WO2012026483A1 - 蒸着処理装置および蒸着処理方法 - Google Patents
蒸着処理装置および蒸着処理方法 Download PDFInfo
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- WO2012026483A1 WO2012026483A1 PCT/JP2011/069027 JP2011069027W WO2012026483A1 WO 2012026483 A1 WO2012026483 A1 WO 2012026483A1 JP 2011069027 W JP2011069027 W JP 2011069027W WO 2012026483 A1 WO2012026483 A1 WO 2012026483A1
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- vapor deposition
- substrate
- material gas
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- thin film
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- 238000007740 vapor deposition Methods 0.000 title claims abstract description 136
- 238000012545 processing Methods 0.000 title claims abstract description 82
- 238000003672 processing method Methods 0.000 title claims description 5
- 239000000463 material Substances 0.000 claims abstract description 153
- 239000000758 substrate Substances 0.000 claims abstract description 146
- 239000010408 film Substances 0.000 claims abstract description 114
- 238000001514 detection method Methods 0.000 claims abstract description 57
- 239000010409 thin film Substances 0.000 claims abstract description 49
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- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 2
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Images
Classifications
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/10—Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
-
- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/06—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the coating material
- C23C14/12—Organic material
-
- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/228—Gas flow assisted PVD deposition
-
- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/54—Controlling or regulating the coating process
- C23C14/542—Controlling the film thickness or evaporation rate
- C23C14/544—Controlling the film thickness or evaporation rate using measurement in the gas phase
-
- C—CHEMISTRY; METALLURGY
- C23—COATING 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
- C23C—COATING 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
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/54—Controlling or regulating the coating process
- C23C14/542—Controlling the film thickness or evaporation rate
- C23C14/545—Controlling the film thickness or evaporation rate using measurement on deposited material
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/10—Deposition of organic active material
- H10K71/16—Deposition of organic active material using physical vapour deposition [PVD], e.g. vacuum deposition or sputtering
- H10K71/164—Deposition of organic active material using physical vapour deposition [PVD], e.g. vacuum deposition or sputtering using vacuum deposition
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/40—Thermal treatment, e.g. annealing in the presence of a solvent vapour
Definitions
- the present invention relates to a vapor deposition processing apparatus and a vapor deposition processing method used for forming a light emitting layer in the manufacture of an organic EL element, for example.
- organic EL elements using electroluminescence (EL) have been developed. Since organic EL elements are self-luminous, they have advantages such as low power consumption and superior viewing angle compared to liquid crystal displays (LCDs) and the like, and future development is expected.
- LCDs liquid crystal displays
- the most basic structure of this organic EL element is a sandwich structure in which an anode (anode) layer, a light emitting layer and a cathode (cathode) layer are formed on a glass substrate.
- anode anode
- a light emitting layer a light emitting layer
- a cathode cathode
- a transparent electrode made of ITO (Indium Tin Oxide) or the like is used for the anode layer on the glass substrate.
- Such an organic EL element is manufactured by sequentially forming a light emitting layer and a cathode layer on a glass substrate on which an ITO layer (anode layer) is formed in advance, and further forming a sealing film layer. Is common.
- the organic layer formation in the organic EL element as described above is generally performed in a vapor deposition apparatus.
- the film thickness of the organic layer or the like in the vapor deposition apparatus needs to be controlled to a predetermined film thickness from the viewpoint of light emission efficiency and the like, and various film thickness control techniques have been devised conventionally.
- FIG. 1 is a schematic explanatory diagram of a vapor deposition processing apparatus 100 that performs film thickness measurement using a crystal resonator, which is a conventional technique for general film thickness control.
- the vapor deposition processing apparatus 100 includes a chamber 101 and a substrate processing chamber 102 that communicate with each other, and a vapor deposition head 110 that communicates with a material gas supply unit 103 is installed therein.
- a substrate G supported by the substrate support 111 is disposed face down in the lower part of the substrate processing chamber 102. Further, a quartz crystal resonator (QCM) 112 made of, for example, quartz is disposed so as to be adjacent to the substrate G on the substrate support 111.
- QCM quartz crystal resonator
- the lower surface of the vapor deposition head 110 is opened, and the opening is opposed to the upper surface of the substrate G.
- the material gas supplied from the material gas supply unit 103 passes through the vapor deposition head 110 and is jetted onto the upper surface of the substrate G from the opening. At this time, the material gas is also jetted from the vapor deposition head 110 to the crystal resonator (QCM) 112 at the same time.
- the chamber 101 is brought into a vacuum state by a vacuum pump 115 communicating with the exhaust pipe 113, and the substrate processing chamber 102 is kept in a vacuum state accordingly.
- the vapor deposition head 110, the chamber 101, and the like are temperature-controlled by a heater (not shown) to such a temperature that no material gas is deposited.
- the film thickness of the thin film deposited on the substrate G is measured by measuring the film thickness of the thin film actually deposited on the crystal resonator (QCM) 112. I was in control. That is, when the vapor deposition conditions of the crystal resonator (QCM) 112 and the substrate G are the same, the thickness of the thin film deposited on each of them has a certain relationship, so that the crystal resonator (QCM) 112 is deposited. From the thickness of the thin film, the thickness of the thin film deposited on the substrate G under the same conditions can be found.
- the target used for film thickness measurement is not limited to the quartz crystal resonator (QCM) 112 but, for example, a dummy substrate on which film formation is performed under substantially the same conditions as the substrate G on which film formation is actually performed. Are known.
- an object of the present invention is to provide a vapor deposition processing apparatus and a vapor deposition processing method capable of controlling the film thickness simultaneously with the formation of a thin film on the substrate G.
- a vapor deposition processing apparatus for depositing a thin film on a substrate by vapor deposition, wherein the material supply section for supplying a material gas is freely depressurized, and the thin film is deposited on the substrate.
- a film forming unit that includes a detecting unit that measures a vapor concentration of a material gas sprayed onto the substrate, and a control unit that controls film forming conditions based on a measurement result of the detecting unit.
- the detection means is selected from an optical detection device, a mass spectrometer, an ionization vacuum gauge (for example, a tough gauge), and a vacuum gauge (for example, a capacitance manometer (hereinafter also referred to as CM)) capable of measuring an absolute pressure. It may be composed of one or more detection means. The detection means can also detect a component of the material gas.
- the control unit can control one or more of the carrier gas flow rate, the heater temperature of the material gas generation unit, the material supply amount, the substrate moving speed, the substrate temperature, and the chamber pressure.
- a vapor deposition method for forming a thin film on a substrate by vapor deposition, wherein the vapor concentration of a material gas sprayed onto the substrate is measured by a detection unit, and the detection unit There is provided a vapor deposition method for controlling film forming conditions based on measurement results.
- the film forming condition is one or more of a carrier gas flow rate, a heater temperature of the material gas generation unit, a material supply amount, a substrate moving speed, a substrate temperature, and a chamber pressure.
- the detection means is one or more devices selected from an optical detection device, a mass spectrometer, a vacuum gauge capable of measuring an absolute pressure, and an ionization vacuum gauge.
- a vapor deposition apparatus capable of controlling the film thickness at a stage before forming a thin film on a substrate or simultaneously (in real time) with forming a thin film on a substrate G.
- FIG. 5 is an explanatory diagram of a manufacturing process of the organic EL element A.
- FIG. It is sectional drawing which looked at the vapor deposition processing apparatus from the side. It is sectional drawing which looked at the vapor deposition processing apparatus concerning 2nd Embodiment from the side. It is sectional drawing which looked at the vapor deposition processing apparatus concerning 3rd Embodiment from the side.
- (A) It is sectional drawing which looked at the vapor deposition processing apparatus concerning 4th Embodiment from the side.
- (B) It is explanatory drawing of a vacuum gauge. It is explanatory drawing of the 1st modification of this invention. It is a schematic explanatory drawing of the vapor deposition processing apparatus concerning a 2nd modification.
- FIG. 2 is an explanatory diagram of a manufacturing process of the organic EL element A manufactured by various film forming apparatuses including the vapor deposition processing apparatus 1 according to the embodiment of the present invention.
- a substrate G having an anode (anode) layer 10 formed thereon is prepared.
- the substrate G is made of a transparent material made of, for example, glass.
- the anode layer 10 is made of a transparent conductive material such as ITO (Indium Tin Oxide).
- ITO Indium Tin Oxide
- a light emitting layer (organic layer) 11 is formed on the anode layer 10 by vapor deposition.
- the light emitting layer 11 has, for example, a multilayer structure in which a hole transport layer, a non-light emitting layer (electron block layer), a blue light emitting layer, a red light emitting layer, a green light emitting layer, and an electron transport layer are stacked.
- a cathode (cathode) layer 12 made of, for example, Ag or Al is formed on the light emitting layer 11 by using, for example, a sputtering method using a mask.
- the light emitting layer 11 is patterned by, for example, dry etching the light emitting layer 11 using the cathode layer 12 as a mask.
- an insulating sealing film layer made of, for example, silicon nitride (SiN) so as to cover the periphery of the light emitting layer 11 and the cathode layer 12 and the exposed portion of the anode layer 10. 13 is formed.
- the sealing film layer 13 is formed by, for example, a ⁇ wave plasma CVD method.
- the organic EL device A thus manufactured can cause the light emitting layer 11 to emit light by applying a voltage between the anode layer 10 and the cathode layer 12.
- Such an organic EL element A can be applied to a display device and a surface light emitting element (illumination, light source, etc.), and can be used for various other electronic devices.
- the detection means for detecting the vapor concentration of the organic material gas is an optical detection device, a mass spectrometer.
- material gas the organic material gas
- the ionization vacuum gauge and the vacuum gauge capable of measuring absolute pressure for example, a capacitance manometer (CM) will be described as first to fourth embodiments.
- FIG. 3 is a cross-sectional view of the vapor deposition apparatus 1 according to the first embodiment of the present invention used in the vapor deposition process shown in FIG.
- an optical detection device 41 that is Fourier transform infrared spectroscopy (FTIR) is used as the detection means for measuring the vapor concentration of the material gas.
- FTIR Fourier transform infrared spectroscopy
- a vapor deposition head that ejects an organic material gas onto the substrate G includes, for example, a hole transport layer, a non-light-emitting layer (electron block layer), a blue light-emitting layer, a red light-emitting layer, a green light-emitting layer, and an electron transport.
- a plurality of organic layers such as layers may be prepared for vapor deposition.
- a case where there is one vapor deposition head is illustrated and described below.
- the vapor deposition processing apparatus 1 is provided with a processing chamber 20 and a substrate processing chamber 21 as a film forming unit for performing a film forming process, and the vapor deposition head extends across the processing chamber 20 and the substrate processing chamber 21. 22 is installed.
- the substrate processing chamber 21 is provided below the processing chamber 20, and a support base 23 that supports the substrate G with the film formation target surface facing upward (in a face-up state) is provided inside the substrate processing chamber 21.
- the vapor deposition head 22 is installed so that the material gas ejection surface 22 ′ (opening surface) of the vapor deposition head 22 faces the upper surface (film formation target surface) of the substrate G.
- the processing chamber 20 communicates with a vacuum pump 26 through an exhaust pipe 25, and is evacuated during film formation.
- the vapor deposition head 22 communicates with the material gas generation unit 30 via a material introduction path 29 that introduces an organic material gas into the vapor deposition head 22.
- the material gas generation unit 30 is provided with a heater for heating an organic material (not shown), and the material gas heated and generated in the material gas generation unit 30 is introduced into the vapor deposition head 22 through the material introduction path 29. And ejected from the vapor deposition head 22 onto the substrate G.
- the material gas generation unit 30 controls a carrier gas control unit 30a for controlling the flow rate of the carrier gas, a material input control unit 30b for controlling the input amount of the organic material, and a vaporization amount when the organic material is vaporized.
- a material vaporization control unit 30c is provided.
- a heater 31 is attached to the vapor deposition head 22, and the heating temperature is controlled to a temperature at which the organic material gas vaporized in the material gas generation unit 30 and flows into the vapor deposition head 22 does not precipitate in the vapor deposition head 22.
- a film thickness sensor 33 capable of measuring the film thickness from the Raman spectrum intensity by reflecting light by reflecting light on the thin film is installed on the substrate G as needed. The thickness of the formed thin film can be measured.
- transmission windows 40 made of, for example, calcium fluoride are provided on both sides of the vapor deposition head 22 and both sides of the substrate processing chamber 21 to transmit light.
- a light emitting part 41 a and a light receiving part 41 b of the optical detection device 41 are arranged on the outside side of the substrate processing chamber 21. Infrared light is transmitted into the vapor deposition head 22 from the light emitting part 41a of the optical detection device 41 through the transmission window 40, the light is received by the light receiving part 41b, and the light at the time of light emission is compared with the light at the time of light reception.
- the gas state gas concentration / component / spectral spectrum
- the optical detection device 41 for example, Fourier transform infrared spectroscopy (FTIR) in which the amount of light absorption is measured using infrared rays can be considered, but the present invention is not limited to this, and for example, atoms Absorption method or single wavelength absorption method (NDIR) may be applied.
- FTIR Fourier transform infrared spectroscopy
- NDIR single wavelength absorption method
- a gas branch path may be formed in the middle of the material supply line, or a lead-in line may be formed, and the gas state can be measured there.
- the vapor deposition processing apparatus 1 is provided with a control unit 42 that sends an instruction signal to the material gas generation unit 30 based on the gas state inside the vapor deposition head 22 obtained by the optical detection device 41 (light receiving unit 41b). Yes.
- the carrier gas control unit 30a controls the flow rate of the carrier gas.
- the material input control unit 30b controls the material input amount.
- the amount of material to be vaporized is controlled by the material vaporization control unit 30 c, and a desired amount of material gas is introduced into the vapor deposition head 22.
- the film thickness of the thin film formed on the substrate G is controlled.
- the film thickness to be formed also changes depending on the moving speed of the substrate G, the temperature of the substrate G, and the pressure inside the processing chamber 20. Therefore, the substrate G can also be changed by changing the moving speed of the substrate G, the temperature of the substrate G, and the pressure inside the processing chamber 20 based on the gas state inside the vapor deposition head 22 obtained by the optical detection device 41. The film thickness of the thin film formed is controlled.
- the film thickness of the film formed on the substrate G is controlled by the film thickness measurement sensor 33 in a state where the material gas temperature (amount of material to be vaporized), the carrier gas flow rate, the material input amount, etc. are set in a predetermined condition.
- the measured reference data is taken and a database (or calibration curve) is created based on the reference data. This is performed using a method of calculating the vapor concentration and amount of the material gas by collating and analyzing the measurement data measured by the optical detection device 41 at the time of actual film formation and the database.
- the difference (desired film thickness) between the set conditions and the current film formation conditions And the current film thickness, the partial pressure of the material gas in the substrate processing chamber, etc.) are used to control the film thickness. That is, a predetermined film thickness of a thin film to be formed is determined in advance based on each condition (material gas temperature, carrier gas flow rate, material input amount, etc.) set at the beginning of film formation, and is actually formed on the substrate G.
- the film thickness of the thin film is different from the predetermined film thickness, the above-described film thickness control is performed immediately (in real time), and the film thickness of the formed thin film can be set to the predetermined film thickness. .
- the amount of the material gas flowing into the vapor deposition head 22 by changing the flow rate of the carrier gas is determined. adjust. It is also conceivable to adjust the amount of material gas generated and vaporized in the material gas generation unit 30 by adjusting the amount of material input and further controlling the temperature of the evaporation unit.
- a threshold value corresponding to the amount of deviation from a predetermined value is determined, and when the measured value is larger than the threshold value, control of the material gas is performed by changing the temperature of the evaporation unit, and the measured value Is smaller than the threshold value, the material gas should be controlled only by the carrier gas flow rate without changing the temperature of the evaporation section.
- the amount of material gas is very sensitive to changes in the temperature of the evaporation section, and even if the temperature changes slightly, the amount of vapor changes greatly, and the amount of change in the film formation rate and film thickness increases. This is because it is not suitable for adjustment.
- the value is smaller than the threshold value, it is appropriate to use a method other than the temperature control of the evaporator, for example, by adjusting the carrier gas flow rate. Further, the reactivity is better when adjusted by the carrier gas flow rate.
- the vapor concentration of the material gas in the vapor deposition head 22 is measured at any time (in real time) by the optical detection device 41. Then, by controlling the vapor concentration of the material gas described above, the vapor concentration of the material gas inside the vapor deposition head 22 is such that the thin film formed on the substrate G has a predetermined thickness and a predetermined film formation rate (per unit time). (The amount of film formation).
- the film thickness and the film formation rate by changing the moving speed of the substrate G.
- the substrate G in the processing chamber 20 A method of increasing the moving speed to reduce the amount of material gas injected per unit area with respect to the substrate G, a method of increasing the temperature of the substrate G, and increasing the pressure in the processing chamber 20 A method of making film formation on G difficult to promote is also conceivable.
- substrate G, and the pressure in a process chamber are used. This can be done by taking a lowering method.
- an organic material gas introduced from the material supply unit 30 is ejected from the vapor deposition head 22 to form a film on the upper surface of the substrate G.
- the concentration / component / spectral spectrum of the organic material gas introduced into the vapor deposition head 22 is measured by the optical detection device 41.
- the material gas concentration at a predetermined position inside the vapor deposition head 22 and the film thickness of the organic thin film formed on the substrate G at that time have a certain correlation when other conditions are the same.
- the concentration / component / spectral spectrum of the organic material gas inside the vapor deposition head 22 is detected, and the conditions such as the amount of material gas generation described above in the material gas generating unit 30 are determined based on the detection result of the concentration / component / spectral spectrum.
- the film thickness and film forming speed of the organic thin film formed on the substrate G are controlled.
- the organic material gas concentration / component / spectral spectrum inside the vapor deposition head 22 are measured at any time (real time measurement). Can be performed.
- the material gas temperature (heater temperature of the material gas generator) and the carrier gas flow rate are changed. It is preferable to make it.
- the difference between the thin film thickness estimated from the measurement of the organic material gas concentration and the desired thin film thickness is very small, it can be controlled by changing the carrier gas flow rate or the substrate moving speed. Is preferred. This is because changes in temperature are directly linked to changes in the vapor concentration of the material gas, so minute changes in the temperature of the material gas significantly affect the film thickness change of the thin film to be deposited. This is because the influence on the thickness of the thin film is small. In addition, the response to the film thickness is excellent.
- FIG. 4 is a cross-sectional view of the vapor deposition apparatus 1 according to the second embodiment of the present invention used in the vapor deposition process shown in FIG.
- a mass spectrometer 43 that is, for example, a quadrupole mass spectrometer (Q-mass) is used as a detection means for measuring the vapor concentration of the material gas.
- Q-mass quadrupole mass spectrometer
- a measuring unit 43 a is provided in the vicinity of the material gas ejection surface 22 ′ of the vapor deposition head 22, and a controller connected to the measuring unit 43 a is provided outside the substrate processing chamber 21.
- a portion 43b is provided.
- the mass spectrometer 43 includes the measurement unit 43a and the controller unit 43b.
- Q-mass quadrupole mass spectrometer
- the inside of the vapor deposition head 22 or the transport path of the material gas may be considered.
- the pressure band it cannot be detected accurately, or the sensitivity is increased due to the adhesion of the material gas.
- the vicinity of the material gas ejection surface 22 ′ in the substrate processing chamber 21 as shown in FIG. 4 is preferable.
- the measurement data detected by the measurement unit 43a is sent from the controller unit 43b to the control unit 42, and based on the control of the control unit 42, the material generation unit 30 controls the material gas temperature (material gas vaporization amount), the input amount of the material gas, The flow rate of the carrier gas is controlled by the carrier gas control unit 30a, the material input control unit 30b, and the material vaporization control unit 30c, respectively.
- Specific control of the temperature of the material gas (amount of material gas vaporization), the input amount of the material gas, and the flow rate of the carrier gas are the same as those described in the first embodiment. Description of is omitted.
- the vapor concentration of the material gas ejected to the substrate G is controlled, so that an organic thin film having a desired film thickness can be formed.
- a film is actually formed on the substrate G only by measuring the material gas introduced into the vapor deposition head 22 by the mass spectrometer 43 without performing film formation on the substrate G or a dummy substrate in advance. Since the film thickness of the thin film can be controlled, the film forming process on the substrate G can be efficiently started.
- FIG. 5 is a cross-sectional view of the vapor deposition apparatus 1 according to the third embodiment of the present invention used in the vapor deposition process shown in FIG.
- an ionization vacuum gauge 45 that is a tough gauge (TG: manufactured by Ampere Co., Ltd.) is used as a detection means for measuring the vapor concentration of the material gas.
- the components other than the ionization vacuum gauge 45 in the second embodiment are the same as those in the first embodiment, and the functional configuration is the same. Detailed explanation is omitted.
- a measurement unit 45 a is provided in the vicinity of the material gas ejection surface 22 ′ of the vapor deposition head 22, and a controller connected to the measurement unit 45 a outside the substrate processing chamber 21.
- a portion 45b is provided.
- the ionization vacuum gauge 45 includes the measurement unit 45a and the controller unit 45b. In the ionization vacuum gauge 45, the degree of vacuum (internal pressure) in the substrate processing chamber 21 that is in a substantially vacuum state is measured in the measurement unit 45a.
- the substrate processing in a state where the material gas is not introduced into the substrate processing chamber 21, that is, the organic material is not heated or generated in the material gas supply unit 30 first, the substrate processing in a state where the material gas is not introduced into the substrate processing chamber 21, that is, the organic material is not heated or generated in the material gas supply unit 30.
- the degree of vacuum (internal pressure) of the chamber 21 is measured (background measurement).
- the degree of vacuum (internal pressure) of the substrate processing chamber 21 after the material gas is introduced into the substrate processing chamber 21 from the material gas generating unit 30 via the vapor deposition head 22 is measured.
- the change in the degree of vacuum in the substrate processing chamber 21 due to the material gas is calculated, and the partial pressure of the material gas is obtained.
- the partial pressure of the material gas is correlated with the vapor concentration of the material gas introduced into the substrate processing chamber 21, the partial pressure of the material gas is continuously measured by the ionization vacuum gauge 45 so that the substrate processing chamber is The change in the vapor concentration of the material gas introduced into 21 will be measured.
- the ionization vacuum gauge 45 (especially the measurement unit 45a) can be installed at any position in the substrate processing chamber 21, and in order to accurately measure the partial pressure of the material gas, It is preferable to provide in the vicinity of the material gas ejection surface 22 ′ of the vapor deposition head 22 as shown in FIG. 5, the vapor deposition head 22, the gas transport path, or the like.
- the measurement data detected by the measurement unit 45a is sent from the controller unit 45b to the control unit 42.
- the material generation unit 30 controls the material gas temperature (material gas vaporization amount), the input amount of the material gas,
- the flow rate of the carrier gas is controlled by the carrier gas control unit 30a, the material input control unit 30b, and the material vaporization control unit 30c, respectively.
- Specific control of the temperature of the material gas (amount of material gas vaporization), the input amount of the material gas, and the flow rate of the carrier gas are the same as those described in the first embodiment. Description of is omitted.
- the substrate G By changing any of the conditions of the material gas temperature (the amount of material gas vaporization), the amount of material gas input and the carrier gas flow rate, or a plurality of these conditions based on the measurement data detected by the ionization vacuum gauge 45, the substrate G The vapor concentration of the material gas ejected with respect to the gas is controlled, so that an organic thin film having a desired film thickness can be formed. Further, the film is actually formed on the substrate G only by measuring the material gas introduced into the vapor deposition head 22 by the ionization vacuum gauge 45 without performing film formation on the substrate G or the dummy substrate in advance. Since the film thickness of the thin film can be controlled, the film forming process on the substrate G can be efficiently started.
- FIG. 6A is a cross-sectional view of the vapor deposition apparatus 1 according to the fourth embodiment of the present invention used in the vapor deposition step shown in FIG.
- FIG.6 (b) is explanatory drawing of the vacuum gauge 46 used in the vapor deposition processing apparatus 1 concerning 4th Embodiment.
- a vacuum gauge 46 capable of measuring an absolute pressure, which is a capacitance manometer (hereinafter also referred to as CM), is used as the detection means for measuring the vapor concentration of the material gas.
- CM capacitance manometer
- the vacuum gauge 46 is attached so as to communicate with the inside of the vapor deposition head 22 as shown in FIG.
- the CM used as the vacuum gauge 46 is one of diaphragm vacuum gauges capable of measuring absolute pressure, and a thin metal plate arranged in the apparatus is elastically deformed by the differential pressure, and the displacement is detected as a capacitance. It is.
- the vacuum gauge 46 is composed of two chambers 46a and 46b provided with a metal diaphragm 47 disposed inside.
- One chamber 46a communicates with the internal space of the vapor deposition head 22, and an insulated electrode 48 is disposed in the other chamber 46b.
- the pressure in the chamber 46b in which the electrode 48 is disposed is used as a reference, and the metal diaphragm 47 is deformed according to the differential pressure between the two chambers (46a, 46b), and the distance between the insulated electrode 48 and the metal diaphragm 47 is increased.
- the corresponding capacitance changes.
- the displacement of the metal diaphragm 47 is obtained using the change amount of the capacitance, and the pressure in the vapor deposition head 22 (in the processing chamber 20) can be obtained by converting the displacement into a pressure.
- the measurement range of the vacuum gauge 46 which is a capacitance manometer can be widely used for pressure measurement from atmospheric pressure to about 10 mPa (0.1 mTorr).
- the light transmission path of the optical detection device 41 is set inside the vapor deposition head 22 and the windows 40 are provided on both sides of the vapor deposition head 22.
- the light transmission path does not necessarily need to be inside the vapor deposition head 22, and may be any place where the organic material gas is sufficiently detected.
- FIG. 7 shows a first modification of the present invention.
- FIG. 7 is a view of the vapor deposition head 22 as viewed from the transport direction of the substrate G (perpendicular to the paper surface).
- the passage path of the light emitted from the optical detection device 41 is between the material gas ejection surface 22 ′ of the vapor deposition head 22 and the upper surface of the substrate G. That is, light is allowed to pass through a space 49 formed between the material gas ejection surface 22 ′ of the vapor deposition head 22 provided in the vapor deposition processing apparatus 1 and the upper surface of the substrate G in a direction orthogonal to the transport direction of the substrate G, respectively.
- An optical detection device 41 that detects the concentration, component, and spectral spectrum of the organic material gas ejected from the vapor deposition head 22 is installed in the substrate processing chamber 21 as in the first embodiment. As in the first embodiment, the material gas supply amount in the material generating unit 30 is controlled by the instruction signal from the optical detection device 41.
- the case where there is one vapor deposition head 22 has been described as an example.
- a hole transport layer, a non-light emitting layer (electron block layer) is used.
- a blue light emitting layer a red light emitting layer
- a green light emitting layer a green light emitting layer
- an electron transport layer six vapor deposition heads 22 are provided and film formation is continuously performed on the substrate G. Therefore, a second modification of the present invention when six vapor deposition heads 22 are installed will be described below with reference to the drawings.
- the optical detection device 61 is used as the detection means for detecting the vapor concentration of the material gas
- the first to fourth embodiments are described as the detection means. Any of the detection means described in (1) may be used.
- FIG. 8 is a schematic explanatory view of a vapor deposition processing apparatus 50 according to a second modification of the present invention.
- the vapor deposition processing apparatus 50 shown in FIG. 8 forms the light emitting layer 11 shown in FIG. 2A by vapor deposition.
- the vapor deposition processing apparatus 50 has a sealed processing chamber 51.
- the processing chamber 51 has a rectangular parallelepiped shape whose longitudinal direction is the direction in which the substrate G is transferred, and the front and rear surfaces of the processing chamber 51 are connected to other film forming processing apparatuses and the like via gate valves 52.
- An exhaust line 53 having a vacuum pump (not shown) is connected to the bottom surface of the processing chamber 51 so that the inside of the processing chamber 51 is decompressed.
- the treatment chamber 51 includes a support base 54 that horizontally supports the substrate G.
- the substrate G is placed on the support base 54 with the upper surface on which the anode layer 10 is formed facing up.
- the support base 54 travels on the rail 55 arranged along the transport direction of the substrate G, and transports the substrate G.
- a plurality (six in FIG. 8) of vapor deposition heads 56 are arranged along the transport direction of the substrate G on the ceiling surface of the processing chamber 51.
- a plurality of material supply sources 57 for supplying vapor (film gas) of a film forming material for forming the light emitting layer 11 is connected to each vapor deposition head 56 via a material supply pipe 58.
- a hole transport layer and a non-light emitting layer are formed on the upper surface of the substrate G.
- a layer, a blue light emitting layer, a red light emitting layer, a green light emitting layer, an electron transport layer, and the like are sequentially formed, and the light emitting layer 11 is formed on the upper surface of the substrate G.
- an optical detection device 61 (light emitting unit 61a on the upstream side in the transport direction, light reception on the downstream side) that passes light in the transport direction of the substrate G (Including the part 61b), the specific spectrum of the organic material gas ejected from each of the plurality of vapor deposition heads 56 can be separated and accurately detected. For this reason, the organic material gas concentration from each of the six vapor deposition heads 56 is simultaneously detected, and the supply control of the material gas can be performed based on the detection.
- the vapor deposition processing apparatus 50 according to the second modification of the present invention six types of organic material gases ejected from the six vapor deposition heads 56 can be simultaneously detected by the single optical detection device 61. This makes it possible to simplify the apparatus and reduce costs.
- the optical detection device 61 detects the concentration / component / spectral spectrum of a plurality of types of organic material gases, whereby the film forming conditions are specified, Similarly to the form, the film thickness of the organic thin film formed on the substrate G is controlled by controlling the concentration, component, and spectral spectrum of these organic material gases.
- an optical detector, a mass spectrometer, an ionization vacuum gauge, and a vacuum gauge 46 capable of measuring absolute pressure are used as detection means for detecting the vapor concentration of the material gas. It has been described that one is installed for detection. However, when the optical detection device 41 is used, a sufficient optical path length for measurement must be ensured in the vapor deposition head 22 or the substrate processing chamber 21, and the vapor deposition processing device 1 that cannot sufficiently secure the optical path length. In this case, sufficient measurement sensitivity may not be obtained.
- the mass spectrometer 43 when Qmass is used as the mass spectrometer 43, for example, as a result of the contact of the material gas with the measurement filament, an organic material may be deposited on the surface of the measurement filament and the measurement sensitivity may deteriorate over time.
- the ionization vacuum gauge 45 When the ionization vacuum gauge 45 is used, measurement may be difficult if the partial pressure of the material gas in the vapor deposition head 22 or the substrate processing chamber 21 is very small.
- two or more of the optical detection device 41, the mass spectrometer 43, the ionization vacuum gauge 45, and the vacuum gauge 46 are used in combination in order to measure the vapor concentration of the material gas with higher accuracy.
- a quartz resonator (QCM), a dummy substrate, or the like conventionally used for measuring the thickness of a thin film formed on the substrate G is used for the optical detection device 41, the mass spectrometer 43, and the ionization vacuum gauge 45. It can also be used in combination with the vacuum gauge 46.
- the crystal resonator when a crystal resonator (QCM) is placed directly under the vapor deposition head, the film thickness actually formed is correlated with the measured value obtained by other means, and if the predetermined correlation is exceeded A method of performing correction is also possible.
- the crystal resonator (QCM) can remove and clean the attached organic film by irradiating with hot N 2 , UV, or the like after being used a predetermined number of times.
- the vapor concentration of the material gas is not sufficiently controlled, and the crystal resonator (QCM), the dummy substrate, the optical detection device 41, the mass spectrometer 43, It may be possible to stabilize the film thickness of the thin film formed on the substrate G by using both the ionization vacuum gauge 45 and the vacuum gauge 46 capable of measuring absolute pressure. After the stabilization of the film thickness, for example, measurement using a crystal resonator (QCM) or a dummy substrate is not performed, and one or several detection means such as the optical detection device 41 is used. It is also possible.
- the present invention relates to a vapor deposition apparatus used for forming a light emitting layer in the manufacture of an organic EL element, for example.
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Abstract
Description
10…アノード層
11…発光層
12…カソード層
13…封止膜層
20、51…処理チャンバー
21…基板処理室
22、56…蒸着ヘッド
23、54…支持台
25…排気管
26…真空ポンプ
29…材料導入路
30…材料ガス生成部
30a…キャリアガス制御部
30b…材料投入制御部
30c…材料気化制御部
31…ヒータ
33…膜厚センサ
40…窓
41、61…光学的検知装置
42…制御部
43…質量分析計
45…電離真空計
46…真空計
47…金属隔膜
48…電極
52…ゲートバルブ
55…レール
57…材料供給源
58…材料供給管
A…有機EL素子
G…基板
図3は、上述した図2(a)に示す蒸着工程に用いられる、本発明の第1の実施の形態にかかる蒸着処理装置1を横から見た断面図である。本実施の形態においては、材料ガスの蒸気濃度を測定する検知手段として、例えば、フーリエ変換型赤外分光法(FTIR)である光学的検知装置41を用いた場合を説明する。なお、通常の蒸着処理装置では、基板Gに有機材料ガスを噴出させる蒸着ヘッドは、例えばホール輸送層、非発光層(電子ブロック層)、青発光層、赤発光層、緑発光層、電子輸送層等の複数の有機層を蒸着するために複数用意される場合もあるが、図3に示す蒸着処理装置1においては蒸着ヘッドが1つの場合を例示し、以下に説明する。
図4は、上述した図2(a)に示す蒸着工程に用いられる、本発明の第2の実施の形態にかかる蒸着処理装置1を横から見た断面図である。本実施の形態においては、材料ガスの蒸気濃度を測定する検知手段として、例えば四重極形質量分析計(Q-mass)である質量分析計43を用いる。なお、図4中、第2の実施の形態における質量分析計43以外の構成要素は、上記第1の実施の形態と同一であり、その機能構成は同一であるため、図中に同じ符号を用いて示し、詳しい説明は省略する。
図5は、上述した図2(a)に示す蒸着工程に用いられる、本発明の第3の実施の形態にかかる蒸着処理装置1を横から見た断面図である。本実施の形態においては、材料ガスの蒸気濃度を測定する検知手段として、例えば、タフゲージ(TG:(株)アンペール社製)である電離真空計45を用いる。なお、図5中、第2の実施の形態における電離真空計45以外の構成要素は、上記第1の実施の形態と同一であり、その機能構成は同一であるため、図中に同じ符号を用いて示し、詳しい説明は省略する。
図6(a)は、上述した図2(a)に示す蒸着工程に用いられる、本発明の第4の実施の形態にかかる蒸着処理装置1を横から見た断面図である。また、図6(b)は第4の実施の形態にかかる蒸着処理装置1において用いられる真空計46の説明図である。本実施の形態においては、材料ガスの蒸気濃度を測定する検知手段として、例えば、キャパシタンスマノメータ(以下、CMとも表記)である絶対圧が測定可能な真空計46を用いる。なお、図6中、第4の実施の形態における真空計46以外の構成要素は、上記第1の実施の形態と同一であり、その機能構成は同一であるため、図中に同じ符号を用いて示し、詳しい説明は省略する。
Claims (8)
- 蒸着によって基板に薄膜を成膜させる蒸着処理装置であって、
材料ガスを供給する減圧自在な材料供給部と、
前記基板に薄膜を成膜する成膜部を備え、
前記成膜部は前記基板に噴射される材料ガスの蒸気濃度を測定する検知手段を有し、
前記検知手段における測定結果に基づいて成膜条件を制御する制御部を設けた、蒸着処理装置。 - 前記検知手段は、光学的検知装置、質量分析計、絶対圧の測定が可能な真空計、電離真空計から選択される1以上の装置から構成される、請求項1に記載の蒸着処理装置。
- 前記検知手段は材料ガスの成分を検出する、請求項1に記載の蒸着処理装置。
- 前記制御部は、キャリアガス流量、材料ガス生成部のヒータ温度、材料供給量、基板移動速度、基板温度、チャンバー圧力のうちの1つまたは複数を制御する、請求項1に記載の蒸着処理装置。
- 蒸着によって基板に薄膜を成膜させる蒸着処理方法であって、
前記基板に噴射される材料ガスの蒸気濃度を検知手段によって測定し、
前記検知手段の測定結果を基に成膜条件を制御する、蒸着処理方法。 - 前記制御は、予め基板に所定の膜厚の薄膜が成膜される成膜条件を定めておき、該成膜条件との差分を測定することで行われる、請求項5に記載の蒸着処理方法。
- 前記成膜条件は、キャリアガス流量、材料ガス生成部のヒータ温度、材料供給量、基板移動速度、基板温度、チャンバー圧力のうちの1つまたは複数である、請求項5に記載の蒸着処理方法。
- 前記検知手段は、光学的検知装置、質量分析計、絶対圧の測定が可能な真空計、電離真空計から選択される1以上の装置である、請求項5に記載の蒸着処理方法。
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US13/818,406 US20130209666A1 (en) | 2010-08-25 | 2011-08-24 | Evaporating apparatus and evaporating method |
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2010
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-
2011
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- 2011-08-24 TW TW100130244A patent/TW201226605A/zh unknown
- 2011-08-24 CN CN2011800407205A patent/CN103080365A/zh active Pending
- 2011-08-24 WO PCT/JP2011/069027 patent/WO2012026483A1/ja active Application Filing
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CN104584184A (zh) * | 2012-07-13 | 2015-04-29 | 诺瓦工厂有限公司 | 用于在真空处理过程中使用的组件 |
US20140106062A1 (en) * | 2012-10-16 | 2014-04-17 | The Regents Of The University Of Michigan | Method of monitoring photoactive organic molecules in-situ during gas-phase deposition of the photoactive organic molecules |
US9062368B2 (en) * | 2012-10-16 | 2015-06-23 | The Regents Of The University Of Michigan | Method of monitoring photoactive organic molecules in-situ during gas-phase deposition of the photoactive organic molecules |
CN116641035A (zh) * | 2023-07-26 | 2023-08-25 | 南京诺源医疗器械有限公司 | 一种用于腹腔镜光学件的镀膜方法 |
CN116641035B (zh) * | 2023-07-26 | 2023-10-13 | 南京诺源医疗器械有限公司 | 一种用于腹腔镜光学件的镀膜方法 |
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US20130209666A1 (en) | 2013-08-15 |
CN103080365A (zh) | 2013-05-01 |
TW201226605A (en) | 2012-07-01 |
JP2012046780A (ja) | 2012-03-08 |
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