Manufacturing device for mask unit

A manufacturing device for mask unit having a mask frame and a mask fixed to the mask frame includes a stage including a frame holding stage, and an alignment stage arranged with a plurality of lift-pins, a holding part for holding a reference plate arranged facing the stage, a mask holding unit, the mask holding unit being arranged between the stage and the reference plate, and a camera for imaging a direction of the stage passing through the reference plate, wherein the mask holding unit holds the mask at a surface on the frame side, the mask holding unit rises and falls above the alignment stage by the plurality of the lift-pins, the plurality of lift-pins includes a plurality of first lift-pins capable of contacting the mask holding unit, and the camera images a first reference marker on the mask and a second reference marker on the reference plate.

CROSS REFERENCE TO RELATED APPLICATIONS

This application is based upon and claims the benefit of priority from the prior Japanese Patent Application No. 2018-139301, filed on Jul. 25, 2018, the entire contents of which are incorporated herein by reference.

FIELD

An embodiment of the present invention is related to a manufacturing device of a mask unit in which a mask is fixed to a frame.

BACKGROUND

A light emitting element is arranged in each pixel of a display device and an image is displayed by individually controlling emitted light. For example, in an organic EL display which uses an organic EL element as a light emitting element, an organic EL element is arranged in each pixel, and the organic EL element has a structure in which a layer (referred to as “organic EL layer” below) including an organic EL material is sandwiched between a pair of electrodes consisting of an anode electrode and a cathode electrode. The organic EL layer is formed from functional layers such as a light emitting layer, an electron injection layer and a hole injection layer, and it is possible to emit light of colors of various wavelengths by selecting these organic materials.

A vapor deposition method is used in the formation of a thin film of an organic EL element which uses a low molecular weight compound as a material. In the vapor deposition method, a vapor deposition material is heated and sublimated by a heater, and a thin film is formed by vapor deposition on the surface of a substrate. At this time, a fine thin film pattern is formed through an opening of a mask using a mask which is arranged with a large number of fine opening patterns.

The mask is used as a mask unit which is fixed to frame having rigidity. For example, Japanese Laid-Open Patent Application No. 2006-265712 discloses a method of fixing a mask having a region which is extremely thin and different in rigidity to a frame in a flat state with no distortion or sag by holding a mask arranged with a region which is extremely thin and has differences in rigidity with tension using a plurality of clamps.

SUMMARY

A manufacturing device for mask unit having a mask frame and a mask fixed to the mask frame related to one embodiment of the present invention includes a stage including a frame holding stage for holding the frame, and an alignment stage arranged with a plurality of lift-pins, a holding part for holding a reference plate arranged facing the stage, a mask holding unit for holding the mask, the mask holding unit being arranged between the stage and the reference plate, and a camera for imaging a direction of the stage passing through the reference plate, wherein the mask holding unit holds the mask at a surface on the frame side, the mask holding unit rises and falls above the alignment stage by the plurality of the lift-pins, the plurality of lift-pins includes a plurality of first lift-pins capable of contacting the mask holding unit, and the camera images a first reference marker formed on the mask and a second reference marker formed on the reference plate.

DESCRIPTION OF EMBODIMENTS

The embodiments of the present invention are explained below while referring to the drawings. However, the present invention can be implemented in many different modes without and should not to be interpreted as being limited to the description of the embodiments exemplified below. Although the drawings may be schematically represented in terms of width, thickness, shape, and the like of each part as compared with their actual mode in order to make explanation clearer, it is only an example and an interpretation of the present invention is not limited. In addition, in the present specification and each drawing, the same symbols (or symbols attached with a, b and the like after a numeral) are provided to the same elements as those described above with reference to preceding figures and a detailed explanation may be omitted accordingly. Furthermore, characters attached with [first] and [second] to each element are convenient symbols used in order to distinguish each element and do not have any further meaning unless otherwise explained.

In the present specification, in the case where certain parts or regions are given as “above (or below)” other parts or regions, as long as there is no particular limitation, these include parts which are not only directly above (or directly below) other parts or regions but also in an upper direction (or lower direction). That is, this includes the case where other structural elements may be included between other parts or regions in an upper direction (or lower direction). Furthermore, in the explanation herein, unless otherwise stated, in a cross-sectional view, a side on which a camera is arranged with respect to a stage is referred to as “above” or “upper”, and a surface seen from “above” or “upper” is referred to as “top surface” or “upper surface side” and the reverse is referred to as “below”, “under”, “bottom” surface or “bottom surface side”.

In the explanation herein, when the directions D1, D2and D3are shown in a diagram, the direction D1and the direction D2intersect and the directions D1and D2intersect the direction D3.

FIRST EMBODIMENT

<Schematic Structure of Mask Unit>

FIG. 1AandFIG. 1Bshow a schematic structure of a mask unit100related to one embodiment of the present invention.FIG. 1Ais a planar view diagram of the mask unit100.FIG. 1Bis a cross-sectional diagram of the line A-A′ inFIG. 1A.

The mask unit100related to the present embodiment is arranged with a mask110and a frame120. The mask110includes a mask pattern part112. The mask pattern part112has a plurality of fine opening patterns (film formation patterns), and a fine thin film pattern is formed via the mask pattern part112which is used for vapor deposition. The shape and arrangement of the mask pattern part112are arbitrary, and for example, elongated slit shaped openings can be arranged in parallel, and rectangular openings can be arranged longitudinally and also in parallel. For example, in the case where a plurality of display panels is manufactured above one substrate, the mask110includes a mask pattern part112corresponding to a film formation pattern at each position corresponding to the plurality of display panels. Therefore, by using the mask unit100related to the present embodiment, it is possible to collectively form a thin film formed from a low molecular weight compound with respect to a plurality of display panels. In the present embodiment, the mask110has a rectangular mask pattern part112on substantially the entire surface at a position corresponding to a display panel. However, the present invention is not limited to this embodiment and the mask pattern part112can have an arbitrary shape in accordance with a film formation pattern. The mask110can use, for example, a film shaped metal having a thickness of 3 μm to 20 μm formed from a magnetic metal such as nickel, a nickel alloy or invar. It is more preferable that the mask110is a metal film (metal sheet) arranged with invar characteristics which has a small thermal expansion coefficient and is not easily affected by heat. The mask110may also be arranged with regions which have different thicknesses.

In the present embodiment, the mask110has a rectangular shape and first reference marks114are provided at the four corners. This is an alignment mark on the mask side which is used for alignment between a reference plate and the mask110when manufacturing the mask unit100described herein. In addition, it can also be used for alignment between a substrate which serves as a vapor deposition object and the mask unit100at the time of vapor deposition.

The mask110is fixed to the frame120at a fixing point116by spot welding or the like. The mask110includes a plurality of fixed points116at an outer periphery thereof. The plurality of fixed points116are preferably formed at least on one side of the mask110and on the opposite side. Forming the plurality of fixed points116on each of the four sides of the mask110is more preferable. The frame120is a frame shaped member which holds the outer periphery part of the mask110and is formed from a material having a small thermal expansion coefficient such as Invar for example. The frame120has at least openings122at positions which correspond to a plurality of display panels of the mask110. That is, in a planar view, the mask pattern part112of the mask110is arranged on the inner side of the opening122of the frame120. The external size of the mask110is larger than the radius of the opening122of the frame120and smaller than the external size of the frame120. In the present embodiment, two masks110are arranged in one frame120. In addition, 12 fixed points116are formed for each mask112. However, the present invention is not limited to this embodiment and the number of masks110and fixed points116can be set to any number.

As is shown inFIG. 1B, the mask110includes a first surface110awhich faces the object to be formed, and a second surface110bwhich contacts the frame120on the opposite side to the first surface110a. The first surface110aof the mask110is preferred to be substantially flat. On the other hand, the second surface110bof the mask110may also have a concave/convex structure. By providing the second surface110bof the mask110with a concave/convex structure, it becomes easier to remove any attached matter by cleaning at the time of maintenance of the mask110.

Next, a manufacturing method and a manufacturing device of the mask unit100are explained.FIG. 2AandFIG. 2Bshow a schematic structure of a mask unit manufacturing device200related to one embodiment of the present invention.FIG. 2Ais a top view diagram of the mask unit manufacturing device200.FIG. 2Bis a side view diagram of the mask unit manufacturing device200.

The mask unit manufacturing device200related to the present embodiment is arranged with a stage210, a mask holding unit220, a support234for supporting a reference plate230and a camera240. The stage210has a flat surface in the direction D1-D2. The mask holding unit220is arranged on the surface of the stage210. In the present embodiment, two mask holding units220are arranged on one stage210. However, the present invention is not limited to this number and the number of mask holding units220may also correspond to the number of mask110. In a planar view, the area of the mask holding unit220is smaller than the area of the stage210.

In the present embodiment, the mask holding unit220holds the first surface110aof the mask110from the opposite side (reverse direction of D3) to the stage210of the mask110using magnetism. As a result, the mask holding unit220is arranged with a magnetic field generator220aand a contact plate220b. In the present embodiment, the magnetic field generator220ais an electromagnet. Since the magnetic field generator220ais an electromagnet, it has a function for controlling at least two states, a state in which a magnetic force is applied and a state in which a magnetic force is not applied to a mask by an electrical or mechanical method. However, the present invention is not limited to this embodiment, and a permanent magnet may also be used as the magnetic field generator220ainstead of an electromagnet. The mask holding unit220holds the mask110on the stage210side of the mask holding unit220. Therefore, the contact plate220bis arranged on the side of the stage210which is in contact with the mask110of the mask holding unit220. The contact plate220bcan be formed using a plate shaped material such as stainless steel or invar with a thickness of 1 mm to 50 mm for example. It is more preferable that the contact plate220bis formed from a material having a small thermal expansion coefficient. By using a material with a small thermal expansion coefficient for the contact plate220b, it is possible to suppress misalignment between the mask110and the frame120due to a temperature change over time when manufacturing the mask unit100. However, the present invention is not limited to this embodiment and as long as the contact plate220bmay be substantially flat and may pass the magnetic force of the magnetic field generator220a. Furthermore, the contact plate220bis arranged with an opening222bat a position of a fixing point116in order to enable welding of the mask110and the frame120described herein. Although an example in which the mask holding unit220includes the magnetic field generator220aand the contact plate220bis shown in the present embodiment, the present invention is not limited to this example, and the contact plate220bmay be omitted. In addition, the magnetic field generator220aand the contact plate220bmay also be formed as an integral unit. When the magnetic field generator220aand the contact plate220bare not distinguished from one another, they are called a mask holding unit220. By adopting this structure, it is possible for the mask holding unit220to hold the first surface110aof the mask110flat in a reverse direction of D3.

A support part234which supports the reference plate230is arranged on the opposite side to the stage210of the mask holding unit220(the direction D3intersecting the direction D1-D2). The support part234detachably supports the reference plate230. The reference plate230can be installed in advance in the mask unit manufacturing device200, or can be appropriately installed in the support part234according to the specifications of the mask unit. The area of the reference plate230is larger than the area of the mask holding unit220in a planar view. A second reference mark232corresponding to the first reference mark114of the mask110is arranged in the reference plate230. These are alignment marks on the side of the reference plate230which are used for alignment between the reference plate230and the mask110when the mask unit100is manufactured as is described herein. The second reference mark232of the reference plate230is arranged further in the direction D1or in the reverse direction D1than a position corresponding to the mask holding unit220. That is, when seen in a planar view, the second reference mark232of the reference plate230is outside in the direction D1or the reverse direction D1than the mask holding unit220. In the present embodiment, the material of the reference plate230is a plate shaped glass with a thickness of 4 mm to 20 mm. However, the present invention is not limited to this embodiment as long as the reference plate230may have permeability. It is more preferable that the material of reference plate230having a small thermal expansion coefficient. When the reference plate230is a material having a small thermal expansion coefficien, it is possible to suppress a misalignment of the second reference mark232due to a temperature change over time when the mask unit100is manufactured.

The camera240is arranged at a position which corresponds to the second reference mark232on the opposite side of the stage210of the reference plate230(direction D3). The camera240images the position of the second reference mark232and the first reference mark114through the reference plate230when aligning the reference plate230and the mask110.

Next, the structure of the stage210is explained in more detail.FIG. 3AandFIG. 3Bshow the structure of a stage of the mask unit manufacturing device related to one embodiment of the present invention.FIG. 3Ais a top view diagram of the stage210.FIG. 3Bis a top view diagram of the stage210arranged with the frame120.

The stage210of the mask unit manufacturing device200related to the present embodiment is arranged with an alignment stage210aand a frame holding stage210b. The stage210in the present embodiment is arranged with two rectangular shaped alignment stages210aand one frame shaped frame holding stage210bwhich surrounds the alignment stages210a. However, the number of alignment stages210ais not limited and may correspond to the number of masks110. The number of frame holding stage210bis also not limited and may correspond to the number of frame holding stages210b.

The frame holding stage210bincludes a plane in the direction D1-D2and holds the frame120described herein. The frame120is fixed to the mask unit manufacturing device200in parallel with the D1-D2plane by the frame holding stage210b.

The two alignment stages210acan each move independently in the D1-D2plane direction (including a rotational direction) with respect to the frame holding stage210b. There is a gap between the alignment stage210aand the frame holding stage210b, so that the alignment stage210acan move with respect to the frame holding stage210bwithin the range of the gap.

The alignment stage210ais arranged with a plurality of first lift pins250and a plurality of second lift pins260. In the alignment stage210a, the plurality of first lift pins250can be arranged on the outer side of the frame120and can contact the mask holding unit220when moving up and down in the direction D3. A magnet or the like may also be arranged at the tip end of the plurality of first lift pins250in contact with the contact plate220bin order to stably hold the contact plate220b. In the alignment stage210a, the plurality of second lift pins260can be arranged on the inner side of the opening122of the frame120and can contact the mask110described herein when the plurality of second lift pins260move up and down in the direction D3. A magnet or the like may also be arranged at the tip end of the plurality of second lift pins260in contact with the mask110in order to stably hold the mask110. By adopting this structure, the mask holding unit220and the mask110can move parallel with respect to the frame120(the rotational direction with the plane direction D1-D2and the direction D3as axes) using the alignment stage210a, the first lift pins250and the second lift pins260. The position and movement of the plurality of first lift pins250and the plurality of second lift pins260are explained in detail herein.

According to the manufacturing device of the mask unit100in the present embodiment, it is possible to align a mask with high accuracy and fix the mask to a frame by the alignment stage210a, the first lift pins250and the second lift pins260.

<Operation of Mask Unit Manufacturing Device and Manufacturing Method of Mask Unit>

FIG. 4AtoFIG. 9Bshow a manufacturing method of a mask unit related to one embodiment of the present invention.FIG. 4Ais a top view diagram of the mask unit manufacturing device200in a state when the mask holding unit220is raised.FIG. 4Bis a side view diagram of the mask unit manufacturing device200in the same state.

As is shown inFIG. 4AandFIG. 4B, the stage210(alignment stage210a) is arranged with a plurality of first lift pins250. The first lift pins250move up from the alignment stage210ain the direction D3and contact the contact plate220bof the mask holding unit220. Furthermore, the first lift pins250raise the mask holding unit220whereby a space is formed between the stage210and the mask holding unit220. In the present embodiment, the first lift pins250are arranged along the direction D1at one end of the alignment stage210ain the direction D2and at opposite end respectively. The plurality of first lift pins250move up and down in synchronization in the direction D3from the alignment stage210a. By adopting this structure, the first lift pins250can be arranged on the outer side of the frame120described herein, and can raise the mask holding unit220parallel to the D1-D2plane in the direction D3.

FIG. 5Ais a top view diagram of the mask unit manufacturing device200in a state when the frame120is put on the stage210.FIG. 5Bis a side view diagram of the mask unit manufacturing device200in the same state.

As is shown inFIG. 5AandFIG. 5B, the frame120is put between the stage210and the mask holding unit220of the mask unit manufacturing device200. The frame120is put into the space which is surrounded by the stage210, the plurality of first lift pins250and the mask holding unit220from the direction D1. That is, the outer dimensions of the contact plate220bof the mask holding unit220are larger than the outer dimensions of the frame120in the direction D2.

The frame120is arranged at a position where the opening122of the frame120corresponds to the magnetic field generator220aof the mask holding unit220by an alignment mechanism (not shown in the diagram). That is, when seen in a planar view, the magnetic field generator220aof the mask holding unit220is arranged in the opening122of the frame120. When seen in a planar view, the magnetic field generator220aand the contact plate220bof the mask holding unit220expose the position of the fixing point116in order to be able to weld at least the mask110and the frame120described herein. In addition, the mask holding unit220is located at a position where at least the mask110and the frame120overlap each other in a planar view. It is preferred that a part of mask holding unit220is larger than the opening122so that the mask110is pressed so as to adhere to the frame120in a region except the fixing point116. The inserted frame120is fixed to the frame holding stage210busing a clamp or a magnet.

FIG. 6Ais a top view diagram of the mask unit manufacturing device200in a state in where the mask110is transported between the frame120and the mask holding unit220.FIG. 6Bis a side view diagram of the mask unit manufacturing device200in the same state.

As is shown inFIG. 6AandFIG. 6B, the mask110is inserted between the frame120which is held by the frame holding stage210band the mask holding unit220. The mask110is inserted into the space which is surrounded by the frame120, the plurality of first lift pins250and the mask holding unit220from the direction D1. That is, the outer dimensions of the contact plate220bof the mask holding unit220are larger than the outer dimensions of the mask110in the direction D2. When seen in a planar view, the mask110is arranged so as to cover the opening122of the frame120. The area of the magnetic field generator220aof the mask holding unit220is smaller than the area of the mask110. In addition, the outer dimensions of the magnetic field generator220aof the mask holding unit220are smaller than the outer dimensions of the mask110. The mask pattern part112of the mask110is arranged at a position which corresponds to the magnetic field generator220aof the mask holding unit220. That is, when seen in a planar view, the mask pattern part112of the mask110is arranged at the position of the magnetic field generator220aof the mask holding unit220. In addition, the outer dimensions of the contact plate220bof the mask holding unit220may be smaller than the outer dimensions of the mask110in the direction D1. When seen in a planar view, the magnetic field generator220aand the contact plate220bof the mask holding unit220expose the position of the fixing point116in order to be able to weld of at least the mask110and the frame120described herein.

The first reference mark114of the mask110is arranged further in the direction D1and the reverse direction D1than the position which corresponds to the mask holding unit220. That is, when seen in a planar view, the magnetic field generator220aand the contact plate220bof the mask holding unit220expose at least the first reference mark114of the mask110.

FIG. 7Ais a top view diagram of the mask unit manufacturing device200in a state when the mask holding unit220is lowered to a position where the mask110can be adsorbed.FIG. 7Bis a side view diagram of the mask unit manufacturing device200in the same state.

The transported mask110is held by the mask holding unit220. As is shown inFIG. 7AandFIG. 7B, the mask holding unit220drops in the reverse direction D3by lowering of the first lift pins250. Here, the contact plate220bof the mask holding unit220contacts the first surface110aof the mask110. That is, the mask110contacts the stage210side of the contact plate220b. The mask holding unit220holds the mask110from the first surface110aside (reverse direction of D3) via the contact plate220bby the magnetic force of the magnetic field generator220a. As a result, it is preferred that the contact plate220band the first surface110aof the mask110are substantially flat. By adopting this structure, it is possible for the mask holding unit220to hold the mask110substantially flat. Since it is not necessary to apply tension to make the mask110flat, it is possible to reduce problems such as distortion of the mask110caused by tension. In addition, since it is not necessary to hold the mask110in the direction D1-D2, it is possible to save space and tile of a plurality of masks.

FIG. 8Ais a top view diagram of the mask unit manufacturing device200in a state where the mask holding unit220lifts the mask110by adsorption.FIG. 8Bis a side view diagram of the mask unit manufacturing device200in the same state.

As is shown inFIG. 8AandFIG. 8B, the first lift pin250moves upwards in the direction D3from the alignment stage210aand the mask holding unit220is raised. Furthermore, the stage210(alignment stage210a) is arranged with a plurality of second lift pins260. The second lift pins260move up from the alignment stage210ain the direction D3and contact the mask110. Furthermore, the second lift pins260raise the mask110thereby forming a space between the stage210and the mask110. The second lift pins260are arranged in an area other than a position corresponding to the mask pattern portion112of the mask110in order to contact the mask110. The second lift pins260are preferably arranged in an area other than a position which corresponds to the display panel of the mask110. In the present embodiment, the second lift pins260are arranged between the plurality of first lift pins250. The second lift pins260are arranged in the opening122of the frame120. The plurality of first lift pins250and the plurality of second lift pins260move up and down in synchronization in the direction D3from the alignment stage210a.

Furthermore, it is possible for the first lift pins250to move in the direction of D1-D2on the outer side of the frame120. It is possible for the second lift pins260to move in the D1-D2plane direction on the inner side of the opening122of the frame120. The plurality of first lift pins250and the plurality of second lift pins260move in synchronization with the alignment stage210ain the D1-D2plane direction. By adopting this structure, it is possible for the alignment stage210a, the first lift pins250and the second lift pins260to integrally rotate the mask holding unit220and the mask110in the D1-D2plane surface direction or the reverse direction D3.

The first lift pins250contact the mask holding unit220, and the second lift pins260contact the mask110. As a result, when the first lift pins250and the second lift pins260move up, the tip end of the first lift pins250are higher than the tip end of the second lift pins260by the thickness of the mask110in the direction D3. That is, range by which the first lift pins250move up with respect to the alignment stage210ais larger than the range by which the second lift pins260move up with respect to the alignment stage210a. The first lift pins250and the second lift pins260maintain this difference in height when they move up and down in synchronization in the direction D3from the alignment stage210adescribed above and when moving in synchronization in the plane direction D1-D2. By adopting this structure, the alignment stage210a, the first lift pins250and the second lift pins260can integrally move the mask holding unit220and the mask110in direction D3, in the plane direction D1-D2and in a rotation direction with the direction D3as axes in parallel with the frame120(plane direction D1-D2). In addition, the mask holding unit220and the second lift pins260can maintain the mask110substantially flat.

The camera240images the positions of the second reference mark232and the first reference mark114in order to align the reference plate230and the mask110. The alignment stage210a, the first lift pins250and the second lift pins260move the mask holding unit220and the mask110in the plane direction D1-D2and thereby alignment of the second reference mark232of the reference plate230and the first reference mark114of the mask110is performed. Here, the alignment stage210a, the first lift pins250and the second lift pins260can function as an alignment means. By adopting this structure, it is possible for the camera240, the alignment stage210a, the first lift pins250and the second lift pins260to align the second reference mark232and the first reference mark114with high accuracy.

FIG. 9Ais a top view diagram of the mask unit manufacturing device200in which the mask110and the mask holding unit220are lowered and the mask110is welded to the frame120.FIG. 9Bis a side view diagram of the mask unit manufacturing device200in which the mask110and the mask holding unit220are lowered and the mask110is welded to the frame120.

As is shown inFIG. 9AandFIG. 9B, when the positions of the second reference mark232and the first reference mark114are aligned, the first lift pin250and the second lift pin260are lowered in the reverse direction D3of the alignment stage210aand the mask holding unit220and the mask110are lowered. The plurality of first lift pins250and the plurality of second lift pins260move down in synchronization in the reverse direction D3of the alignment stage210a. By adopting this structure, the first lift pin250and the second lift pin260can integrally lower the mask holding unit220and the mask110in parallel to the plane direction D1-D2in the reverse D3direction. In addition, it is possible for the mask holding unit220and the second lift pins260to maintain the mask110substantially flat.

The alignment mask110is fixed to the frame120by a welder270. The mask110is spot welded to the frame120at a fixed point116using a laser of the welder270. The outer dimensions of the contact plate220bof the mask holding unit220in the direction D2are larger than the outer dimensions of the frame120. As a result, welding of the mask110and the frame120may be carried out via the opening222bof the contact plate220b. The mask110which is welded to the frame120is subsequently removed from the mask unit manufacturing device200and thereby a mask unit100is provided which can be used for vapor deposition.

According to the manufacturing method of the mask unit100in the present embodiment, it is possible to fix a mask to a frame with a higher degree of accuracy by holding the mask110substantially flat from the side opposite to the stage210using the mask holding unit220.

Second Embodiment

The structure of the mask unit related to the present embodiment is the same as the structure of the mask unit related to the first embodiment. In the manufacturing method of the mask unit related to the present embodiment, instead of raising the mask110and the mask holding unit220using the plurality of first lift pins250and the plurality of second lift pins260(refer toFIG. 8AandFIG. 8B), the mask110and the mask holding unit220are raised by the first lift pins250(refer toFIG. 10AandFIG. 10B). The remaining structure is the same as the manufacturing method of the mask unit related to the first embodiment. An explanation which is the same as the first embodiment is omitted, and parts which are different from the manufacturing method of the mask unit related to the first embodiment are explained.

<Operation of Mask Unit Manufacturing Device and Manufacturing Method of Mask Unit>

FIG. 10Ais a top view diagram of the mask unit manufacturing device200in which the mask110and the mask holding unit220are raised.FIG. 10Bis a side view diagram of the mask unit manufacturing device200in which the mask110and the mask holding unit220are raised.

As is shown inFIG. 10AandFIG. 10B, the first lift pins250move up from the alignment stage210ain the direction D3and contact the contact plate220bof the mask holding unit220. The first lift pins250raise the mask holding unit220. In the present embodiment, the mask holding unit220holds the mask110from the first surface110aside by the magnetic force of the magnetic field generator220aeven without the support of the second lift pins260. That is, the mask110is raised integrally with the mask holding unit220together with the rising of first lift pins250from the alignment stage210a.

Furthermore, it is possible for the first lift pins250to move in the plane direction D1-D2on the outer side of the frame120. The plurality of first lift pins250move in synchronization with the alignment stage210ain the plane direction D1-D2. It is possible for the alignment stage210aand the first lift pins250to integrally move the mask holding unit220and the mask110in the plane direction D1-D2.

By adopting this structure, the alignment stage210aand the first lift pins250can integrally move the mask holding unit220and the mask110in direction D3, in parallel to the plane direction D1-D2and in parallel to a rotation direction with the direction D3as axes.

According to the manufacturing method of the mask unit100of the present embodiment explained above, for example, even if the second surface110bof the mask110has a concave/convex structure, it is possible to align the mask with a high degree of accuracy and fix the mask to a frame.

Third Embodiment

The structure of the mask unit related to the present embodiment is the same as the structure of the mask unit related to the first embodiment. In the manufacturing method of the mask unit related to the present embodiment, instead of raising the mask110and the mask holding unit220using the plurality of first lift pins250and the plurality of second lift pins260(refer toFIG. 8AandFIG. 8B), the mask110and the mask holding unit220are raised by the second lift pins260(refer toFIG. 11AandFIG. 11B). The remaining structure is the same as the manufacturing method of the mask unit related to the first embodiment. An explanation which is the same as the first embodiment is omitted, and parts which are different from the manufacturing method of the mask unit related to the first embodiment are explained.

<Operation of Mask Unit Manufacturing Device and Method of Manufacturing Mask Unit>

FIG. 11Ais a top view diagram of the mask unit manufacturing device200in which the mask110and the mask holding unit220are raised.FIG. 11Bis a side view diagram of the mask unit manufacturing device200in which the mask110and the mask holding unit220are raised.

As is shown inFIG. 11AandFIG. 11B, the second lift pins260move up from the alignment stage210ain the direction D3and contact the mask110. The second lift pins260raise the mask110. In the present embodiment, the mask holding unit220is supported by the second lift pins250via the mask110even without the support of the first lift pins250. That is, the mask holding unit220is raised integrally with the mask110together with the rising of second lift pins260from the alignment stage210a.

Furthermore, it is possible for the second lift pins260to move in the plane direction D1-D2on the inner side of the opening122of the frame120. The plurality of second lift pins260move in synchronization with the alignment stage210ain the plane direction D1-D2. The alignment stage210aand the second lift pin260can integrally move the mask holding unit220and the mask110in the plane direction D1-D2by a sufficient magnetic force of the magnetic field generator220a.

By adopting this structure, the alignment stage210aand the second lift pins260can integrally move the mask holding unit220and the mask110in direction D3, in parallel to the plane direction D1-D2and in parallel to a rotation direction with the direction D3as axes.

According to the manufacturing method of the mask unit100of the present embodiment explained above, it is possible to align the mask with a high degree of accuracy and fix it to a frame.

Although one embodiment of the present invention was explained above, it is possible for one embodiment of the present invention to be modified into various forms as described below.

Modified Example 1

As is shown inFIG. 3AandFIG. 3B, in the first to third embodiments, the alignment stage210ahas a rectangular shape and the frame holding stage210bhas a frame shape in order to surround the alignment stage210a. As a result, a part of the frame120also contacts the alignment stage210a. However, the present invention is not limited to this structure and it is sufficient that in the alignment stage210a, the plurality of first lift pins250are arranged on the outer side of the frame120and the plurality of second lift pins260are arranged in the opening122of the frame120. It is sufficient that the frame holding stage210bis able to stably hold the frame120. For example,FIG. 12is a top view diagram of a stage210related to a modified example of the present invention. As is shown inFIG. 12, the alignment stage210amay also protrude into a shape which includes a plurality of the first lift pins250. The frame holding stage210bmay also be recessed in order to avoid the plurality of first lift pins250and may be discontinuous. By this type of arrangement, it is possible to further increase the area where the frame holding stage210bholds the frame120.

Modified Example 2

In the first to third embodiments, the mask holding unit220is formed to hold the first surface110aof the mask110by a magnetic force. However, the present invention is not limited to this structure and the mask holding unit220may also be formed to hold the first surface110aof the mask110by a vacuum suction force. In this case, the mask holding unit220may be arranged with a vacuum suction machine and a contact plate. The contact plate may be arranged with a suction hole and be substantially flat. By adopting this structure, the manufacturing method of the mask unit100related to the present modified example can realize alignment of the mask with a high degree of accuracy and fix the mask to a frame.