WO2021085685A1

WO2021085685A1 - Material deposition arrangement, vacuum deposition system, and method for manufacturing a material deposition arrangement

Info

Publication number: WO2021085685A1
Application number: PCT/KR2019/014625
Authority: WO
Inventors: Hwa Young LA
Original assignee: Applied Materials, Inc
Priority date: 2019-10-31
Filing date: 2019-10-31
Publication date: 2021-05-06
Also published as: CN114599814A; KR20220070300A

Abstract

A material deposition arrangement for depositing a material on a substrate in a vacuum deposition chamber is described. The material deposition arrangement comprises a crucible configured to evaporate a material through an opening, a distribution assembly configured to discharge a evaporated material through a plurality of nozzles, and first and second carbon rings between the crucible and the distribution assembly, wherein the crucible comprises a first flange extending outward around the opening, wherein the distribution assembly comprises a second flange at a connecting portion with the crucible, wherein the first flange comprises a first molybdenum ring on an upper surface thereof, wherein the second flange comprises a second molybdenum ring on a lower surface thereof, and wherein the first carbon ring is in contact with the first molybdenum ring, and the second carbon ring is in contact with the second molybdenum ring.

Description

MATERIAL DEPOSITION ARRANGEMENT, VACUUM DEPOSITION SYSTEM, AND METHOD FOR MANUFACTURING A MATERIAL DEPOSITION ARRANGEMENT

Embodiments of the present disclosure relate to material deposition apparatuses for depositing materials on a substrate. More particularly, embodiments of the present disclosure relate to material deposition arrangements for depositing metallic materials on a substrate in a vacuum deposition chamber, vacuum deposition systems, and methods for manufacturing a material deposition arrangement, in particular for OLED manufacturing.

An organic light-emitting diode (OLED) is a light-emitting diode in which an electroluminescent layer is a film of organic compound that emits light in response to an electric current. Since OLEDs emit light directly without involving any backlight and color filters, the color gamut and viewing angles possible with OLED displays are greater than those of traditional LCD displays. Further, OLEDs can be manufactured on flexible substrates, and accordingly, they can be utilized in a variety of applications.

Organic materials and metallic materials are deposited on a substrate in a vacuum deposition chamber for OLED manufacturing. Metallic materials are employed as, for example, electrode materials or electron transport layer (ETL) materials. The materials to be deposited are evaporated in a material deposition arrangement, and the evaporated materials are deposited on a substrate through nozzles. Metallic materials are evaporated in a material deposition arrangement at a temperature of about 1,000°C or above, or of about 1,500°C or above.

A conventional material deposition arrangement has a vertically extending pipe-shaped body. Materials to be deposited are fed through an opening provided at the top of the body. For metallic materials, the materials to be fed have a shape of grains or pellets with dimensions ranging between about 1mm and about 5mm. Metallic grains or pellets fed from the top of the material deposition arrangement may cause damage to the inner wall of the material deposition arrangement.

For more convenient feeding and refill of the materials to be deposited and maintenance of the material deposition arrangement, a material deposition arrangement with a detachable crucible has been proposed. The crucible can be detached from a distribution assembly of the material deposition arrangement in order to feed materials to be deposited. As the materials to be deposited can be fed into the crucible from the top of the crucible which has been detached, damage to the inner wall of the distribution assembly can be prevented.

In the material deposition arrangement having a detachable crucible, it is important to seal the connecting portion between the crucible and the distribution assembly. Evaporated materials may permeate the gap between the crucible and the distribution assembly or may leak through the gap. In particular, metallic materials that have permeated the gap between the crucible and the distribution assembly may weld the crucible and the distribution assembly together, thereby making it impossible to separate the crucible and the distribution assembly from each other. Conventional sealing elements (e.g., rubber O-rings) cannot be used at a temperature of about 1,000°C or above for evaporating metallic materials.

Embodiments of the present disclosure provide a material deposition arrangement, a vacuum deposition system, and a method for manufacturing a material deposition arrangement, that can prevent leakage of evaporated materials, in particular evaporated metallic materials.

A material deposition arrangement, a vacuum deposition system, and a method for manufacturing a material deposition arrangement are provided in accordance with independent claims. Further aspects, advantages, and features are apparent from the dependent claims, the description, and the accompanying drawings.

According to an aspect of the present disclosure, a material deposition arrangement for depositing materials on a substrate is provided. The material deposition arrangement comprises: a crucible having an inner volume for receiving a material and a first flange; a distribution assembly having an inner hollow space and a second flange to be fastened to the first flange; and first and second sealing rings interposed between the first flange and the second flange, wherein the first flange comprises a first molybdenum-containing region in at least a region of an upper surface thereof, wherein the second flange comprises a second molybdenum-containing region in at least a region of a lower surface thereof, wherein the first sealing ring is in contact with the first molybdenum-containing region, wherein the second sealing ring is in contact with the second molybdenum-containing region, and wherein at least surfaces of the first sealing ring and the second sealing ring comprise a carbon material.

In accordance with another aspect of the present disclosure, a material deposition arrangement for depositing materials on a substrate in a vacuum deposition chamber is provided. The material deposition arrangement comprises: a crucible configured to evaporate a material through an opening; a distribution assembly configured to discharge a evaporated material through a plurality of nozzles; and first and second carbon layers between the crucible and the distribution assembly, wherein the crucible comprises a first flange around the opening, wherein the distribution assembly comprises a second flange at a connecting portion with the crucible, wherein the first flange comprises a first molybdenum layer on at least a portion of a sufrace of the first flange, wherein the second flange comprises a second molybdenum layer on at least a portion of a suface of the second flange, and wherein the first carbon layer is in contact with the first molybdenum layer, and the second carbon layer is in contact with the second molybdenum layer.

According to a further aspect of the present disclosure, a vacuum deposition system is provided. The vacuum deposition system comprises a vacuum deposition chamber, and a material deposition arrangement in accordance with any embodiments described herein.

In accordance with a yet further aspect of the present disclosure, a method for manufacturing a material deposition arrangement is provided. The method for manufacturing a material deposition arrangement comprises: providing a crucible having a first flange comprising a first molybdenum-containing region on at least an upper surface thereof, wherein the first molybdenum-containing region consists essentially of molybdenum (Mo), or is formed of an alloy containing at least 50% by weight of molybdenum; placing a first sealing ring on the upper surface of the first flange, wherein at least surfaces of the first sealing ring are formed of a carbon material; placing a second sealing ring on the first sealing ring, wherein at least surfaces of the second sealing ring are formed of a carbon material; and placing a distribution assembly having a second flange comprising a second molybdenum-containing region on at least a lower surface thereof on the second sealing ring, wherein the second molybdenum-containing region consists essentially of molybdenum (Mo), or is formed of an alloy containing at least 50% by weight of molybdenum.

The above and other aspects, features, and advantages of the present disclosure will become apparent from the detailed description of the following aspects in conjunction with the accompanying drawings, in which:

Fig. 1 shows a schematic cross-sectional side view of a vacuum deposition system according to an embodiment of the present disclosure;

Fig. 2 shows a cross-sectional side view of a connecting structure between a crucible and a distribution assembly of a material deposition arrangement according to an embodiment of the present disclosure;

Fig. 3 shows an exploded perspective view of the connecting structure between the crucible and the distribution assembly of the material deposition arrangement according to an embodiment of the present disclosure;

Fig. 4 shows a cross-sectional side view of a connecting structure between a crucible and a distribution assembly of a material deposition arrangement according to another embodiment of the present disclosure;

Fig. 5 shows an exploded perspective view of the connecting structure between the crucible and the distribution assembly of the material deposition arrangement according to the other embodiment of the present disclosure; and

Fig. 6 shows a flow chart illustrating a method for manufacturing a material deposition arrangement in accordance with a further aspect of the present disclosure.

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

Within the following description of the drawings, the same reference numbers refer to same components. Only the differences with respect to individual embodiments are described.

Before various embodiments of the present disclosure are described in more detail, some aspects with respect to some terms and expressions used herein are explained.

In the present disclosure, a "vacuum deposition system" is to be understood as a system or arrangement configured for vacuum deposition of materials on a substrate. In particular, a "vacuum deposition arrangement" can be understood as a system or arrangement configured for vacuum deposition of organic or metallic materials, e.g. for OLED display manufacturing.

In the present disclosure, a "vacuum deposition chamber" is to be understood as a chamber configured for vacuum deposition. The term "vacuum", as used herein, can be understood in the sense of a technical vacuum having a vacuum pressure of less than, for example, 10 mbar. Typically, the pressure in a vacuum chamber as described herein may be between 10^-5　mbar and about 10^-8　mbar, more typically between 10^-5　mbar and 10^-7　mbar, and even more typically between about 10^-6 mbar and about 10^-7　mbar.

In the present disclosure, a "material deposition arrangement" is to be understood as an arrangement configured for material deposition on a substrate as described herein. In particular, a "material deposition arrangement" can be understood as an arrangement or assembly configured for providing a source of material to be deposited on a substrate. In particular, a "material deposition arrangement" may be understood as an arrangement or assembly having a crucible configured to evaporate the source material to be deposited and a distribution assembly configured for providing the evaporated material to the substrate. For instance, the source material to be deposited may be a metallic material for use as electrode materials or electron transport layer materials in organic light emitting diode (OLED) production.

In the present disclosure, a "crucible" can be understood as a device having a reservoir for the material to be evaporated by heating the crucible. Accordingly, a "crucible" can be understood as a source material reservoir which can be heated to evaporate the source material into a gas by at least one of evaporation and sublimation of the source material. Typically, the crucible includes a heater to evaporate the source material in the crucible into a gaseous source material. For instance, initially the material to be evaporated can be in the form of a powder or a grain. The reservoir can have an inner volume for receiving the source material to be evaporated, e.g. a metallic material.

In the present disclosure, a "distribution assembly" can be understood as an assembly configured for providing evaporated material, particularly a plume of evaporated material, from the distribution assembly to the substrate. For example, the distribution assembly may include a distribution tube. For instance, a distribution tube as described herein may provide a line source with a plurality of openings and/or nozzles which are arranged in at least one line along the length of the distribution tube.

Accordingly, the distribution assembly can be a linear distribution showerhead, for example, having a plurality of openings (or an elongated slit) disposed therein. A showerhead as understood herein can have an enclosure, hollow space, or tube, in which the evaporated material can be provided or guided, for example from the evaporation crucible to the substrate. According to embodiments which can be combined with any other embodiments described herein, the length of the distribution tube may correspond at least to the height of the substrate to be deposited. In particular, the length of the distribution tube may be longer than the height of the substrate to be deposited, at least by 10% or even 20%. Accordingly, a uniform deposition at the upper end of the substrate and/or the lower end of the substrate can be provided.

In the present disclosure, a "heater" can be understood as a heating unit or heating device configured to heat the source material, particularly to evaporate the source material into a gaseous source material. Upon heating the source material by the heater as described herein, the source material provided in the inner volume of the crucible is heated up to a temperature at which the source material evaporates. For a metallic source material, the heater can heat the source material to a temperature of, for instance, at least about 1,000°C, or at least about 1,500°C.

In the present disclosure, a "ring shape" can be understood as a curved or bent loop shape that is closed around the central opening thereof. For instance, a "ring shape" can be understood as a shape comprising a rectangular ring or a polygonal ring as well as a circular ring.

Fig. 1 shows a schematic cross-sectional side view of a vacuum deposition system according to an embodiment of the present disclosure.

With exemplary reference to Fig. 1, according to embodiments which can be combined with any other embodiments described herein, the vacuum deposition system 1 is configured to deposit materials on a substrate 20 in a vacuum deposition chamber 10. The vacuum deposition system 1 comprises the vacuum deposition chamber 10, a substrate support 30 configured to support the substrate 20, and one or more material deposition arrangements 100 for evaporating a source material 50. The material deposition arrangement 100 comprises a crucible 110 configured to evaporate the source material 50 to be deposited and a distribution assembly 160 configured to provide the evaporated material to the substrate 20.

The source material 50 may be metallic materials for use as electrode materials or electron transport layer (ETL) materials in OLED manufacturing. For example, the source material 50 may comprise silver (Ag), aluminum (Al), magnesium (Mg), or ytterbium (Yb).

The crucible 110 and the distribution assembly 160 may be formed of a material having thermal/mechanical stability at a temperature for evaporating the source material 50 (of at least about 1,000°C, or of at least about 1,500°C), and also having chemical stability against the source material 50. The crucible 110 and the distribution assembly 160 may be formed, for example, of materials comprising a material selected from a group consisting of tantalum (Ta), molybdenum (Mo), and tungsten (W), or a combination thereof.

The crucible 110 comprises a first wall 120 for defining an inner volume 130 for storing the source material 50 therein and a heater for providing heat to evaporate the source material 50 within the inner volume 130. The first wall 120 is open toward the top thereof to form a first opening 132. The heater may, for example, comprise a heating coil 112 disposed outside the first wall 120 of the crucible 110. The heater can heat the metallic source materials for use as electrode materials or the ETL materials, for example, to at least about 1,000°C, or to at least about 1,500°C.

The first wall 120 comprises a first bottom wall 121 for defining the bottom of the crucible 120, a first side wall 122 extending upward from the first bottom wall 121, a first bottleneck wall 123 extending radially inward and upward from the first side wall 122, and a first flange 124 extending radially outward from the upper end of the first bottleneck wall 123.

The distribution assembly 160 comprises a second wall 170 for defining an inner hollow space 180. The second wall 170 may have a substantially tubular shape. The second wall 170 is open toward the bottom thereof to form a second opening 182.

The second wall 170 comprises a second top wall 171 for defining the top of the distribution assembly 160, a second side wall 172 extending downward from the second top wall 171, a second bottleneck wall 173 extending radially inward and downward from the second side wall 172, and a second flange 174 extending radially outward from the lower end of the second bottleneck wall 173.

The first opening 132 in the crucible 110 and the second opening 182 in the distribution assembly 160 communicate each other. The evaporated material from the crucible 110 flows into the inner hollow space 180 of the distribution assembly 160 through the first opening 132 and the second opening 182, and then the evaporated material is distributed to a plurality of nozzles 184 formed on the second side wall 172.

The first flange 124 of the crucible 110 and the second flange 174 of the distribution assembly 160 are connected to each other with a first sealing ring 140, a second sealing ring 190, and a spacer 150 interposed therebetween. The first flange 124 and the second flange 174 may be fastened and clamped by a fastener such as a clamp 155.

Fig. 2 shows a cross-sectional side view of a connecting structure between a crucible and a distribution assembly of a material deposition arrangement according to an embodiment of the present disclosure, and Fig. 3 shows an exploded perspective view of the connecting structure between the crucible and the distribution assembly of the material deposition arrangement according to an embodiment of the present disclosure.

With exemplary reference to Figs. 2 and 3, according to embodiments which can be combined with any other embodiments described herein, the first flange 124 extends radially outward around the first opening 132 of the crucible 110. A first step 126 may be formed on the upper surface 125 of the first flange 124. The second flange 174 extends radially outward around the second opening 182 of the distribution assembly 160. A second step 176 may be formed on the lower surface 175 of the second flange 174.

The first sealing ring 140 may have a ring shape in which the upper and lower surfaces thereof are substantially flat. The inner diameter of the first sealing ring 140 is substantially the same as or larger than the diameter of the first opening 132 of the crucible 110, and the outer diameter of the first sealing ring 140 is smaller than the outer diameter of the first flange 124. The first sealing ring 140 is placed on the upper surface 125 of the first flange 124. The first sealing ring 140 is guided to rest in a precise position by the first step 126 of the upper surface 125 of the first flange 124.

The second sealing ring 190 may have a ring shape in which the upper and lower surfaces thereof are substantially flat. The inner diameter of the second sealing ring 190 is substantially the same as or larger than the diameter of the second opening 182 of the distribution assembly 160, and the outer diameter of the second sealing ring 190 is smaller than the outer diameter of the second flange 174. The second sealing ring 190 may have substantially the same shape as the first sealing ring 140. The second sealing ring 190 is placed under the lower surface 175 of the second flange 174. The second sealing ring 190 is guided to rest in a precise position by the second step 176 of the lower surface 175 of the second flange 174.

The first sealing ring 140 and the second sealing ring 190 are formed of a material having thermal/mechanical stability at a temperature for evaporating the source material and also having chemical stability and non-wettability against the source material. The first sealing ring 140 and the second sealing ring 190 may formed of a material comprising carbon. In one embodiment, the first sealing ring 140 and the second sealing ring 190 may be formed of non-porous graphite such as glassy graphite (vitreous graphite). In another embodiment, the surfaces of the first sealing ring 140 and the second sealing ring 190 may be formed of a material comprising carbon. For example, the inner body of the first sealing ring 140 and the second sealing ring 190 may be formed of pyrolytic boron nitride (PBN), or aluminum nitride (AlN), etc., and the surfaces thereof may be formed of glassy graphite.

The upper surface 125 of the first flange 124 of the crucible 110 comprises a first molybdenum-containing region 127. The lower surface 175 of the second flange 174 of the distribution assembly 160 comprises a second molybdenum-containing region 177. The molybdenum-containing

regions

127 and 177 are formed of an alloy containing molybdenum. The molybdenum-containing

regions

127 and 177 contain at least 50% by weight, typically 70% or more by weight, and more typically 90% or more by weight of molybdenum (Mo). The molybdenum-containing

regions

127 and 177 may be formed of molybdenum (Mo), or of an alloy containing molybdenum, such as a lanthanated molybdenum (Mo-La) alloy.

The first and second molybdenum-containing

regions

127 and 177 are in direct contact with the first sealing ring 140 and the second sealing ring 190, respectively. For example, the first molybdenum-containing region 127 may be formed in a region on the upper surface 125 of the first flange 124 on which the first sealing ring 140 rests, and the second molybdenum-containing region 177 may be formed in a region on the lower surface 175 of the second flange 174 on which the second sealing ring 190 rests.

The region where the first molybdenum-containing region 127 and the first sealing ring 140 make contact with each other completely encircles the first opening 132 of the crucible 110. In one embodiment, the first molybdenum-containing region 127 may be the entire upper surface 125 of the first flange 124. In another embodiment, the first molybdenum-containing region 127 may be the entirety of the first flange 124 of the crucible 110. In a further embodiment, the first molybdenum-containing region 127 may be the entire crucible 110. In other words, the crucible 110 may be formed of molybdenum (Mo), or of an alloy containing molybdenum (Mo) such as a lanthanated molybdenum (Mo-La) alloy.

Likewise, the region where the second molybdenum-containing region 177 and the second sealing ring 190 make contact with each other completely encircles the second opening 182 of the distribution assembly 160. In one embodiment, the second molybdenum-containing region 177 may be the entire lower surface 175 of the second flange 174. In another embodiment, the second molybdenum-containing region 177 may be the entirety of the second flange 174 of the distribution assembly 160. In a further embodiment, the second molybdenum-containing region 177 may be the entire distribution assembly 160. In other words, the distribution assembly 160 may be formed of molybdenum (Mo), or of an alloy containing molybdenum (Mo) such as a lanthanated molybdenum (Mo-La) alloy.

A spacer 150 may be placed on a radially outer side of the first sealing ring 140 and the second sealing ring 190. The spacer 150 may have a ring shape in which the upper and lower surfaces thereof are substantially flat. The inner diameter of the spacer 150 is substantially the same as the outer diameter of the first sealing ring 140 and the second sealing ring 190. The outer diameter of the spacer 150 is substantially the same as or smaller than the outer diameter of the first flange 124 and the second flange 174. The spacer 150 prevents the first flange 124 and the second flange 174 from making direct contact with each other. The spacer 150 may be guided to rest in a precise position by the outer diameter of the first sealing ring 140 and/or the second sealing ring 190. In an alternative embodiment, the spacer 150 may be guided to rest in a precise position by steps formed on the upper surface 125 of the first flange 124 and on the lower surface 175 of the second flange 174. In this case, the first sealing ring 140 and the second sealing ring 190 may be guided to be placed in the inner diameter of the spacer 150.

The spacer 150 is configured to prevent deformation and breakage of portions of the crucible 110 and the distribution assembly 160, in particular deformation and breakage of the first flange 124 and the second flange 174 due to thermal expansion thereof at a temperature for evaporating the source material 50. In one embodiment, the spacer 150 may be formed of an alloy comprising tungsten, such as tungsten-cerium oxide (WC), tungsten-lanthanum oxide (WL), tungsten-lanthanum oxide-zirconium oxide (WLZ), tungsten-rhenium (WRe), or tungsten-copper (WCu).

The crucible 110 is heated to a temperature of at least about 1,000°C, or of at least about 1,500°C to evaporate the source material 50. Molybdenum in the first molybdenum-containing region 127 and carbon in the first sealing ring 140 react to each other at a temperature of about 1,000°C or above to form molybdenum carbide (Mo_xC_y), for example, Mo₂C or MoC.

That is, molybdenum carbide (Mo_xC_y) is formed at the interface between the upper surface 125 of the first flange 124 and the first sealing ring 140. Molybdenum carbide (Mo_xC_y) formed at the interface bonds the first flange 124 and the first sealing ring 140 together so as to hermetically seal the interface. Accordingly, the material evaporated from the crucible 110 does not leak between the first flange 124 and the first sealing ring 140.

Likewise, molybdenum in the second molybdenum-containing region 177 and carbon in the second sealing ring 190 react to each other to form molybdenum carbide (Mo_xC_y) at the interface therebetween. That is, molybdenum carbide (Mo_xC_y) is formed at the interface between the lower surface 175 of the second flange 174 and the second sealing ring 190. Molybdenum carbide (Mo_xC_y) formed at the interface bonds the second flange 174 and the second sealing ring 190 together so as to hermetically seal the interface. Accordingly, the material evaporated from the crucible 110 does not leak between the second flange 174 and the second sealing ring 190.

Since the first sealing ring 140 and the second sealing ring 190 are pressed against each other by means of the clamp 155, it is difficult for the material evaporated from the crucible 110 to permeate between the first sealing ring 140 and the second sealing ring 190. In addition, the first sealing ring 140 and the second sealing ring 190 are non-wettable by the evaporated material, in particular by the metallic gas. For example, the first sealing ring 140 and the second sealing ring 190 are formed of glassy graphite which is non-wettable by silver (Ag), magnesium (Mg), or ytterbium (Yb) gas. Therefore, the evaporated material hardly leaks between the first sealing ring 140 and the second sealing ring 190.

As such, the embodiments of the present disclosure can provide secure sealing between the detachable crucible 110 and the distribution assembly 160.

Fig. 4 shows a cross-sectional side view of a connecting structure between a crucible and a distribution assembly of a material deposition arrangement according to another embodiment of the present disclosure, and Fig. 5 shows an exploded perspective view of the connecting structure between the crucible and the distribution assembly of the material deposition arrangement according to the other embodiment of the present disclosure.

With exemplary reference to Figs. 4 and 5, according to embodiments which can be combined with any other embodiments described herein, a first recess 128 of a ring shape is formed on the upper surface 125 of the first flange 124, and a second recess 178 of a ring shape is formed on the lower surface 175 of the second flange 174.

A first molybdenum ring 129 is seated in the first recess 128, and is welded to the first flange 124 in the first recess 128. Similarly, a second molybdenum ring 179 is seated in the second recess 178, and is welded to the second flange 174 in the second recess 178. Welding may be performed, for example, by electron beam welding (EBW).

The first and second molybdenum rings 129 and 179 serve as the first and second molybdenum-containing

regions

127 and 177 described above. The first and second molybdenum rings 129 and 179 may consist essentially of molybdenum (Mo), or may be formed of an alloy containing molybdenum (Mo), for example a lanthanated molybdenum (Mo-La) alloy.

The employment of the first and second molybdenum rings 129 and 179 provides freedom in selecting materials for the crucible 110 and the distribution assembly 160, in particular for the first and

second flanges

124 and 174. For instance, the materials for the crucible 110 and the distribution assembly 160 may not contain molybdenum (Mo). This may allow the crucible 110 and the distribution assembly 160 to be formed of a material that provides more thermal/mechanical stability. For example, the crucible 110 and the distribution assembly 160 may be formed of tantalum (Ta) or tungsten (W), or of an ally containing one or more of tantalum (Ta) or tungsten (W).

A first sealing ring 140 is placed on the upper surface 125 of the first flange 124, in particular on the first molybdenum ring 129, and a second sealing ring 190 is placed under the lower surface 175 of the second flange 174, in particular under the second molybdenum ring 179. The first sealing ring 140 and the second sealing ring 190 are formed of a material having chemical stability and non-wettability to the source material 50. For instance, the first sealing ring 140 and the second sealing ring 190 may be formed of glassy carbon.

Molybdenum (Mo) in the first molybdenum ring 129 and carbon in the first sealing ring 140 react to each other at a temperature of about 1,000°C or above to form molybdenum carbide (Mo_xC_y). Likewise, molybdenum (Mo) in the second molybdenum ring 179 and carbon in the second sealing ring 190 react to each other at a temperature of about 1,000°C or above to form molybdenum carbide (Mo_xC_y) at the interface therebetween. As a result, the gaps between the upper surface 125 of the first flange 124 and the first sealing ring 140 and between the lower surface 175 of the second flange 174 and the second sealing ring 190 can be completely sealed.

In addition, the first sealing ring 140 comprises one or more ring-shaped bumps 143 protruding from the upper surface 141 of the first sealing ring 140. Although Figs. 4 and 5 show bumps 143 formed only on the upper surface 141 of the first sealing ring 140, the ring-shaped bumps may instead be formed on the lower surface 191 of the second sealing ring 190, or both on the upper surface 141 of the first sealing ring 140 and the lower surface 191 of the second sealing ring 190.

A ring-shaped gasket layer 153 is placed between the first sealing ring 140 and the second sealing ring 190. The inner diameter of the gasket layer 153 is substantially the same as the inner diameter of the first sealing ring 140 and the second sealing ring 190. The outer diameter of the gasket layer 153 is substantially the same as or larger than the outer diameter of the first sealing ring 140 and the second sealing ring 190. In an embodiment, the outer diameter of the gasket layer 153 is substantially the same as the outer diameter of the first flange 124 and the second flange 174.

The gasket layer 153 is formed of a softer material than those of the first sealing ring 140 and the second sealing ring 190, in order to more securely seal any gaps that may be caused by the surfaces, which are not perfectly even, of the first sealing ring 140 and the second sealing 190 formed of a relatively rigid material. The gasket layer 153 is formed of a material having thermal/mechanical stability at a temperature for evaporating the source material and also having chemical stability and non-wettability against the source material. According to an embodiment that can be combined with any other embodiments described herein, the gasket layer 153 may comprise a graphite gasket, such as a plurality of staked graphite foils.

The gasket layer 153 can provide a more hermetic seal between the first sealing ring 140 and the second sealing ring 190 when the first sealing ring 140 and the second sealing ring 190 are clamped and pressed against each other by a fastener, for example by a bolt 156 and a nut 157. For instance, the gasket layer 153 formed of graphite foils more perfectly seal the gaps that may exist between the surfaces of the first sealing ring 140 and the second sealing ring 190 formed of relatively rigid glassy carbon. Furthermore, the plurality of ring-shaped bumps 143 formed on the upper surface 141 of the first sealing ring 140 apply even greater pressure to the gasket layer 153, thereby increasing the sealing performance of the gasket layer 153.

A first spacer 151 is placed on a radially outer side of the first sealing ring 140, and a second spacer 159 is placed on a radially outer side of the second sealing ring 190. The first spacer 151 and the second spacer 159 are configured to prevent deformation and breakage of the first flange 124 and the second flange 174 due to thermal expansion thereof. In an embodiment, the first spacer 151 and the second spacer 159 may be formed of an alloy comprising tungsten, such as tungsten-cerium oxide (WC), tungsten-lanthanum oxide (WL), tungsten-lanthanum oxide-zirconium oxide (WLZ), tungsten-rhenium (WRe), or tungsten-copper (WCu).

The first flange 124 and the second flange 174 may be clamped by a fastener, for example by a bolt 156 and a nut 157. For instance, a through hole is formed in each of the first flange 124, first spacer 151, gasket layer 153, second spacer 159, and second flange 174 for the bolt 156 to pass through, and the bolt 156 passes through from the upper side of the second flange 174 to the lower side of the first flange 124. The nut 157 is then fastened to an end of the bolt 156 that has passed through the lower side of the first flange 124, thereby clamping the first flange 124 and the second flange 174.

Fig. 6 shows a flow chart illustrating a method for manufacturing a material deposition arrangement in accordance with a further aspect of the present disclosure. The material deposition arrangement may be the material deposition arrangement 100 in accordance with the embodiments described herein.

A method 600 comprises providing a crucible 110 having a first flange 124 comprising a first molybdenum-containing region 127 on at least an upper surface 125 thereof (block 610). According to an embodiment that can be combined with any other embodiments described herein, providing a crucible 110 having a first flange 124 comprising a first molybdenum-containing region 127 at least on an upper surface 125 thereof (block 610) may comprise providing the crucible 110 having the first flange 124 with a first recess 128 of a ring shape formed on the upper surface 125 and welding a first molybdenum ring 129 into the first recess 128.

The method 600 further comprises placing a first sealing ring 140 on the upper surface 125 of the first flange 124 (block 620). The first sealing ring 140 and the first molybdenum-containing region 127 make direct contact with each other on at least a region, wherein the contact region completely encircles a first opening 132 of the crucible 110.

The method 600 further comprises placing a first spacer 151 on a radially outer side of the first sealing ring 140 (block 630), placing a gasket layer 153 on the first sealing ring 140 (block 640), placing a second sealing ring 190 on the gasket layer 153 (block 650), and placing a spacer 159 on a radially outer side of the second sealing ring 190 (block 660).

Furthermore, the method 600 comprises providing a distribution assembly 160 having a second flange 174 comprising a second molybdenum-containing region 177 at least on a lower surface 175 thereof (block 670). According to an embodiment that can be combined with any other embodiments described herein, the providing a distribution assembly 160 having a second flange 174 comprising a second molybdenum-containing region 177 on at least a lower surface 175 thereof (block 670) may comprise providing the distribution assembly 160 having the second flange 174 with a second recess 178 of a ring shape formed on the lower surface 175 and welding a second molybdenum ring 179 into the second recess 178.

The method 600 further comprises aligning the first flange 124 of the crucible 110 with the second flange 174 of the distribution assembly 160 and clamping the first flange 124 and the second flange 174 together using a fastener (block 680).

Further, the method 600 further comprises heating the crucible 110 to form molybdenum carbide between the first molybdenum-containing region 127 and the first sealing ring 140 and between the second molybdenum-containing region 177 and the second sealing ring 190 (block 690).

In light of the embodiments described herein, it will be appreciated that a material deposition arrangement, a vacuum deposition system, and a method for manufacturing a material deposition arrangement that are improved is provided, particularly for OLED manufacturing.

Embodiments of the material deposition arrangement described herein provide improved sealing performance with respect to evaporated metallic materials at a temperature of about 1,000°C or above, or of about 1,500°C or above. Moreover, the embodiments of the material deposition arrangement described herein still maintain a possibility of detaching the crucible from the distribution assembly even after a material deposition process. In this way, the embodiments of the material deposition arrangement described herein provide convenience in feeding and refilling materials to be deposited and in maintenance of the crucible of the material deposition arrangement.

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.

In particular, this written description uses examples to disclose the disclosure, including the best mode, and also to enable any person skilled in the art to practice the described subject-matter, including making and using any devices or systems and performing any incorporated methods. While various specific embodiments have been disclosed in the foregoing, mutually non-exclusive features of the embodiments described above may be combined with each other. The patentable scope is defined by the claims, and other examples are intended to be within the scope of the claims if the claims have structural elements that do not differ from the literal language of the claims, or if the claims include equivalent structural elements with insubstantial differences from the literal language of the claims.

Claims

A material deposition arrangement comprising:

a crucible having an inner volume for receiving a material and a first flange;

a distribution assembly having an inner hollow space and a second flange to be fastened to the first flange; and

first and second sealing rings interposed between the first flange and the second flange,

wherein the first flange comprises a first molybdenum-containing region in at least a region of an upper surface,

wherein the second flange comprises a second molybdenum-containing region in at least a region of a lower surface,

wherein the first sealing ring is in contact with the first molybdenum-containing region,

wherein the second sealing ring is in contact with the second molybdenum-containing region, and

wherein at least surfaces of the first sealing ring and the second sealing ring comprise a carbon material.
The material deposition arrangement of claim 1,

wherein at least the surfaces of the first sealing ring and the second sealing ring are formed of glassy graphite.
The material deposition arrangement of claim 1,

wherein the first sealing ring and the second sealing ring have a substantially identical shape, and the second sealing ring is placed on the first sealing ring.
The material deposition arrangement of claim 1,

wherein at least one of the first molybdenum-containing region or the second molybdenum-containing region consists essentially of molybdenum (Mo), or is formed of an alloy containing at least 50% by weight of molybdenum.
The material deposition arrangement of claim 1,

wherein the first molybdenum-containing region comprises a molybdenum ring disposed within a ring-shaped recess formed on the upper surface of the first flange.
The material deposition arrangement of claim 1,

wherein the second molybdenum-containing region comprises a molybdenum ring disposed within a ring-shaped recess formed on the lower surface of the second flange.
The material deposition arrangement of claim 1, further comprising:

a gasket layer disposed between the first sealing ring and the second sealing ring,

wherein the gasket layer is formed of a carbon material.
The material deposition arrangement of claim 7,

wherein the gasket layer comprises at one layer of a graphite foil.
The material deposition arrangement of claim 1,

wherein at least one bump protruding in a ring shape is formed on at least one of the upper surface of the first sealing ring or the lower surface of the second sealing ring.
The material deposition arrangement of claim 1, further comprising:

at least one spacer arranged on a radially outer side of the first sealing ring and the second sealing ring.
A material deposition arrangement comprising:

a crucible configured to evaporate a material through an opening;

a distribution assembly configured to discharge the evaporated material through a plurality of nozzles; and

first and second carbon layers interposed between the crucible and the distribution assembly,

wherein the crucible comprises a first flange around the opening,

wherein the distribution assembly comprises a second flange at a connecting portion with the crucible,

wherein the first flange comprises a first molybdenum layer on at least a portion of a surface of the first flange,

wherein the second flange comprises a second molybdenum layer on at least a portion of a surface of the second flange, and

wherein the first carbon layer is in contact with the first molybdenum layer, and the second carbon layer is in contact with the second molybdenum layer.
A vacuum deposition system comprising:

a vacuum deposition chamber; and

a material deposition arrangement according to any of claims 1 to 11, in the vacuum deposition chamber.
A method for manufacturing a material deposition arrangement comprising:

providing a crucible having a first flange comprising a first molybdenum-containing region on at least an upper surface, wherein the first molybdenum-containing region consists essentially of molybdenum (Mo), or is formed of an alloy containing at least 50% by weight of molybdenum;

placing a first sealing ring on the upper surface of the first flange, wherein at least surfaces of the first sealing ring are formed of a carbon material;

placing a second sealing ring on the first sealing ring, wherein at least surfaces of the second sealing ring are formed of a carbon material; and

placing, on the second sealing ring, a distribution assembly having a second flange comprising a second molybdenum-containing region on at least a lower surface, wherein the second molybdenum-containing region consists essentially of molybdenum (Mo), or is formed of an alloy containing at least 50% by weight of molybdenum.
The method of claim 13,

wherein providing the crucible comprises:

providing a crucible having a first flange with a first ring-shaped recess formed on a upper surface of the first flange; and

welding a first molybdenum ring into the first recess.
The method of claim 13, further comprising:

placing a gasket layer between the first sealing ring and the second sealing ring,

wherein the gasket layer comprises at least one layer of a graphite foil.