順序。 又,即便氣化器300不連續運轉,氣化效率亦會因自最近之清零起算之氣化時間之累計而減少。即便反覆執行氣化器300之運轉、停止,只要將氣化時間累計,仍能計算出氣化效率之減少量。 作為本實施形態之元件結構體之製造方法,如上所述以補償對應於處理時間而減少之氣化之樹脂材料之供給的方式控制供給狀態。藉此,使樹脂材料之成膜速率不管氣化持續時間如何經過而均穩定,並且如圖16所示,即便於對複數個基板S依序進行成膜之情形時,亦可使樹脂材料之成膜速率不管成膜次數及成膜時間而均穩定。因此,能防止成膜特性產生變動,從而能防止膜特性(膜厚)變動。 再者,各步驟之控制可由控制部400執行,檢量線之計算或成膜時間之計算及累計亦由控制部400所具有之運算部執行。進而,必要資料之記憶亦由控制部400所具有之記憶部執行。 以下,對藉由本實施形態之元件結構體之製造裝置1000而製造出之元件結構體10進行說明。 圖4係表示本實施形態之元件結構體之概略剖視圖。圖5係表示圖4之元件結構體之俯視圖。圖6係表示元件結構體之主要部分之放大圖。於各圖中,X軸、Y軸及Z軸方向表示相互正交之三軸方向,於本實施形態中,X軸及Y軸方向表示相互正交之水平方向,Z軸方向表示鉛直方向。 本實施形態之元件結構體10具備:基板2,其包含器件層3(功能層);第1無機材料層41(第一層),其形成於基板2之正面2a,被覆功能層3,並且具有局部性之凸部,包含氮化矽(SiNx )等無機材料;及第2無機材料層42(第三層),其被覆第1無機材料層41,且與第一層41相同。於本實施形態中,元件結構體10係由具有有機EL發光層之發光元件所構成。 基板2具有正面2a(第1面)與背面2c(第2面),例如係由玻璃基板、塑料基板等所構成。基板2之形狀不特別限定,於本實施形態中,其形成為矩形。基板2之大小、厚度等不特別限定,可對應於元件尺寸之大小,使用具有適宜之大小、厚度之基板。於本實施形態中,由在一片大型基板S上所製作出之相同元件之集合體而製作出複數個元件結構體10。 器件層3(功能層)係由包含上部電極及下部電極之有機EL發光層所構成。除此種構成以外,器件層3亦可為由如液晶元件中之液晶層或發電元件中之發電層等般包含容易因水分、氧等而劣化之性質之材料的各種功能元件所構成。 器件層3成膜於基板2正面2a之特定區域。器件層3之平面形狀不特別限定,於本實施形態中,其形成為大致矩形,但除此種形狀以外,亦可採用圓形、線形等形狀。器件層3不限於配置在基板2正面2a之例,只要配置在基板2之正面2a及背面2c中之至少一面即可。 第1無機材料層41(第一層)設置於配置器件層3之基板2之面2a,構成將器件層3之正面3a及側面3s被覆之凸部。第1無機材料層41具有自基板2之正面2a向圖6中之上方突出之立體結構。 第1無機材料層41係包含能保護器件層3免受水分或氧影響之無機材料。於本實施形態中,第1無機材料層41係由水蒸氣阻隔特性優異之氮化矽(SiNx )所構成,但其材料不限定於此。亦可由氧化矽或氮氧化矽等其他矽化合物、或氧化鋁等具有水蒸氣阻隔性之其他無機材料構成第1無機材料層41。 第1無機材料層41例如係使用適宜之遮罩而成膜於基板2之正面2a。於本實施形態中,使用具有大小能收容器件層3之矩形開口部之遮罩而成膜第1無機材料層41。成膜方法不特別限定,可應用CVD(Chemical Vapor Deposition)法、濺鍍法、或ALD(Atomic Layer Deposition)法等。第1無機材料層41之厚度不特別限定,例如為200 nm~2 μm。 第2無機材料層42(第二層)與第1無機材料層41同樣地,係包含能保護器件層3免受水分或氧影響之無機材料,且係以將第1無機材料層41之正面41a及側面41s被覆之方式設置於基板2之正面2a。於本實施形態中,第2無機材料層42係由水蒸氣阻隔特性優異之氮化矽(SiNx )所構成,但其材料不限定於此。亦可由氧化矽或氮氧化矽等其他矽化合物、或氧化鋁等具有水蒸氣阻隔性之其他無機材料構成第2無機材料層42。 第2無機材料層42例如係使用適宜之遮罩而成膜於基板2之正面2a。於本實施形態中,使用具有大小能收容第1無機材料層41之矩形開口部之遮罩而成膜第2無機材料層42。成膜方法不特別限定,可應用CVD(Chemical Vapor Deposition)法、濺鍍法、或ALD(Atomic Layer Deposition)法等。第2無機材料層42之厚度不特別限定,例如為200 nm~2 μm。 本實施形態之元件結構體10進而具有第1樹脂材51。第1樹脂材51偏集存在於第1無機材料層41(凸部)之周圍。於本實施形態中,第1樹脂材51介置於第1無機材料層41與第2無機材料層42之間,且偏集存在於第1無機材料層41之側面41s與基板2之正面2a之邊界部2b。第1樹脂材51具有將形成於邊界部2b附近之第1無機材料層41與基板正面2a之間之間隙G(圖6)填充之功能。 於圖6中,將元件結構體10之邊界部2b之周邊結構放大表示。由於第1無機材料層41係由無機材料之CVD膜或濺鍍膜所形成,故而對包含器件層3之基板2之凹凸結構面之覆蓋特性(階差被覆性)相對較低。其結果,如圖6所示般將器件層3之側面3s被覆之第1無機材料層41有於基板正面2a附近覆蓋特性降低,被覆膜厚極小,或根本不存在被覆膜之狀態之虞。 因此,於本實施形態中,藉由使第1樹脂材51偏集存在於如上所述之第1無機材料層41周邊之被覆不良區域,會抑制水分或氧自該被覆不良區域向器件層3內部侵入。又,於第2無機材料層42之成膜時,藉由使第1樹脂材51作為第2無機材料層42之基底層發揮功能,能進行第2無機材料層42之恰當成膜,從而能將第1無機材料層41之側面41s以所期望之膜厚得當地被覆。 第1樹脂材51之形成方法如下:將藉由噴霧氣化而氣化之樹脂材料供給至基板正面2a使之凝縮而形成樹脂材料膜5a,使樹脂材料膜5a硬化而形成樹脂膜5,而後,藉由將非主要部分去除之定域化步驟而形成第1樹脂材51。 以下,對藉由本實施形態之元件結構體之製造裝置而執行之元件結構體之製造方法進行說明。 圖7~圖11係模式性地表示本實施形態之元件結構體之製造方法中的第1樹脂材51之形成方法之步驟圖。 (器件層之形成步驟例~步驟A) 首先,於圖1所示之元件結構體之製造裝置1000中,將自加載互鎖真空室210搬入至核心室200之基板S藉由未圖示之基板搬送機器人自核心室200搬送至功能層形成部204。於該功能層形成部204中,在基板S上之特定區域形成器件層3(功能層)。 於本實施形態中,作為成為功能層3之區域,可使用基板S上之複數個區域,例如,於X軸方向及Y軸方向分別各有2個地以特定間隔排列之4個區域配置、或單個成為功能層3之區域。 器件層3之形成方法不特別限定,可根據器件層3之材料、構成等進行適宜選擇。例如,將基板S搬送至功能層形成部204之成膜室等,向基板S上進行特定材料之蒸鍍、濺鍍等,進而實施圖案加工等,藉此便能於基板S上之特定區域上形成所期望之器件層3。圖案加工之方法不特別限定,例如可採用蝕刻等。 再者,關於元件結構體之製造裝置1000之具體構成,圖1中省略了詳細說明。功能層形成部204可採用由多個處理室構成,且具有能於相鄰之處理室之間搬送基板S之搬送裝置的構成。或可採用真空裝置以外之構成。即,無需經由加載互鎖真空室210而能於元件結構體之製造裝置1000之外部對基板S進行處理。 (第一層之形成步驟例~步驟A) 其次,將形成有器件層3之基板S藉由未圖示之基板搬送機器人自功能層形成部204搬出,並經由核心室200搬入至第一層形成部201。 於第一層形成部201中,以將器件層3被覆之方式,於包含器件層3之區域之基板S上之特定區域形成第1無機材料層41(第一層)。藉此,如圖7所示,以於基板S上具有凸部之方式形成將器件層3被覆之第1無機材料層41。 於本步驟中,例如,亦可使用具有與第1無機材料層41之區域對應之個數個開口之遮罩,例如形成由氮化矽構成之第1無機材料層41作為保護層之一部分。 此處,第一層形成部201可設定為具有CVD處理裝置、或濺鍍處理裝置之構成。又,雖未圖示,但於第一層形成部201之成膜室,設置有用以配置基板S之載台、配置於基板S上之遮罩、支持遮罩並對載台上之基板S進行遮罩之對位等之遮罩對準裝置、及成膜材料供給裝置等。 將形成有器件層3之基板S藉由配置於核心室200之基板搬送機器人等配置於第一層形成部201之載台上。藉由遮罩對準裝置等,以使器件層3經由遮罩之開口露出之方式,於基板S上之特定位置配置遮罩。 然後,例如,藉由CVD法,以將器件層3被覆之方式形成由氮化矽等構成之第1無機材料層41。再者,第1無機材料層41之形成方法不限於CVD法,例如亦可採用濺鍍法。於該情形時,第一層形成部201係以具有濺鍍裝置之方式構成。 (樹脂膜之形成步驟例~成膜步驟~步驟B、步驟C) 其次,將形成有具有凸部之第1無機材料層41之基板S藉由未圖示之基板搬送機器人自第一層形成部201搬出,並經由核心室200搬入至樹脂成膜部100。 此時,將腔室110內之氣體藉由真空排氣裝置排出而使腔室110內維持真空狀態。以後,藉由連續地驅動真空排氣裝置,而使腔室110之環境維持真空環境。 此時,藉由加溫裝置,以使至少上部空間107及下部空間108之內表面側之溫度成為樹脂材料之氣化溫度以上之方式對腔室110進行設定。同時,藉由基板冷卻裝置102a,將配置於載台102上之基板S連同載台102一併冷卻至低於樹脂材料之氣化溫度之溫度。 又,藉由加熱器112d,形成將樹脂材料供給管112(第一配管)加溫至樹脂材料之氣化溫度以上之狀態。 樹脂成膜部100執行於形成有第1無機材料層41之基板S形成樹脂材料膜5a之步驟、及使樹脂材料膜5a硬化而形成樹脂膜5之步驟。於本步驟中,首先,使用樹脂成膜部100,例如,形成包含紫外線硬化型丙烯酸樹脂之材料之樹脂材料膜5a。 關於樹脂成膜部100中之樹脂材料膜5a之形成步驟,於基板S搬入前,首先如圖3所示,作為檢量線獲取步驟S01與補償時間設定步驟S02,獲取檢量線,設定補償時間。 繼而,如圖3所示,作為外部排氣切換步驟S03、氣化開始步驟S04及氣化持續時間計測步驟S05,於氣化器300中進行使樹脂材料之氣化穩定地進行之處理。 於該氣化穩定化處理之期間,藉由控制部400使閥112V成為關閉狀態,而形成氣體無法流入至樹脂材料供給管112之狀態,並且使閥113V成為打開狀態,而維持氣體能流入至樹脂材料迂迴管113之狀態。 再者,氣化器300中之樹脂材料之氣化較佳為根據所供給之氣化樹脂材料量之穩定度而於成膜處理前維持必要時間。 繼而,如圖3所示,作為膜厚設定步驟S06、供給時間設定步驟S07及基板搬入步驟S08,設定成膜膜厚,藉由控制部400設定該處理所需之處理時間,如上所述,將搬入至樹脂成膜部100之基板S載置於載台102上。 在配置於載台102上之基板S上,藉由遮罩載置裝置等將未圖示之遮罩配置於基板S上之特定位置。 繼而,以遮罩對準狀態、腔室110內之環境、腔室110之內壁之溫度、樹脂材料供給管112之溫度、基板S之溫度等條件成為特定狀態之方式,藉由控制部400進行設定。 繼而,如圖3所示,作為供給開始步驟S09與供給時間計測步驟S10,藉由控制部400對閥112V及閥113V之開閉狀態進行切換。藉此,使閥112V成為打開狀態,而使氣體流入至樹脂材料供給管112,並且使閥113V成為關閉狀態,而形成氣體不向樹脂材料迂迴管113V流入之狀態。藉此,對腔室110供給氣化之樹脂材料。 將自氣化器300供給之氣化之樹脂材料通過樹脂材料供給管112之內部,自上部空間107經由簇射板105供給至下部空間108內。 於下部空間108中,藉由簇射板105而大致均勻地供給至基板S整個表面之氣化之樹脂材料如圖8所示,於基板正面2a凝縮而成為液狀之樹脂材料膜5a。液狀之樹脂材料膜5a中,於在基板正面2a上具有劣角之角部、凹部、間隙部等處,藉由表面張力而樹脂材料膜5a之膜厚變厚。 於該步驟B中,以補償對應於氣化持續時間而減少之樹脂材料之方式,藉由控制部400控制處理時間(供給時間),藉此使成膜速率均勻化。 此時,亦可藉由未圖示之遮罩,使樹脂材料膜5a僅形成於靠近凸部41之部分(附近之位置)等區域。再者,較佳為將樹脂材料之液化及成膜速率考慮在內,藉由控制部400而控制自氣化器300供給之樹脂材料之供給量。 於基板S之表面液化之樹脂材料藉由毛細管現象滲入至微細之間隙,或藉由樹脂材料之表面張力進而凝集,因此能一面使基板S上之微細之凹凸平滑化,一面形成樹脂材料膜5a。藉此,於在基板S之表面上具有劣角之角部、凹部、間隙部等處,樹脂材料膜5a之膜厚變厚。尤其是,能將第1無機材料層41之側面41s與基板2之正面2a之邊界部2b之微細之間隙藉由樹脂材料膜5a而填埋。 又,氣化之樹脂材料因腔室110被加熱而不會於腔室110內壁等之表面凝縮。 在經過基於所設定之補償時間之供給時間後,如圖3所示,作為供給停止步驟S11,於基板S之表面形成特定厚度之樹脂材料膜5a。其後,藉由控制部400使閥112V成為關閉狀態而形成氣體無法流入至腔室110之狀態,並且使閥113V成為打開狀態而形成氣體能流入至樹脂材料迂迴管113之狀態。 由於腔室110被連續排氣,故而氣化樹脂材料排出至腔室110外部而停止成膜。 於該狀態下,一面維持腔室110內之真空環境,一面自UV照射裝置122向基板S之表面照射紫外線。被照射出之紫外線透過包含石英等紫外線透過材料之頂板120及簇射板105而到達腔室110內之基板S上。 於腔室110內向基板S照射之紫外線之一部分入射至基板S之表面,而於形成在基板S表面之包含樹脂材料之樹脂材料膜5a產生光聚合反應,從而液狀膜5a硬化。如圖9所示,於基板S之表面形成樹脂膜5。於本實施形態中,形成丙烯酸樹脂之薄膜。 繼而,藉由遮罩載置裝置等將未圖示之遮罩自基板S上之成膜位置向退避位置移動。 於步驟B結束後,如圖3所示,作為基板搬出步驟S12,將形成有樹脂膜5之基板S藉由未圖示之基板搬送機器人自樹脂成膜部100搬出。 於複數個基板S依序形成樹脂膜5之情形時,重複執行上述方法,於需進行樹脂成膜部100之維護、或氣化器300之維護之情形時,作為氣化停止步驟S13,停止氣化器300中之樹脂材料之氣化。 (樹脂材之形成步驟例~定域化步驟~步驟C) 其次,將自樹脂成膜部100搬出之基板S藉由未圖示之基板搬送機器人經由核心室200搬入至定域化處理部202。 此處,定域化處理部202可設為具有乾式蝕刻處理裝置、尤其是電漿蝕刻處理裝置之構成。 又,雖未圖示,但定域化處理部202亦可為平行平板型之電漿處理裝置。於該情形時,在定域化處理部202中,將基板S載置於電極,向腔室內導入蝕刻氣體,將藉由高頻電源而產生之高頻經由天線照射至腔室內而產生電漿,並且自高頻電源對載置有基板S之電極施加偏壓電壓。將電漿中存在之離子引入至載置於電極之基板,對形成於基板S表面之樹脂膜5進行蝕刻而將其去除。 此處,藉由產自氧化性氣體等蝕刻氣體之電漿中之離子對樹脂膜5進行蝕刻。此時,為將離子引向電極上之基板S,亦可對電極施加偏壓電壓。 藉由蝕刻將膜厚較薄之平坦部分之樹脂膜5去除,於在基板S之表面上具有劣角之角部、凹部、間隙部等處殘存有較平坦部厚之部分之樹脂膜5。該殘存之部分成為第1樹脂材51。 再者,於上述第一層形成部201或第二層形成部203具有濺鍍裝置或電漿CVD裝置之情形時,該形成部201、203不僅具有成膜功能,亦可兼具定域化處理部202之功能。於該情形時,例如,作為第一層形成部201、第二層形成部203及定域化處理部202,可使用同一處理裝置。 於定域化處理部202中,如圖10所示,於形成有樹脂膜5之基板S中,例如,藉由電漿蝕刻,作為步驟C,如圖11所示將樹脂膜5之大部分去除。該電漿處理可根據蝕刻速率而計算出處理時間,且進行特定之處理時間。 進而,可於定域化處理部202設置檢測裝置。該檢測裝置測定對電極施加之偏壓電壓,根據測定值之變化判斷出基板S上之樹脂膜5已幾乎全被去除,並將該判斷結果(檢測結果)用作蝕刻處理之終點 因該乾式蝕刻處理而殘留於基板S上之第1樹脂材51如圖11所示,定域化(局部存在)於第1無機材料層41之側面41s與基板2之正面2a之邊界部2b。進而,第1樹脂材51偏集存在於能將第1無機材料層41表面之微細之凹凸平滑化之部分。 (第二層之形成步驟例~步驟D) 將局域存在地形成有第1樹脂材51之基板S藉由未圖示之基板搬送機器人自定域化處理部202搬出,並經由核心室200搬入至第二層形成部203。 於第二層形成部203中,以將形成有第1樹脂材51之第1無機材料層41被覆之方式,於包含凸部之基板S上之特定區域形成第2無機材料層42(第二層)。 於該步驟D中,與第1無機材料層41同樣地,使用具有與第2無機材料層42之區域對應之個數個開口之遮罩,形成與第1無機材料層41為相同材料之例如包含氮化矽之第2無機材料層42(第二層)。藉此,能利用第1無機材料層41(第一層)、第1樹脂材51及第2無機材料層42(第二層)將器件層3(功能層)被覆,使其等作為保護器件層3之保護層發揮功能。 此處,第二層形成部203可設定為具有CVD處理裝置或濺鍍處理裝置之構成。 第二層形成部203可具有與上述第一層形成部201相同之裝置構成。例如,作為第一層形成部201及第二層形成部203,可使用同一處理裝置、或使第二層形成部203兼具第一層形成部201之功能。 又,於第二層形成部203為電漿CVD處理裝置之情形時,第二層形成部203可兼具定域化處理部202之功能。若於第二層形成部203中進行第1樹脂材51之定域化,則能於定域化後,直接形成第2無機材料層42(第二層)。 其後,將形成有第2無機材料層42之基板S藉由未圖示之基板搬送機器人自第二層形成部203搬出,並經由核心室200及加載互鎖真空室210搬出至元件結構體之製造裝置1000之外部。 於本實施形態之元件結構體之製造裝置1000中,作為步驟B,藉由樹脂成膜部100形成樹脂膜5。其後,於定域化處理部202,作為步驟C形成藉由電漿蝕刻處理而定域化之第1樹脂材51。其後,形成第2無機材料層42(第二層),藉此能於邊界部2b等被要求具有作為保護層之阻隔性之部位,確實地形成第2無機材料層42(第二層)。 而且,藉由控制部400以使樹脂材料之成膜速率穩定化之方式進行控制,具體而言,於步驟B中,補償對應於使氣化器300動作之氣化持續時間而減少之樹脂材料量。因此,藉由以延長成膜時間即供給時間之方式控制供給狀態,能使成膜速率穩定,從而防止膜特性變動。 根據本實施形態之元件結構體之製造方法,如圖15所示,於相對於目標膜厚而僅單純地將供給時間設定為固定之情形時,如圖16所示,就對應於氣化持續時間(丙烯酸供給量)而減少之膜厚而言,追加對應於氣化持續時間(丙烯酸供給量)而延長之補償時間來設定供給時間(處理時間)。可知藉此即便多次重複,亦會形成相同之膜厚。即,能補償成膜速率之減少。 以下,對藉由本實施形態之元件結構體之製造裝置1000而製造出之元件結構體之另一例進行說明。 於藉由本實施形態之元件結構體之製造裝置1000而製造出之本例之元件結構體10中,並不僅限於樹脂材偏集存在於第1無機材料層41(凸部)之周圍即邊界部2b之結構,例如,亦可為該樹脂材料殘留於邊界部2b以外之基板2之正面2a或第1無機材料層41之正面41a等。 於該情形時,如圖12所示,第2無機材料層42(第二層)具有經由第2樹脂材52積層於第1無機材料層41之上之區域。第2樹脂材52介置於第1無機材料層41與第2無機材料層42之間,且獨立於第1樹脂材51地偏集存在於第1無機材料層41之正面41a。 如上所述,根據本實施形態之元件結構體10,器件層3之側面由第1無機材料層41(第一層)及第2無機材料層42(第二層)被覆,因此能防止水分或氧向器件層3侵入。 又,根據本實施形態,第1樹脂材51偏集存在於邊界部2b,因此能防止伴隨第1無機材料層41或第2無機材料層42之覆蓋性不良而產生之阻隔特性之降低,從而能長期維持穩定之元件特性。 以下,對藉由本實施形態之元件結構體之製造裝置1000而製造出之元件結構體之另一例進行說明。 如圖13所示,本例之元件結構體20進而具有介置於第1無機材料層41與第2無機材料層42之間之第2樹脂材52。第2樹脂材52獨立於第1樹脂材51地偏集存在於第1無機材料層41之表面。 於本例之元件結構體20中,第1無機材料層41之表面未必平坦,例如,例示了如下情形,即:於成膜前(基板搬送時或向成膜裝置中投入前)或成膜時等,微粒P混入至膜中,而導致形成有凹凸。若微粒混入至第1無機材料層41,則第1無機材料層41對器件層3之覆蓋特性降低,而有無法獲得所期望之阻隔特性之虞。 因此,本例之元件結構體20具有於因微粒P之混入等而產生之第1無機材料層41之被覆不良部填充有第2樹脂材52之結構。較為典型的是,該第2樹脂材52藉由表面張力而偏集存在於第1無機材料層41之表面與微粒P之周面之邊界部32b。藉此,器件層3之被覆性提高,並且藉由使第2樹脂材52作為基底發揮功能,能實現第2無機材料層42之恰當成膜。再者,成膜時亦能於平坦部分較薄地形成樹脂膜5。於微粒P之周邊,藉由表面張力形成較平坦部厚之樹脂膜5。 第2樹脂材52係以與第1樹脂材51相同之方法形成。第2樹脂材52亦可係由與第1樹脂材51相同之有機物所構成。於該情形時,能於同一步驟中同時形成第1樹脂材51與第2樹脂材52。 此處,於定域化處理部202中,在如下時候停止樹脂膜5之蝕刻,即,藉由蝕刻,將較薄之部分去除,而使較厚之部分殘存,即,於存在微粒P之部位以外之部分,將樹脂膜5去除,從而第1無機材料層41露出。藉此,當自上方沿著鉛直方向俯視凸部時,被微粒P遮住之邊界部32b之樹脂膜5不會被過蝕刻,從而樹脂膜5確實地殘存於微粒P周邊之邊界部32b。其結果,於微粒P附近之邊界部32b,樹脂膜5呈現平穩之表面形狀。假如完全不存在微粒P,則當已藉由各向異性蝕刻將樹脂膜5實質上去除時,樹脂膜5會被完全去除,從而第1無機材料層41露出。 再者,蝕刻之停止可基於電漿之發光光譜分析之結果、或各向異性蝕刻之經過時間而執行。 此時,邊界部2b處之樹脂膜5不會被去除,從而樹脂膜5定域化,藉此形成第1樹脂材51。同樣地,邊界部32b處之樹脂膜5不會被去除,從而樹脂膜5定域化,藉此形成第2樹脂材52。 於本例中,亦可獲得與上述元件結構體10之製造相同之作用效果。又,根據本例,能藉由第2樹脂材52補償微粒P之混入所致之膜質降低,因此既能確保所期望之阻隔特性又能實現生產性之提高。 以下,對藉由本實施形態之元件結構體之製造裝置1000而製造出之元件結構體之另一例進行說明。 如圖14所示,本例之元件結構體30例如具有:基板21,其具有器件層3(功能層);凸部40,其將器件層3之側面3s被覆;第1無機材料層41(第一層)及第2無機材料層42(第二層),其等係以將凸部40及器件層3被覆之方式形成於基板21之表面。 凸部40形成於基板21之正面21a,於中央部具有收容器件層3之凹部40a。於本例中,凹部40a之底面形成於較基板21之正面21a高之位置,亦可形成於與正面21a相同之高度位置,或可形成於較正面21a低之位置。 本例之元件結構體30進而具有介置於第1無機材料層41與第2無機材料層42之間之樹脂材53。樹脂材53分別偏集存在於凸部40之外側面與基板21之正面21a之邊界部21b、及凸部40之內側面與器件層3之邊界部22b。 藉此,能抑制第1無機材料層41及第2無機材料層42對凸部40及器件層3之正面3a之被覆不良,從而能實現阻隔特性之提高。可利用與上述第1樹脂材51及第2樹脂材52相同之方法形成樹脂材53。 於如此般具有凹凸之基板S中,藉由偏集存在之樹脂材使無法由無機材料層覆蓋之部分更平坦化。從而能使成膜於樹脂材之上之無機材料層更均勻且覆蓋性良好地成膜。進而,樹脂材對水等之密封低於無機材料層,但偏集存在之樹脂材被無機材料層覆蓋而不會露出於外部環境,故而密封性提高。即,較佳為使樹脂材以不露出於外部環境之方式偏集存在,而非使之呈膜狀。 以上,對本發明之較佳實施形態進行了說明,於上文已說明過,其等僅為本發明之例示性說明,應瞭解其不應被認為係進行限定者。可於不自本發明之範圍脫離之條件下進行追加、省略、替換及其他變更。因此,關於本發明,不應視為係由上述說明限定,其係由申請範圍限制。 例如,於以上實施形態中,將第1無機材料層41(第一層)被覆之第2無機材料層42(第二層)係由單數層所構成,但第2無機材料層42(第二層)亦可係由多層膜所構成。於該情形時,亦可於成膜各層之每一步驟將樹脂材料供給至基板上而形成偏集存在於基板凹凸部之樹脂材,藉此能實現阻隔性之進一步提高。 進而,於以上實施形態中,形成第1無機材料層41(第一層)後,會使第1樹脂材51於成為凸部之第1無機材料層41之周圍定域化,但亦可於藉由第一層形成部201形成第1無機材料層41前,藉由樹脂成膜部100及定域化處理部202,使第1樹脂材51偏集存在於器件層3之周圍。藉此能提高第1無機材料層41對器件層3之被覆效率。 以下,基於圖式對本發明之第2實施形態之成膜方法、成膜裝置、元件結構體之製造方法及元件結構體之製造裝置進行說明。 圖17係表示本實施形態之元件結構體之製造方法(成膜方法)之流程圖,於本實施形態中,與上述第1實施形態不同之處係與成膜速率之補償方法相關之方面,對除此以外之與上述第1實施形態對應之構成標註相同之符號,並省略其之說明。 於上述第1實施形態中,為補償所減少之成膜速率,延長每一片基板S之成膜時間,但於本實施形態中,控制自氣化器300對樹脂成膜部100供給之樹脂材料之供給量而使之經時增加。 具體而言,於成膜樹脂材料膜5a時,控制樹脂材料之供給。如圖17所示,具有檢量線獲取步驟S01、補償樹脂量設定步驟S32、外部排氣切換步驟S03、氣化開始步驟S04、氣化樹脂量累計步驟S35、膜厚設定步驟S06、供給樹脂量設定步驟S37、基板搬入步驟S08、供給開始步驟S09、供給樹脂量計測步驟S30、供給控制步驟S31、供給停止步驟S11、基板搬出步驟S12及氣化停止步驟S13。 於圖17所示之補償樹脂量設定步驟S32中,與第1實施形態中之補償時間設定步驟S02對應,相對於在檢量線獲取步驟S01中獲取到之檢量線,以對最初所設定之與成膜處理相當之樹脂材料之供給量補償其之減少部分之方式,對應於累計樹脂材料供給量而設定相對於1片之成膜處理之時間經過而增加樹脂材料之供給量之補償樹脂量。該補償樹脂量係以相對於所要成膜之目標膜厚而補償成膜速率之減少之方式設定。補償樹脂量或成膜速率之變化傾向記憶於控制部。 與圖17所示之氣化開始步驟S04同時地,作為與圖3所示之氣化持續時間計測步驟S05對應之步驟即氣化樹脂量累計步驟S35,開始成為計算出補償樹脂量之基準之氣化持續樹脂量之累計(計測)。 繼而,於圖17所示之膜厚設定步驟S06與供給樹脂量設定步驟S37(與供給時間設定步驟S07對應)中,預先根據目標膜厚、及成膜開始時之氣化持續樹脂量而計算出補償樹脂量。 具體而言,對應於氣化之樹脂材料之氣化持續樹脂量,以隨著供給時間之經過而逐漸增加之方式設定1次成膜中所供給之樹脂量。 繼而,於圖3所示之基板搬入步驟S08中,向樹脂成膜部100搬入基板S。 繼而,於圖3所示之供給開始步驟S09中,藉由控制部400對閥112V及閥113V之開閉狀態進行切換,而自氣化器300對樹脂材料供給管112(第一配管)供給樹脂材料,開始成膜。 此時,作為與圖3所示之供給時間計測步驟S10對應之步驟即供給樹脂量計測步驟S30,開始被換算為成膜膜厚之樹脂材料供給量之計測。 於成膜中,作為圖17所示之供給控制步驟S31,按照在供給樹脂量設定步驟S37中設定之供給樹脂量,藉由控制部400以補償成膜速率之減少之方式,對應於氣化持續樹脂量之累計量而將閥112V之開度以逐漸增大之方式調整來進行成膜。 此處,閥112V係設定為能夠調整開度之構成。 繼而,於圖17所示之供給停止步驟S11中,藉由控制部400對閥112V及閥113V之開閉狀態進行切換,而自氣化器300對樹脂材料迂迴管113(第二配管)供給樹脂材料,獲得目標膜厚而結束成膜。 繼而,作為圖17所示之基板搬出步驟S12,將已成膜之基板S自樹脂成膜部100搬出。 必要時,將自膜厚設定步驟S06至基板搬出步驟S12重複執行複數次。此時,將氣化樹脂量累計步驟S35之氣化持續樹脂量累計,根據該值,每次於供給樹脂量設定步驟S37重新計算出補償樹脂量而控制成膜中之閥112V之開度。 具體而言,根據氣化器300中之樹脂材料之氣化持續樹脂量之增加,為了補償因加熱固化之產生等而減少之樹脂量,以隨著成膜時間之增加而增大供給樹脂量來補償成膜速率之減少之方式進行設定。 繼而,作為圖17所示之氣化停止步驟S13,將氣化器300中之氣化停止,結束氣化持續樹脂量之計測。再者,膜厚設定步驟S06及供給樹脂量設定步驟S37只要處於在基板搬入步驟S08以後執行之步驟、即實際進行成膜之步驟之前即可,其實施時期、順序不限於上述步驟順序。 又,即便氣化器300不連續運轉,氣化效率亦會因自最近之清零起算之氣化時間之累計而減少。即便反覆執行氣化器300之運轉、停止,只要將氣化持續樹脂量累計,仍能計算出氣化效率之減少量。 作為本實施形態之元件結構體之製造方法,如上所述以補償對應於氣化持續樹脂量而減少之氣化樹脂材料的方式控制供給狀態。藉此,使樹脂材料之成膜速率不管氣化持續樹脂量如何經過均穩定。進而,即便於對複數個基板S依序進行成膜之情形時,亦可使樹脂材料之成膜速率不管膜次數、及自上次之清零起算之成膜時之氣化持續樹脂量而均穩定。因此,能防止成膜特性產生變動,從而能防止膜特性(膜厚)變動。 再者,各步驟之控制可由控制部400執行,檢量線之計算或成膜樹脂量之計算及累計亦由控制部400所具有之運算部執行。進而,必要資料之記憶亦由控制部400所具有之記憶部執行。 以下,基於圖式對本發明之第3實施形態之成膜方法、成膜裝置、元件結構體之製造方法及元件結構體之製造裝置進行說明。 圖18係表示本實施形態之元件結構體之製造方法(成膜方法)之流程圖,於本實施形態中,與上述第2實施形態不同之處係與補償成膜速率之樹脂供給方法相關之方面,對除此以外之與上述第2實施形態對應之構成標註相同之符號,並省略其之說明。 具體而言,於成膜樹脂材料膜5a時,控制樹脂材料之供給。如圖18所示,具有檢量線獲取步驟S01、補償樹脂量設定步驟S32、外部排氣切換步驟S03、氣化開始步驟S04、氣化樹脂量累計步驟S35、膜厚設定步驟S06、供給樹脂量設定步驟S37、基板搬入步驟S08、供給開始步驟S09、供給樹脂量計測步驟S30、供給停止步驟S11、基板搬出步驟S12及氣化停止步驟S13。 於本實施形態之成膜中,按照在供給樹脂量設定步驟S37中設定之供給樹脂量,藉由控制部400以補償成膜速率之減少之方式,對應於氣化持續樹脂量之累計量而將來自氣化器300之樹脂材料原料容器150之樹脂材料供給量以逐漸增大之方式調整而實施成膜。 此時,控制對加熱部152以霧狀噴出液狀之樹脂材料之每單位時間之供給量。 又,必要時,將自膜厚設定步驟S06至基板搬出步驟S12重複執行複數次,此時,將氣化樹脂量累計步驟S35之氣化持續樹脂量累計,根據該值,每次於供給樹脂量設定步驟S37重新計算出補償樹脂量而控制成膜中來自樹脂材料原料容器150之樹脂材料供給量。 具體而言,根據氣化器300中之樹脂材料之氣化持續樹脂量之增加,為了補償因加熱固化之產生等而減少之樹脂量,以隨著成膜時間之增加而增大供給樹脂量來補償成膜速率之減少之方式進行設定。 作為本實施形態之元件結構體之製造方法,如上所述以補償對應於氣化持續樹脂量而減少之氣化樹脂材料的方式,控制對氣化器300供給之樹脂材料之供給量使之經時增加,藉此使樹脂材料之成膜速率不管氣化持續樹脂量如何經過而均穩定。進而,即便於對複數個基板S依序進行成膜之情形時,亦可使樹脂材料之成膜速率不管成膜次數、及自上次之清零起算之成膜時之氣化持續樹脂量而均穩定。因此,能防止成膜特性產生變動,從而能防止膜特性(膜厚)變動。 產業上之可利用性 作為本發明之活用例,可列舉有機EL裝置之密封或電子器件之密封。Hereinafter, a film forming method, a film forming apparatus, a method for manufacturing a device structure, and a device for manufacturing a device structure according to a first embodiment of the present invention will be described based on drawings. FIG. 1 is a schematic diagram showing a device (film-forming device) for manufacturing a device structure according to this embodiment. FIG. 2 is a schematic diagram showing a device manufacturing apparatus for the element structure according to this embodiment. FIG. 3 is a flowchart showing a method of manufacturing the element structure according to this embodiment. In FIG. 1, reference numeral 1000 denotes a device for manufacturing the element structure. As described below, the device structure manufacturing device 1000 of this embodiment manufactures an element structure such as an organic EL element. As shown in FIG. 1, the manufacturing apparatus 1000 includes a first layer forming section 201, a resin film forming section 100, a localization processing section 202, a second layer forming section 203, and a functional layer forming section that forms a functional layer that becomes an organic EL layer. 204. The core chamber 200 and a loading interlocking vacuum chamber 210 connected to the outside. The core chamber 200 is connected to the first layer forming portion 201, the resin film forming portion 100, the localization processing portion 202, the second layer forming portion 203, the functional layer forming portion 204, and the load-locking vacuum chamber 210. The inside of the load-locking vacuum chamber 210 is a substrate for inserting the manufacturing apparatus 1000 that is transported to the element structure from another device or the like. In the core room 200, for example, a substrate transfer robot (not shown) is disposed. Thereby, each of the core chamber 200 and the first layer forming portion 201, the resin film forming portion 100, the localization processing portion 202, the second layer forming portion 203, the functional layer forming portion 204, and the loading interlocking vacuum chamber 210 can be performed. The substrate is transferred between them. The substrate can be transferred outside the manufacturing apparatus 1000 of the element structure through the loading interlocking vacuum chamber 210. The core chamber 200, each of the film forming chambers 100, 201, 202, 203, and 204, and the loading interlocking vacuum chamber 210 respectively constitute a vacuum chamber connected to a vacuum exhaust system (not shown). The manufacturing of the element structure 10 by using the manufacturing device 1000 having the above-mentioned element structure can automate each manufacturing step, and can simultaneously manufacture efficiently using a plurality of film forming chambers, thereby improving productivity. The first layer forming portion 201 forms a first layer 41 in the element structure 10 described below. The first layer 41 covers the functional layer 3 disposed on one surface side 2a of the substrate 2 and has local convex portions including nitride. Silicon (SiN x ) And other inorganic materials. The first layer forming portion 201 is a film forming chamber for forming the first layer 41 by, for example, a CVD (Chemical Vapor Deposition) method, a sputtering method, or an ALD (Atomic Layer Deposition) method. . The functional layer forming section 204 forms a functional layer 3 in the element structure 10 described below. In addition, the functional layer forming portion 204 may be provided outside the loading interlocking vacuum chamber 210. The second layer forming portion 203 forms a film forming chamber of the second layer 42 in the element structure 10 described below by covering the first layer 41 and the resin material 51. The second layer 42 is the same as the first layer 41 Ground contains inorganic materials. Furthermore, when the second layer 42 and the first layer 41 contain the same material, the second layer forming portion 203 and the first layer forming portion 201 may be set to the same configuration, or a film forming chamber ( The common film-forming chamber) forms a second layer 42 and a first layer 41. Furthermore, when either the second layer forming portion 203 and the first layer forming portion 201 or the common film forming chamber is constituted by a plasma CVD apparatus, the forming portion 201, 203, or the film forming chamber is not only With the above-mentioned functions, the functions of the localization processing unit 202 described below may be combined. For example, the substrate on which the resin film is formed is carried into a plasma CVD apparatus, and an oxidizing gas is introduced to generate a plasma, whereby the resin film can be etched to localize the resin film to form a resin material. Thereafter, the second layer 42 can also be formed directly in the plasma CVD apparatus. The resin film forming portion 100 is a film forming chamber, that is, a vaporized resin material is supplied to the inside of the resin film forming portion 100, a resin material film containing a resin material is formed on the first layer 41, and the resin material film is hardened to A resin film is formed. As shown in FIG. 2, the resin film forming section 100 includes a chamber 110 capable of reducing the pressure in an internal space, a gasifier 300 for supplying a vaporized resin material to the chamber 110 (processing chamber), and a control section 400. As described below, the internal space of the chamber 110 is composed of an upper space 107 and a lower space 108. A vacuum exhaust device (vacuum exhaust device, vacuum pump, etc.) (not shown) is connected to the chamber 110. The vacuum exhaust device is capable of exhausting the gas in the internal space so that the internal space of the chamber 110 becomes a vacuum environment. Way composition. As shown in FIG. 2, a shower plate 105 is arranged in the internal space of the chamber 110, and a space on the upper side of the shower plate 105 in the chamber 110 constitutes an upper space 107. A top plate 120 including a member capable of transmitting ultraviolet light such as quartz is provided on the uppermost part of the chamber 110, and an ultraviolet light irradiation device 122 (UV irradiation device) is arranged on the upper side of the top plate 120. Here, the shower plate 105 is also formed of a member capable of transmitting ultraviolet light, whereby the ultraviolet light energy introduced from the irradiation device 122 through the top plate 120 to the upper space 107 passes through the shower plate 105 toward the shower plate 105. The lower side lower space 108 travels. Thereby, the acrylic material film (resin material film) formed on the substrate S described below can be irradiated with ultraviolet light after film formation, and the acrylic material film can be hardened to form an acrylic resin film (resin film). A heating device (not shown) is arranged in the chamber 110. The temperature of the inner wall surface of the chamber 110 constituting the upper space 107 and the lower space 108 can be set to be equal to or higher than the vaporization temperature of the resin material, preferably about 40 to 250 ° C, and is controlled by a heating device. A stage 102 (substrate holding portion) on which the substrate S is placed is disposed in the lower space 108 located below the shower plate 105 in the chamber 110. On the stage 102, a position where a substrate is to be arranged is set in advance on the surface. The stage 102 is disposed in the chamber 110 with the surface exposed. The symbol S indicates a substrate disposed at a specific position on the surface of the substrate stage 102. A substrate cooling device 102 a for cooling the substrate S is provided on the stage 102. The substrate cooling device 102 a supplies a refrigerant to the inside of the stage 102 and cools the substrate S on the upper surface of the stage 102. Specifically, the temperature of the substrate S is controlled by a cooling device 102a built into the stage 102 (substrate holding portion) on which the substrate S is placed, and is controlled below the vaporization temperature of the resin material, preferably below zero (0 ° C). For example, about -30 ℃ ~ 0 ℃. A shower plate 105 is provided at a position on the upper side of the stage 102 so as to face the entire surface of the stage 102. The shower plate 105 is composed of a plate-shaped member provided with a plurality of through holes. The plate-shaped member includes an ultraviolet transmitting material such as quartz. The shower plate 105 divides the internal space of the chamber 110 into an upper space and a lower space. A mask (not shown) is provided in the lower space 108, and the position of the mask can be set to a specific position during film formation. As the substrate moves, the mask can move in a manner that retracts from the substrate. The upper space 107 of the chamber 110 communicates with the vaporizer 300 via a pipe 112 (resin material supply pipe) and a valve 112V. The vaporized resin material can be supplied to the upper space 107 of the chamber 110 through the resin material supply pipe 112. One end of the resin material bypass pipe 113 having the valve 113V is connected to the resin material supply pipe 112 (first pipe) closer to the gasifier 300 than the valve 112V. The other end of the resin material bypass pipe 113 (second piping) is connected to the outside through the exhaust pipe 114, and the gas can be discharged through the resin material bypass pipe 113. The exhaust pipe 114 is connected to a liquefaction recovery device, and can liquefy and recover the resin material. The opening and closing driving of the valves 112V and 113V is controlled by the control unit 400. The control unit 400 is controlled in a manner capable of switching between a film-forming state and a non-film-forming state. The film-forming state refers to supplying the gasified resin material from the gasifier 300 into the chamber 110; The film formation state is directed to the outside to exhaust the gasified resin material from the gasifier 300 without supplying it to the chamber 110. The valve 112V, the valve 113V, and the control unit 400 constitute a switching unit having a resin material supplied to the inside of the chamber 110 through the resin material supply pipe 112 or a resin material discharge to the outside of the chamber 110 through the resin material bypass pipe 113. Qi selection function. The gasifier 300 can supply a gasified resin material to the chamber 110. As shown in FIG. 2, the gasifier 300 includes a gasification tank 130, a discharge portion 132, and a resin material raw material container 150. As shown in FIG. 2, the gasification tank 130 includes an internal space for vaporizing a liquid resin material, and a spray portion 132 for spraying the liquid resin material in a mist state is arranged above the internal space. The gasification tank 130 is formed in a substantially cylindrical shape, but may be set to another cross-sectional shape. The inner surface of the gasification tank 130 may include, for example, SUS, Al, and the like. One end of a resin material liquid supply pipe 140 connected to the resin material raw material container 150 via a valve 140V and a carrier gas supply pipe 130G that supplies a carrier gas such as nitrogen are connected to the ejection section 132. The other end of the resin material liquid supply pipe 140 is connected to the resin material raw material container 150 and is located inside the liquid resin material stored in the resin material raw material container 150. The resin material raw material container 150 is connected to a pressurized gas supply pipe 150G for supplying a material liquid such as nitrogen, and the liquid material can be conveyed to the resin material liquid supply pipe 140 so as to increase the internal pressure of the resin material raw material container 150 to be pressurized Resin material. The ejection portion 132 is configured to eject the liquid resin material supplied from the resin material liquid supply pipe 140 into the internal space of the vaporization tank 130 in a mist state together with a carrier gas. The ejection portion 132 is provided at a substantially central position on the top of the gasification tank 130. A heating portion 135 having an inclined surface may be provided in the internal space of the gasification tank 130, and the heating material may be sprayed with a resin material in a mist form. A vacuum gauge PG is provided in the gasification tank 130 so that the internal pressure can be measured. In addition, a temperature control device for controlling the temperature of the surface in contact with the internal space is provided on the side wall of the gasification tank 130. Specifically, a heater for heating the side wall of the gasification tank 130 is provided. The resin material supply pipe 112 (first pipe) connected to the gasification tank 130 is also provided with a heater as the same temperature adjustment device. This heater is wound around a resin material supply pipe (first pipe) so that the vaporized resin material does not condense on the wall surface. Furthermore, a heater may be provided in the resin material bypass pipe 113 as the same temperature adjustment device. These heaters can set the temperature exposed on the surface of the vaporized resin material to a state higher than the vaporization temperature of the resin material, thereby preventing the resin material from liquefying. At the same time, the temperature is set in a manner that minimizes the heat curing of the resin material. When the vaporizer 300 vaporizes the resin material, the vaporization tank 130 and the resin material supply pipe 112 (first pipe) are heated by a heater. At the same time, the control unit 400 causes the valve 112V to be in a closed state so that gas cannot flow into the resin material supply pipe 112, and the valve 113V is opened to form a state in which gas can flow into the resin material bypass pipe 113. In this state, the internal pressure of the resin material raw material container 150 is raised, and the liquid resin material supplied from the resin material liquid supply pipe 140 is sprayed together with the carrier gas from the ejection portion 132 to the inside of the vaporization tank 130. Space spurted. In this case, the resin material and the carrier gas supplied to the ejection section 132 may be further heated. The resin material sprayed from the spraying portion 132 into the internal space of the gasification tank 130 in a mist state together with the carrier gas is vaporized inside the heated gasification tank 130. In addition, in this embodiment, there may be a case where an ultraviolet curable resin material is used as the resin material. The ultraviolet-curable resin material may be partially polymerized or deteriorated by heating or the like. After such a change, there is a possibility that the evaporation temperature rises, and the resin does not evaporate and remains on the surface of the heating unit 135 or the gasification tank 130, so that the evaporation amount changes. While the gasification of the resin material is stably performed, the control unit 400 causes the valve 112V to be opened, thereby forming a state in which gas can flow into the resin material supply pipe 112, and the valve 113V is closed, thereby preventing gas formation. It flows into the state of the resin material bypass pipe 113. Thereby, the vaporized resin material can be supplied to the chamber 110 and a film formation process can be performed. Driven by the switching unit, that is, only by switching the opening and closing states of the valve 112V and the valve 113V by the control unit 400, it is possible to select to supply the resin material to the resin material supply pipe 112 (the first pipe) and to bypass the resin material. The pipe 113 (second pipe) supplies a resin material. Therefore, the supply amount of the vaporized resin material supplied to the chamber 110 can be stabilized, so that the film formation rate at the start of film formation can be stabilized. The resin film-forming portion 100 is formed, for example, so that film formation and ultraviolet irradiation can be performed in the same chamber 110. The film-forming portion is formed of a UV-curable acrylic resin material at a vaporization temperature of about 40 to 250 ° C. Film; the above ultraviolet irradiation is used to harden the resin material after film formation. Thereby, any processing step can be performed with the same apparatus configuration, and productivity can be improved. In the resin film-forming portion 100, as step B in the method of manufacturing the element structure (film-forming method) according to this embodiment, the supply of the resin material is controlled when the following liquid resin material film 5a is formed. As shown in FIG. 3, step B includes a calibration curve acquisition step S01, a compensation time setting step S02, an external exhaust switching step S03, a gasification start step S04, a gasification duration measurement step S05, a film thickness setting step S06, and a supply The time setting step S07, the substrate carrying-in step S08, the supply start step S09, the supply time measuring step S10, the supply stopping step S11, the substrate carrying out step S12, and the vaporization stopping step S13. In the calibration line acquisition step S01 shown in FIG. 3, the film thickness is measured for each substrate with a fixed film forming time as shown in FIG. 15 with respect to the supply amount of the gasified resin material from the gasifier 300. . At this time, in a state where the supply amount of the resin material from the resin material raw material container 150 is fixed and stably supplied, a plurality of substrates S are sequentially formed into a film with the same film forming processing time, and each measurement is performed. The decrease in film thickness (reduction) is used as the calibration curve. As shown in FIG. 15, with respect to the cumulative supply amount to the gasifier 300 (the cumulative resin material supply amount (g) of the gasifier), that is, as the gasification duration elapses, the film thickness of each substrate (= Film rate). In response to this decrease, a straight line is drawn as a calibration line in the figure. In the compensation time setting step S02 shown in FIG. 3, the method corresponding to the calibration line obtained in the calibration line acquisition step S01 in order to compensate for the decrease with respect to the initially set film formation processing time corresponds to Set the compensation time to increase the film-forming processing time per sheet by accumulating the supply of resin material. The compensation time is set in such a manner as to compensate for a decrease in the film formation rate with respect to a target film thickness to be formed. Changes in the compensation time or film formation rate are stored in the control unit. Next, in the external exhaust gas switching step S03 shown in FIG. 3, the opening and closing states of the valve 112V and the valve 113V are switched by the control unit 400, and the resin material bypass pipe 113 (second pipe) is switched by the self-gasifier 300 Supply resin material. In the gasification start step S04 shown in FIG. 3, in this state, as described above, the gasification of the resin material is started in the gasifier 300. At the same time, as the gasification duration measurement step S05 shown in FIG. 3, the measurement of the gasification duration that becomes the reference for calculating the compensation time is started. Next, in the film thickness setting step S06 and the supply time setting step S07 shown in FIG. 3, the compensation time is calculated in advance based on the target film thickness and the duration of vaporization at the start of film formation. Specifically, it is set so as to extend the film forming time, ie, the supply time, corresponding to the gasification duration of the gasified resin material. Then, in the substrate carrying-in step S08 shown in FIG. 3, the substrate S is carried into the resin film forming section 100. Then, in the supply start step S09 shown in FIG. 3, the control unit 400 switches the opening and closing states of the valve 112V and the valve 113V, and the resinizer 300 supplies the resin to the resin material supply pipe 112 (the first pipe). The material begins to form a film. At the same time, as the supply time measurement step S10 shown in FIG. 3, the measurement of the supply amount of the resin material converted into the film thickness of the film is started. Then, in the supply stop step S11 shown in FIG. 3, the control unit 400 switches the opening and closing states of the valve 112V and the valve 113V according to the supply time set in the supply time setting step S07, and the self-gasifier 300 The resin material bypass pipe 113 (second pipe) supplies a resin material, obtains a target film thickness, and finishes film formation. Then, as the substrate carrying-out step S12 shown in FIG. 3, the film-formed substrate S is carried out from the resin film forming section 100. If necessary, the steps from the film thickness setting step S06 to the substrate carrying-out step S12 are repeatedly performed a plurality of times. At this time, the gasification duration measured in the gasification duration measurement step S05 is accumulated, and based on the value, the compensation time is recalculated each time in the supply time setting step S07 to control the switching time in the supply stop step S11. Specifically, according to an increase in the gasification duration of the resin material in the gasifier 300, in order to compensate the amount of the resin material reduced due to the occurrence of heat curing, etc., the film forming time is extended by compensating the supply time, that is, the supply time. Way to set. Then, as the gasification stop step S13 shown in FIG. 3, the gasification in the gasifier 300 is stopped, and the measurement of the gasification duration is terminated. In addition, the film thickness setting step S06 and the supply time setting step S07 are only required to be performed after the substrate carrying-in step S08, that is, before the film formation step is actually performed, and the implementation time and sequence are not limited to the above-mentioned sequence of steps. In addition, even if the gasifier 300 is discontinuously operated, the gasification efficiency is reduced due to the accumulation of the gasification time since the recent zeroing. Even if the operation and stop of the gasifier 300 are repeatedly performed, as long as the gasification time is accumulated, the reduction amount of the gasification efficiency can still be calculated. As a method of manufacturing the element structure of the present embodiment, as described above, the supply state is controlled so as to compensate the supply of the gasified resin material that decreases in accordance with the processing time. Thereby, the film forming rate of the resin material is stabilized regardless of the elapse of the gasification duration, and as shown in FIG. 16, even when a plurality of substrates S are sequentially film-formed, the resin material can be made The film formation rate is stable regardless of the number of film formation times and film formation time. Therefore, it is possible to prevent variations in film formation characteristics, and to prevent variations in film characteristics (film thickness). In addition, the control of each step can be performed by the control unit 400, and the calculation of the calibration curve or the calculation and accumulation of the film formation time can also be performed by the operation unit of the control unit 400. Furthermore, the memory of the necessary data is also executed by the memory section of the control section 400. Hereinafter, the element structure 10 manufactured by the device structure manufacturing apparatus 1000 of this embodiment is demonstrated. FIG. 4 is a schematic cross-sectional view showing an element structure according to this embodiment. FIG. 5 is a plan view showing the element structure of FIG. 4. FIG. 6 is an enlarged view showing a main part of the element structure. In each figure, the X-axis, Y-axis, and Z-axis directions indicate three-axis directions orthogonal to each other. In this embodiment, the X-axis and Y-axis directions indicate horizontal directions that are orthogonal to each other, and the Z-axis direction indicates a vertical direction. The element structure 10 of this embodiment includes a substrate 2 including a device layer 3 (functional layer), and a first inorganic material layer 41 (first layer), which is formed on the front surface 2a of the substrate 2 and covers the functional layer 3, and Local bumps, including silicon nitride (SiN x ) And other inorganic materials; and a second inorganic material layer 42 (third layer), which covers the first inorganic material layer 41 and is the same as the first layer 41. In this embodiment, the element structure 10 is composed of a light-emitting element having an organic EL light-emitting layer. The substrate 2 has a front surface 2a (first surface) and a rear surface 2c (second surface), and is made of, for example, a glass substrate, a plastic substrate, or the like. The shape of the substrate 2 is not particularly limited, and in this embodiment, it is formed in a rectangular shape. The size, thickness, and the like of the substrate 2 are not particularly limited, and a substrate having a suitable size and thickness can be used in accordance with the size of the element size. In this embodiment, a plurality of element structure bodies 10 are produced from an assembly of the same elements produced on a large substrate S. The device layer 3 (functional layer) is composed of an organic EL light-emitting layer including an upper electrode and a lower electrode. In addition to such a configuration, the device layer 3 may be composed of various functional elements such as a liquid crystal layer in a liquid crystal element, a power generation layer in a power generation element, or the like, which include materials that are easily deteriorated by moisture, oxygen, and the like. The device layer 3 is formed on a specific region of the front surface 2 a of the substrate 2. The planar shape of the device layer 3 is not particularly limited. In this embodiment, it is formed into a substantially rectangular shape. However, in addition to this shape, a circular shape, a linear shape, or the like may be used. The device layer 3 is not limited to the example of being disposed on the front surface 2 a of the substrate 2, and may be disposed on at least one of the front surface 2 a and the back surface 2 c of the substrate 2. The first inorganic material layer 41 (first layer) is provided on the surface 2a of the substrate 2 on which the device layer 3 is disposed, and constitutes a convex portion covering the front surface 3a and the side surface 3s of the device layer 3. The first inorganic material layer 41 has a three-dimensional structure protruding from the front surface 2 a of the substrate 2 to the upper side in FIG. 6. The first inorganic material layer 41 is an inorganic material that can protect the device layer 3 from moisture or oxygen. In this embodiment, the first inorganic material layer 41 is a silicon nitride (SiN) having excellent water vapor barrier properties. x ), But the material is not limited to this. The first inorganic material layer 41 may be composed of another silicon compound such as silicon oxide or silicon oxynitride, or another inorganic material having water vapor barrier properties such as alumina. The first inorganic material layer 41 is formed on the front surface 2 a of the substrate 2 by using a suitable mask, for example. In this embodiment, the first inorganic material layer 41 is formed by using a mask having a rectangular opening having a size capable of accommodating the device layer 3. The film formation method is not particularly limited, and a CVD (Chemical Vapor Deposition) method, a sputtering method, or an ALD (Atomic Layer Deposition) method can be applied. The thickness of the first inorganic material layer 41 is not particularly limited, and is, for example, 200 nm to 2 μm. The second inorganic material layer 42 (second layer) is the same as the first inorganic material layer 41, and includes an inorganic material that can protect the device layer 3 from moisture or oxygen, and the front surface of the first inorganic material layer 41 41a and the side surface 41s are covered on the front surface 2a of the substrate 2. In this embodiment, the second inorganic material layer 42 is a silicon nitride (SiN) having excellent water vapor barrier properties. x ), However, the material is not limited to this. Other silicon compounds such as silicon oxide or silicon oxynitride, The second inorganic material layer 42 is composed of other inorganic materials having water vapor barrier properties such as alumina. The second inorganic material layer 42 is formed on the front surface 2 a of the substrate 2 by using a suitable mask, for example. In this embodiment, The second inorganic material layer 42 is formed using a mask having a rectangular opening having a size capable of accommodating the first inorganic material layer 41. The film forming method is not particularly limited, CVD (Chemical Vapor Deposition) method can be applied, Sputtering method, Or ALD (Atomic Layer Deposition) method. The thickness of the second inorganic material layer 42 is not particularly limited. For example, 200 nm to 2 μm. The element structure 10 according to this embodiment further includes a first resin material 51. The first resin material 51 is unevenly distributed around the first inorganic material layer 41 (convex portion). In this embodiment, The first resin material 51 is interposed between the first inorganic material layer 41 and the second inorganic material layer 42. Moreover, the partial set exists in the boundary portion 2b between the side surface 41s of the first inorganic material layer 41 and the front surface 2a of the substrate 2. The first resin material 51 has a function of filling a gap G (FIG. 6) between the first inorganic material layer 41 formed near the boundary portion 2 b and the substrate front surface 2 a. In Figure 6, The peripheral structure of the boundary portion 2b of the element structure 10 is enlarged. Since the first inorganic material layer 41 is formed of a CVD film or a sputtering film of an inorganic material, Therefore, the covering characteristic (step coverage) of the uneven structure surface of the substrate 2 including the device layer 3 is relatively low. the result, As shown in FIG. 6, the first inorganic material layer 41 that covers the side surface 3s of the device layer 3 has reduced coverage characteristics near the front surface 2a of the substrate. The film thickness is extremely small, Or there is no possibility of the state of the coating film at all. therefore, In this embodiment, By biasing the first resin material 51 to exist in the coating failure area around the first inorganic material layer 41 as described above, Intrusion of moisture or oxygen into the device layer 3 from the poor coverage region is suppressed. also, When the second inorganic material layer 42 is formed, By making the first resin material 51 function as a base layer of the second inorganic material layer 42, Appropriate film formation of the second inorganic material layer 42 can be performed, As a result, the side surface 41s of the first inorganic material layer 41 can be appropriately covered with a desired film thickness. The method of forming the first resin material 51 is as follows: The resin material vaporized by spray gasification is supplied to the substrate front surface 2a to be condensed to form a resin material film 5a. Hardening the resin material film 5a to form the resin film 5, then, The first resin material 51 is formed by a localization step of removing non-essential parts. the following, The manufacturing method of the element structure performed by the manufacturing apparatus of the element structure of this embodiment is demonstrated. FIG. 7 to FIG. 11 are steps diagrams schematically showing a method of forming the first resin material 51 in the method of manufacturing the element structure of the present embodiment. (Example of Steps for Forming a Device Layer ~ Step A) First, In the manufacturing apparatus 1000 of the element structure shown in FIG. 1, The substrate S carrying the self-loading interlocking vacuum chamber 210 into the core chamber 200 is transferred from the core chamber 200 to the functional layer forming unit 204 by a substrate transfer robot (not shown). In the functional layer forming portion 204, A device layer 3 (functional layer) is formed in a specific region on the substrate S. In this embodiment, As a region to be functional layer 3, Multiple areas on the substrate S can be used, E.g, Four areas are arranged in the X-axis direction and the Y-axis direction, each of which is arranged at a specific interval. Or a single area becomes the functional layer 3. The method for forming the device layer 3 is not particularly limited, According to the material of device layer 3, The structure and the like are appropriately selected. E.g, The substrate S is transferred to a film forming chamber or the like of the functional layer forming section 204, Vapor deposition of a specific material on the substrate S, Sputtering, etc. Furthermore, pattern processing is performed, Thereby, a desired device layer 3 can be formed on a specific region on the substrate S. The method of pattern processing is not particularly limited, For example, etching can be used. Furthermore, Regarding the specific configuration of the device structure manufacturing device 1000, Detailed description is omitted in FIG. 1. The functional layer forming section 204 may be configured by a plurality of processing chambers. Furthermore, it has a structure which can transfer the board | substrate S between adjacent processing chambers. Alternatively, a structure other than a vacuum device may be used. which is, The substrate S can be processed outside the manufacturing apparatus 1000 of the element structure without the need to pass through the interlocking vacuum chamber 210. (Example of forming steps of the first layer-Step A) Second, The substrate S on which the device layer 3 is formed is carried out from the functional layer forming section 204 by a substrate transfer robot (not shown). Then, it is carried in to the first floor forming section 201 through the core chamber 200. In the first layer forming portion 201, By covering the device layer 3, A first inorganic material layer 41 (first layer) is formed in a specific region on the substrate S including the region of the device layer 3. With this, As shown in Figure 7, A first inorganic material layer 41 covering the device layer 3 is formed so as to have a convex portion on the substrate S. In this step, E.g, A mask having a plurality of openings corresponding to the area of the first inorganic material layer 41 may also be used. For example, a first inorganic material layer 41 made of silicon nitride is formed as a part of the protective layer. Here, The first layer forming portion 201 can be set to have a CVD processing apparatus, Or the structure of a sputtering treatment device. also, Although not shown, But in the film forming chamber of the first layer forming portion 201, Setting a stage for arranging the substrate S, A mask disposed on the substrate S, A mask alignment device supporting a mask and positioning the substrate S on the stage, etc. And film-forming material supply device. The substrate S on which the device layer 3 is formed is placed on a stage of the first layer forming section 201 by a substrate transfer robot or the like arranged in the core chamber 200. By masking the alignment device, etc., In a manner that the device layer 3 is exposed through the opening of the mask, A mask is arranged at a specific position on the substrate S. then, E.g, With the CVD method, A first inorganic material layer 41 made of silicon nitride or the like is formed so as to cover the device layer 3. Furthermore, The method for forming the first inorganic material layer 41 is not limited to the CVD method. For example, a sputtering method can also be used. In that case, The first layer forming portion 201 is configured to have a sputtering device. (Examples of resin film formation steps ~ film formation steps ~ step B, Step C) Second, The substrate S on which the first inorganic material layer 41 having the convex portion is formed is carried out from the first layer forming portion 201 by a substrate transfer robot (not shown), Then, it is carried into the resin film forming section 100 through the core chamber 200. at this time, The gas in the chamber 110 is exhausted by a vacuum exhaust device to maintain a vacuum state in the chamber 110. after, By continuously driving the vacuum exhaust, The environment of the chamber 110 is maintained in a vacuum environment. at this time, With a heating device, The chamber 110 is set so that the temperature of at least the inner surface side of the upper space 107 and the lower space 108 becomes equal to or higher than the vaporization temperature of the resin material. Simultaneously, With the substrate cooling device 102a, The substrate S disposed on the stage 102 is cooled together with the stage 102 to a temperature lower than the vaporization temperature of the resin material. also, With the heater 112d, The resin material supply pipe 112 (the first pipe) is heated to a temperature higher than the vaporization temperature of the resin material. The resin film forming section 100 performs a step of forming a resin material film 5a on the substrate S on which the first inorganic material layer 41 is formed, And a step of hardening the resin material film 5a to form the resin film 5. In this step, First of all, Using the resin film forming section 100, E.g, A resin material film 5a containing a material of an ultraviolet curable acrylic resin is formed. Regarding the step of forming the resin material film 5a in the resin film forming section 100, Before substrate S is moved in, First, as shown in Figure 3, As the calibration curve acquisition step S01 and the compensation time setting step S02, Get the calibration line, Set the compensation time. Then, As shown in Figure 3, As external exhaust switching step S03, Gasification start step S04 and gasification duration measurement step S05, In the gasifier 300, a process for stably performing gasification of a resin material is performed. During the gasification stabilization process, The valve 112V is closed by the control unit 400, The formation gas cannot flow into the resin material supply pipe 112, And the valve 113V is opened, The state in which the gas can flow into the resin material bypass pipe 113 is maintained. Furthermore, It is preferable that the gasification of the resin material in the gasifier 300 is maintained for a necessary time before the film formation process according to the stability of the amount of the gasified resin material supplied. Then, As shown in Figure 3, As the film thickness setting step S06, The supply time setting step S07 and the board carrying-in step S08, Set the film thickness The processing time required for the processing is set by the control section 400, As mentioned above, The substrate S carried into the resin film forming section 100 is placed on a stage 102. On the substrate S disposed on the stage 102, A mask (not shown) is arranged at a specific position on the substrate S by a mask mounting device or the like. Then, Align with mask, The environment in the chamber 110, The temperature of the inner wall of the chamber 110, The temperature of the resin material supply pipe 112, The conditions such as the temperature of the substrate S become a specific state, The setting is performed by the control section 400. Then, As shown in Figure 3, As the supply start step S09 and the supply time measurement step S10, The opening and closing states of the valve 112V and the valve 113V are switched by the control unit 400. With this, Make the valve 112V open, And the gas flows into the resin material supply pipe 112, And the valve 113V is closed, On the other hand, the formation gas does not flow into the resin material bypass pipe 113V. With this, The chamber 110 is supplied with a vaporized resin material. The vaporized resin material supplied from the vaporizer 300 passes through the inside of the resin material supply pipe 112, It is supplied from the upper space 107 into the lower space 108 via the shower plate 105. In the lower space 108, The vaporized resin material supplied to the entire surface of the substrate S by the shower plate 105 is shown in FIG. It is condensed on the substrate front surface 2a and becomes a liquid resin material film 5a. In the liquid resin material film 5a, Corners with bad angles on the front surface 2a of the substrate, Recess, Gaps, etc. The film thickness of the resin material film 5a is increased by the surface tension. In step B, By compensating for the reduction in resin material corresponding to the duration of gasification, The processing time (supply time) is controlled by the control unit 400, Thereby, the film formation rate is made uniform. at this time, You can also use a mask (not shown), The resin material film 5a is formed only in a region such as a portion (a nearby position) near the convex portion 41. Furthermore, Taking into account the liquefaction and film formation rate of the resin material, The supply amount of the resin material supplied from the gasifier 300 is controlled by the control unit 400. The resin material liquefied on the surface of the substrate S penetrates into a fine gap by a capillary phenomenon, Or by the surface tension of the resin material, Therefore, the fine unevenness on the substrate S can be smoothed at the same time, A resin material film 5a is formed on one side. With this, Corners with bad corners on the surface of the substrate S, Recess, Gaps, etc. The thickness of the resin material film 5a is increased. especially, A fine gap between the side surface 41s of the first inorganic material layer 41 and the boundary portion 2b of the front surface 2a of the substrate 2 can be filled with the resin material film 5a. also, The vaporized resin material does not condense on the surface of the inner wall and the like of the chamber 110 because the chamber 110 is heated. After the supply time based on the set compensation time, As shown in Figure 3, As the supply stop step S11, A resin material film 5a having a specific thickness is formed on the surface of the substrate S. Since then, The state where the valve 112V is closed by the control unit 400 prevents the gas from flowing into the chamber 110, The valve 113V is opened to form a state where gas can flow into the resin material bypass pipe 113. Since the chamber 110 is continuously exhausted, Therefore, the vaporized resin material is discharged to the outside of the chamber 110 and the film formation is stopped. In this state, While maintaining the vacuum environment in the chamber 110, One surface of the substrate S is irradiated with ultraviolet rays from the UV irradiation device 122. The irradiated ultraviolet rays pass through the top plate 120 and the shower plate 105 containing ultraviolet transmitting materials such as quartz, and reach the substrate S in the chamber 110. A part of the ultraviolet rays irradiated to the substrate S in the chamber 110 is incident on the surface of the substrate S, A photopolymerization reaction occurs on the resin material film 5a containing a resin material formed on the surface of the substrate S. As a result, the liquid film 5a is hardened. As shown in Figure 9, A resin film 5 is formed on the surface of the substrate S. In this embodiment, Forms a thin film of acrylic resin. Then, A mask (not shown) is moved from a film formation position on the substrate S to a retracted position by a mask mounting device or the like. After the end of step B, As shown in Figure 3, As the substrate carrying out step S12, The substrate S on which the resin film 5 is formed is carried out from the resin film forming section 100 by a substrate transfer robot (not shown). When the resin film 5 is sequentially formed on the plurality of substrates S, Repeat the above method, When the maintenance of the resin film forming part 100 is required, Or in the case of maintenance of the gasifier 300, As the gasification stop step S13, The gasification of the resin material in the gasifier 300 is stopped. (Examples of forming steps of resin material ~ localization step ~ step C) Next, The substrate S carried out from the resin film forming unit 100 is carried into the localization processing unit 202 through the core chamber 200 by a substrate transfer robot (not shown). Here, The localization processing unit 202 may be provided with a dry etching processing device, In particular, the structure of a plasma etching processing apparatus. also, Although not shown, However, the localized processing unit 202 may be a parallel plate type plasma processing apparatus. In that case, In the localization processing section 202, Placing the substrate S on the electrode, Introducing an etching gas into the chamber, The high frequency generated by the high frequency power is irradiated into the cavity through the antenna to generate a plasma, A bias voltage is applied from a high-frequency power source to the electrode on which the substrate S is placed. Introducing the ions present in the plasma to the substrate placed on the electrode, The resin film 5 formed on the surface of the substrate S is etched to remove it. Here, The resin film 5 is etched by ions in a plasma generated from an etching gas such as an oxidizing gas. at this time, In order to direct the ions to the substrate S on the electrode, A bias voltage may be applied to the electrodes. The resin film 5 having a thinner flat portion is removed by etching, Corners with bad corners on the surface of the substrate S, Recess, The resin film 5 having a thicker portion than the flat portion remains in the gap portion and the like. The remaining portion becomes the first resin material 51. Furthermore, When the first layer forming portion 201 or the second layer forming portion 203 has a sputtering device or a plasma CVD device, The forming section 201, 203 not only has a film-forming function, It may also have the function of the localization processing unit 202. In that case, E.g, As the first layer forming portion 201, The second layer forming section 203 and the localization processing section 202, The same processing device can be used. In the localization processing unit 202, As shown in Figure 10, In the substrate S on which the resin film 5 is formed, E.g, By plasma etching, As step C, As shown in FIG. 11, most of the resin film 5 is removed. The plasma treatment can calculate the processing time according to the etching rate. And for a specific processing time. and then, A detection device may be provided in the localization processing section 202. The detection device measures a bias voltage applied to an electrode, It is judged from the change of the measured value that the resin film 5 on the substrate S has been almost completely removed, The determination result (detection result) is used as the end point of the etching process. The first resin material 51 remaining on the substrate S due to the dry etching process is shown in FIG. 11. Localized (locally existing) at the boundary portion 2b between the side surface 41s of the first inorganic material layer 41 and the front surface 2a of the substrate 2. and then, The first resin material 51 is unevenly distributed in a portion where the fine unevenness on the surface of the first inorganic material layer 41 can be smoothed. (Example of forming steps of the second layer to step D) The substrate S where the first resin material 51 is locally formed is carried out by a substrate transfer robot 202 (not shown) from the localization processing unit 202. Then, it is carried into the second floor forming section 203 through the core chamber 200. In the second layer forming portion 203, By covering the first inorganic material layer 41 on which the first resin material 51 is formed, A second inorganic material layer 42 (second layer) is formed in a specific region on the substrate S including the convex portion. In step D, Similarly to the first inorganic material layer 41, Using a mask having a plurality of openings corresponding to the area of the second inorganic material layer 42, A second inorganic material layer 42 (second layer) including, for example, silicon nitride, which is the same material as the first inorganic material layer 41, is formed. With this, Can use the first inorganic material layer 41 (the first layer), The first resin material 51 and the second inorganic material layer 42 (second layer) cover the device layer 3 (functional layer), They are made to function as a protective layer of the protective device layer 3. Here, The second layer forming portion 203 can be configured to have a CVD processing apparatus or a sputtering processing apparatus. The second layer forming portion 203 may have the same device configuration as the first layer forming portion 201 described above. E.g, As the first layer forming portion 201 and the second layer forming portion 203, Can use the same processing device, Alternatively, the second layer forming portion 203 can also function as the first layer forming portion 201. also, When the second layer forming portion 203 is a plasma CVD processing apparatus, The second layer forming section 203 can also function as the localization processing section 202. When the localization of the first resin material 51 is performed in the second layer forming portion 203, After localization, The second inorganic material layer 42 (second layer) is directly formed. Since then, The substrate S on which the second inorganic material layer 42 is formed is carried out from the second layer forming section 203 by a substrate transfer robot (not shown), It is carried out to the outside of the manufacturing apparatus 1000 of the element structure through the core chamber 200 and the load-locking vacuum chamber 210. In the manufacturing apparatus 1000 of the element structure of this embodiment, As step B, The resin film 5 is formed by the resin film forming section 100. Since then, In the localization processing section 202, As step C, a first resin material 51 localized by a plasma etching process is formed. Since then, Forming a second inorganic material layer 42 (second layer), Thereby, it is possible to obtain a barrier layer at a portion such as the boundary portion 2b, The second inorganic material layer 42 (second layer) is reliably formed. and, The control unit 400 controls the film forming rate of the resin material in a stable manner. in particular, In step B, The amount of resin material reduced corresponding to the duration of the gasification that caused the gasifier 300 to operate is compensated. therefore, By controlling the supply state by extending the film-forming time, that is, the supply time, Can make the film formation rate stable, This prevents changes in film characteristics. According to the manufacturing method of the element structure of this embodiment, As shown in Figure 15, When the supply time is simply set to be fixed with respect to the target film thickness, As shown in Figure 16, In terms of a reduction in film thickness corresponding to the duration of gasification (acrylic acid supply), The supply time (processing time) is set by adding a compensation time extended corresponding to the gasification duration (acrylic acid supply amount). It can be seen that even if repeated many times, The same film thickness will also be formed. which is, Can compensate for the decrease in film formation rate. the following, Another example of the element structure manufactured by the device 1000 for manufacturing the element structure of the present embodiment will be described. In the element structure 10 of this example, which is manufactured by the device structure manufacturing device 1000 of the present embodiment, It is not limited to the structure in which the resin material is partially distributed around the first inorganic material layer 41 (convex portion), that is, the boundary portion 2b. E.g, This resin material may be left on the front surface 2a of the substrate 2 other than the boundary portion 2b, or the front surface 41a of the first inorganic material layer 41, or the like. In that case, As shown in Figure 12, The second inorganic material layer 42 (second layer) has a region laminated on the first inorganic material layer 41 via the second resin material 52. The second resin material 52 is interposed between the first inorganic material layer 41 and the second inorganic material layer 42. In addition, a partial set separate from the first resin material 51 exists on the front surface 41 a of the first inorganic material layer 41. As mentioned above, According to the element structure 10 of this embodiment, The side surface of the device layer 3 is covered with a first inorganic material layer 41 (first layer) and a second inorganic material layer 42 (second layer). Therefore, intrusion of moisture or oxygen into the device layer 3 can be prevented. also, According to this embodiment, The first resin material 51 is partially distributed in the boundary portion 2b, Therefore, it is possible to prevent a reduction in the barrier properties caused by poor coverage of the first inorganic material layer 41 or the second inorganic material layer 42, Thus, stable device characteristics can be maintained for a long time. the following, Another example of the element structure manufactured by the device 1000 for manufacturing the element structure of the present embodiment will be described. As shown in Figure 13, The element structure 20 of this example further includes a second resin material 52 interposed between the first inorganic material layer 41 and the second inorganic material layer 42. The second resin material 52 is unevenly distributed on the surface of the first inorganic material layer 41 independently of the first resin material 51. In the element structure 20 of this example, The surface of the first inorganic material layer 41 is not necessarily flat, E.g, Illustrates the following scenario, which is: Before film formation (when the substrate is transported or before it is put into the film formation device) or during film formation, etc. Fine particles P are mixed into the film, As a result, unevenness is formed. If fine particles are mixed into the first inorganic material layer 41, The coverage characteristic of the first inorganic material layer 41 to the device layer 3 is reduced, There is a possibility that desired barrier properties cannot be obtained. therefore, The element structure 20 of this example has a structure in which a coating failure portion of the first inorganic material layer 41 caused by the incorporation of the particles P and the like is filled with a second resin material 52. More typically, The second resin material 52 is unevenly distributed on the boundary portion 32 b between the surface of the first inorganic material layer 41 and the peripheral surface of the fine particles P due to surface tension. With this, The coverage of device layer 3 is improved, And by having the second resin material 52 function as a base, It is possible to achieve proper film formation of the second inorganic material layer 42. Furthermore, The resin film 5 can also be formed thinly on the flat portion during film formation. Around the particles P, The resin film 5 which is thicker than the flat portion is formed by surface tension. The second resin material 52 is formed in the same manner as the first resin material 51. The second resin material 52 may be made of the same organic material as the first resin material 51. In that case, The first resin material 51 and the second resin material 52 can be formed simultaneously in the same step. Here, In the localization processing unit 202, The etching of the resin film 5 is stopped as follows, which is, By etching, Remove the thinner part, Leaving the thicker part, which is, In the part other than the part where the particles P are present, Removing the resin film 5, As a result, the first inorganic material layer 41 is exposed. With this, When the projection is viewed from above in the vertical direction, The resin film 5 in the boundary portion 32b covered by the particles P is not over-etched. Therefore, the resin film 5 is surely left on the boundary portion 32 b around the fine particles P. the result, A boundary portion 32b near the particles P, The resin film 5 has a smooth surface shape. If there is no particle P at all, When the resin film 5 has been substantially removed by anisotropic etching, The resin film 5 will be completely removed, As a result, the first inorganic material layer 41 is exposed. Furthermore, The stop of etching can be based on the results of plasma emission spectrum analysis, Or, the elapsed time of the anisotropic etching is performed. at this time, The resin film 5 at the boundary portion 2b will not be removed. Thus, the resin film 5 is localized, Thereby, the first resin material 51 is formed. Similarly, The resin film 5 at the boundary portion 32b will not be removed. Thus, the resin film 5 is localized, Thereby, the second resin material 52 is formed. In this example, It is also possible to obtain the same effect as that of the manufacturing of the element structure 10 described above. also, According to this example, The second resin material 52 can compensate the film quality degradation caused by the incorporation of the fine particles P, Therefore, it is possible to ensure the desired barrier properties and improve productivity. the following, Another example of the element structure manufactured by the device 1000 for manufacturing the element structure of the present embodiment will be described. As shown in Figure 14, The element structure 30 in this example has, for example ,: Substrate 21, It has a device layer 3 (functional layer); Convex portion 40, It covers the side 3s of the device layer 3; The first inorganic material layer 41 (the first layer) and the second inorganic material layer 42 (the second layer), These are formed on the surface of the substrate 21 by covering the convex portion 40 and the device layer 3. The convex portion 40 is formed on the front surface 21a of the substrate 21, The central portion includes a recessed portion 40 a that houses the device layer 3. In this example, The bottom surface of the recess 40a is formed at a position higher than the front surface 21a of the substrate 21, It can also be formed at the same height position as the front surface 21a, Or it may be formed in a position lower than the front surface 21a. The element structure 30 of this example further includes a resin material 53 interposed between the first inorganic material layer 41 and the second inorganic material layer 42. The resin material 53 is located at the boundary portions 21b and 21b, And the boundary portion 22 b between the inner surface of the convex portion 40 and the device layer 3. With this, It is possible to suppress poor coating of the first inorganic material layer 41 and the second inorganic material layer 42 on the convex portion 40 and the front surface 3a of the device layer 3, Thereby, the improvement of the barrier property can be realized. The resin material 53 can be formed by the same method as the first resin material 51 and the second resin material 52 described above. In such a substrate S having such unevenness, The resin material that exists in the partial set flattens the portion that cannot be covered by the inorganic material layer. Therefore, the inorganic material layer formed on the resin material can be formed more uniformly and with good coverage. and then, The sealing of the resin material to water is lower than that of the inorganic material layer, However, the resin material that exists in a partial set is covered by the inorganic material layer and will not be exposed to the external environment. Therefore, the sealing performance is improved. which is, It is preferable that the resin material is present in a localized manner so as not to be exposed to the external environment. Instead of making it film-like. the above, The preferred embodiment of the present invention has been described. As explained above, These are merely illustrative illustrations of the present invention, It should be understood that it should not be considered a qualifier. Additions can be made without departing from the scope of the invention, Omitted, Replacement and other changes. therefore, Regarding the present invention, Should not be construed as being limited by the above description, It is limited by the scope of the application. E.g, In the above embodiment, The second inorganic material layer 42 (second layer) covering the first inorganic material layer 41 (first layer) is composed of a singular layer. However, the second inorganic material layer 42 (second layer) may be composed of a multilayer film. In that case, It is also possible to supply a resin material to the substrate at each step of forming each layer of the film to form a resin material that is biased in the uneven portion of the substrate. This can further improve the barrier properties. and then, In the above embodiment, After the first inorganic material layer 41 (the first layer) is formed, Localizes the first resin material 51 around the first inorganic material layer 41 that becomes a convex portion, However, before the first inorganic material layer 41 is formed by the first layer forming portion 201, With the resin film forming section 100 and the localization processing section 202, The first resin material 51 is unevenly distributed around the device layer 3. This can improve the coating efficiency of the first inorganic material layer 41 to the device layer 3. the following, A film forming method according to a second embodiment of the present invention based on a drawing, Film forming device, A method for manufacturing the element structure and a device for manufacturing the element structure will be described. FIG. 17 is a flowchart showing a manufacturing method (film forming method) of the element structure according to this embodiment. In this embodiment, The difference from the first embodiment is related to the method for compensating the film formation rate. The other components corresponding to the first embodiment are marked with the same symbols, The description is omitted. In the first embodiment described above, To compensate for the reduced film formation rate, Extending the film-forming time of each substrate S, However, in this embodiment, The supply amount of the resin material supplied from the vaporizer 300 to the resin film forming section 100 is controlled to increase over time. in particular, When the resin material film 5a is formed, Control the supply of resin materials. As shown in Figure 17, With calibration line acquisition step S01, Compensation resin amount setting step S32, External exhaust switching step S03, Gasification start step S04, Gasification resin amount accumulation step S35, Film thickness setting step S06, Supply resin amount setting step S37, Board loading step S08, Supply start step S09, Supply resin amount measurement step S30, Supply control step S31, Supply stop step S11, The substrate carrying-out step S12 and the vaporization stop step S13. In the compensation resin amount setting step S32 shown in FIG. 17, Corresponds to the compensation time setting step S02 in the first embodiment, Relative to the calibration curve obtained in the calibration curve acquisition step S01, In order to compensate for the decrease in the supply amount of the resin material equivalent to the film-forming treatment originally set, A compensation resin amount that increases the supply amount of the resin material with respect to the elapse of the film-forming treatment of one sheet corresponding to the cumulative supply amount of the resin material is set. The amount of the compensating resin is set so as to compensate for a decrease in the film forming rate with respect to a target film thickness to be formed. The tendency of changes in the amount of compensation resin or film formation rate is stored in the control section. Simultaneously with the gasification start step S04 shown in FIG. 17, As a step corresponding to the gasification duration measurement step S05 shown in FIG. 3, that is, the gasified resin amount accumulation step S35, The accumulation (measurement) of the gasification-continuous resin amount that started to be the basis for calculating the amount of the compensated resin. Then, In the film thickness setting step S06 and the resin supply amount setting step S37 (corresponding to the supply time setting step S07) shown in FIG. 17, According to the target film thickness, And the amount of resin that continues to be vaporized at the beginning of film formation to calculate the amount of compensated resin. in particular, Corresponds to the amount of resin that continues to vaporize from the vaporized resin material, The amount of resin supplied in one film formation is set so as to gradually increase with the passage of the supply time. Then, In the substrate carrying-in step S08 shown in FIG. 3, The substrate S is carried into the resin film forming section 100. Then, In the supply start step S09 shown in FIG. 3, The control unit 400 switches the opening and closing states of the valve 112V and the valve 113V. The self-gasifier 300 supplies the resin material to the resin material supply pipe 112 (the first pipe). Filming started. at this time, As a step corresponding to the supply time measurement step S10 shown in FIG. 3, that is, the supply resin amount measurement step S30, The measurement of the supply amount of the resin material converted into the film thickness was started. During film formation, As the supply control step S31 shown in FIG. 17, According to the resin supply amount set in the resin supply amount setting step S37, By means of the control unit 400 to compensate for the decrease in the film formation rate, The film opening was performed by adjusting the opening degree of the valve 112V gradually in accordance with the cumulative amount of the gasification-continuous resin amount. Here, The valve 112V is configured so that the opening degree can be adjusted. Then, In the supply stop step S11 shown in FIG. 17, The control unit 400 switches the opening and closing states of the valve 112V and the valve 113V. The self-gasifier 300 supplies the resin material to the resin material bypass pipe 113 (second pipe), The target film thickness is obtained and the film formation is completed. Then, As the substrate unloading step S12 shown in FIG. 17, The formed substrate S is carried out from the resin film forming section 100. when necessary, The film thickness setting step S06 to the substrate unloading step S12 are repeatedly performed a plurality of times. at this time, Accumulate the amount of gasified resin continuously in step S35, Based on this value, Each time the resin supply amount setting step S37 is recalculated, the opening degree of the valve 112V in the film formation is controlled. in particular, According to the increase in the amount of resin that continues to vaporize the resin material in the gasifier 300, In order to compensate the amount of resin that is reduced due to heat curing, etc., It is set so as to increase the amount of resin supplied as the film-forming time increases to compensate for the decrease in film-forming rate. Then, As the gasification stop step S13 shown in FIG. 17, Stopping gasification in the gasifier 300, The measurement of the resin content during the gasification is terminated. Furthermore, The film thickness setting step S06 and the resin supply amount setting step S37 are only required to be performed after the substrate carrying-in step S08. That is, before the actual film forming step is performed, Its implementation period, The sequence is not limited to the above-mentioned sequence of steps. also, Even if the gasifier 300 does not operate continuously, Gasification efficiency will also decrease due to the accumulation of gasification time since the most recent zeroing. Even if the operation of the gasifier 300 is repeatedly performed, stop, As long as the amount of resin that continues to vaporize is accumulated, The reduction in gasification efficiency can still be calculated. As a manufacturing method of the element structure of this embodiment, As described above, the supply state is controlled in such a manner as to compensate for the gasification resin material that decreases in accordance with the amount of resin that continues to vaporize. With this, The film forming rate of the resin material is stabilized regardless of the amount of resin that continues to be vaporized. and then, That is, when it is convenient to sequentially form a plurality of substrates S, It can also make the film forming rate of resin materials regardless of the number of times of film, And the gasification continuous resin amount at the time of film formation since the last clearing was stable. therefore, Can prevent changes in film formation characteristics, Therefore, variations in film characteristics (film thickness) can be prevented. Furthermore, The control of each step can be performed by the control section 400, The calculation of the calibration curve or the calculation and accumulation of the amount of the film-forming resin is also performed by a calculation section included in the control section 400. and then, The memory of the necessary data is also performed by the memory section of the control section 400. the following, A film forming method according to a third embodiment of the present invention based on a drawing, Film forming device, A method for manufacturing the element structure and a device for manufacturing the element structure will be described. FIG. 18 is a flowchart showing a manufacturing method (film forming method) of the element structure according to this embodiment. In this embodiment, The difference from the second embodiment is related to the resin supply method for compensating the film formation rate. The other components corresponding to the second embodiment are marked with the same symbols, The description is omitted. in particular, When the resin material film 5a is formed, Control the supply of resin materials. As shown in Figure 18, With calibration line acquisition step S01, Compensation resin amount setting step S32, External exhaust switching step S03, Gasification start step S04, Gasification resin amount accumulation step S35, Film thickness setting step S06, Supply resin amount setting step S37, Board loading step S08, Supply start step S09, Supply resin amount measurement step S30, Supply stop step S11, The substrate carrying-out step S12 and the vaporization stop step S13. In the film formation of this embodiment, According to the resin supply amount set in the resin supply amount setting step S37, By means of the control unit 400 to compensate for the decrease in the film formation rate, The film is formed by adjusting the supply amount of the resin material from the resin material raw material container 150 of the vaporizer 300 in accordance with the cumulative amount of the resin that has been vaporized continuously, and increasing the amount. at this time, The supply amount of the liquid resin material to the heating portion 152 in a mist form is controlled per unit time. also, when necessary, Repeat the process from the film thickness setting step S06 to the substrate unloading step S12 multiple times. at this time, Accumulate the amount of gasified resin continuously in step S35, Based on this value, Each time the resin supply amount setting step S37 is recalculated to compensate the resin amount and control the resin material supply amount from the resin material raw material container 150 during film formation. in particular, According to the increase in the amount of resin that continues to vaporize the resin material in the gasifier 300, In order to compensate the amount of resin that is reduced due to heat curing, etc., It is set so as to increase the amount of resin supplied as the film-forming time increases to compensate for the decrease in film-forming rate. As a manufacturing method of the element structure of this embodiment, As described above, in a manner of compensating for a gasification resin material that is reduced corresponding to the amount of resin that continues to gasify, Controlling the amount of resin material supplied to the gasifier 300 to increase it over time, As a result, the film forming rate of the resin material is stabilized regardless of the amount of resin that continues to be vaporized. and then, That is, when it is convenient to sequentially form a plurality of substrates S, It can also make the film forming rate of resin materials regardless of the number of film forming times, And the gasification continuous resin amount at the time of film formation since the last clearing was stable. therefore, Can prevent changes in film formation characteristics, Therefore, variations in film characteristics (film thickness) can be prevented. Industrial applicability As a utilization example of the present invention, Examples include sealing of organic EL devices and sealing of electronic devices.

2‧‧‧基板2‧‧‧ substrate

2a‧‧‧正面(第1面)2a‧‧‧ Front (1st side)

2b‧‧‧邊界部2b‧‧‧Border

2c‧‧‧背面(第2面)2c‧‧‧ back (second side)

3‧‧‧器件層(功能層)3‧‧‧device layer (functional layer)

3a‧‧‧正面3a‧‧‧ front

3s‧‧‧側面3s‧‧‧side

5‧‧‧樹脂膜5‧‧‧ resin film

5a‧‧‧樹脂材料膜5a‧‧‧Resin material film

10‧‧‧元件結構體10‧‧‧ Element Structure

20‧‧‧元件結構體20‧‧‧ Element Structure

21‧‧‧基板21‧‧‧ substrate

21a‧‧‧正面21a‧‧‧front

21b‧‧‧邊界部21b‧‧‧Border

22b‧‧‧邊界部22b‧‧‧Border

30‧‧‧元件結構體30‧‧‧ element structure

32b‧‧‧邊界部32b‧‧‧Border

40‧‧‧凸部40‧‧‧ convex

40a‧‧‧凹部40a‧‧‧Concave

41‧‧‧第1無機材料層(第一層)41‧‧‧ 1st inorganic material layer (first layer)

41a‧‧‧正面41a‧‧‧front

41s‧‧‧側面41s‧‧‧side

42‧‧‧第2無機材料層(第二層)42‧‧‧ 2nd inorganic material layer (second layer)

51‧‧‧第1樹脂材51‧‧‧The first resin material

52‧‧‧第2樹脂材52‧‧‧The second resin material

53‧‧‧第1樹脂材53‧‧‧The first resin material

100‧‧‧樹脂成膜部(成膜室)100‧‧‧Resin film forming section (film forming room)

102‧‧‧載台102‧‧‧ carrier

102a‧‧‧基板冷卻裝置102a‧‧‧ substrate cooling device

105‧‧‧簇射板105‧‧‧ shower plate

107‧‧‧上部空間107‧‧‧ Upper Space

108‧‧‧下部空間108‧‧‧ lower space

110‧‧‧腔室110‧‧‧ chamber

112‧‧‧樹脂材料供給管(第一配管)112‧‧‧Resin material supply pipe (first piping)

112V‧‧‧閥112V‧‧‧Valve

113‧‧‧樹脂材料迂迴管(第二配管)113‧‧‧Resin material bypass (second piping)

113V‧‧‧閥113V‧‧‧ Valve

114‧‧‧排氣管114‧‧‧ exhaust pipe

120‧‧‧頂板120‧‧‧Top plate

122‧‧‧UV照射裝置122‧‧‧UV irradiation device

130‧‧‧氣化槽130‧‧‧Gasification tank

130G‧‧‧載氣供給管130G‧‧‧ carrier gas supply pipe

132‧‧‧噴出部132‧‧‧Ejection Department

135‧‧‧加溫部135‧‧‧Heating Department

140‧‧‧樹脂材料液供給管140‧‧‧Resin material liquid supply pipe

140V‧‧‧閥140V‧‧‧ valve

150‧‧‧樹脂材料原料容器150‧‧‧Resin material raw material container

150G‧‧‧加壓氣體供給管150G‧‧‧Pressurized gas supply pipe

200‧‧‧核心室200‧‧‧Core Room

201‧‧‧第一層形成部(成膜室)201‧‧‧First layer forming section (film forming room)

202‧‧‧定域化處理部202‧‧‧Localization processing department

203‧‧‧第二層形成部(成膜室)203‧‧‧Second layer forming section (film forming room)

204‧‧‧功能層形成部(成膜室)204‧‧‧Functional layer forming section (film forming room)

210‧‧‧加載互鎖真空室210‧‧‧Loading interlocking vacuum chamber

300‧‧‧氣化器300‧‧‧Gasifier

400‧‧‧控制部400‧‧‧Control Department

1000‧‧‧元件結構體之製造裝置1000‧‧‧ device manufacturing device

G‧‧‧間隙G‧‧‧ Clearance

P‧‧‧微粒P‧‧‧ Particle

S‧‧‧基板S‧‧‧ substrate

圖1係表示本發明之第1實施形態之元件結構體之製造裝置的概略模式圖。 圖2係表示本發明之第1實施形態之元件結構體之製造裝置中的樹脂成膜部之模式剖視圖。 圖3係表示本發明之第1實施形態之元件結構體之製造方法的流程圖。 圖4係表示藉由本發明之第1實施形態之元件結構體之製造裝置而製造出之元件結構體之概略剖視圖。 圖5係表示藉由本發明之第1實施形態之元件結構體之製造裝置而製造出之元件結構體之俯視圖。 圖6係上述元件結構體之主要部分之放大剖視圖。 圖7係表示本發明之第1實施形態之元件結構體之製造方法中的步驟之步驟圖。 圖8係表示本發明之第1實施形態之元件結構體之製造方法中的步驟之步驟圖。 圖9係表示本發明之第1實施形態之元件結構體之製造方法中的步驟之步驟圖。 圖10係表示本發明之第1實施形態之元件結構體之製造方法中的步驟之步驟圖。 圖11係表示本發明之第1實施形態之元件結構體之製造方法中的步驟之步驟圖。 圖12係表示藉由本發明之第1實施形態之元件結構體之製造裝置而製造出之元件結構體之構成之變化例的概略剖視圖。 圖13係表示藉由本發明之第1實施形態之元件結構體之製造裝置而製造出之元件結構體之構成之變化例的概略剖視圖。 圖14係表示藉由本發明之第1實施形態之元件結構體之製造裝置而製造出之元件結構體之構成之變化例的概略剖視圖。 圖15係表示樹脂材料之氣化持續時間(供給量)與固定處理時間內之成膜厚度之關係的曲線圖。 圖16係表示本發明之第1實施形態之元件結構體之製造方法中的樹脂材料之氣化持續時間(供給量)與加入有補償時間之成膜厚度之關係的曲線圖。 圖17係表示本發明之第2實施形態之元件結構體之製造方法的流程圖。 圖18係表示本發明之第3實施形態之元件結構體之製造方法的流程圖。FIG. 1 is a schematic diagram showing an apparatus for manufacturing an element structure according to a first embodiment of the present invention. FIG. 2 is a schematic cross-sectional view showing a resin film forming portion in the device structure manufacturing apparatus according to the first embodiment of the present invention. Fig. 3 is a flowchart showing a method of manufacturing the element structure according to the first embodiment of the present invention. FIG. 4 is a schematic cross-sectional view showing an element structure manufactured by the device manufacturing apparatus for the element structure according to the first embodiment of the present invention. Fig. 5 is a plan view showing an element structure manufactured by the device manufacturing apparatus for the element structure according to the first embodiment of the present invention. FIG. 6 is an enlarged cross-sectional view of a main part of the element structure. FIG. 7 is a step diagram showing steps in the method of manufacturing the element structure according to the first embodiment of the present invention. FIG. 8 is a step diagram showing steps in the method of manufacturing the element structure according to the first embodiment of the present invention. FIG. 9 is a step diagram showing the steps in the method of manufacturing the element structure according to the first embodiment of the present invention. FIG. 10 is a step diagram showing steps in the method of manufacturing the element structure according to the first embodiment of the present invention. FIG. 11 is a step diagram showing steps in the method of manufacturing the element structure according to the first embodiment of the present invention. FIG. 12 is a schematic cross-sectional view showing a modified example of the configuration of the element structure manufactured by the device manufacturing apparatus for the element structure of the first embodiment of the present invention. FIG. 13 is a schematic cross-sectional view showing a modification example of the configuration of the element structure manufactured by the device manufacturing apparatus for the element structure according to the first embodiment of the present invention. FIG. 14 is a schematic cross-sectional view showing a modification example of the configuration of the element structure manufactured by the device manufacturing apparatus for the element structure of the first embodiment of the present invention. FIG. 15 is a graph showing the relationship between the vaporization duration (supply amount) of the resin material and the film formation thickness during a fixed processing time. FIG. 16 is a graph showing the relationship between the vaporization duration (supply amount) of the resin material and the film thickness with the compensation time added in the method of manufacturing the element structure according to the first embodiment of the present invention. Fig. 17 is a flowchart showing a method of manufacturing the element structure according to the second embodiment of the present invention. FIG. 18 is a flowchart showing a method of manufacturing the element structure according to the third embodiment of the present invention.

Claims (12)

一種成膜方法,其係將液狀之樹脂材料以霧狀噴出至加熱部而使之氣化,且將氣化之蒸氣供給至基板上而成膜樹脂材料膜者;且 以補償對應於將上述樹脂材料供給至上述加熱部之量之合計即氣化累計量而減少的上述樹脂材料之氣化率之方式控制成膜條件。A film forming method is a method in which a liquid resin material is sprayed into a heating portion in a mist state to vaporize, and a vaporized vapor is supplied to a substrate to form a resin material film; The film formation conditions are controlled in such a manner that the total amount of the resin material supplied to the heating portion, that is, the cumulative amount of vaporization, decreases the vaporization rate of the resin material. 如請求項1之成膜方法,其中上述成膜條件包括對每一片上述基板成膜上述樹脂材料膜之成膜時間、或對上述加熱部以霧狀噴出液狀之樹脂材料之每單位時間之供給量的至少任一者。The film-forming method of claim 1, wherein the film-forming conditions include a film-forming time for filming the resin material film on each of the substrates, or a unit of time for spraying the liquid resin material in a mist state to the heating portion. At least one of the supply amounts. 如請求項1或2之成膜方法,其中上述加熱部具有傾斜面。The film forming method according to claim 1 or 2, wherein the heating portion has an inclined surface. 如請求項1或2之成膜方法,其中上述樹脂材料係紫外線硬化型丙烯酸樹脂之材料。The film forming method according to claim 1 or 2, wherein the resin material is a material of an ultraviolet curable acrylic resin. 一種成膜裝置,其係將液狀之樹脂材料以霧狀噴出至加熱部而使之氣化,且將氣化之蒸氣供給至基板上而成膜樹脂材料膜者;且具有: 記錄部,其記錄包含將樹脂材料供給至上述加熱部之累計量之氣化運轉資料;及 控制部,其參照上述氣化運轉資料,決定將成膜時間延長之時間、或使對上述加熱部以霧狀噴出上述液狀之樹脂材料之每單位時間之供給量增加之增加量的至少任一者。A film-forming device is a device that sprays a liquid resin material in a mist state to a heating portion to vaporize it, and supplies the vaporized vapor to a substrate to form a resin material film; and has: a recording portion, Its record contains the gasification operation data of the cumulative amount of the resin material supplied to the heating unit; and the control unit, which refers to the gasification operation data, decides the time to extend the film formation time, or makes the heating unit misty. At least any one of an increase in the amount of supply per unit time of the above-mentioned liquid resin material is ejected. 一種元件結構體之製造方法,其包括: 第1步驟,其係形成第一層,該第一層被覆配置於基板一面之功能層,並且具有局部性之凸部,包含無機材料; 第2步驟,其係以被覆覆蓋上述基板之一面側之上述第一層之方式,將液狀之樹脂材料以氣化形式供給而形成包含上述樹脂材料之樹脂材料膜; 第3步驟,其係自側剖面觀察上述第一層,使位於包含上述凸部之外側面與上述基板之一面之邊界部之位置的上述樹脂材料膜之一部分殘存,而將位於與殘存上述樹脂材料膜之位置不同之位置的該樹脂材料膜去除;及 第4步驟,其係以被覆上述所殘存之樹脂材料膜之一部分、及藉由上述樹脂材料膜之去除而露出之上述第一層之方式形成包含無機材料之第二層;且 於上述第2步驟中,以補償對應於氣化之上述樹脂材料之氣化持續時間而減少之上述樹脂材料之方式控制供給狀態。A method for manufacturing an element structure, comprising: a first step of forming a first layer, the first layer covering a functional layer disposed on one side of a substrate, and having a localized convex portion including an inorganic material; a second step It is to form a resin material film containing the above-mentioned resin material by supplying the liquid resin material in a vaporized form so as to cover the first layer on one side of the substrate; the third step is a side section Observe the first layer, leaving a portion of the resin material film at a position including a boundary portion between the outer side of the convex portion and one surface of the substrate, and leave the resin material film at a position different from the position where the resin material film remains. Removal of the resin material film; and a fourth step of forming a second layer containing an inorganic material by covering a part of the remaining resin material film and the first layer exposed by the removal of the resin material film ; And in the above second step, in a manner of compensating for the resin material that has been reduced corresponding to the gasification duration of the gasified resin material System supply state. 如請求項6之元件結構體之製造方法,其中於上述第2步驟中,對應於與氣化之上述樹脂材料之供給時間對應的上述樹脂材料之供給量,而延長上述樹脂材料膜之成膜時間。For example, in the method for manufacturing a component structure according to claim 6, in the second step, the film formation of the resin material film is extended corresponding to the supply amount of the resin material corresponding to the supply time of the vaporized resin material. time. 如請求項7之元件結構體之製造方法,其中於上述第2步驟中之上述樹脂材料膜之成膜處理時,將氣化之上述樹脂材料供給至成膜室之內部,並且於上述樹脂材料膜之非成膜處理時,將氣化之上述樹脂材料送出至上述成膜室之外部;且 獲得將上述樹脂材料之供給量作為上述樹脂材料之氣化量進行累計所得之累計量,且根據上述累計量而控制上述樹脂材料膜之成膜時間。The method for manufacturing a component structure according to claim 7, wherein during the film forming treatment of the resin material film in the second step, the vaporized resin material is supplied to the inside of the film forming chamber, and the resin material is When the film is not film-formed, the vaporized resin material is sent to the outside of the film-forming chamber; and a cumulative amount obtained by accumulating the supply amount of the resin material as the vaporization amount of the resin material is obtained, and according to The accumulated amount controls the film forming time of the resin material film. 如請求項6至8中任一項之元件結構體之製造方法,其中上述第3步驟係自側剖面觀察上述第一層,以上述凸部之外側面中之包含頂部之區域露出之方式將上述樹脂材料膜去除。The manufacturing method of the element structure according to any one of claims 6 to 8, wherein the third step is to observe the first layer from a side section, and expose the region including the top portion on the outer side surface of the convex portion so as to expose the first layer. The resin material film is removed. 如請求項6至8中任一項之元件結構體之製造方法,其中上述第3步驟係使用乾式蝕刻法作為將上述樹脂材料膜去除之方法。The manufacturing method of the element structure according to any one of claims 6 to 8, wherein the third step described above uses a dry etching method as a method for removing the resin material film. 如請求項10之元件結構體之製造方法,其中上述第3步驟係檢測對上述樹脂材料膜進行蝕刻處理之條件中之特定條件之變化,且將所檢測出之檢測結果用作該蝕刻處理之終點。For example, the manufacturing method of the element structure of claim 10, wherein the third step is to detect a change in a specific condition among the conditions for performing the etching treatment on the resin material film, and use the detected detection result as the etching treatment. end. 一種元件結構體之製造裝置,其具有: 第一層形成部,其形成第一層,該第一層被覆配置於基板一面側之功能層,並且具有局部性之凸部,包含無機材料; 樹脂成膜部,其能自對液狀之樹脂材料進行加熱而使之氣化之氣化器供給氣化之上述樹脂材料,形成被覆上述第一層且包含上述樹脂材料之樹脂材料膜; 定域化處理部,其係自側剖面觀察上述第一層,使位於包含上述凸部之外側面與上述基板之一面之邊界部之位置的上述樹脂材料膜之一部分殘存,而將位於與殘存上述樹脂材料膜之位置不同之位置的該樹脂材料膜去除;及 第二層形成部,其以被覆位於上述基板之一面側之上述凸部、上述所殘存之樹脂材料膜之一部分、及藉由上述去除而露出之上述第一層之方式形成包含無機材料之第二層;並且具備: 供給管,其連接於上述氣化器所具備之氣化槽,於成膜時將氣化之上述樹脂材料供給至上述樹脂成膜部; 外部管,其連接於上述氣化槽,於非成膜處理時將氣化之上述樹脂材料送出至上述樹脂成膜部之外部;及 切換閥,其對上述供給管與上述外部管進行切換;且 具有控制部,其以補償對應於氣化持續時間而減少之上述樹脂材料之方式,控制對上述樹脂成膜部供給樹脂材料之供給時間。An apparatus for manufacturing an element structure, comprising: a first layer forming portion that forms a first layer; the first layer covers a functional layer disposed on one side of a substrate, and has a local convex portion including an inorganic material; a resin; A film forming part, which can supply the vaporized resin material from a vaporizer that heats the liquid resin material to vaporize, to form a resin material film covering the first layer and containing the resin material; The chemical treatment unit is a part of the resin material film located at a position including a boundary portion between an outer side surface of the convex portion and one of the substrates when the first layer is viewed from a side section, and the resin is located and remained. The resin material film is removed at different positions of the material film; and a second layer forming portion that covers the convex portion on one side of the substrate, a portion of the remaining resin material film, and removes The exposed first layer forms a second layer containing an inorganic material, and includes: a supply pipe connected to a gas provided in the gasifier. The gasification tank supplies the vaporized resin material to the resin film formation part during film formation; the outer tube is connected to the gasification tank, and sends out the vaporized resin material to the resin during non-film formation treatment Outside of the film forming section; and a switching valve that switches the supply pipe and the external pipe; and has a control section that controls the formation of the resin in a manner that compensates for the resin material that decreases in accordance with the duration of vaporization. Supply time for supplying resin material to the film portion.
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