WO2019228611A1

WO2019228611A1 - Methods of handling masks in a vacuum system, and vacuum system

Info

Publication number: WO2019228611A1
Application number: PCT/EP2018/064056
Authority: WO
Inventors: Sebastian Gunther ZANG; Stefan Bangert; Shinichi Kurita; Jürgen Henrich; Andreas Sauer
Original assignee: Applied Materials, Inc.
Priority date: 2018-05-29
Filing date: 2018-05-29
Publication date: 2019-12-05
Also published as: KR102444830B1; KR20200138387A; TW202012657A; CN112204164B; CN112204164A

Abstract

A method of handling masks in a vacuum system is described. The method includes (a) transporting a mask carrier (10) carrying a first mask (11) in a non-horizontal orientation (V) along a transport path in the vacuum system, (b) changing the orientation of the mask carrier (10) carrying the first mask (11) from the non-horizontal orientation (V) to an essentially horizontal orientation (H), and (c) unloading the first mask (11) from the mask carrier (10) arranged in the essentially horizontal orientation (H) in the vacuum system. According to a further aspect, a vacuum system including a mask handling module for handling masks is described. (FIG. 1C)

Description

METHODS OF HANDLING MASKS IN A VACUUM SYSTEM,

AND VACUUM SYSTEM

TECHNICAL FIELD

[0001] Embodiments of the present disclosure relate to methods of handling masks under vacuum in a vacuum system, and particularly to methods of handling masks configured for masked deposition of an evaporated material on substrates in a vacuum system. Further embodiments relate to vacuum systems configured to deposit an evaporated material on substrates through masks. More specifically, vacuum systems comprising a mask handling module for handling masks under vacuum in a vacuum system are described. In particular, methods of handling masks in a vacuum system, and vacuum systems are described.

BACKGROUND

[0002] Opto-electronic devices that make use of organic materials are becoming increasingly popular for a number of reasons. Many of the organic materials used to manufacture such devices are relatively inexpensive, such that organic opto-electronic devices have the potential for cost advantages over inorganic devices. The inherent properties of organic materials may be advantageous for applications such as for the deposition on flexible or inflexible substrates. Examples of organic opto-electronic devices include organic light emitting devices (OLEDs), organic phototransistors, organic photovoltaic cells, and organic photodetectors.

[0003] The organic materials of OLEDS may provide performance advantages over conventional materials. For example, the wavelength at which an organic emissive layer emits light may be readily tuned with appropriate dopants. OLEDs make use of thin organic films that emit light when a voltage is applied across the device. OLEDs are becoming an increasingly interesting technology for use in applications such as flat panel displays, illumination, and backlighting. [0004] Materials, particularly organic materials, are typically deposited on a substrate in a vacuum system under sub-atmospheric pressure, i.e. under vacuum. During the deposition, a mask is arranged in front of the substrate, wherein the mask may have at least one opening or a plurality of openings that define an opening pattern corresponding to a material pattern to be deposited on the substrate, e.g. by evaporation. The substrate is typically arranged behind the mask during deposition and is aligned relative to the mask. For example, a mask carrier may be used to carry the mask into a deposition chamber of the vacuum system, and a substrate carrier may be used to carry the substrate into the deposition chamber for arranging the substrate behind the mask.

[0005] It may be beneficial to remove used masks from the vacuum system at regular time intervals, e.g. for cleaning the masks or for exchanging the masks. Further, it may be beneficial to load masks to be used into the vacuum system at regular time intervals, e.g. for providing a mask exchange and for providing clean, unused masks in the vacuum system. However, the exchange of masks is typically time-consuming and may lead to idle times of the system which increase the cost of ownership.

[0006] Accordingly, it would be beneficial to provide methods for a quick and efficient mask handling in a vacuum system as well as a vacuum system with a mask handling module configured for a quick and efficient mask handling. In particular, simplifying and accelerating the mask transport and the mask exchange in a vacuum system configured for the masked deposition of an evaporated material on substrates would be beneficial.

SUMMARY

[0007] In light of the above, methods of handling masks in a vacuum system, and vacuum systems are described.

[0008] According to an aspect of the present disclosure, a method of handling masks in a vacuum system is provided. The method includes (a) transporting a mask carrier carrying a first mask in a non-horizontal orientation along a transport path in the vacuum system, (b) changing the orientation of the mask carrier carrying the first mask from the non-horizontal orientation to an essentially horizontal orientation, and (c) unloading the first mask from the mask carrier arranged in the essentially horizontal orientation in the vacuum system. [0009] Stages (a), (b), and (c) are typically carried out in succession.

[0010] According to another aspect of the present disclosure, a method of handling masks in a vacuum system is provided. The method includes (d) loading a second mask on a mask carrier that is arranged in an essentially horizontal orientation in the vacuum system, (e) changing the orientation of the mask carrier carrying the second mask from the essentially horizontal orientation to a non-horizontal orientation, and (f) transporting the mask carrier carrying the second mask in the non-horizontal orientation along a transport path in the vacuum system.

[0011] Stages (d), (e), and (f) are typically carried out in succession. In some embodiments, (a), (b), and (c) are carried out in succession in order to unload a first mask from the mask carrier, and, subsequently, (d), (e), and (f) are carried out in succession in order to load a second mask on the mask carrier and to transport the second mask to a deposition chamber. The first mask may be a used mask, and the second mask may be a mask to be used in the vacuum system.

[0012] According to a further aspect of the present disclosure, a vacuum system is provided. The vacuum system includes a plurality of deposition chambers housing a respective vapor source configured to deposit an evaporated material on a substrate, a mask handling module configured to connect and separate masks and mask carriers under vacuum and to change an orientation of the masks between an essentially horizontal orientation and a non-horizontal orientation, and a mask transport system configured to transport the mask carriers carrying the masks in the non-horizontal orientation between the mask handling module and the plurality of deposition chambers.

[0013] In some embodiments, the mask handling module includes a mask carrier support configured to support a mask carrier, and an actuator configured to change the orientation of the mask carrier support between the non-horizontal orientation and the essentially horizontal orientation.

[0014] In some embodiments, the mask handling module further includes a vacuum robot with one or more mask holding portions having an essentially horizontal orientation for at least one of (i) unloading a first mask from the mask carrier supported by the mask carrier support, and (ii) loading a second mask on the mask carrier supported by the mask carrier support.

[0015] In some embodiments, the vacuum system includes one single mask handling module for connecting masks and mask carriers, from which the mask carriers are transported to a plurality of deposition chambers, particularly four, six, eight, ten or more deposition chambers.

[0016] According to another aspect of the present disclosure, a method of handling masks in a vacuum system is provided. The method includes loading masks into the vacuum system in an essentially horizontal orientation, changing an orientation of the masks from the essentially horizontal orientation to a non-horizontal orientation and connecting the masks to mask carriers with a mask handling module, transporting the mask carriers carrying the masks in a non-horizontal orientation from the mask handling module to a plurality of deposition chambers, and depositing evaporated material on a plurality of substrates through the masks in the plurality of deposition chambers.

[0017] Further aspects, advantages and features of the present disclosure are apparent from the description and the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

[0018] So that the manner in which the above recited features of the present disclosure can be understood in detail, a more particular description of the present disclosure, briefly summarized above, may be had by reference to embodiments. The accompanying drawings relate to embodiments of the disclosure and are described in the following. Typical embodiments are depicted in the drawings and are detailed in the description which follows.

[0019] FIGS. 1A to 1D are schematic illustrations of stages of a method of handling masks according to embodiments described herein;

[0020] FIGS. 2A to 2D are schematic illustrations of stages of a method of handling masks according to embodiments described herein; [0021] FIGS. 3 A to 3G are schematic illustrations of stages of a method of handling masks according to embodiments described herein;

[0022] FIG. 4 is a schematic view of a vacuum system according to embodiments described herein;

[0023] FIG. 5 is a flow diagram illustrating a method of handling masks according to embodiments described herein.

DETAILED DESCRIPTION OF EMBODIMENTS

[0024] Reference will now be made in detail to the various embodiments, one or more examples of which are illustrated in the figures. Each example is provided by way of explanation and is not meant as a limitation. For example, features illustrated or described as part of one embodiment can be used on or in conjunction with any other embodiment to yield yet a further embodiment. It is intended that the present disclosure includes such modifications and variations.

[0025] Within the following description of the drawings, same reference numbers refer to same or to similar components. Generally, only the differences with respect to the individual embodiments are described. Unless specified otherwise, the description of a part or aspect in one embodiment applies to a corresponding part or aspect in another embodiment as well.

[0026] FIGS. 1A to 1D schematically illustrate subsequent stages (a), (b), (c) of a method of handling a first mask 11 according to methods described herein. The first mask 11 is configured for a masked deposition on a substrate. In other words, the first mask 11 is configured to be arranged in front of a substrate that is to be coated with a material pattern defined by an opening pattern of the mask. For example, the first mask 11 may be configured for a masked evaporation process, wherein a material pattern is formed on a substrate by evaporation. The evaporated material may include organic compounds in some embodiments. For example, an OLED device may be manufactured. In some embodiments, another material, e.g. a metal such as silver or magnesium, may be deposited on a substrate through the mask. [0027] In some embodiments, a mask may include a mask frame and a sheet with a plurality of openings that is held by the mask frame. The mask frame may be configured for supporting and holding the sheet which is typically a delicate component. For example, the mask frame may surround the sheet. The sheet may be permanently fixed to the mask frame, e.g. by welding, or the sheet may be releasably fixed to the mask frame. A circumferential edge of the sheet may be fixed to the mask frame.

[0028] The mask may include a plurality of openings formed in a pattern for depositing a corresponding material pattern on a substrate by a masked deposition process. During the deposition, the mask may be arranged at a close distance in front of the substrate or in direct contact with the front surface of the substrate. For example, the mask may be a fine metal mask (FMM) with a plurality of openings, e.g. 100,000 openings, 1,000,000 openings or more. For example, a pattern of organic pixels can be deposited on the substrate. Other types of masks are possible, e.g. edge exclusion masks.

[0029] In some embodiments, the mask may be at least partially made of a metal, e.g. of a metal with a small thermal expansion coefficient such as invar. The mask may include a magnetic material so that the mask can be magnetically attracted toward the substrate during deposition. In some embodiments, the mask frame may include a magnetic material so that the mask frame can be attracted to a mask carrier by magnetic forces.

[0030] The mask may have a surface area of 0.5 m² or more, particularly 1 m² or more. For example, a height of the mask may be 0.5 m or more, particularly 1 m or more, and/or a width of the mask may be 0.5 m or more, particularly 1 m or more. A thickness of the mask may be 1 cm or less, wherein the mask frame may be thicker than the mask. In particular, the sheet of the mask may have a thickness of 1 mm or less.

[0031] In some embodiments, a mask, e.g. the first mask 11, is transported through the vacuum system while being carried by a mask carrier 10, e.g. between two or more vacuum chambers of the vacuum system. For example, the first mask 11 may enter a first vacuum chamber of the vacuum system, may be fixed to the mask carrier 10, and the mask carrier 10 carrying the first mask 11 may be transported within the vacuum system into a second vacuum chamber, e.g. a deposition chamber. One or more further vacuum chambers, e.g. transition chambers or routing chambers, may be arranged between the first vacuum chamber and the second vacuum chamber. After a predetermined deposition time, the used first mask may be carried back to the first vacuum chamber by the mask carrier 10 for being separated from the mask carrier and for being unloaded from the vacuum system, e.g. for cleaning.

[0032] The first mask 11 may be carried by the mask carrier 10 during the transport in the vacuum system. For example, the mask carrier 10 which holds the first mask 11 may be transported along a transport path in the vacuum system, e.g. from a first vacuum chamber to a second vacuum chamber. In some embodiments, the mask carrier 10 may be guided along mask tracks through the vacuum system. For example, the mask carrier 10 may include a guided portion configured to be guided along the mask tracks.

[0033] In some embodiments, the mask carrier 10 is contactlessly transported by a mask transport system 50, which may be a magnetic levitation system. In particular, a magnetic levitation system may be provided so that at least a part of the weight of the mask carrier 10 is carried by the magnetic levitation system. The mask carrier 10 can then be guided essentially contactlessly along mask tracks through the vacuum system. A drive, such as a linear motor, for moving the mask carrier along the mask tracks may be provided.

[0034] The mask carrier 10 may carry the first mask 11 in a non-horizontal orientation (V) during the transport and/or during the deposition. For example, the first mask 11 may be held by the mask carrier 10 in an essentially vertical orientation during the transport and/or during the deposition.

[0035] A“non-horizontal orientation” of a device as used herein may be an orientation of the device in which an angle between a main surface of the device and a horizontal plane is 20° or more, particularly 45° more, more particularly 80° or more. An“essentially vertical orientation” of a device as used herein may be understood as an orientation of the device in which an angle between a main surface of the device and the gravity vector is 10° or less. For example, when a mask or a mask carrier is provided in an essentially vertical orientation, an angle between a main surface of the mask or the mask carrier and the gravity vector is 10° or less. In some embodiments, the orientation of the mask may not be (exactly) vertical during transport and/or during deposition, but slightly inclined with respect to the vertical axis, e.g. by an inclination angle between -1° and -5°. A negative angle refers to an orientation of the mask wherein the mask is inclined downward. However, also an exactly vertical orientation (+/-l°) of the mask and the mask carrier during transport and/or during deposition is possible. A mask which is carried by the mask carrier 10 in an essentially vertical orientation is schematically depicted in FIG. 1A. In particular, the main surface of the mask carrier 10 and the gravity vector enclose an angle of 10° or less.

[0036] In particular, a mask holding surface of the mask carrier 10 may be essentially vertically oriented during the transport of the mask. Holding a large area mask in an essentially vertical orientation is challenging because the mask may bend due to the weight of the mask, or the mask may slide down from the mask holding surface in the case of an insufficient grip force.

[0037] An essentially horizontal orientation of a mask as used herein refers to a mask position in which the main surface of the mask is provided in an essentially horizontal orientation, i.e. an angle between the main surface of the mask and a horizontal plane is 10° or less. In FIG. 1C, the mask carrier 10 and the first mask 11 have an essentially horizontal orientation.

[0038] The mask carrier 10 may include a chucking or clamping device for chucking or clamping a mask to a holding surface of the mask carrier 10. For example, the mask carrier 10 may include a clamp 23, particularly a plurality of clamps, for clamping the mask to the mask carrier. Alternatively or additionally, the mask carrier 10 may include a magnetic chuck for chucking the mask to the mask carrier, e.g. an electropermanent magnet arrangement. The mask carrier 10 typically includes a body with an opening, wherein the mask is positioned to cover the opening, such that evaporated material can be directed through the mask while the mask is being carried by the mask carrier.

[0039] In stage (a) depicted in FIG. 1A, the mask carrier 10 carrying the first mask 11 is transported in a non-horizontal orientation, particularly in an essentially vertical orientation, along a transport path T in the vacuum system in a vacuum environment. For example, the pressure in the vacuum system may be 10 mbar or less, particularly 1 mbar or less. The transport path T extends perpendicular to the paper plane of FIG. 1 A. [0040] In some embodiments, which may be combined with other embodiments described herein, the mask carrier 10 carrying the first mask 11 is transported from a first vacuum chamber, e.g. a deposition chamber which houses a vapor source, to a second vacuum chamber, e.g. a mask handling module 20. For example, a distance between the first vacuum chamber and the second vacuum chamber may be several meters, e.g. 5 m, 10 m or more.

[0041] The first mask 11 may be a used mask which is to be unloaded from the vacuum system for cleaning purposes. The first mask 11 is transported to the second vacuum chamber while being carried by the mask carrier 10. During the transport, the mask carrier 10 and the first mask 11 may be continuously provided in the non-horizontal orientation (V), particularly in the essentially vertical orientation, as is depicted in FIG. 1A.

[0042] The mask handling module 20 may be configured for separating and unloading the first mask 11 from the mask carrier 10 and/or for unloading the first mask 11 from the vacuum system. In particular, the first mask 11 may be separated from the mask carrier 10, and the separated mask may be unloaded from the vacuum system. Accordingly, the mask carrier 10 may remain inside the vacuum system, whereas the first mask 11 can be unloaded from the vacuum system without the mask carrier 10.

[0043] The mask carrier 10 may be contactlessly transported in the vacuum system by a mask transport system 50, particularly by a magnetic levitation system. The magnetic levitation system may include a plurality of actively controllable magnetic bearings configured to contactlessly hold the mask carrier 10 at a transport track 51. One or more distance sensors may measure a gap width between the transport track 51 and the mask carrier 10, and a magnetic levitation force of one or more actively controllable magnetic bearings may be controlled depending on the measured distance, in order to maintain the mask carrier at an essentially constant distance with respect to the transport track 51.

[0044] In some embodiments, the magnetic levitation system may include one or more side stabilization devices configured to stabilize the mask carrier 10 in a horizontal direction perpendicular to the transport path T. The one or more side stabilization devices may include passive magnets arranged at the transport track 51, e.g. permanent magnets. The passive magnets may magnetically interact with magnetic counterparts arranged at the mask carrier, such that the mask carrier can be contactlessly stabilized at a predetermined horizontal position at the transport track 51.

[0045] In some embodiments, a drive unit configured to move the mask carrier 10 along the transport path T may be provided. The drive unit may include a linear motor. A stator of the linear motor may be provided at the transport track, e.g. at a lower section 52 of the transport track.

[0046] As is schematically depicted in FIG. 1A, the mask carrier 10 may stop at a position close to a mask carrier support 22 of the mask handling module 20. The mask carrier support 22 may be configured for supporting the mask carrier 10 and for changing the orientation of the mask carrier 10.

[0047] As is schematically depicted in FIG. 1B, support sections 21 of the mask carrier support 22 may be movable toward the mask carrier 10 for bringing the mask carrier support 22 in contact with the mask carrier 10. The support sections 21 may optionally be configured for clamping the mask carrier 10 to the mask carrier support 22. In some implementations, the support sections 21 are configured as clamp plates for mechanically or magnetically clamping the mask carrier 10 to the mask carrier support 22. In some embodiments, the support sections 21 may move toward the mask carrier by a distance of 20 mm or more, particularly 40 mm or more. The mask carrier 10 may be clamped to the support sections 21 by activating a magnetic chuck which attracts the mask carrier 10 to the mask carrier support 22.

[0048] In some embodiments, the support sections 21 may be movable relative to a base body 26 of the mask carrier support 22 toward and away from the mask transport system 50. After clamping the mask carrier 10 to the support sections 21, the mask carrier can be moved with the support sections 21 away from the mask transport system 50. In particular, the mask carrier 10 can be transferred away from the mask transport system 50 in an essentially horizontal direction.

[0049] In stage (b) depicted in FIG. 1C, the orientation of the mask carrier 10 which carries the first mask 11 is changed from the non-horizontal orientation (V) to an essentially horizontal orientation (H). [0050] In particular, the orientation of the mask carrier support 22 having the mask carrier 10 supported thereon is changed from the non-horizontal orientation (V) to the essentially horizontal orientation (H), as is depicted in FIG. 1C. For example, the mask carrier support 22 may be rotatable around or may be pivotable with respect to an essentially horizontal rotation axis A. Accordingly, the orientation of the mask carrier 10 together with the first mask 11 is changed from the essentially vertical orientation depicted in FIG. 1B to the essentially horizontal orientation depicted in FIG. 1C.

[0051] In some embodiments, which may be combined with other embodiments described herein, the mask carrier support 22 may be configured as a swing table with support sections 21 for supporting the mask carrier. The swing table (or“vacuum swing module”) may be movable between a first position and a second position. In the first position, the mask carrier can be supported on the support sections of the swing table in the non-horizontal orientation, and, in the second position, the mask carrier can be supported on the support sections of the swing table in the essentially horizontal orientation.

[0052] According to methods described herein, the orientation of the first mask 11 is changed together with the orientation of the mask carrier 10. In particular, the first mask 11 is rotated while being fixed to the mask carrier 10. Mask and mask carrier can be rotated together while being supported by the mask carrier support 22.

[0053] Changing the orientation of the mask carrier 10 in FIG. 1C may include supporting the mask carrier 10 carrying the first mask 11 on the mask carrier support 22 and changing orientation of the mask carrier support 22, e.g. by rotating the mask carrier support 22 around an essentially horizontal axis A.

[0054] In stage (c) depicted in FIG. 1D, the first mask 11 is unloaded from the mask carrier 10 while the mask carrier is arranged in the essentially horizontal orientation (H) on the mask carrier support 22.

[0055] Unloading the first mask 11 from the mask carrier 10 may include detaching the first mask 11 from the mask carrier 10, e.g. by releasing a clamp 23 which fixes the first mask to the mask carrier. Alternatively or additionally, the first mask 11 may be detached from the mask carrier by releasing a chucking device, e.g. a magnetic chuck. [0056] As is depicted in FIG. 1D, the mask carrier 10 may include a clamp 23, particularly a plurality of clamps, which hold the first mask at the mask carrier. Unloading the first mask 11 from the mask carrier 10 may include disengaging the clamp 23, such that the first mask 11 can be taken off the mask carrier 10.

[0057] In some embodiments, which may be combined with other embodiments described herein, unloading the first mask 11 from the mask carrier 10 may further include lifting up the first mask 11 from the mask carrier 10, as is schematically depicted in FIG. 1D. For example, a plurality of lifting pins may be provided for lifting up the first mask 11 from the mask carrier 10. The lifting pins may be movable relative to the mask carrier support 22 for lifting up the first mask 11 from the mask carrier 10 which may be supported on the support sections 21 of the mask carrier support 22. After lifting the first mask 11 from the mask carrier 10, a mask holding portion 32 of a vacuum robot may be inserted between the first mask 11 and the mask carrier 10, and the mask holding portion 32 having the first mask 11 supported thereon may be moved away from the mask carrier support 22.

[0058] After unloading the first mask 11 from the mask carrier 10, the first mask 11 may be unloaded from the vacuum system, e.g. by transferring the first mask 11 into a load lock chamber where a mask holder, e.g. a mask shelf, may be arranged. The first mask 11 may be placed in a slot of the mask shelf with a vacuum robot. An opening between the load lock chamber and the vacuum system may be closed, the load lock chamber may be set at atmospheric pressure, and the mask shelf with the first mask 11 may be removed from the load lock chamber, e.g. with a lifting apparatus such as a crane.

[0059] Transporting a mask through the vacuum system while being carried by a mask carrier 10 in a non-horizontal orientation in stage (a) may be beneficial for the following reasons: (1) The mask can be transported through the vacuum system over a large distance of several meters or tens of meters by the mask carrier while reducing the risk of damaging the mask. For example, the mask may be transported between a mask handling module and a deposition chamber through a plurality of further vacuum chambers. Only the mask carrier may interact with the mask transport system 50 during this transport. (2) Due to the non-horizontal orientation of the mask and the mask carrier during the transport, space can be saved and a compact vacuum system having a reduced footprint can be provided. [0060] Changing the orientation of the mask together with the mask carrier, and unloading the mask from the mask carrier while being arranged in an essentially horizontal orientation according to embodiments described herein may be beneficial for the following reasons: (1) The risk of damaging the mask during the orientation change can be reduced because the first mask is held and supported by the mask carrier during the orientation change. (2) Separating the mask from the mask carrier while being arranged essentially horizontally is particularly easy and failure -resistant because a horizontally oriented mask can be supported on a simple horizontally arranged mask holding portion without any risk of falling down. (3) The mask can be directly inserted into a horizontal slot of a mask shelf after the unloading from the mask carrier.

[0061] According to embodiments described herein, the mask handling can be facilitated, and a quick and easy orientation change of the mask can be provided. Further, the mask can be separated from the mask carrier and unloaded from the vacuum system with a reduced risk of damaging the mask. Accordingly, the mask traffic in the vacuum system can be accelerated and the throughput of the vacuum system can be increased.

[0062] After unloading the first mask 11 from the mask carrier 10, a second mask 12 can be loaded onto the mask carrier 10. The second mask 12 may be a clean mask that is to be used for the deposition of an evaporated material on a substrate in a deposition chamber.

[0063] FIGS. 2A to 2D schematically show subsequent stages (d), (e), and (f) of a method of handling masks according to embodiments described herein. Stages (d), (e), and (f) may be carried out after stages (a), (b), and (c) depicted in FIGS. 1A to 1D. In particular, after unloading the first mask 11 from the mask carrier 10 in stages (a), (b), and (c), a second mask 12 may be loaded onto the mask carrier 10, and the second mask 12 may be carried along a transport path in the vacuum system by the mask carrier 10. However, the present disclosure is not limited to the sequence (a), (b), (c), (d), (e), (f). For example, in some embodiments, only the stages (d), (e), and (f) are carried out in succession for loading a mask onto a mask carrier, changing the orientation of the mask together with the mask carrier, and transporting the mask carrier along a transport path in the vacuum system. [0064] As is schematically depicted in FIG. 2A, a method of mask handling according to embodiments described herein includes, in stage (d), loading a second mask 12 on the mask carrier 10 that is arranged in an essentially horizontal orientation (H) in the vacuum system. The mask carrier 10 may be supported on a mask carrier support 22 that is provided in an essentially horizontal orientation.

[0065] After or during the loading of the second mask 12 on the mask carrier 10, the second mask 12 may optionally be aligned with respect to the mask carrier 10, e.g. by optically detecting a position of the second mask 12 relative to the mask carrier 10, and correcting the relative position between the second mask 12 and the mask carrier 10, until the second mask 12 is correctly positioned on the mask carrier 10. Aligning the mask that is provided in an essentially horizontal orientation may be easier and more accurate as comparted to an alignment of a mask having a non-horizontal or vertical orientation.

[0066] The loading of the second mask 12 on the mask carrier 10 may optionally include attaching the second mask 12 to the mask carrier 10, e.g. with a clamp 23 or with another chucking device, e.g. a magnetic chuck. FIG. 2B schematically shows the second mask 12 being loaded on, and attached to the mask carrier 10 which is horizontally supported on support sections 21 of the mask carrier support 22.

[0067] The method according to embodiments described herein further includes, in stage (e), changing the orientation of the mask carrier 10 carrying the second mask 12 from the essentially horizontal orientation (H) to a non-horizontal orientation (V), particularly to an essentially vertical orientation, as is schematically depicted in FIG. 2C. For example, the mask carrier support 22 with the mask carrier 10 supported thereon may be rotated by an angle of 45° or more and 135° or less, particularly about 90°, until the mask carrier 10 is arranged in the essentially vertical orientation depicted in FIG. 2C. In particular, the orientation change of the mask carrier may include a rotation by an angle of 80° or more and 90° or less. More particularly, the mask carrier may be rotated downward by about - 87° in stage (b), and may be rotated upward by about +87° in stage (e).

[0068] In particular, an actuator such as a motor may be provided for changing the orientation of the mask carrier support 22, particularly between the essentially horizontal orientation (H) and the non-horizontal orientation (V), such as an essentially vertical orientation.

[0069] As is schematically depicted in FIG. 2C, the mask carrier 10 may be rotated together with the second mask 12 that is attached thereto. By rotating the second mask 12 together with the mask carrier, the risk of damaging the second mask 12 can be reduced.

[0070] The method according to embodiments described herein further includes, in stage (f), transporting the mask carrier 10 carrying the second mask 12 in the non-horizontal orientation (V) along a transport path (T) in the vacuum system. The transport path (T) may extend perpendicular to the paper plane of FIG. 2D. For example, the second mask 12 may be carried by the mask carrier 10 into a deposition chamber where the second mask 12 may be used for depositing an evaporated material on substrates through the second mask.

[0071] In some embodiments, transporting the mask carrier 10 includes contactlessly transporting the mask carrier 10 along a transport track 51 with a mask transport system 50, particularly with a magnetic levitation system. Reference is made to the above explanations, which are not repeated here.

[0072] FIGS. 3 A to 3G are schematic illustrations of stages of a method of handling masks according to embodiments described herein. More specifically, a first mask 11 carried by a mask carrier 10 is unloaded from the mask carrier (see FIGS. 3 A to 3D), and subsequently a second mask 12 is loaded on the mask carrier 10 (see FIGS. 3E to 3G). The first mask 11 may be a used mask that is to be unloaded from the vacuum system, e.g. for being cleaned, and the second mask 12 may be a clean mask that is to be transported into a deposition chamber of the vacuum system for being used in an evaporation process.

[0073] FIG. 3A is a schematic view of a mask handling module 20 that is configured to separate the first mask 11 from the mask carrier 10 and to connect the second mask 12 to the mask carrier 10. The mask handling module 20 includes a mask carrier support 22 configured to support the mask carrier 10. In some embodiments, the mask carrier support 22 is movable between the essentially horizontal orientation (H) depicted in FIG. 3A and the non-horizontal orientation (V), e.g. the essentially vertical orientation depicted in FIG. 1A. In particular, an actuator may be provided for changing the orientation of the mask carrier support 22 between the non-horizontal orientation and the essentially horizontal orientation.

[0074] As is depicted in FIG. 3A, the mask carrier 10 may be supported on the mask carrier support 22 in the essentially horizontal orientation (H). For example, the mask carrier 10 may be positioned on top of one or more support sections 21 of the mask carrier support, e.g. after the orientation change to the essentially horizontal orientation. The first mask 11 may be fixed to the mask carrier 10, e.g. via a clamp 23, particularly via a plurality of clamps.

[0075] In some embodiments, which may be combined with other embodiments described herein, unloading the first mask 11 from the mask carrier 10 may include detaching the first mask 11 from the mask carrier 10, e.g. by releasing the clamp 23, particularly by releasing a plurality of clamps. For example, clamp lifting pins 29 may move upward for releasing the clamps. FIG. 3B shows the mask carrier 10 after detaching the first mask 11 from the mask carrier.

[0076] Subsequently, the first mask 11 may be lifted up from the mask carrier 10, e.g. with a plurality of lifting pins 24 that are movable relative to the support sections 21 of the mask carrier support 22 in an essentially vertical direction. For example, the first mask 11 may be lifted up by a distance of 100 mm or more and/or 200 mm or less from the mask carrier 10.

[0077] In some embodiments, unloading the first mask 11 from the mask carrier 10 may further include inserting a mask holding portion 32 of a vacuum robot between the lifted first mask and the mask carrier. In particular, the mask holding portion 32 may be inserted in a gap between the mask carrier 10 and the first mask 11, after the first mask 11 has been lifted up by a distance of 50 mm or more, particularly 100 mm or more, from the mask carrier. FIG. 3C shows the mask handling module after the insertion of the mask holding portion 32 of the vacuum robot. The mask holding portion 32 may be a movable robot hand of a vacuum robot, e.g. including a plate section for supporting a mask thereon.

[0078] Thereupon, the mask holding portion 32 with the first mask 11 supported thereon may be moved away from the mask carrier 10, e.g. in a vertical direction and/or in a horizontal direction, as is schematically depicted in FIG. 3D. In particular, the mask holding portion 32 may transfer the first mask 11 into a mask holder which may be arranged in a load-lock chamber. The load lock chamber may be arranged next to the mask handling module, such that the vacuum robot can move out with the mask holding portion 32 into the load chamber through a first opening and place the first mask 11 into a mask holder, e.g. into a slot of a mask shelf. In particular, the vacuum robot may place the first mask 11 into a horizontal slot of a mask shelf that is arranged in a load lock chamber. The mask shelf may have a plurality of slots, e.g. five, ten or more slots.

[0079] The first mask 11 may be unloaded from the vacuum system via the load-lock chamber, e.g. by closing the first opening between the vacuum system and the load-lock chamber, setting the load-lock chamber under atmospheric pressure, and removing the mask shelf from the load-lock chamber through a second opening, e.g. with a lifting device.

[0080] After unloading the first mask 11 from the mask carrier 10, the second mask 12 may be loaded on the mask carrier, as is schematically depicted in FIG. 3E.

[0081] Loading the second mask 12 on the mask carrier 10 may include moving the second mask 12 to a position on top of the mask carrier 10 with the mask holding portion of the vacuum robot or with a second mask holding portion 33 of the vacuum robot. For example, the second mask 12 may be transferred by the vacuum robot from a mask shelf provided in a load-lock chamber to a position on top of the mask carrier 10 while the mask carrier is supported by the mask carrier support 22.

[0082] In some embodiments, which may be combined with other embodiments described herein, the mask handling module 20 may include a vacuum robot with one, two or more individually movable robot hands. Each robot hand may include a mask holding portion configured to grab a mask and to transfer the mask between the mask carrier support 22 and one or more mask holders, e.g. mask shelfs. In some embodiments, the vacuum robot may be provided with at least two individually movable mask holding portions. Accordingly, the second mask may be grabbed by the second mask holding portion while the first mask is being unloaded from the mask carrier by the first mask holding portion. Thus, the mask exchange can be accelerated. The robot hands may be movable in at least two directions, e.g. vertically and horizontally. For example, the robot hands may be movable up and down, and/or may be extendable and retractable relative to a central robot body toward/from the mask carrier support.

[0083] In some embodiments, the vacuum robot is positioned next to the mask carrier support and includes two or more robot hands which are rotatable around an axis and include a respective mask holding portion which is movable in a vertical and/or horizontal direction.

[0084] As is schematically depicted in FIG. 3E, the second mask 12 may be positioned on lifting pins 24 by lowering the second mask holding portion 33 of the vacuum robot until the second mask 12 comes in contact with and is supported by the lifting pins 24. The lifting pins 24 may hold the second mask 12 at a distance above the mask carrier 10. Subsequently, the lifting pins may be lowered until the second mask 12 is placed on the mask carrier 10.

[0085] In some embodiments, which may be combined with other embodiments described herein, loading the second mask 12 on the mask carrier 10 may further include aligning the second mask 12 with respect to the mask carrier 10, e.g. utilizing an optical alignment system configured to align the second mask 12 relative to the mask carrier 10 in two transverse horizontal directions. The alignment of the second mask 12 relative to the mask carrier is schematically depicted in FIG. 3F.

[0086] After the alignment of the second mask 12, the second mask 12 may be attached to the mask carrier 10, particularly with the clamp 23 or with a magnetic chuck, as is schematically depicted in FIG. 3G.

[0087] After loading the second mask 12 on the mask carrier 10, the orientation of the mask carrier support 22 may be changed from the essentially horizontal orientation (H) depicted in FIG. 3G to the non-horizontal orientation depicted in FIG. 2C. Thereupon, the mask carrier 10 carrying the second mask 12 may be transported in the vacuum system in the non-horizontal orientation, e.g. toward a deposition chamber. [0088] According to another aspect described herein, a vacuum system 100 is provided. The vacuum system includes a plurality of deposition chambers 101, wherein each deposition chamber houses a deposition source, such as a vapor source 105.

[0089] The present disclosure is however not restricted to vacuum systems with vapor sources. For example, a chemical vapor deposition (CVD) system, a physical vapor deposition (PVD) system, e.g. a sputter system, or an evaporation system may be provided.

[0090] The vacuum system 100 may be a vacuum deposition system configured to coat substrates, e.g. thin glass substrates, with a layer stack, e.g. for display applications. The substrates may be attached to substrate carriers in the vacuum system, and the substrate carriers may be transported through the vacuum system by a substrate transport system. The substrate carriers may be transported by the substrate transport system into a plurality of deposition chambers in succession, in order to deposit a stack of different materials on the substrates. The main surfaces of the substrates may be coated with thin coating layers in the deposition chambers, while the substrates are positioned in front of a vapor source which moves past the substrate at a predetermined speed. Alternatively, the substrates may be transported past the coating devices at a predetermined speed during the deposition.

[0091] The substrates may be inflexible substrates, e.g. wafers, slices of transparent crystal such as sapphire or the like, glass substrates, or a ceramic plates. However, the present disclosure is not limited thereto and the term substrate may also embrace flexible substrates such as a web or a foil, e.g. a metal foil or a plastic foil.

[0092] The substrates may be large area substrates in some embodiments. A large area substrate may have a surface area of 1 m² or more. Specifically, a large area substrate may be used for display manufacturing and be a glass or plastic substrate. For example, substrates as described herein shall embrace substrates which are typically used for an LCD (Liquid Crystal Display), a PDP (Plasma Display Panel), and the like. In some embodiments, a large area substrate can be GEN 4.5, which corresponds to about 0.67 m² substrates (0.73 x 0.92m), GEN 5, which corresponds to about 1.4 m² substrates (1.1 m x 1.3 m), or larger. A large area substrate can further be GEN 7.5, which corresponds to about 4.29 m² substrates (1.95 m x 2.2 m), GEN 8.5, which corresponds to about 5.7m² substrates (2.2 m x 2.5 m), or even GEN 10, which corresponds to about 8.7 m² substrates (2.85 m x 3.05 m). Even larger generations such as GEN 11 and GEN 12 and corresponding substrate areas can similarly be implemented. In some implementations, an array of smaller sized substrates with surface areas down to a few cm², e.g. 2 cm x 4 cm and/or various individual shapes may be positioned on a single substrate support. The masks may be larger than the substrates in some embodiments in order to provide for a complete overlap with the substrates during deposition.

[0093] In some implementations, a thickness of the substrate in a direction perpendicular to the main surface of the substrate may be 1 mm or less, e.g. from 0.1 mm to 1 mm, particularly from 0.3 mm to 0.6 mm, e.g. 0.5 mm. Even thinner substrates are possible.

[0094] The vacuum system 100 further includes a mask handling module 20 configured to connect and separate masks and mask carriers under vacuum. The mask handling module 20 is further configured to change an orientation of the masks between an essentially horizontal orientation (H) and a non-horizontal orientation (V), particularly an essentially vertical orientation.

[0095] In some embodiments, the mask handling module 20 is configured to change the orientation of the mask carriers together with the respective mask attached thereto, as is depicted in FIGS 1A to 1D. In other embodiments, the mask handling module 20 is configured to detach a mask from a mask carrier, and to change the orientation of the detached mask. In particular, the mask handling module may be configured to rotate a mask without a mask carrier between an essentially horizontal orientation and an essentially vertical orientation.

[0096] The vacuum system 100 further includes a mask transport system configured to transport the mask carriers carrying the masks in the non-horizontal orientation between the mask handling module 20 and the plurality of deposition chambers 101. For example, masks to be used may be fixed to a respective mask carrier by the mask handling module 20 and may be transported to a respective deposition chamber by the mask transport system, and used masks to be unloaded from the vacuum system may be transported from a respective deposition chamber back to the mask handling module to be detached from the respective mask carrier and unloaded from the vacuum system. [0097] FIG. 4 is a schematic view of a vacuum system 100 according to embodiments described herein.

[0098] The vacuum system 100 includes a plurality of deposition chambers 101, particularly four or more deposition chambers, more particularly six or more deposition chambers, or even ten or more deposition chambers. A vapor source 105 configured for depositing evaporated material on substrates by evaporation may be arranged in each of the deposition chambers 101.

[0099] A vapor source 105 may include an evaporation crucible configured to evaporate a material, and a distribution pipe with a plurality of openings for directing the evaporated material toward a substrate which is arranged in a deposition area of a deposition chamber. The distribution pipe may extend in an essentially vertical direction. In some embodiments, the distribution pipe may be rotatably mounted. For example, the distribution pipe may be rotatable between a first deposition area of a deposition chamber and a second deposition area of the deposition chamber, wherein the first deposition area and the second deposition area may be arranged on opposite sides of the vapor source 105. Accordingly, after the deposition of an evaporated material on a first substrate arranged in the first deposition area, the distribution pipe may be rotated by an angle of about 180° for depositing the evaporated material on a second substrate arranged in the second deposition area of the deposition chamber.

[00100] In FIG. 4, two substrates 15 are exemplarily depicted in the two deposition areas of the deposition chamber 102 on opposite sides of the vapor source 105. The remaining substrates are not depicted in FIG. 4 for the sake of simplicity.

[00101] In some embodiments, the vapor source 105 is movable past the substrate during deposition, particularly along a linear source path. In particular, the vapor source 105 may be rotatable around an axis and movable along a linear source path past the substrate.

[00102] The vacuum system 100 of FIG. 4 further includes a mask handling module 20 that is configured to connect masks to mask carriers and to separate masks from mask carriers. In particular, used masks are typically separated from the respective mask carriers by the mask handling module, in order to unload the used masks from the vacuum system while the mask carriers can remain in the vacuum system. Masks to be used are typically connected to respective mask carriers by the mask handling module, in order to transport the masks to be used from the mask handling module into the respective deposition chamber.

[00103] The mask handling module 20 may be configured to change the orientation of a mask, particularly together with the mask carrier carrying the mask, between an essentially horizontal orientation and a non-horizontal orientation.

[00104] In particular, the mask handling module 20 may include a mask carrier support 22 configured to support a mask carrier 10 and to change the orientation of the mask carrier between the essentially horizontal orientation and the essentially vertical orientation. For example, an actuator may be provided for changing the orientation of the mask carrier support 22 between the non-horizontal orientation (V) and the essentially horizontal orientation (H).

[00105] In some embodiments, the mask handling module 20 may further include a vacuum robot 30. The vacuum robot may be configured to unload a first mask 11 from a mask carrier that is supported by the mask carrier support. The vacuum robot may be further configured to load a second mask 12 on a mask carrier that is supported by the mask carrier support.

[00106] More specifically, the vacuum robot 30 may be arranged next to the mask carrier support 22 and may include at least one movable mask holding portion configured to grab a mask from the mask carrier that is supported by the mask carrier support in the essentially horizontal orientation. Further, the at least one movable mask holding portion may be configured to move a mask on top of a mask carrier that is supported on the mask carrier support and to load the mask on the mask carrier.

[00107] In particular, the vacuum robot 30 may include a plurality of movable robot hands, each robot hand including a mask holding portion. The vacuum robot 30 depicted in FIG. 4 includes three movable robot hands, wherein a first mask holding portion of a first movable robot hand may unload the first mask 11 from the mask carrier, and a second mask holding portion of a second movable robot hand may simultaneously take the second mask 12 from a mask shelf. After unloading the first mask 11 from the mask carrier by the first robot hand, the second robot hand may load the second mask 12 on the mask carrier. A quick and time-saving mask exchange can be provided.

[00108] The vacuum robot 30 may be provided next to the mask carrier support 22 in a vacuum chamber of the vacuum system, and one, two or more load lock chambers 108 may be arranged next to the vacuum chamber. Mask holders, e.g. mask shelfs 109, may be provided in the load lock chambers 108. The vacuum robot 30 may be configured to transfer masks between the one, two or more load lock chambers 108 and the mask carrier support 22.

[00109] As is schematically depicted in FIG. 4, the vacuum system may include one single mask handling module 20 for handling the masks that are to be distributed into the plurality of deposition chambers 101, particularly four, six, eight, ten or more deposition chambers. The mask handling module 20 may be configured in accordance with any of the embodiments described herein and is suitable for a quick and efficient mask handling. Accordingly, the masks can be very quickly connected to and disconnected from the mask carriers by the mask handling module 20, such that one single mask handling module is sufficient for handling the masks that are to be utilized in the plurality of deposition chambers 101.

[00110] In some embodiments, which may be combined with other embodiments described herein, the plurality of deposition chambers 101 includes four, eight, ten or more deposition chambers, and the vacuum system 100 includes one single mask handling module 20 for connecting masks and mask carriers to be transported to the four, eight, ten or more deposition chambers, and/or for disconnecting these mask from the mask carriers after a predetermined time of use.

[00111] In some embodiments, which may be combined with other embodiments described herein, the vacuum system 100 includes a main transportation path 5 with transportation tracks for transporting mask carriers and substrate carriers along the main transportation path 5, the mask handling module 20 being connected to a first section of the main transportation path 5, a substrate handling module 115 configured to connect and separate substrates and substrate carriers being connected to a second section of the main transportation path 5, and the plurality of deposition chambers 101 being connected to a third section of the main transportation path 5. The main transportation path 5 may extend in an essentially linear direction, the first section may be a first end section of the main transportation path 5, and the second section may be a second end section of the main transportation path 5. The third section may be partially or entirely provided between the first section and the second section.

[00112] In some embodiments, the vacuum system 100 may include one or more mask holders, particularly mask shelfs 109, for receiving the masks that are to be unloaded from and loaded into the vacuum system. The one or more mask holders may be provided in one or more load lock chambers 108 which are positioned adjacent to the mask handling module 20. The mask shelfs may be provided with a plurality of horizontally extending slots for housing a respective mask. In particular, the mask shelfs may be configured as mask cassettes that can be unloaded from the vacuum system with a lifting device and be transported at atmospheric pressure to a cleaning or maintenance station for cleaning or servicing the masks.

[00113] FIG. 5 is a flow diagram illustrating a method of handling masks according to embodiments described herein.

[00114] In box 510, masks are loaded into the vacuum system in an essentially horizontal orientation. For example, the masks which are horizontally arranged in a plurality of slots of a mask shelf are placed in a load lock chamber. A vacuum robot of the mask handling module may take the masks from the respective slots and place the masks on a mask carrier that is supported on a mask carrier support, respectively.

[00115] In box 520, the masks are connected to masks carriers with the mask handling module. After connecting a mask to a mask carrier, an orientation of the mask may be changed from the essentially horizontal orientation to a non-horizontal orientation, particularly an essentially vertical orientation. Alternatively, the orientation of a mask may be changed from the essentially horizontal orientation to the non-horizontal orientation before connecting the mask to the mask carrier. [00116] In box 530, the mask carriers carrying the masks are transported in the non horizontal orientation from the mask handling module to a plurality of deposition chambers. For example, each of the masks is transported to a predetermined deposition chamber where the mask is to be used for masked deposition on a substrate while being held by a mask carrier. In particular, the masks may be distributed to a plurality of deposition chambers from one single mask handling module which may be configured for assembling and disassembling masks and mask carriers and for changing the mask orientation.

[00117] In box 540, an evaporated material is deposited on a plurality of substrates through the masks in the plurality of deposition chambers.

[00118] According to embodiments described herein, masks and mask carriers are mated under vacuum in a horizontal orientation, and the mask carriers carrying the masks are pivoted by a swing table to be provided in an essentially vertical orientation. The mask carriers carrying the masks are transported in the vacuum system to deposition chambers in the essentially vertical orientation. In some embodiments, the mask carriers are contactlessly transported by a magnetic levitation system.

[00119] According to embodiments described herein, the masks are transported in the vacuum system while being carried by mask carriers in an essentially vertical orientation (+/-10⁰). This mask carrier concept enables the usage of one single mask exchange area with a mask exchange module adapted for connecting and separating the masks and the mask carriers that are used in the vacuum system. In particular, the masks that are used in the vacuum system can be loaded into and unloaded from the vacuum system via one single mask exchange area which may optionally be provided at a first end section of the vacuum system. In some embodiments, the substrates that are coated in the vacuum system can be loaded into and unloaded from the vacuum system via one single substrate exchange area which may optionally be provided at a second end section of the vacuum system opposite to the first end section.

[00120] In particular, the vacuum system may include a plurality of deposition chambers provided laterally with respect to an essentially linearly extending main transportation path, wherein the mask handling area may be arranged at the first end section of the main transportation path. Accordingly, clean masks that are to be used in the vacuum system are (only) transported in one direction along the main transportation path, i.e. from the mask handling area toward a deposition chamber. Used masks that are to be unloaded from the vacuum system are (only) transported in the opposite direction along the main transportation path, i.e. from a deposition chamber toward the mask handling area. The mask traffic in the system can be simplified.

[00121] While the foregoing is directed to embodiments of the disclosure, other and further embodiments of the disclosure may be devised without departing from the basic scope thereof, and the scope thereof is determined by the claims that follow.

Claims

1. A method of handling masks in a vacuum system, comprising: a) transporting a mask carrier (10) carrying a first mask (11) in a non-horizontal orientation along a transport path in the vacuum system; b) changing the orientation of the mask carrier (10) carrying the first mask (11) from the non-horizontal orientation to an essentially horizontal orientation; and c) unloading the first mask (11) from the mask carrier (10) arranged in the essentially horizontal orientation in the vacuum system.

2. The method of claim 1, wherein the non-horizontal orientation is an essentially vertical orientation.

3. The method of claim 1 or 2, wherein the mask carrier (10) is transported from a deposition chamber housing a vapor source (105) to a mask handling module (20) including a mask carrier support (22) that is movable between the non-horizontal orientation and the essentially horizontal orientation.

4. The method of any of claims 1 to 3, wherein transporting the mask carrier (10) comprises contactlessly transporting the mask carrier (10) with a mask transport system (50) comprising a magnetic levitation system.

5. The method of any of claims 1 to 4, wherein changing the orientation comprises supporting the mask carrier (10) carrying the first mask (11) on a mask carrier support (22), and rotating the mask carrier support (22).

6. The method of any of claims 1 to 5, wherein unloading comprises detaching the first mask (11) from the mask carrier (10), particularly by releasing a clamp (23) or a magnetic chuck.

7. The method of any of claims 1 to 6, wherein unloading comprises: lifting up the first mask (11) from the mask carrier (10) that is supported on a mask carrier support (22), particularly with a plurality of lifting pins (24) that are movable relative to the mask carrier support (22); inserting a mask holding portion (32) of a vacuum robot (30) between the first mask (11) and the mask carrier (10); and moving the mask holding portion (32) having the first mask (11) supported thereon away from the mask carrier support (22).

8. The method of any of claims 1 to 7, further comprising after the unloading: moving the first mask (11) with a vacuum robot (30) into a mask shelf (109) arranged in a load lock chamber (108).

9. A method of mask handling in a vacuum system, particularly according to any of the preceding claims, comprising: d) loading a second mask (12) on a mask carrier (10) that is arranged in an essentially horizontal orientation (H) in the vacuum system; e) changing the orientation of the mask carrier (10) carrying the second mask (12) from the essentially horizontal orientation to a non-horizontal orientation; and f) transporting the mask carrier (10) carrying the second mask (12) in the non horizontal orientation along a transport path in the vacuum system.

10. The method of claim 9, further comprising before changing the orientation: aligning the second mask (12) with respect to the mask carrier (10); and attaching the second mask (12) to the mask carrier (10), particularly with a clamp (23) or a magnetic chuck.

11. A vacuum system (100), comprising: a plurality of deposition chambers (101) respectively housing a vapor source (105); a mask handling module (20) configured to connect and separate masks and mask carriers under vacuum and to change an orientation of the masks between an essentially horizontal orientation and a non-horizontal orientation; and a mask transport system (50) configured to transport the mask carriers carrying the masks in the non-horizontal orientation between the mask handling module (20) and the plurality of deposition chambers (101).

12. The vacuum system of claim 11, wherein the mask handling module (20) comprises: a mask carrier support (22) configured to support a mask carrier (10); an actuator configured to change the orientation of the mask carrier support (22) between the non-horizontal orientation and the essentially horizontal orientation; and a vacuum robot (30) with at least one mask holding portion (32) for at least one of unloading a first mask (11) from the mask carrier supported by the mask carrier support (22), and

loading a second mask (12) onto the mask carrier supported by the mask carrier support (22).

13. The vacuum system of claim 11 or 12, wherein the plurality of deposition chambers (101) comprises four, eight, ten or more deposition chambers, and wherein the vacuum system (100) comprises one single mask handling module (20) for connecting masks and mask carriers to be transported to the four, eight, ten or more deposition chambers.

14. The vacuum system of any of claims 11 to 13, comprising a main transportation path (5) with transportation tracks for transporting mask carriers and substrate carriers along the main transportation path (5), the mask handling module (20) being connected to a first section of the main transportation path (5), a substrate handling module (115) configured to connect and separate substrates and substrate carriers being connected to a second section of the main transportation path (5), and the plurality of deposition chambers (101) being connected to a third section of the main transportation path (5).

15. A method of handling masks in a vacuum system (100), comprising: loading masks into the vacuum system (100) in an essentially horizontal orientation; changing an orientation of the masks from the essentially horizontal orientation to a non-horizontal orientation and connecting the masks to mask carriers with a mask handling module (20); transporting the mask carriers carrying the masks in a non-horizontal orientation from the mask handling module (20) to a plurality of deposition chambers (101); and depositing evaporated material on a plurality of substrates through the masks in the plurality of deposition chambers (101).