Method of manufacturing organic light emitting display apparatus

A method of manufacturing an organic light emitting display apparatus by utilizing a deposition apparatus for forming an organic layer on a substrate includes: fixing the substrate to a mask assembly for forming a common layer or a mask assembly for forming a pattern layer in a loading unit; when the one or more deposition assemblies are separated from the substrate, forming an intermediate layer by depositing a deposition material discharged from the one or more deposition assemblies in a deposition unit of the deposition apparatus onto the substrate while the substrate is moved relative to the one or more deposition assemblies by a first conveyer unit; and separating the substrate on which the deposition is finished from the mask assembly for forming the common layer or the mask assembly for forming the pattern layer in an unloading unit.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of Korean Patent Application No. 10-2013-0161780, filed Dec. 23, 2013 in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.

BACKGROUND

Aspects of one or more embodiments of the present invention are directed toward a method of manufacturing an organic light emitting display apparatus.

2. Description of the Related Art

Organic light emitting display apparatuses have wider viewing angles, better contrast characteristics, and faster response speeds than other display devices, and thus, have drawn attention as a next-generation display device.

An organic light emitting display apparatus includes an intermediate layer between a first electrode and a second electrode that face each other, and the intermediate layer includes an emission layer. The electrodes and the intermediate layer may be formed using (utilizing) various methods, one of which is an independent deposition method. When an organic light emitting display apparatus is manufactured by using the deposition method, a fine metal mask (FMM) having the same pattern as that of an organic layer to be formed is disposed to closely contact a substrate on which the organic layer and the like are formed, and an organic layer material is deposited toward the FMM to form the organic layer having the desired pattern on the substrate.

Information disclosed in this Background section was already known to the inventors of the present invention before achieving the present invention or is technical information acquired in the process of achieving the present invention. Therefore, it may contain information that does not form the prior art that is already known in this country to a person of ordinary skill in the art.

SUMMARY

Aspects of one or more embodiments of the present invention are directed toward a method of manufacturing an organic light emitting display apparatus.

According to an embodiment of the present invention, a method of manufacturing an organic light emitting display apparatus by utilizing a deposition apparatus for forming an organic layer on a substrate includes: fixing the substrate to a mask assembly for forming a common layer or a mask assembly for forming a pattern layer in a loading unit; when one or more deposition assemblies are separated from the substrate, forming an intermediate layer by depositing a deposition material discharged from the one or more deposition assemblies in a deposition unit of the deposition apparatus onto the substrate while the substrate is moved relative to the one or more deposition assemblies by a first conveyer unit; and separating the substrate on which the deposition is finished from the mask assembly for forming the common layer or the mask assembly for forming the pattern layer in an unloading unit.

The substrate may be fixed to the mask assembly for forming the common layer in the loading unit, and the deposition material may be formed on the substrate as a common layer.

The forming of the intermediate layer may include forming at least a red emission layer (EML), a green EML, and a blue EML on the substrate as respective common layers.

The substrate may be fixed to the mask assembly for forming the pattern layer in the loading unit, and the deposition material may be formed on the substrate in a pattern.

The forming of the intermediate layer may include forming a red EML, a green EML, and a blue EML on the substrate as respective pattern layers.

Either the mask assembly for forming the common layer or the mask assembly for forming the pattern layer may be coupled to the substrate.

The forming of the intermediate layer may include: forming one EML while the substrate is moved relative to the one or more deposition assemblies when where the substrate is fixed on the mask assembly for forming the pattern layer; returning the mask assembly for forming the pattern layer, to which the substrate is fixed, to the loading unit; and forming another EML on the substrate while the substrate is moved relative to the one or more deposition assemblies.

While one EML is formed, a shielding member may be between the substrate and the one or more deposition assemblies that include a deposition material for forming a different EML.

After the returning of the mask assembly, the mask assembly for forming the pattern layer may be offset with respect to a previous position of the mask assembly on the substrate.

The forming of the intermediate layer may include: forming one or more common layers on the substrate while the substrate is moved relative to the one or more deposition assemblies when where the substrate is fixed on the mask assembly for forming the common layer; separating the substrate from the mask assembly for forming the common layer, and fixing the substrate to the mask assembly for forming the pattern layer; and patterning a red EML, a green EML, and a blue EML on the substrate while the substrate is moved relative to the one or more deposition assemblies when where the substrate is fixed to the mask assembly for forming the pattern layer.

The patterning of the EML on the substrate may include offsetting the mask assembly for forming the pattern layer with respect to a previous position of the mask assembly on the substrate after patterning one EML on the substrate.

The method may further include: after the patterning of the EML on the substrate, separating the substrate from the mask assembly for forming the pattern layer, and fixing the substrate to the mask assembly for forming the common layer; and forming one or more common layers on the substrate while the substrate is moved relative to the one or more deposition assemblies when where the substrate is fixed to the mask assembly for forming the common layer.

The forming of the intermediate layer may include: stacking one or more intermediate layers, including at least an EML configured to emit light having a color, sequentially at a sub-pixel region on the substrate; stacking one or more intermediate layers, including at least an EML configured to emit light having a different color, sequentially at the sub-pixel region on the substrate; and stacking one or more intermediate layers, including at least an EML configured to emit light having a different color, sequentially at the sub-pixel region on the substrate.

The method may further include stacking a red EML, a green EML, and a blue EML at other sub-pixel regions on the substrate.

The forming of the intermediate layer may include: forming one or more common layers on the substrate; patterning an EML at each of a plurality of sub-pixel regions on the substrate; and forming one or more common layers on the substrate.

The method may further include, after the separating of the substrate from the mask assembly, returning the mask assembly for forming the common layer or the mask assembly for forming the pattern layer to the loading unit on a second conveyer unit.

The mask assembly for forming the common layer or the mask assembly for forming the pattern layer may move between the first conveyer unit and the second conveyer unit.

Each of the mask assembly for forming the common layer and the mask assembly for forming the pattern layer may include: a mask including one or more openings for defining deposition regions on the substrate; a mask tray having a surface on which the mask is mounted; and a magnet plate on a surface of the substrate which is opposite to the surface on which the mask is mounted, the magnet plate may be configured to apply a magnetic force to the mask.

The magnet plate may be configured to generate a magnetic force in a direction from the mask toward the magnet plate.

A plurality of the deposition assemblies may be in the deposition unit to sequentially perform the deposition on the substrate.

DETAILED DESCRIPTION

Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to the like elements throughout. In this regard, the present embodiments may have different forms and should not be construed as being limited to the descriptions set forth herein. Accordingly, the embodiments are merely described below, by referring to the figures, to explain aspects of the present description. It will be understood that although the terms “first”, “second”, etc. may be used herein to describe various components, these components should not be limited by these terms. These components are only used to distinguish one component from another. As used herein, the singular forms “a,” “an,” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “includes,” “including,” “comprises,” and/or “comprising” used herein specify the presence of stated features, components, or layers but do not preclude the presence or addition of one or more other features, components, or layers. Sizes of layers or elements in the drawings may be exaggerated for convenience of explanation. In other words, because sizes and thicknesses of layers and components in the drawings are arbitrarily illustrated for convenience of explanation, the following embodiments are not limited thereto. As used herein, the term “and/or” includes any and all combinations of one or more of the associated listed items. Expressions such as “at least one of,” when preceding a list of elements, modify the entire list of elements and do not modify the individual elements of the list. Further, the use of “may” when describing embodiments of the present invention relates to “one or more embodiments of the present invention.”

FIG. 1is a schematic plan view of a deposition apparatus1according to an embodiment of the present invention, andFIG. 2is a schematic side view of a deposition unit of the deposition apparatus shown inFIG. 1.

Referring toFIGS. 1 and 2, the deposition apparatus1according to the present embodiment includes a deposition unit100, a loading unit200, an unloading unit300, and a conveyer unit400.

In the loading unit200, a substrate500is coupled to a mask assembly for depositing a common layer (refer to610ofFIG. 4) or a mask assembly for depositing a pattern layer (refer to620ofFIG. 6) (hereinafter, the mask assembly610for depositing the common layer will be described as an example). For example, a mask tray (refer to611ofFIG. 4) and a mask (refer to612ofFIG. 4) are arranged in the loading unit200, and the substrate500is mounted thereon. In this embodiment, a magnet plate (refer to613ofFIG. 4) is coupled to an upper portion (e.g., an upper side or surface) of the substrate500. Here, the magnet plate (613ofFIG. 4) generates a magnetic power (e.g., a magnetic field) to attract the mask (611ofFIG. 4) toward the magnet plate (613ofFIG. 4), and thus, the substrate500and the mask (612ofFIG. 4) are closely coupled to each other.

The deposition unit100is formed at a side of (e.g., in-line with) the loading unit200to receive the mask assembly (610ofFIG. 4), to which the substrate500is coupled, from the loading unit200, and deposition material (e.g., a set or predetermined deposition material) is deposited onto the substrate500at the deposition unit100.

In the unloading unit300, the substrate500, on which the deposition has been completed while passing through the deposition unit100, is separated from the mask assembly (610ofFIG. 4). The mask assembly (610ofFIG. 4) that is separated from the substrate500is returned to the loading unit200via a second conveyer unit420. In order to perform the deposition operation on one substrate500a plurality of times, the mask assembly (610ofFIG. 4), to which the substrate500is removably coupled, may be returned to the loading unit200via the second conveyer unit420to perform the deposition operation again.

The deposition unit100may include at least one deposition chamber101. According to the present embodiment shown inFIGS. 1 and 2, the deposition unit100includes the chamber101in which a plurality of deposition assemblies100-1through100-11may be disposed. According to the present embodiment shown inFIG. 1, first through eleventh deposition assemblies100-1through100-11may be disposed in the chamber101; however, the number of deposition assemblies may vary depending on, for example, a deposition material and deposition conditions. The chamber101is maintained in vacuum during the deposition process.

The conveyer unit400includes a first conveyer unit410and the second conveyer unit420for conveying the mask assembly (610ofFIG. 4). For example, the first and second conveyer units410and420are respectively disposed above and below the deposition assemblies100-1through100-11in the chamber101, and the mask assembly (610ofFIG. 4) circulates between (e.g., alternates or moves along) the first and second conveyer units410and420to perform the deposition operation successively (e.g., repeatedly).

The first conveyer unit410conveys the mask assembly (610ofFIG. 4) to which the substrate500is coupled in an in-line manner, so that an organic layer may be formed on the substrate500by the deposition assembly100-1.

The second conveyer unit420returns the mask assembly (610ofFIG. 4), from which the substrate500has been separated in the unloading unit300after one deposition cycle is completed, to the loading unit200while the mask assembly610passes through the deposition unit100. Otherwise, the mask assembly (610ofFIG. 4), to which the substrate500is coupled, may be returned to the loading unit200via the second conveyer unit420in order to perform the deposition operation for a plurality of times on the one substrate500.

Here, according to the present embodiment shown inFIG. 1, the mask assembly (610ofFIG. 4), to which the substrate500is fixed, may be at least moved to the deposition unit100. For example, the substrate500having the mask assembly (610ofFIG. 4) fixed thereto may be sequentially moved from the loading unit200, to the deposition unit100, and to the unloading unit300by the first conveyer unit410, and the mask assembly (610ofFIG. 4) that is separated from the substrate500in the unloading unit300is returned to the loading unit200by the second conveyer unit420.

The first conveyer unit410passes through the chamber101when passing through the deposition unit100, and the second conveyer unit420conveys the mask assembly (610ofFIG. 4) from which the substrate500is separated.

In the present embodiment,FIGS. 1 and 2show that the first conveyer unit410and the second conveyer unit420are respectively disposed above and below the deposition assemblies100-1through100-11; however, embodiments of the present invention are not limited thereto, that is, the first and second conveyer units410and420may be variously formed or located, for example, at left and right sides of the deposition assemblies100-1through100-11.

Here, the first and second conveyer units410and420may include various members to move (e.g., move in a reciprocal manner) the mask assembly (610ofFIG. 4), for example, a roller, a linear motor (LM) guide, a magnetic levitation member, etc.

FIG. 3is a cross-sectional view of an active matrix organic light emitting display apparatus manufactured by the deposition apparatus shown inFIG. 1.

Referring toFIG. 3, various components of the organic light emitting display apparatus are formed on a substrate500. Here, the substrate500may be the substrate500shown inFIG. 2or a part of the substrate500obtained by cutting the substrate500(e.g., a cross-sectional view of the substrate500). The substrate500may be formed of a transparent material, for example, a glass material, a plastic material, or a metal material.

Common layers such as a buffer layer51, a gate insulating layer53, and an interlayer insulating layer55may be formed on an entire surface of the substrate500, a patterned semiconductor layer52including a channel region52a, a source contact region52b, and a drain contact region52cmay be formed on the substrate500, and a gate electrode54, a source electrode56, and a drain electrode57that configure (or form) a thin film transistor (TFT) with the patterned semiconductor layer52may be formed on the substrate500.

Here, the semiconductor layer52may be formed to include various materials. For example, the semiconductor layer52may include an inorganic semiconductor material such as amorphous silicon or crystalline silicon. As another example, the semiconductor layer52may include an oxide semiconductor or an organic semiconductor material.

Also, a protective layer58covers the TFT, and a planarization layer59located on the protective layer58and having a planarized upper surface may be formed on the entire surface of the substrate500. An organic light emitting device (OLED) including a patterned pixel electrode61, an opposite electrode62corresponding (e.g., roughly corresponding) to the entire surface of the substrate500, and an intermediate layer63of a multi-layered structure including an emission layer and disposed between the pixel electrode61and the opposite electrode62may be located on the planarization layer59. Some of (e.g., one or more layers of) the intermediate layer63may be a common layer roughly corresponding to the entire surface of the substrate50, and other layers of the intermediate layer63may be pattern layers that are patterned to correspond to the pixel electrode61. The pixel electrode61may be electrically coupled to (e.g., electrically connected to) the TFT via a via opening (e.g., a via hole). A pixel defining layer60covering edges of the pixel electrode61and having openings for defining pixel regions may be formed on the planarization layer59to correspond to the entire surface of the substrate500.

In the organic light emitting display apparatus, at least some of the components may be manufactured by the deposition apparatus or a method of manufacturing the organic light emitting display apparatus according to the previous embodiments.

For example, the intermediate layer63may be formed by the method of manufacturing the deposition apparatus or the organic light emitting display apparatus according to the above embodiments. For example, a hole injection layer (HIL), a hole transport layer (HTL), an emission layer (EML), an electron transport layer (ETL), and an electron injection layer (EIL) may be included in the intermediate layer63and may be formed by the method of manufacturing the deposition apparatus or the organic light emitting display apparatus according to the above embodiments.

That is, when forming each layer of the intermediate layer63on a substrate on which the pixel electrode61is formed, one of the deposition source and the substrate moves relative to the other during the deposition operation. The deposition source is spaced from (e.g., spaced apart from or separated from) the substrate.

Also, in the organic light emitting display apparatus shown inFIG. 3, each unit pixel includes a plurality of sub-pixels that may emit light of various colors. For example, the organic light emitting display apparatus may include sub-pixels respectively emitting red, green, and blue light (e.g., an RGB organic light emitting display), sub-pixels emitting white light (e.g., a white OLED organic light emitting display), or sub-pixels respectively emitting red, green, blue, and white light (e.g., an RGBW organic light emitting display).

That is, the sub-pixels may each include intermediate layers having organic emission layers that emit light having various colors. For example, the sub-pixels include intermediate layers having organic emission layers that emit light having red, green, and/or blue colors.

As another example, the sub-pixels that emit fight having various colors may include intermediate layers (or organic emission layers) that emit light having the same color, for example, white, and may include a color converting layer or a color filter that coverts the white light into a light having a certain color (e.g., a predetermined color).

The intermediate layer emitting the white light may have a variety of structures, for example, a structure in which at least a light-emitting substance emitting a red light, a light-emitting substance emitting a green light, and a light-emitting substance emitting a blue light are stacked on one another. In another example, the intermediate layer emitting the white light may include a structure in which at least a light-emitting substance emitting a red light, a light-emitting substance emitting a green light, and a light-emitting substance emitting a blue light are mixed.

The red, greed, and blue colors are examples, and the present embodiment is not limited thereto. In other words, any combination of other various colors which is capable of emitting a white light may be employed in addition to a combination of red, green, and blue colors.

FIG. 4is a perspective view of the deposition unit100ofFIG. 1.

Referring toFIG. 4, the deposition unit100of the deposition apparatus1according to the embodiment of the present invention may include one or more deposition assemblies100-1through100-11and the conveyer unit (refer to400ofFIG. 1). Hereinafter, the configuration of the deposition unit100will be described.

The substrate500, that is, a deposition target, is disposed in the deposition unit100. The substrate500may be a substrate for a flat panel display apparatus, that is, a large sized substrate of 40 inches or greater, such as a mother glass from which a plurality of flat panel display apparatuses may be manufactured.

Here, according to the present embodiment, the deposition is performed while the mask assembly610, to which the substrate500is coupled, moves relative to the deposition assemblies100-1through100-11. That is, the deposition is performed (e.g., continuously performed) while the mask assembly610, to which the substrate500is coupled and is disposed to face the deposition assemblies100-1through100-11, moves along a direction denoted by an arrow A shown inFIG. 4. That is, the deposition is performed in a scanning manner while moving the substrate500in the direction denoted by the arrow A ofFIG. 4. Here, inFIG. 4, the deposition is performed while the mask assembly610, to which the substrate500is coupled, moves along the A direction in the chamber; however, the embodiments are not limited thereto, that is, the deposition assemblies100-1through100-11may be moved along the direction A while the substrate500is fixed during the deposition process.

In addition, to perform the deposition while the mask assembly610, to which the substrate500is coupled, and the deposition assemblies100-1through100-11move relative to each other, the deposition assemblies100-1through100-11and the substrate500are configured to be separated from each other by a distance (e.g., a predetermined distance).

Each of the deposition assemblies100-1through100-11includes at least one deposition source110disposed to face the substrate500in the chamber101and configured to receive and heat (e.g., vaporize) a deposition material. In addition, when the deposition material in the deposition source110is vaporized, the deposition material is deposited onto the substrate500. Here, each of the deposition assemblies100-1through100-11includes three deposition sources; however, the embodiments of the present invention are not limited thereto, that is, the number and the kinds of the deposition sources may vary depending on, for example, a shape of the deposition apparatus1, a deposition amount, and a processing time.

Here, according to the deposition apparatus and the deposition method according to the present embodiment, the mask assembly610for forming the common layer and the mask assembly (620ofFIG. 6) for forming the pattern layer are disposed and are configured to be replaceable, and thus, an organic light emitting display apparatus emitting red, green, and blue colors (e.g., an RGB organic light emitting display) including sub-pixels respectively emitting red, green, and blue light in one deposition apparatus, and an organic light emitting display apparatus having a white OLED including sub-pixels emitting white light, and an organic light emitting display apparatus emitting red, green, blue, and white colors (e.g., an RGBW organic light emitting display) including sub-pixels respectively emitting red, green, blue, and white light may be selectively manufactured. This will be described in more detail below.

In general, the RGB organic light emitting display apparatus is generally manufactured by (utilizing) a fine metal mask (FMM) in a cluster deposition apparatus. In addition, the white OLED organic light emitting display apparatus is generally manufactured by (utilizing) an open mask in an in-line deposition apparatus.

However, manufacturing the RGB display utilizing the FMM is not suitable for manufacturing a large-sized organic light emitting display apparatus using (utilizing) a mother glass having a large size because the mask may curve due to weight thereof when the corresponding large-sized mask is used (utilized), and the pattern may be distorted due to the curvature. In addition, the RGB pattern cannot be formed using the open mask that forms the white OLED.

To address the above problem, according to the deposition apparatus and the deposition method of the present embodiment, the mask assembly610for forming the common layer and the mask assembly (620ofFIG. 6) for forming the pattern layer are disposed together, and the mask assembly610for forming the common layer and the mask assembly620for forming the pattern layer are configured to be replaceable (e.g., the substrate500can be selectively coupled to either the mask assembly610for forming the common layer or the mask assembly620for forming the pattern layer).

Referring back toFIG. 4, the mask assembly610for forming the common layer includes a mask tray611, a mask612, and a magnet plate613.

For example, the mask612includes one or more openings to define deposition regions on the substrate500. InFIG. 4, the mask612is formed as an open mask in which the opening is formed (e.g., entirely formed) to be used as a mask for forming the common layer.

The mask tray611is formed so that the mask612is mounted thereon and acts as a shuttle that is conveyed by the first conveyer unit410to the second conveyer unit420when the mask612and/or the substrate500is mounted thereon.

The magnet plate613is at a surface of the substrate500, which is opposite to a surface of the mask that contacts the mask612, to apply a magnetic force (e.g., a predetermined magnetic force or field) to the mask612. The magnet plate613generates the magnetic force in a direction from the mask612toward the magnet plate613so that the substrate500and the mask612are closely coupled to each other, and thereby preventing a gap from being generated between the substrate500and the mask612. Here, the magnet plate613may be formed of an elastic, flexible material.

In addition, the eleven deposition assemblies100-1through100-11shown inFIG. 4may be used to form the intermediate layer of the organic light emitting display apparatus.

As an example of arranging the eleven deposition assemblies100-1through100-11, the first deposition assembly100-1includes a deposition material for forming the HIL and HTL, the second deposition assembly100-2includes a deposition material for forming a blue EML, the third deposition assembly100-3includes a deposition material for forming the ETL, the fourth deposition assembly100-4includes a deposition material for forming a charge generation layer (CGL), the fifth deposition assembly100-5includes a deposition material for forming the ETL and a deposition material for forming a blue EML, the sixth deposition assembly100-6includes a deposition material for forming the ETL, the seventh deposition assembly100-7includes a deposition material for forming a CGL, the eighth deposition assembly100-8includes a deposition material for forming the HTL, the ninth deposition assembly100-9includes deposition materials for forming a red EML and a green EML, the tenth deposition assembly100-10includes a deposition material for forming the ETL, and the eleventh deposition layer100-11includes a deposition material for forming the EIL. The arrangement of the deposition assemblies may be variously modified. Also, the deposition assembly that is not used in the deposition operation may not include a deposition material.

Here, a white OLED organic light emitting display apparatus in which a deposition material for emitting red light, a deposition material for emitting green light, a deposition material for emitting blue light are stacked may be manufactured by using the deposition apparatus according to the embodiment shown inFIG. 4.

FIG. 5is a cross-sectional view of an intermediate layer of an organic light emitting display apparatus manufactured by using the deposition apparatus shown inFIG. 4.

Referring toFIG. 5, the organic light emitting display apparatus manufactured by using the deposition apparatus ofFIG. 4includes pixel electrodes61R,61G, and61B, an intermediate layer631, and an opposite electrode62. In addition, the intermediate layer631includes an HTL631a, a blue EML631b, a CGL631c, a red EML631d, a green EML631e, and an ETL631f. The intermediate layer631may be formed as below.

The mask assembly610includes the mask tray611, the mask612, and the magnet plate613, and the mask612is an open mask. Thus, a common layer is formed on the substrate500while the substrate500, coupled to the mask assembly610, passes through or over the deposition assemblies100-1through100-11. That is, the HTL631ais formed on the substrate500when the substrate500passes through the first deposition assembly100-1, the blue EML631bis formed on the substrate500when the substrate500passes through the second deposition assembly100-2, the CGL631cis formed on the substrate500when the substrate500passes through the fourth and/or the seventh deposition assemblies100-4and/or100-7, the red EML631dand the green EML631eare formed on the substrate500when the substrate500passes through the ninth deposition assembly100-9, and the EIL631fis formed on the substrate500when the substrate500passes through the tenth deposition assembly100-10. Here, all the formed layers are formed as common layers.

As described above, the red EML, the green EML, and the blue EML are stacked (or formed) through only one scanning operation by using the mask assembly610to form the intermediate layer emitting the white light, and thereby manufacturing the white OLED organic light emitting display apparatus.

FIG. 6is a perspective view of the deposition unit shown inFIG. 1according to another embodiment, andFIG. 7is a side view of a shielding member shown inFIG. 6.

In a deposition unit100′ of the deposition apparatus according to another embodiment of the present invention shown inFIGS. 6 and 7, an RGB organic light emitting display apparatus including an organic emission layer, in which a plurality of sub-pixels respectively emit red, green, and blue light, may be manufactured through a plurality of scanning operations by using the mask assembly620for forming the pattern layer. This will be described in more detail below.

Referring toFIGS. 6 and 7, the deposition unit100′ of the deposition apparatus according to another embodiment of the present invention includes one or more deposition assemblies100-1′ through100-11′ and the mask assembly620for forming a pattern layer. Here, the mask assembly620for forming the pattern layer includes a mask tray621, a mask622, and a magnet plate623. In addition, the deposition unit100′ includes shielding members121,122, and123formed to block (e.g., cover) a certain deposition assembly.

For example, the mask622includes a plurality of openings (e.g., slits) for defining deposition regions on the substrate500. That is,FIG. 6shows the mask622for forming the pattern layer which includes the plurality of openings having shapes (e.g., predetermined shapes) to pattern the deposition materials on desired regions of the substrate500.

The mask tray621is configured so that the mask622is mounted thereon and acts as a shuttle conveyed by the first conveyer unit410or the second conveyer unit420when the mask622and/or the substrate500is mounted thereon.

The magnet plate623is at a surface of the substrate500, which is opposite to another surface of the substrate500which contacts the mask622, to apply a magnetic force (e.g., a predetermined magnetic force or field) to the mask622. The magnet plate623generates the magnetic force in a direction from the mask622toward the magnet plate623so that the substrate500and the mask622are closely coupled to each other, and thereby preventing a gap from being generated between the substrate500and the mask622. Here, the magnet plate623may be formed of an elastic, flexible material.

The first shielding member121includes a pair of shielding plates121aand121bdisposed at opposite sides of the sixth deposition assembly100-6′ in order to block the deposition material discharged from the sixth deposition assembly100-6′ by covering or uncovering (e.g., opening or closing) the sixth deposition assembly100-6′ through movements of the shielding plates121aand121b. The second and third shielding members122and123have the same structures as that of the first shielding member121(e.g., the second shielding member122includes a pair of shielding plates122aand122b, and the third shielding member123includes a pair of shielding plates123aand123b).

In addition, the eleven deposition assemblies100-1′ through100-11′ shown inFIG. 6may be used to form an intermediate layer of the organic light emitting display apparatus.

As an example of arranging the eleven deposition assemblies100-1′ through100-11′, the first deposition assembly100-1′ and the second deposition assembly100-2′ include deposition materials for forming an HIL, the third, fourth, and fifth deposition assemblies100-3′ through100-5′ include a deposition material for forming an HTL, the sixth deposition assembly100-6′ includes a deposition material for forming a red EML, the seventh deposition assembly100-7′ includes a deposition material for forming a green EML, the eighth deposition assembly100-8′ includes a deposition material for forming a blue EML, the ninth and tenth deposition assemblies100-9′ and100-10′ include a deposition material for forming an ETL, and the eleventh deposition layer100-11′ includes a deposition material for forming an EIL. The arrangement of the deposition assemblies may be variously modified. Also, the deposition assembly that is not used in the deposition operation may not include a deposition material.

Here, the RGB organic light emitting display apparatus, including the plurality of sub-pixels respectively emitting the red, green, and blue light, manufactured by using the mask assembly620for forming the pattern layer may be manufactured by using the deposition apparatus shown inFIG. 6.

FIG. 8is a cross-sectional view of an intermediate layer of an organic light emitting display apparatus that is manufactured by using the deposition apparatus shown inFIG. 6.

Referring toFIG. 8, the organic light emitting display apparatus manufactured by using the deposition apparatus ofFIG. 6includes pixel electrodes61R,61G, and61B, an intermediate layer632, and an opposite electrode62. In addition, the intermediate layer632is patterned with respect to each of sub-pixels.

That is, a red sub-pixel includes an HIL632a-R, an HTL632b-R, a red EML632R, and an ETL632c-R that are sequentially patterned and stacked. In addition, a green sub-pixel includes an HIL632a-G, an HTL632b-G, a green EML632G, and an ETL632c-G that are sequentially patterned and stacked. In addition, a blue sub-pixel includes an HIL632a-B, an HTL632b-B, a blue EML632B, and an ETL632c-B that are sequentially patterned and stacked. In addition, the opposite electrode62is formed as a common layer for covering the intermediate layer632. Although the opposite electrode62appears to be a pattern layer becauseFIG. 8omits spaces between the sub-pixels, the opposite electrode62is formed as a common layer (e.g., the opposite electrode62is not patterned to correspond to the sub-pixels61R,61G, and61B).

The intermediate layer632may be formed as below.

The mask assembly620for forming the pattern layer includes the mask tray621, the mask622, and the magnet plate623, and the mask622is formed as a pattern mask including a plurality of openings (e.g., slits). Thus, pattern layers are formed on the substrate500when the substrate500, coupled to the mask assembly620for forming the pattern layer, passes through (or over) the deposition assemblies100-1′ through100-11′.

That is, during a first scanning operation, when the substrate500passes through the first and second deposition assemblies100-1′ and100-2′, the HIL632a-R is formed on the substrate500, when the substrate500passes through the third, fourth, and fifth deposition assemblies100-3′,100-4′, and100-5′, the HTL632b-R is formed on the substrate500. In addition, when the substrate500passes through the sixth deposition assembly100-6′, the red EML632R is formed on the substrate500, and when the substrate500passes through the ninth and tenth deposition assemblies100-9′ and100-10′, the ETL632c-R is formed on the substrate500. Here, all of the layers are formed as the pattern layers stacked at the red sub-pixel. Here, the second shielding member122is formed between (e.g., is extended between) the seventh deposition assembly100-7′ for forming the green EML and the substrate500so the green light emitting material is not deposited on the substrate500, and the third shielding member123is disposed between (e.g., is extended between) the eighth deposition assembly100-8′ for forming the blue EML and the substrate500so the blue light emitting material is not deposited on the substrate500.

The mask assembly620for forming the pattern layer (and the substrate500coupled thereto) on which the scanning deposition operation is performed once is returned to the loading unit200by the second conveyer unit (420ofFIG. 2). Thereafter, the mask assembly620for forming the pattern layer is offset (e.g., offset by a predetermined degree) with respect to the substrate500for forming next pattern layer (e.g., the mask assembly620may be offset or moved with respect to a previous position of the mask assembly620on the substrate500).

Likewise, during a second scanning operation, the HIL632a-G, the HTL632b-G, the green EML632G, and the ETL632c-G are formed on the substrate500when the substrate500passes through the deposition assemblies100-1′ through100-111′. Here, all of the layers are formed as pattern layers at the green sub-pixel, and the intermediate layer is horizontally separated by a gap (e.g., by a predetermined gap) from the intermediate layer formed during the first scanning operation. Here, the first shielding member121is formed between (e.g., is extended between) the sixth deposition assembly100-6′ for forming the red EML632R and the substrate500so the red light emitting material is not deposited on the substrate500, and the third shielding member123is disposed between (e.g., is extended between) the eighth deposition assembly100-8′ for forming the blue EML and the substrate500so the blue light emitting material is not deposited on the substrate500.

The mask assembly620for forming the pattern layer (and the substrate500coupled thereto), on which the second scanning deposition operation is performed, is returned to the loading unit200by the second conveyer unit (420ofFIG. 2). Thereafter, the mask assembly620for forming the pattern layer is offset (e.g., offset by a predetermined degree) with respect to the substrate500for forming (before forming) next pattern layer.

Likewise, during a third scanning operation, the HIL632a-B, the HTL632b-B, the blue EML632B, and the ETL632c-B are formed on the substrate500when the substrate500passes through the deposition assemblies100-1′ through100-11′. Here, all of the layers are formed as pattern layers at the blue sub-pixel, and the intermediate layer is horizontally separated by a gap (e.g., by a predetermined gap) from the intermediate layers formed during the first and second scanning operations. Here, the first shielding member121is formed between (e.g., is extended between) the sixth deposition assembly100-6′ for forming the red EML632R and the substrate500so the red light emitting material is not deposited on the substrate500, and the second shielding member122is disposed between (e.g., is extended between) the seventh deposition assembly100-7′ for forming the green EML and the substrate500so the green light emitting material is not deposited on the substrate500.

As described above, the RGB organic light emitting display apparatus may be manufactured by forming the intermediate layer including the organic emission layers respectively emitting red, green, and blue light at the plurality of sub-pixels through the plurality of scanning operation by using the mask assembly620for forming the pattern layer.

FIG. 9is a schematic perspective view showing another embodiment of the deposition unit ofFIG. 1.

In the deposition unit100″ according to another embodiment of the present invention shown inFIG. 9, an RGB organic light emitting display apparatus having a structure in which each of the plurality of sub-pixels includes an organic emission layer emitting red, green, or blue light may be manufactured through a scanning operation by using the mask assembly610for forming a common layer and the mask assembly620for forming a pattern layer. This will be described in more detail below.

Referring toFIG. 9, the deposition unit100″ of the deposition apparatus according to another embodiment of the present invention includes one or more deposition assemblies100-1″ through100-11″, the mask assembly610for forming a common layer, and the mask assembly620for forming a pattern layer. Here, the mask assembly610for forming the common layer includes the mask tray611, the mask612, and the magnet plate613, and the mask assembly620for forming the pattern layer includes the mask tray621, the mask622, and the magnet plate623. In the present embodiment, the mask assembly610for forming the common layer is the same or substantially the same as the mask assembly for forming the common layer described with reference toFIG. 4, and the mask assembly620for forming the pattern layer is the same or substantially the same as the mask assembly described with reference toFIG. 6, and thus, detailed descriptions thereof may not be repeated.

The eleven deposition assemblies100-1″ through100-11″ shown inFIG. 9may be used to form the intermediate layer of the organic light emitting display apparatus.

As an example of arranging the eleven deposition assemblies, the first deposition assembly100-1″ and the second deposition assembly100-2″ include deposition materials for forming an HIL, the third, fourth, and fifth deposition assemblies100-3″ through100-5″ include a deposition material for forming an HTL, the sixth deposition assembly100-6″ includes a deposition material for forming a red EML, the seventh deposition assembly100-7″ includes a deposition material for forming a green EML, the eighth deposition assembly100-8″ includes a deposition material for forming a blue EML, the ninth and tenth deposition assemblies100-9″ and100-10″ include a deposition material for forming an ETL, and the eleventh deposition layer100-11″ includes a deposition material for forming an EIL. In one embodiment, the arrangement of the deposition assemblies may be variously modified. Also, the deposition assembly that is not used in the deposition operation may not include a deposition material.

Here, the RGB organic light emitting display apparatus having a structure in which the plurality of sub-pixels respectively emit red, green, and blue light manufactured by using the mask assembly610for forming the common layer and the mask assembly620for forming the pattern layer may be manufactured by using the deposition apparatus according to the present embodiment shown inFIG. 9.

FIG. 10is a cross-sectional view of an intermediate layer in the organic light emitting display apparatus manufactured by using the deposition apparatus shown inFIG. 9.

Referring toFIG. 10, the organic light emitting display apparatus manufactured by using the deposition apparatus shown inFIG. 9includes pixel electrodes61R,61G, and61B, an intermediate layer633, and an opposite electrode62. In addition, the intermediate layer633includes an HIL633a, an HTL633b, a red EML633R, a green EML633G, a blue EML633B, and an ETL633c.

In the intermediate layer633, the EMLs633R,633G, and633B are patterned with respect to the sub-pixels, and the HIL633a, the HTL633b, and the ETL633care formed as common layers. The intermediate layer633is formed as below.

The mask assembly610for forming the common layer includes the mask tray611, the mask612, and the magnet plate613. Here, the mask612is formed as an open mask, and thus, the common layer is formed on the substrate500when the substrate500, coupled to the mask assembly610for forming the common layer, passes through (or over) the deposition assemblies.

In addition, the mask assembly620for forming the pattern layer includes the mask tray621, the mask622, and the magnet plate623. Because the mask622is formed as a pattern mask including the plurality of openings (e.g., slits), pattern layers are formed on the substrate500when the substrate500coupled to the mask assembly620for forming the pattern layer passes through the deposition assemblies.

The deposition starts when the substrate500is coupled to the mask assembly610for forming the common layer. That is, the HIL633ais formed on the substrate500when the substrate500passes through the first and second deposition assemblies100-1″ and100-2″, and the HTL633bis formed on the substrate500when the substrate500passes through the third through fifth deposition assemblies100-3″ through100-5″. Here, the HIL633aand the HTL633bare formed and stacked as common layers.

After separating the substrate500from the mask assembly610for forming the common layer, the substrate500is coupled to the mask assembly620for forming the pattern layer. After that, the red EML633R is formed at the red sub-pixel on the substrate500when the substrate500passes through the sixth deposition assembly100-6″. Then, the mask assembly620for forming the pattern layer is offset (e.g., offset by a predetermined degree) with respect to the substrate500. That is, for forming next pattern layer, the mask assembly620for forming the pattern layer is moved in a direction parallel with the substrate500. After that, the green EML633G is formed at the green sub-pixel of the substrate500when the substrate500passes through the seventh deposition assembly100-7″. Then, the mask assembly620for forming the pattern layer is offset (e.g., offset a predetermined degree) with respect to the substrate500. After that, the blue EML633B is formed at the blue sub-pixel of the substrate500when the substrate500passes through the eighth deposition assembly100-8″. Here, the red EML633R, the green EML633G, and the blue EML633B are formed at the sub-pixels as pattern layers (patterned layers).

Then, the substrate500is separated from the mask assembly620for forming the pattern layer and is then coupled to the mask assembly610for forming the common layer. After that, the ETL633cis formed on the substrate500when the substrate500passes through the ninth and tenth deposition assemblies100-9″ and100-10″. Here, the ETL is formed and stacked as a common layer.

As described above, by using the mask assembly610for forming the common layer and the mask assembly620for forming the pattern layer together (e.g., concurrently), the RGB organic light emitting display apparatus having the intermediate layer including the plurality of sub-pixels respectively emitting red, green, and blue light may be manufactured by moving along one scanning direction.

FIG. 11is a cross-sectional view of an intermediate layer of an organic light emitting display apparatus manufactured by using a deposition apparatus according to another embodiment of the present invention. In the present embodiment, an RGBW organic light emitting display apparatus in which a plurality of sub-pixels respectively emit red, green, blue, and white light may be manufactured by using a mask assembly for forming a pattern layer through a plurality of scanning operations.

Referring toFIG. 11, the organic light emitting display apparatus according to the present embodiment includes pixel electrodes61R,61G,61B, and61W, an intermediate layer634, and an opposite electrode62. In addition, the intermediate layer634is patterned for each of the sub-pixels.

That is, an HIL634a-R, an HTL634b-R, a red EML634R, and an ETL634c-R are sequentially patterned at a red sub-pixel. In addition, an HIL634a-G, an HTL634b-G, a green EML634G, and an ETL634c-G are sequentially patterned at a green sub-pixel. Also, an HIL634a-B, an HTL634b-B, a blue EML634B, and an ETL634c-B are sequentially patterned at a blue sub-pixel. In addition, an HTL634d-W, a blue EML634e-W, a CGL634f-W, a red EML634g-W, a green EML634h-W, and an ETL6341-W are sequentially patterned at a white sub-pixel. In addition, the opposite electrode62is formed as a common layer for covering the entire intermediate layer634.

As described above, the RGBW organic light emitting display apparatus may be manufactured by forming the intermediate layer emitting the red, green, blue, or white light at each of the plurality of sub-pixels through the plurality of scanning operations by using the mask assembly for forming the pattern layer.

According to the embodiments of the present invention, the deposition processes may be flexibly applied to a large-sized organic light emitting display apparatus. That is, the RGB, the RGBW, or the white OLED organic light emitting display apparatus may be selectively manufactured by using the same deposition apparatus, and thus, the manufacturing equipment may be managed flexibly. Also, a layout of the equipment may be reduced when compared with a comparable cluster deposition apparatus, space utility may be improved, and the processing time may be reduced by applying the in-line deposition apparatus.

As described above, according to the one or more of the above embodiments of the present invention, spatial efficiency and manufacturing efficiency may be improved.