WO2018066611A1 - 蒸着マスクの製造方法、有機半導体素子の製造方法、及び有機elディスプレイの製造方法 - Google Patents
蒸着マスクの製造方法、有機半導体素子の製造方法、及び有機elディスプレイの製造方法 Download PDFInfo
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- WO2018066611A1 WO2018066611A1 PCT/JP2017/036161 JP2017036161W WO2018066611A1 WO 2018066611 A1 WO2018066611 A1 WO 2018066611A1 JP 2017036161 W JP2017036161 W JP 2017036161W WO 2018066611 A1 WO2018066611 A1 WO 2018066611A1
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- Prior art keywords
- mask
- vapor deposition
- resin
- opening
- resin mask
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- 238000007740 vapor deposition Methods 0.000 title claims abstract description 295
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 69
- 239000004065 semiconductor Substances 0.000 title claims description 29
- 229920005989 resin Polymers 0.000 claims abstract description 393
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- 239000010410 layer Substances 0.000 description 41
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Images
Classifications
-
- 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
- C23C14/04—Coating on selected surface areas, e.g. using masks
- C23C14/042—Coating on selected surface areas, e.g. using masks using masks
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B23—MACHINE TOOLS; METAL-WORKING NOT OTHERWISE PROVIDED FOR
- B23K—SOLDERING OR UNSOLDERING; WELDING; CLADDING OR PLATING BY SOLDERING OR WELDING; CUTTING BY APPLYING HEAT LOCALLY, e.g. FLAME CUTTING; WORKING BY LASER BEAM
- B23K26/00—Working by laser beam, e.g. welding, cutting or boring
- B23K26/36—Removing material
- B23K26/38—Removing material by boring or cutting
- B23K26/382—Removing material by boring or cutting by boring
-
- 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
-
- 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
- H10K71/166—Deposition of organic active material using physical vapour deposition [PVD], e.g. vacuum deposition or sputtering using selective deposition, e.g. using a mask
Definitions
- Embodiments of the present disclosure relate to a method for manufacturing a vapor deposition mask, a method for manufacturing an organic semiconductor element, and a method for manufacturing an organic EL display.
- Formation of a vapor deposition pattern using a vapor deposition mask is usually performed by bringing a vapor deposition mask provided with an opening corresponding to a pattern to be vapor-deposited and an object to be vapor-deposited, and allowing a vapor deposition material released from a vapor deposition source to pass through the opening. It is performed by adhering to a vapor deposition object.
- a metal mask having a resin mask opening having a resin mask opening corresponding to the pattern to be vapor deposited and a metal mask opening (sometimes referred to as a slit).
- a vapor deposition mask (for example, Patent Document 1) formed by laminating and is known.
- a metal vapor deposition mask (shadow mask) is also known (for example, Patent Document 2).
- the embodiment of the present disclosure enables formation of a higher-definition vapor deposition pattern in a vapor deposition mask in which a resin mask and a metal mask are laminated, or in a vapor deposition mask with a frame in which the vapor deposition mask is fixed to a frame.
- a method of manufacturing a vapor deposition mask in which a metal mask having a metal mask opening is stacked on one surface of a resin mask having a resin mask opening corresponding to a pattern to be formed by vapor deposition.
- a method for manufacturing a mask comprising: preparing a resin plate with a metal mask in which the metal mask is laminated on one surface of a resin plate; and irradiating a laser through a metal mask opening of the resin plate with the metal mask.
- any one of the plurality of resin mask openings And a sharp angle formed by one inner wall surface forming the one resin mask opening and the other surface of the resin mask in the cross section in the thickness direction of the resin mask.
- the other inner wall surface that forms one of the resin mask opening and the acute angle of the other surface of the resin mask is different, so to form a resin mask opening.
- a vapor deposition mask manufacturing method in which a metal mask having a metal mask opening is stacked on one surface of a resin mask having a resin mask opening corresponding to a pattern to be formed by vapor deposition.
- a method of manufacturing a vapor deposition mask comprising: preparing a resin plate with a metal mask in which the metal mask is laminated on one surface of a resin plate; and a laser through a metal mask opening of the resin plate with the metal mask.
- one inner wall surface forming the one resin mask opening and the resin mask in the thickness direction cross section of the resin mask may be formed so that the acute angle formed with the other surface is different from the acute angle formed with the other inner wall surface forming the one resin mask opening and the other surface of the resin mask.
- a method of manufacturing a vapor deposition mask is a method of manufacturing a vapor deposition mask having an opening corresponding to a pattern to be vapor-deposited, and includes a step of preparing a resin plate and irradiating a laser. Forming a plurality of openings in the resin plate, and in the step of forming the openings, one of the surfaces of the vapor deposition mask that is positioned on the vapor deposition source side is defined as one surface of the vapor deposition mask. Then, any one of the plurality of openings is formed between one inner wall surface forming the one opening and the other surface of the vapor deposition mask in the thickness direction cross section of the vapor deposition mask. The opening is formed so that the acute angle formed is different from the acute angle formed between the other inner wall surface forming the one opening and the other surface of the vapor deposition mask.
- a method of manufacturing a vapor deposition mask is a method of manufacturing a vapor deposition mask having an opening corresponding to a pattern to be vapor-deposited, and includes a step of preparing a resin plate and irradiating a laser. Forming a plurality of openings in the resin plate, and in the step of forming the openings, one of the surfaces of the vapor deposition mask that is positioned on the vapor deposition source side is defined as one surface of the vapor deposition mask.
- an acute angle formed by one inner wall surface of the inner wall surface that forms one of the plurality of openings and the other surface of the vapor deposition mask, and the other The opening is formed such that an acute angle formed by one inner wall surface of the inner wall surface forming one opening and the other surface of the vapor deposition mask is different.
- the step of forming the resin mask opening in the cross section in the thickness direction of the vapor deposition mask, one inner wall surface that forms the one opening and the other of the vapor deposition mask
- the opening may be formed so that the acute angle formed with the surface is different from the acute angle formed between the other inner wall surface forming the one opening and the other surface of the vapor deposition mask.
- the manufacturing method of the organic-semiconductor element of one Embodiment of this indication includes the vapor deposition pattern formation process of forming a vapor deposition pattern in a vapor deposition target object using a vapor deposition mask, The said vapor deposition mask used by the said vapor deposition pattern formation process The above-described vapor deposition mask.
- the organic semiconductor element manufactured by said manufacturing method is used for the manufacturing method of the organic electroluminescent display of one Embodiment of this indication.
- the deposition mask manufacturing method of the present disclosure it is possible to manufacture a deposition mask capable of forming a high-definition deposition pattern. Moreover, according to the manufacturing method of the organic-semiconductor element of this indication, an organic-semiconductor element can be manufactured accurately. Moreover, according to the manufacturing method of the organic EL display of this indication, an organic EL display can be manufactured accurately.
- (A) is a front view which shows an example when the vapor deposition mask of this indication is planarly viewed from the metal mask side
- (b) is a schematic sectional drawing of (a). It is a schematic sectional drawing which shows an example of the vapor deposition mask of this indication. It is a schematic sectional drawing which shows an example of the vapor deposition mask of this indication. It is a schematic sectional drawing which shows an example of the vapor deposition mask of this indication. It is a schematic sectional drawing which shows an example of the vapor deposition mask of this indication. It is a figure which shows the relationship between the vapor deposition material discharge
- FIG. 17 (b) is a schematic cross-sectional view along AA of (a).
- a vapor deposition mask 100 includes a resin mask 20 having a plurality of resin mask openings 25 corresponding to a pattern to be produced by vapor deposition, and a metal mask.
- the metal mask 10 having the opening 15 has a configuration in which the resin mask opening 25 and the metal mask opening 15 are stacked so as to overlap each other.
- 1A is a front view showing an example when the vapor deposition mask 100 according to the embodiment of the present disclosure is viewed in plan from the metal mask side
- FIG. 1B is a front view of FIG. FIG.
- the resin mask 20 has a plurality of resin mask openings 25, and any one of the plurality of resin mask openings 25.
- 25 (for example, the resin mask opening portion indicated by reference numeral 25a in FIG. 2) is one inner wall surface (in the illustrated form, the inner surface facing one side) that forms the one resin mask opening portion 25 in the cross section in the thickness direction of the resin mask 20.
- An acute angle (for example, “ ⁇ 1” of the resin mask opening indicated by reference numeral 25a in FIG. 2) formed between the inner wall surface located on the left side of the wall surface and the other surface of the resin mask 20 (the lower surface of the resin mask in the illustrated form).
- condition A the condition satisfying this configuration may be referred to as “condition A”.
- the vapor deposition mask 100 includes a plurality of the resin mask openings 25 in the cross section in the thickness direction of the resin mask 20 in addition to the above configuration or instead of the above configuration.
- One inner wall surface of the inner wall surface that forms one resin mask opening portion 25 (for example, the resin mask opening portion indicated by reference numeral 25a in FIG. 3) (in the illustrated form, the inner wall surface located on the right side of the opposed inner wall surfaces)
- the other surface of the resin mask 20 in the illustrated form, the lower surface of the resin mask) (for example, “ ⁇ a” of the resin mask opening indicated by reference numeral 25a in FIG.
- condition B the condition satisfying this configuration may be referred to as “condition B”.
- an acute angle formed by the inner wall surface forming the resin mask opening 25 and the other surface of the resin mask 20 (the surface not in contact with the metal mask) is referred to as “gradient”.
- the cross section in the thickness direction of the resin mask 20 one inner wall surface that forms the one resin mask opening 25 and one inner wall surface that forms the other resin mask opening 25 are:
- it means an inner wall surface located on the same direction side. The same applies to the other inner wall surface.
- the shape of the inner wall face of the resin mask opening part 25 is a linear shape, it may be a shape other than a straight line, for example, a shape that repeats a curvature or a mountain or valley fold.
- the acute angle formed by the inner wall surface and the other surface of the resin mask may be an acute angle formed by an approximate curve (for example, linear approximation) of the shape of the inner wall surface and the other surface of the resin mask.
- the resin mask opening 25 that satisfies one or both of the above “condition A” and “condition B” is appropriately arranged according to the discharge angle of the vapor deposition material discharged from the vapor deposition source, and the like. Thus, the generation of shadows can be suppressed.
- the vapor deposition mask 100 has an opening shape of the resin mask opening 25 when the resin mask 20 is viewed in cross section according to the emission angle of the vapor deposition material emitted from the vapor deposition source.
- the occurrence of shadows can be suppressed by making the difference appropriately (see FIGS. 5 and 6).
- 5 and 6 are diagrams showing the relationship between the vapor deposition material released from the vapor deposition source and the resin mask opening 25. In FIG. 5, the vapor deposition material is discharged from one vapor deposition source, and FIG. Then, the vapor deposition material is discharged from the three vapor deposition sources.
- the “gradient” of the resin mask opening 25 (for example, resin mask openings indicated by reference numerals 25x and 25z in FIGS. 5 and 6) at a predetermined position from the vapor deposition source.
- the “gradient” of the resin mask opening for example, the resin mask opening indicated by reference numeral 25y in FIGS. 5 and 6) at a position closer to this, and one resin mask opening 25 (for example, resin mask openings indicated by reference numerals 25x and 25z in FIGS. 5 and 6)
- the “gradient” formed by one inner wall surface and the other surface of the resin mask is set to the same resin mask opening (for example, 5 and FIG. 6 are different from the “gradient” formed by the other inner wall surface and the other surface of the resin mask, which form the resin mask openings indicated by reference numerals 25x and 25z in FIGS.
- the vapor deposition source is not limited to the illustrated form, and may be two or four or more vapor deposition sources. Moreover, the linear source vapor deposition source which can scan a vapor deposition source in a predetermined direction may be sufficient. Regardless of the form of the vapor deposition source, the resin mask 20 has any one of the above “condition A” and “condition B” in consideration of the emission angle of the vapor deposition material emitted from the vapor deposition source. A resin mask opening 25 that fills either or both is provided.
- the shadow referred to in the present specification means that a part of the vapor deposition material released from the vapor deposition source is a resin mask opening on one surface of the resin mask 20 (the lower surface in the form shown in FIGS. 5 and 6). It means a phenomenon in which an undeposited portion having a film thickness thinner than a target vapor deposition film thickness is generated by colliding with the vicinity of the portion 25 or the inner wall surface of the resin mask opening 25 and not reaching the vapor deposition object.
- the inner wall surface of the resin mask opening 25 referred to in the present specification is the surface of the resin mask that forms the resin mask opening 25 itself, in other words, the surface facing the space in the resin mask opening. That means.
- FIG. 2 is a schematic cross-sectional view illustrating an example of the vapor deposition mask 100 according to the embodiment of the present disclosure.
- the resin mask 20 serves as a resin mask opening 25 as a resin mask opening. Part 25a, resin mask opening 25b, resin mask opening 25c, and resin mask opening 25d.
- all the resin mask openings 25 have the same cross-sectional shape, and a “gradient formed by one inner wall surface forming one vapor deposition mask opening and the other surface of the resin mask 20.
- the “gradient” formed by the other inner wall surface forming the same resin mask opening 25 and the other surface of the resin mask 20 is different. That is, in the form shown in FIG.
- the relationship of the “gradient” in the resin mask opening 25a is ⁇ 1 ⁇ ⁇ 2, and the resin mask opening 25a and another resin mask opening 25 (resin mask opening 25b).
- the “gradient” be reduced as the distance from the vapor deposition source increases.
- the resin mask 20 has a resin mask opening 25a, a resin mask opening 25b, a resin mask opening 25c, and a resin mask opening 25d as the resin mask opening 25.
- the “gradient” formed by one inner wall surface of the resin mask opening 25 and the other surface of the resin mask is the same (the “gradient indicated by reference sign ⁇ 1 in FIG. 3). ”),
- The“ gradient ”formed by one inner wall surface of each resin mask opening 25 and the other surface of the resin mask is made different (the“ gradient ”indicated by reference signs ⁇ a, ⁇ b, ⁇ c, ⁇ d in FIG. 3). It may be different).
- the vapor deposition mask 100 of the form shown in FIG. 4 is on the reference line passing through the center in the width direction, and is a form assuming that the vapor deposition source is located on the metal mask side, and the resin mask 20 is the resin mask opening 25.
- the resin mask opening 25a, the resin mask opening 25b, the resin mask opening 25c, and the resin mask opening 25d are provided.
- the “gradient” ⁇ 4 of the resin mask opening 25b and the “ The “gradient” ⁇ 2 of the resin mask opening 25a and the “gradient” ⁇ 7 of the resin mask opening 25d are smaller than the “gradient” ⁇ 6.
- each “gradient” may be different. Some “gradients” may be the same.
- the “gradient” of the resin mask opening 25 is not limited in any way, and may be appropriately determined in consideration of the emission angle of the vapor deposition material emitted from the vapor deposition source. In addition, it is preferable that the “gradient” of each resin mask opening 25 be an angle smaller than the discharge angle of the vapor deposition material. As an example, the range of “gradient” is in the range of 5 ° to 85 °, and may be in the range of 15 ° to 75 °, in the range of 25 ° to 65 °, and the like.
- the opening shape of the resin mask opening 25 when the vapor deposition mask 100 is viewed from the metal mask side is a rectangular shape, but the opening shape is not particularly limited, and the resin mask opening
- the opening shape of 25 may be a rhombus or a polygon, or may be a shape having a curvature such as a circle or an ellipse.
- the rectangular or polygonal opening shape is a preferable opening shape of the resin mask opening 25 in that the light emission area can be increased as compared with the opening shape having a curvature such as a circle or an ellipse.
- the thickness direction cross section of the resin mask 20 is the thickness direction cross section orthogonal to the inner wall surface of the said opening part, when the opening shape of the resin mask opening part 25 is a rectangle or a polygonal shape.
- a shape having a curvature such as a circle or an ellipse, it means a cross section in the thickness direction perpendicular to the tangent.
- a high-definition resin mask opening 25 can be formed by laser processing or the like, and a lightweight material with a small dimensional change rate and moisture absorption rate over time is used. It is preferable.
- Such materials include polyimide resin, polyamide resin, polyamideimide resin, polyester resin, polyethylene resin, polyvinyl alcohol resin, polypropylene resin, polycarbonate resin, polystyrene resin, polyacrylonitrile resin, ethylene vinyl acetate copolymer resin, ethylene- Examples thereof include vinyl alcohol copolymer resin, ethylene-methacrylic acid copolymer resin, polyvinyl chloride resin, polyvinylidene chloride resin, cellophane, and ionomer resin.
- a resin material having a moisture absorption rate of 1.0% or less is preferable, and a resin material having both conditions is particularly preferable. .
- this resin material By using this resin material as a resin mask, the dimensional accuracy of the resin mask opening 25 can be improved, and the dimensional change rate and moisture absorption rate with heat and time can be reduced.
- the resin mask 20 having a resin mask opening that satisfies one or both of the above “condition A” and “condition B” further improves the effect of suppressing the generation of shadows.
- the thickness of the resin mask 20 is preferably 25 ⁇ m or less, and more preferably less than 10 ⁇ m.
- the thickness of the resin mask 20 is preferably 25 ⁇ m or less, and more preferably less than 10 ⁇ m.
- the thickness of the resin mask 20 is preferably 4 ⁇ m or more and 8 ⁇ m or less, it is possible to more effectively prevent the influence of shadows when forming a high-definition pattern exceeding 400 ppi. .
- By setting the thickness of the resin mask 20 within a preferable range it is possible to suppress the occurrence of defects such as pinholes and deformation.
- the resin mask 20 and the metal mask 10 to be described later may be joined directly or via an adhesive layer, but the resin mask 20 and the metal mask 10 may be joined via an adhesive layer.
- a metal mask 10 is laminated on one surface of the resin mask 20.
- the metal mask 10 is made of metal, and a metal mask opening 15 extending in the vertical direction or the horizontal direction is disposed as shown in FIG.
- the arrangement example of the metal mask openings 15 is not particularly limited, and the metal mask openings 15 extending in the vertical direction and the horizontal direction may be arranged in a plurality of rows in the vertical direction and the horizontal direction, and the metal extending in the vertical direction.
- the mask openings 15 may be arranged in a plurality of rows in the horizontal direction, and the metal mask openings extending in the horizontal direction may be arranged in a plurality of rows in the vertical direction.
- the plurality of metal mask openings 15 may be randomly arranged. Further, the number of metal mask openings 15 may be one.
- vertical direction and “lateral direction” refer to the vertical and horizontal directions of the drawing, and are any of the longitudinal direction and the width direction of the vapor deposition mask, resin mask, and metal mask. May be.
- the longitudinal direction of the vapor deposition mask, the resin mask, and the metal mask may be “vertical direction”
- the width direction may be “vertical direction”.
- the shape of the vapor deposition mask when viewed in plan is a rectangular shape is described as an example, but other shapes, for example, a circular shape, a polygonal shape such as a rhombus shape, etc. It is good.
- the longitudinal direction, the radial direction, or an arbitrary direction of the diagonal line is defined as a “longitudinal direction”, and a direction orthogonal to the “longitudinal direction” is referred to as a “width direction (sometimes referred to as a short direction)”. do it.
- the material of the metal mask 10 is not particularly limited, and any conventionally known material can be appropriately selected and used in the field of the evaporation mask, and examples thereof include metal materials such as stainless steel, iron-nickel alloy, and aluminum alloy. . Among them, an invar material that is an iron-nickel alloy can be suitably used because it is less deformed by heat.
- the thickness of the metal mask 10 is not particularly limited, it is preferably 100 ⁇ m or less, more preferably 50 ⁇ m or less, and more preferably 35 ⁇ m or less in order to more effectively prevent the occurrence of shadows. Particularly preferred. When the thickness is less than 5 ⁇ m, the risk of breakage and deformation increases and handling tends to be difficult.
- the shape of the opening of the metal mask opening 15 when viewed in plan is a rectangular shape, but the opening shape is not particularly limited, and the opening shape of the metal mask opening 15 is Any shape such as a trapezoidal shape or a circular shape may be used.
- the cross-sectional shape of the metal mask opening 15 formed in the metal mask 10 is not particularly limited, but may be a shape having a spread toward the vapor deposition source as shown in FIG. preferable. More specifically, the bottom of the metal mask 10 is formed by a straight line connecting the lower bottom tip of the metal mask opening 15 of the metal mask 10 and the upper bottom tip of the metal mask opening 15 of the metal mask 10.
- the angle formed with the upper surface of the metal mask is preferably in the range of 5 ° to 85 °, more preferably in the range of 15 ° to 80 °, and more preferably 25 ° to 65 °. More preferably within the following range. In particular, within this range, an angle smaller than the vapor deposition angle of the vapor deposition machine to be used is preferable.
- the opening space of the metal mask opening 15 may be partitioned by a bridge (not shown).
- the method for laminating the metal mask 10 on one surface of the resin mask 20 is not particularly limited, and the resin mask 20 and the metal mask 10 may be bonded using various adhesives, and the resin mask has self-adhesiveness. May be used. Resin mask 20 and metal mask 10 may have the same size or different sizes. If the resin mask 20 is made smaller than the metal mask 10 and the outer peripheral portion of the metal mask 10 is exposed in consideration of the optional fixing to the frame thereafter, the metal mask 10 It is preferable because it can be easily fixed to the frame.
- the resin mask 20 of the vapor deposition mask 100 according to the embodiment (A) and the embodiment (B) described below satisfies one or both of the “condition A” and the “condition B”. .
- the vapor deposition mask 100 of the embodiment (A) is a vapor deposition mask for simultaneously forming vapor deposition patterns for a plurality of screens, and a plurality of metal masks are formed on one surface of the resin mask 20.
- the metal mask 10 provided with the opening 15 is laminated, and the resin mask 20 is provided with a resin mask opening 25 necessary for forming a plurality of screens, and each metal mask opening 15 includes at least one. It is provided at a position that overlaps the entire screen.
- the vapor deposition mask 100 of the embodiment (A) is a vapor deposition mask used for simultaneously forming vapor deposition patterns for a plurality of screens, and the vapor deposition patterns corresponding to a plurality of products are simultaneously formed with one vapor deposition mask 100. Can do.
- the “resin mask opening” referred to in the vapor deposition mask of the embodiment (A) means a pattern to be produced using the vapor deposition mask 100 of the embodiment (A).
- the vapor deposition mask is used in an organic EL display.
- the shape of the resin mask opening 25 is the shape of the organic layer.
- “one screen” consists of an assembly of resin mask openings 25 corresponding to one product.
- a metal mask 10 provided with a plurality of metal mask openings 15 is provided on one surface of a resin mask, and each metal mask opening has at least one entire screen. It is provided at the overlapping position.
- the length in the vertical direction of the metal mask openings 15 is the same.
- the length of the metal mask opening 15 is the same as the horizontal length. There are no metal wire portions having the same thickness.
- pitch (P3, P4) between the screens is in the range of 1 mm to 100 mm.
- the pitch between screens means the pitch between adjacent resin mask openings in one screen and another screen adjacent to the one screen. The same applies to the pitch between the resin mask openings 25 and the pitch between the screens in the vapor deposition mask of the embodiment (B) described later.
- the pitch between two or more screens provided at a position overlapping one metal mask opening 15 may be substantially equal to the pitch between the resin mask openings 25 constituting one screen. Good.
- grooves (not shown) extending in the vertical direction or the horizontal direction of the resin mask 20 may be formed in the resin mask 20.
- the resin mask 20 may thermally expand, which may cause changes in the size and position of the resin mask opening 25, but the expansion of the resin mask is absorbed by forming a groove.
- the resin mask 20 may prevent the resin mask 20 from expanding in a predetermined direction as a whole due to accumulation of thermal expansion occurring at various portions of the resin mask, thereby changing the size and position of the resin mask opening 25.
- the groove may be provided between the resin mask openings 25 constituting one screen or at a position overlapping the resin mask openings 25, but is preferably provided between the screens.
- the groove may be provided only on one surface of the resin mask, for example, the surface in contact with the metal mask, or may be provided only on the surface not in contact with the metal mask. Alternatively, it may be provided on both surfaces of the resin mask 20.
- the depth and width of the groove are not particularly limited. However, when the depth of the groove is too deep or too wide, the rigidity of the resin mask 20 tends to decrease, so this point is taken into consideration. It is necessary to set it. Further, the cross-sectional shape of the groove is not particularly limited, and may be arbitrarily selected in consideration of a processing method such as a U shape or a V shape. The same applies to the vapor deposition mask of the embodiment (B).
- the vapor deposition mask of embodiment (B) has one metal mask opening on one surface of the resin mask 20 provided with a plurality of resin mask openings 25 corresponding to the pattern to be produced by vapor deposition.
- the plurality of resin mask openings 25 are provided at positions that overlap one metal mask opening 15 provided in the metal mask 10.
- the resin mask opening 25 referred to in the vapor deposition mask of the embodiment (B) means a resin mask opening necessary for forming the vapor deposition pattern on the vapor deposition target, and for forming the vapor deposition pattern on the vapor deposition target.
- the unnecessary resin mask opening may be provided at a position that does not overlap with one metal mask opening 15.
- FIG. 11 is a front view when the vapor deposition mask which shows an example of the vapor deposition mask of embodiment (B) is planarly viewed from the metal mask side.
- the metal mask 10 having one metal mask opening 15 is provided on the resin mask 20 having the plurality of resin mask openings 25, and the plurality of resin masks are provided. All of the openings 25 are provided at positions overlapping the one metal mask opening 15.
- the metal line portion thicker than the thickness of the metal mask or the same thickness as the metal mask does not exist between the resin mask openings 25.
- a high-definition vapor deposition pattern is formed according to the dimensions of the resin mask opening 25 provided in the resin mask 20 without being interfered by the metal line portion. Is possible.
- the resin mask 20 in the vapor deposition mask of the embodiment (B) is made of resin, and as shown in FIG. 11, a resin mask opening 25 corresponding to a pattern to be vapor deposited is formed at a position overlapping with one metal mask opening 15. A plurality are provided.
- the resin mask opening 25 corresponds to the pattern to be produced by vapor deposition, and the vapor deposition material discharged from the vapor deposition source passes through the resin mask opening 25, so that the vapor deposition object corresponds to the resin mask opening 25.
- a vapor deposition pattern is formed.
- the resin mask openings are arranged in a plurality of rows in the vertical and horizontal directions is described. However, the resin mask openings may be arranged only in the vertical or horizontal direction.
- “One screen” in the vapor deposition mask 100 of the embodiment (B) means an aggregate of the resin mask openings 25 corresponding to one product, and when the one product is an organic EL display, 1 An aggregate of organic layers necessary to form one organic EL display, that is, an aggregate of resin mask openings 25 serving as an organic layer is “one screen”.
- the vapor deposition mask of the embodiment (B) may be composed of only “one screen” or may be a plurality of “one screen” arranged for a plurality of screens. When the screens are arranged, it is preferable that the resin mask openings 25 are provided at predetermined intervals for each screen unit (see FIG. 7 of the vapor deposition mask of the embodiment (A)). There is no particular limitation on the form of “one screen”. For example, when one resin mask opening 25 is one pixel, one screen can be constituted by millions of resin mask openings 25.
- the metal mask 10 in the vapor deposition mask 100 of the embodiment (B) is made of metal and has one metal mask opening 15.
- the one metal mask opening 15 overlaps with all the resin mask openings 25 when viewed from the front of the metal mask 10, in other words, the resin mask.
- the resin mask openings 25 are arranged at positions where all the resin mask openings 25 can be seen.
- a metal part constituting the metal mask 10, that is, a part other than one metal mask opening 15 may be provided along the outer edge of the vapor deposition mask 100 as shown in FIG. 11, and as shown in FIG.
- the size of the mask 10 may be made smaller than the resin mask 20 to expose the outer peripheral portion of the resin mask 20. Further, the size of the metal mask 10 may be made larger than that of the resin mask 20, and a part of the metal portion may protrude outward in the horizontal direction or in the vertical direction of the resin mask. In any case, the size of one metal mask opening 15 is smaller than the size of the resin mask 20.
- W1 and W2 have widths that can sufficiently satisfy durability and handling properties.
- an appropriate width can be appropriately set according to the thickness of the metal mask 10, as an example of a preferable width, both W1 and W2 are 1 mm or more and 100 mm or less as in the metal mask of the vapor deposition mask of the embodiment (A). Within range.
- the vapor deposition mask 100 is the vapor deposition mask 100 in which the resin mask 20 having the resin mask opening 25 and the metal mask 10 having the metal mask opening 15 are stacked is described as an example.
- the vapor deposition mask may be a vapor deposition mask (not shown) made only of the resin mask 20 or a vapor deposition mask (not shown) made only of the metal mask 10.
- the structure of the resin mask opening 25 or the metal mask opening 15 is configured to satisfy either one or both of the above “condition A” and “condition B”. Can be suppressed.
- it can also be applied to a vapor deposition mask containing a material different from a resin material or a metal material.
- an acute angle formed by one inner wall surface of one of the plurality of openings and the other surface of the vapor deposition mask may be different.
- the resin mask 20 is removed from the vapor deposition mask described above, and the configuration of the metal mask opening 15 is changed to the above "condition A",
- the metal mask opening 15 may satisfy either or both of “Condition B”.
- the thickness of the metal mask 10 is preferably in the range of 5 ⁇ m to 35 ⁇ m.
- the vapor deposition mask with frame 200 according to the embodiment of the present disclosure has a configuration in which the vapor deposition mask 100 according to each embodiment of the present disclosure described above is fixed to the frame 60. Description of the vapor deposition mask 100 is omitted.
- the frame 60 and the vapor deposition mask 100 can be fixed using spot welding, adhesive, screwing, or other methods for fixing with a laser beam or the like.
- the prepared resin plate may be only the resin plate, or may be a resin plate with a metal mask in which the metal mask described above is laminated on one surface of the resin plate. It may be a resin plate with a metal layer in which a metal layer described below is provided on a part of one surface.
- a laser mask 220 is placed on the resin plate, and the laser is irradiated through the laser mask 220 to thereby perform the above “condition A” and “condition B”.
- the opening can be formed so as to satisfy either one or both of the above.
- the laser mask includes an opening region 221 that allows the laser energy to pass through without being attenuated, and an attenuation region 222 that is positioned around the opening region 221 and attenuates the laser energy. Is provided. By using a laser mask having such an attenuation region 222, the energy of the laser that has passed through the attenuation region 222 is attenuated.
- the vapor deposition pattern forming process for forming a vapor deposition pattern by a vapor deposition method using a vapor deposition mask.
- a vapor deposition pattern is formed using the vapor deposition pattern forming method of the present disclosure described above.
- the manufacturing method of the organic-semiconductor element of this indication is not limited to these processes, It is applicable to the arbitrary processes in manufacture of a conventionally well-known organic-semiconductor element.
- vapor deposition for forming the organic semiconductor element can be performed in a state where the vapor deposition mask and the vapor deposition object are closely adhered to each other, A high-definition organic semiconductor element can be manufactured.
- the organic semiconductor element manufactured with the manufacturing method of the organic semiconductor element of this indication the organic layer, light emitting layer, cathode electrode, etc. of an organic EL element can be mentioned, for example.
- the method of manufacturing an organic semiconductor element of the present disclosure is preferably used for manufacturing R (red), G (green), and B (blue) light emitting layers of organic EL devices that require high-definition pattern accuracy. it can.
- Organic EL Display Manufacturing Method uses the organic semiconductor element manufactured by the manufacturing method of the organic semiconductor element of the present disclosure described above in the manufacturing process of the organic EL display.
- Examples of the organic EL display using the organic semiconductor element manufactured by the organic semiconductor element manufacturing method of the present disclosure include a notebook personal computer (see FIG. 16A) and a tablet terminal (see FIG. 16B).
- Mobile phones see FIG. 16C
- smart phones see FIG. 16D
- video cameras see FIG. 16E
- digital cameras see FIG. 16F
- smart watches see FIG. 16.
- Examples thereof include organic EL displays used in g).
- the vapor deposition mask which concerns on embodiment of this indication, the manufacturing method of an organic-semiconductor element, and the vapor deposition mask used for the manufacturing method of an organic EL display are the resin mask 20 which has the resin mask opening part 25, and a metal mask opening part.
- the vapor deposition mask according to the embodiment of the present disclosure has been described in place of the vapor deposition mask of this embodiment.
- a vapor deposition mask in which the metal layer 10A is partially disposed on the resin mask 20 having the resin mask opening 25 may be used.
- the vapor deposition mask of this form can also be used for the manufacturing method of an organic-semiconductor element, or the manufacturing method of an organic electroluminescent display.
- the resin mask opening 25 in this embodiment also satisfies one or both of the “condition A” and “condition B”.
- the vapor deposition mask in which the metal layer 10A is partially arranged on the resin mask 20 having the resin mask opening 25 it is compared with the vapor deposition mask not having the metal layer 10A, that is, the vapor deposition mask composed only of the resin mask 20.
- durability can be improved.
- the position where the metal layer 10A is provided and the shape of the metal layer 10A in plan view are not particularly limited. That is, the planar shape of the metal layer 10A can be appropriately designed according to the position where the metal layer 10A is provided.
- the shape of the resin mask 20 constituting the vapor deposition mask 100 when viewed in plan is a rectangle having a long side and a short side
- a metal You may arrange
- the metal layer 10 ⁇ / b> A may be disposed in parallel with the long side of the resin mask while forming a strip shape having the same length as the long side of the resin mask 20.
- the metal layer 10 ⁇ / b> A is not necessarily in contact with the peripheral edge of the resin mask 20, and may be disposed only inside the resin mask 20.
- the metal layer 10A is disposed at a position overlapping the frame in the thickness direction. It is good also as a form which does not.
- the metal layer 10 ⁇ / b> A does not necessarily have a strip shape, and may be arranged so as to be scattered on the resin mask 20.
- the metal layer 10A shown in FIG. 19 is a square, but is not limited to this, and is not limited to this. Any shape can be employed, such as a "" shape, a "T” shape, or even a "cross” shape or a "star” shape.
- a plurality of metal layers 10A are provided on a single resin mask 20
- the metal layer 10A may be regularly arranged or randomly arranged.
- the material of the metal mask 10 can be used as it is.
- the thickness of the metal layer 10 ⁇ / b> A may be the thickness described for the metal mask 10.
Abstract
Description
図1(a)、(b)に示すように、本開示の実施の形態に係る蒸着マスク100は、蒸着作製するパターンに対応する複数の樹脂マスク開口部25を有する樹脂マスク20と、金属マスク開口部15を有する金属マスク10とが、樹脂マスク開口部25と金属マスク開口部15とが重なるようにして積層されてなる構成を呈している。なお、図1(a)は、本開示の実施の形態に係る蒸着マスク100を金属マスク側から平面視したときの一例を示す正面図であり、図1(b)は、図1(a)のA-A概略断面図である。
図1(b)に示すように、樹脂マスク20の一方の面上には、金属マスク10が積層されている。金属マスク10は、金属から構成され、図1(a)に示すように、縦方向或いは横方向に延びる金属マスク開口部15が配置されている。金属マスク開口部15の配置例について特に限定はなく、縦方向、及び横方向に延びる金属マスク開口部15が、縦方向、及び横方向に複数列配置されていてもよく、縦方向に延びる金属マスク開口部15が、横方向に複数列配置されていてもよく、横方向に延びる金属マスク開口部が縦方向に複数列配置されていてもよい。また、縦方向、或いは横方向に1列のみ配置されていてもよい。また、複数の金属マスク開口部15は、ランダムに配置されていてもよい。また、金属マスク開口部15は1つであってもよい。なお、本願明細書で言う「縦方向」、「横方向」とは、図面の上下方向、左右方向をさし、蒸着マスク、樹脂マスク、金属マスクの長手方向、幅方向のいずれの方向であってもよい。例えば、蒸着マスク、樹脂マスク、金属マスクの長手方向を「縦方向」としてもよく、幅方向を「縦方向」としてもよい。また、本願明細書では、蒸着マスクを平面視したときの形状が矩形状である場合を例に挙げて説明しているが、これ以外の形状、例えば、円形状や、ひし形状等の多角形状としてもよい。この場合、対角線の長手方向や、径方向、或いは、任意の方向を「長手方向」とし、この「長手方向」に直交する方向を、「幅方向(短手方向と言う場合もある)」とすればよい。
図7に示すように、実施形態(A)の蒸着マスク100は、複数画面分の蒸着パターンを同時に形成するための蒸着マスクであって、樹脂マスク20の一方の面上に、複数の金属マスク開口部15が設けられた金属マスク10が積層されてなり、樹脂マスク20には、複数画面を構成するために必要な樹脂マスク開口部25が設けられ、各金属マスク開口部15が、少なくとも1画面全体と重なる位置に設けられている。
次に、実施形態(B)の蒸着マスクについて説明する。図11に示すように、実施形態(B)の蒸着マスクは、蒸着作製するパターンに対応した樹脂マスク開口部25が複数設けられた樹脂マスク20の一方の面上に、1つの金属マスク開口部15が設けられた金属マスク10が積層されてなり、当該複数の樹脂マスク開口部25の全てが、金属マスク10に設けられた1つの金属マスク開口部15と重なる位置に設けられている。
本開示の実施の形態に係るフレーム付き蒸着マスク200は、フレーム60に上記で説明した本開示の各実施の形態に係る蒸着マスク100が固定されてなる構成を呈している。蒸着マスク100についての説明は省略する。
本開示の各実施の形態に係る蒸着マスクを用いた蒸着パターンの形成に用いられる蒸着方法については、特に限定はなく、例えば、反応性スパッタリング法、真空蒸着法、イオンプレーティング、電子ビーム蒸着法等の物理的気相成長法(Physical Vapor Deposition)、熱CVD、プラズマCVD、光CVD法等の化学気相成長法(Chemical Vapor Deposition)等を挙げることができる。また、蒸着パターンの形成は、従来公知の真空蒸着装置などを用いて行うことができる。
次に、本開示の実施形態に係る蒸着マスクの製造方法について説明する。
図20(a)や(b)に示すように、樹脂板にレーザーを照射するにあたり、角度を付けて照射することにより、上記「条件A」、及び「条件B」の何れか一方、又は双方を満たすように、開口部を形成することができる。なお、角度を付けるにあっては、図20(a)に示すように、レーザー自体に角度を付けてもよく、図20(b)に示すように、レーザー自体は真上から照射し、樹脂板に角度をつけて設置してもよい。また、図示はしないが、反射体などを用いて、照射されるレーザーの光路を変化させることで、レーザーに角度をつけることも可能である。
図21に示すように、樹脂板にレーザーを照射するにあたり、図21中の(1)、(2)、(3)・・・に示すように、レーザーを多段階に照射することにより上記「条件A」、及び「条件B」の何れか一方、又は双方を満たすように、開口部を形成することができる。この場合においては、レーザーを照射する位置をずらしつつ、その焦点距離を浅くしていくことで、所望の開口部を形成してもよく、レーザーの位置をずらしながら、照射するレーザーのエネルギーを変えていくことで、所望の開口部を形成してもよい。
図22に示すように、樹脂板にレーザーを照射するにあたり、樹脂板上にレーザー用マスク220を設置し、当該レーザー用マスク220を通してレーザーを照射することにより上記「条件A」、及び「条件B」の何れか一方、又は双方を満たすように、開口部を形成することができる。より具体的には、このレーザー用マスクには、レーザーのエネルギーを減衰させることなく、そのまま通過させる開口領域221と、当該開口領域221の周囲に位置し、レーザーのエネルギーを減衰させる減衰領域222とが設けられている。このような減衰領域222を有するレーザー用マスクを用いることにより、当該減衰領域222を通過したレーザーのエネルギーは減衰しているため、開口領域を通過したレーザーにより、開口部が形成されたタイミングにおいて、当該開口部の周辺は未だ貫通されていない状態を作り出すことができ、これにより上記「条件A」、及び「条件B」の何れか一方、又は双方を満たすように、開口部を形成することができる。このような減衰領域222の形成方法については特に限定されることはなく、例えばハーフトーンマスクなどの技術を応用することができ、この減衰領域222による減衰の割合や減衰領域222の配置を適宜設計することにより、上記「条件A」、及び「条件B」の何れか一方、又は双方を満たすように、開口部を形成することができる。
次に、本開示の実施の形態に係る有機半導体素子の製造方法について説明する。本開示の有機半導体素子の製造方法は、蒸着マスクを用いて蒸着対象物に蒸着パターンを形成する工程を含み、蒸着パターンを形成する蒸着パターン形成工程において、上記で説明した本開示の各実施の形態に係る蒸着マスクが用いられる。
次に、本開示の実施の形態に係る有機ELディスプレイ(有機エレクトロルミネッセンスディスプレイ)の製造方法について説明する。本開示の有機ELディスプレイの製造方法は、有機ELディスプレイの製造工程において、上記で説明した本開示の有機半導体素子の製造方法により製造された有機半導体素子が用いられる。
15…金属マスク開口部
20…樹脂マスク
25、25a、25b、25c、25d…樹脂マスク開口部
60…フレーム
100…蒸着マスク
Claims (8)
- 蒸着作製するパターンに対応する樹脂マスク開口部を有する樹脂マスクの一方の面上に、金属マスク開口部を有する金属マスクが積層されてなる蒸着マスクの製造方法であって、
樹脂板の一方の面に前記金属マスクが積層された金属マスク付き樹脂板を準備する工程と、
前記金属マスク付き樹脂板の金属マスク開口部を通してレーザーを照射することで前記樹脂板に複数の樹脂マスク開口部を形成する工程と、を含み、
前記樹脂マスク開口部を形成する工程においては、
前記複数の前記樹脂マスク開口部のうちの何れか1つの樹脂マスク開口部は、前記樹脂マスクの厚み方向断面において、当該1つの樹脂マスク開口部を形作る一方の内壁面と前記樹脂マスクの他方の面とのなす鋭角と、当該1つの樹脂マスク開口部を形作る他方の内壁面と前記樹脂マスクの他方の面とのなす鋭角とが異なる、ように樹脂マスク開口部を形成する、蒸着マスクの製造方法。 - 蒸着作製するパターンに対応する樹脂マスク開口部を有する樹脂マスクの一方の面上に、金属マスク開口部を有する金属マスクが積層されてなる蒸着マスクの製造方法であって、
樹脂板の一方の面に前記金属マスクが積層された金属マスク付き樹脂板を準備する工程と、
前記金属マスク付き樹脂板の金属マスク開口部を通してレーザーを照射することで前記樹脂板に複数の樹脂マスク開口部を形成する工程と、を含み、
前記樹脂マスク開口部を形成する工程においては、
前記樹脂マスクの厚み方向断面において、前記複数の前記樹脂マスク開口部のうちの1つの樹脂マスク開口部を形作る内壁面の一方の内壁面と前記樹脂マスクの他方の面とのなす鋭角と、他の1つの樹脂マスク開口部を形作る内壁面の一方の内壁面と前記樹脂マスクの他方の面とのなす鋭角とが異なる、ように樹脂マスクを形成する、蒸着マスクの製造方法。 - 前記樹脂マスク開口部を形成する工程において、
前記樹脂マスクの厚み方向断面において、前記1つの樹脂マスク開口部を形作る一方の内壁面と前記樹脂マスクの他方の面とのなす鋭角と、当該1つの樹脂マスク開口部を形作る他方の内壁面と前記樹脂マスクの他方の面とのなす鋭角とが異なる、ように樹脂マスクを形成する、請求項2に記載の蒸着マスクの製造方法。 - 蒸着作製するパターンに対応する開口部を有する蒸着マスクの製造方法であって、
樹脂板を準備する工程と、
レーザーを照射することで前記樹脂板に複数の開口部を形成する工程と、を含み、
前記開口部を形成する工程においては、
前記蒸着マスクの面のうち、蒸着源側に位置する面を蒸着マスクの一方の面としたときに、
前記複数の開口部のうちの何れか1つの開口部は、前記蒸着マスクの厚み方向断面において、当該1つの開口部を形作る一方の内壁面と前記蒸着マスクの他方の面とのなす鋭角と、当該1つの開口部を形作る他方の内壁面と前記蒸着マスクの他方の面とのなす鋭角とが異なる、ように開口部を形成する、蒸着マスクの製造方法。 - 蒸着作製するパターンに対応する開口部を有する蒸着マスクの製造方法であって、
樹脂板を準備する工程と、
レーザーを照射することで前記樹脂板に複数の開口部を形成する工程と、を含み、
前記開口部を形成する工程においては、
前記蒸着マスクの面のうち、蒸着源側に位置する面を蒸着マスクの一方の面としたときに、
前記蒸着マスクの厚み方向断面において、前記複数の開口部のうちの1つの開口部を形作る内壁面の一方の内壁面と前記蒸着マスクの他方の面とのなす鋭角と、他の1つの開口部を形作る内壁面の一方の内壁面と前記蒸着マスクの他方の面とのなす鋭角とが異なる、ように開口部を形成する、蒸着マスクの製造方法。 - 前記樹脂マスク開口部を形成する工程において、
前記蒸着マスクの厚み方向断面において、前記1つの開口部を形作る一方の内壁面と前記蒸着マスクの他方の面とのなす鋭角と、当該1つの開口部を形作る他方の内壁面と前記蒸着マスクの他方の面とのなす鋭角とが異なる、ように開口部を形成する請求項5に記載の蒸着マスクの製造方法。 - 有機半導体素子の製造方法であって、
蒸着マスクを用いて蒸着対象物に蒸着パターンを形成する蒸着パターン形成工程を含み、
前記蒸着パターン形成工程で用いられる前記蒸着マスクが、前記請求項1乃至6の何れか1項に記載の蒸着マスクの製造方法によって製造された蒸着マスクである、
有機半導体素子の製造方法。 - 有機ELディスプレイの製造方法であって、
請求項8に記載の有機半導体素子の製造方法により製造された有機半導体素子が用いられる、
有機ELディスプレイの製造方法。
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