Vapor deposition mask and manufacturing method for organic EL display device

A vapor deposition mask including a metallic substrate provided with a plurality of openings for passing vapor deposition particles, wherein at least a portion of the plurality of openings are structured by one or more opening groups in which the plurality of openings are repeatedly arranged in accordance with a constant rule, and a plurality of protrusions of identical height are arranged to support the entire substrate from one side, and are provided only outside the opening group formation region.

TECHNICAL FIELD

The present disclosure relates to a vapor deposition mask, a method of manufacturing a vapor deposition mask, and a method of manufacturing an organic EL display device.

BACKGROUND ART

In recent years, a variety of flat panel displays have been developed. In particular, from the viewpoints of achieving low power consumption, thinning, high image quality, and the like, organic (Electroluminescent) EL display devices have attracted significant attention as excellent flat panel displays.

In the manufacturing process of such organic EL display devices, in many cases a separately patterning vapor deposition method is used to form a vapor deposition film that includes a high-definition light emitting layer on a substrate.

When such a separately patterning vapor deposition method is used to carry out a vapor deposition, there can be problems where, when the separately patterning vapor deposition mask and the substrate on which the vapor deposition film is formed are completely adhered to one another when the vapor deposition is performed, then defects may occur in the vapor deposition film after the vapor deposition when separating the separately patterning vapor deposition mask from the substrate. Explaining specifically by way of example, first, after forming a red light-emitting layer on a substrate using a separately patterning vapor deposition mask for forming a red light-emitting layer, in the case where a green light-emitting layer is formed on the substrate by using a separately patterning vapor deposition mask for forming a green light-emitting layer in which an opening is formed at a position different from the separately patterning vapor deposition mask for forming the red light-emitting layer, when the vapor deposition and the substrate on which the red light-emitting layer are completed adhered to one another and vapor deposition is performed, the non-opening portion of the separately patterning vapor deposition mask for forming the green light-emitting layer is in direct contact with the red light-emitting layer on the substrate, such that defects may occur in the red light-emitting layer when separating the separately patterning vapor deposition mask for forming the green light-emitting layer from the substrate.

In order to solve such problems, the following attempts have been made thus far.

FIGS. 18A and 18Bare diagrams for explaining a case in which edge covers108aand108bhaving different heights are formed in the same active matrix substrate100, and the active matrix substrate100and the separately patterning vapor deposition mask101do not completely adhere to one another as a result of the tall height of the edge cover108b.

As illustrated inFIG. 18A, an edge cover108bwith a tall height is provided on the surface of the active matrix substrate100opposing the separately patterning vapor deposition mask101, a constant distance can be maintained due to the edge cover108such that the active matrix substrate100and the separately patterning vapor deposition mask101do not completely adhere to one another.

In a state where the active matrix substrate100and the separately patterning vapor deposition mask101are maintained at a constant distance, the vapor deposition particles emitted from a vapor deposition source (not shown) may be formed in a predetermined shape on the active matrix substrate100via the opening103of the separately patterning vapor deposition mask101.

FIG. 18Bis a diagram illustrating a schematic configuration of the active matrix substrate100.

As illustrated in the figures, the active matrix substrate100may have a configuration in which a TFT element105, an interlayer insulating film106which is a flattening film, an electrode107, and edge covers108aand108bare provided on a substrate104.

The primary role of the edge covers (also referred to as banks) is to be formed so as to cover the end portion of the electrode107in order to prevent vapor deposition films such as the light emitting layers from being thinly formed at the end portion of the electrode107and prevent short circuits from occurring between the electrode107and the opposing electrode (not shown). Then, considering that a shared layer (for example, an electrode layer opposing the electrode107) is formed in a level shape in a subsequent process, it is difficult to form the height of the edge cover to be greater than or equal to a predetermined height.

Accordingly, in the active matrix substrate100, the edge cover formed at the boundary of the active area in which the plurality of electrodes107are regularly formed may be an edge cover108bwith a tall height (a height of 2 μm), and the edge cover formed within the active area may be an edge cover108awith a low height (a height of 1 μm).

By using the active matrix substrate100when performing vapor deposition with the separately patterning vapor deposition method, as the active matrix substrate100and the separately patterning vapor deposition mask101can be maintained at a constant distance by the edge cover108bso as not to completely adhere to one another, it is possible to suppress the occurrence of defects in the vapor deposition film such as the light-emitting layer or the like when separating the separately patterning vapor deposition mask101from the active matrix substrate100.

In addition, PTL1 describes a configuration in which a protrusion is provided on the side of a separately patterning vapor deposition mask.

FIG. 19is a diagram illustrating a schematic configuration of the separately patterning vapor deposition mask201disclosed in PTL1.

As illustrated in the figure, the separately patterning vapor deposition mask201includes a mask body202and a frame body203, and on a surface of the mask body202opposite to the substrate on which the vapor deposition film is to be formed, protrusions205are formed between openings204adjacent in the vertical direction of the figure.

By using the separately patterning vapor deposition mask201when vapor deposition is carried out using the separately patterning vapor deposition method, as the separately patterning vapor deposition mask201and the substrate on which the vapor deposition film is to be formed can be prevented from completely adhering to one another, it is disclosed that it is possible to suppress the occurrence of defects in the vapor deposition film such as the light-emitting layer or the like when separating the separately patterning vapor deposition mask201from the substrate on which the vapor deposition film is formed.

CITATION LIST

Patent Literature

SUMMARY

Technical Problem

However, in the active matrix substrate100depicted inFIG. 18AandFIG. 18B, as the height of the edge cover108bwith the tall height may be slightly different for each position in the same active matrix substrate100or for each active matrix substrate100, it is difficult to maintain the active matrix substrate100and the separately patterning vapor deposition mask101at a constant distance using the edge cover108bprovided on the active matrix substrate100side.

Additionally, in the case of the separately patterning vapor deposition mask201disclosed in PTL1, as illustrated inFIG. 19, the protrusions205are formed between the openings204adjacent to each other in the vertical direction in the figure on the entire surface opposed to the substrate where the vapor deposition film of the mask body202is to be formed.

Accordingly, when such a separately patterning vapor deposition mask201is applied to an active matrix substrate having an edge cover, all the protrusions205come into contact with the edge cover. In general, however, since the material for forming the edge cover is different from the material for forming the interlayer insulating film106depicted inFIG. 18B, which is a flattening film, and, as the film thickness is formed relatively thinly as described above, the upper surface of the edge cover is not particularly flat. Further, as the height of the edge cover may be slightly different for each position in the same active matrix substrate or for each active matrix substrate, the uniformity may be reduced.

Therefore, when the separately patterning vapor deposition mask201is applied to an active matrix substrate having an edge cover, as it is difficult to maintain the separately patterning vapor deposition mask201and the active matrix substrate having the edge cover at a constant distance, there can be problems where it is difficult to form uniform vapor deposition films on active matrix substrates having edge covers.

Further, in the case where protrusions205are formed between the adjacent openings204as in the separately patterning vapor deposition mask201disclosed in PTL1, the rigidity of the separately patterning vapor deposition mask201becomes non-uniform within the surface of the separately patterning vapor deposition mask201, such that it becomes difficult to bond the mask body202to the frame body203while finely adjusting the openings204. Accordingly, it is difficult to form a uniform vapor deposition film on the active matrix substrate via the openings204of the separately patterning vapor deposition mask201.

The present disclosure has been made in view of the above problems, and has a goal of providing a vapor deposition mask capable of forming a uniform vapor deposition film on an active matrix substrate and a method for manufacturing the vapor deposition mask.

Solution to Problem

In order to solve the above problems, a vapor deposition mask of the present disclosure relates to a vapor deposition mask including a substrate provided with a plurality of openings to pass vapor deposition particles, wherein at least a portion of the plurality of openings are structured by one or more opening groups, the plurality of openings being repeatedly arranged in accordance with a constant rule, an opening group formation region is a region in the substrate including at least a plurality of openings belonging to each of the opening groups and a region between adjacent openings of the plurality of openings belonging to each of the opening groups, and a plurality of protrusions of identical height are arranged to support the entire substrate from one side, and are provided only outside the opening group formation region.

According to the above configuration, as the plurality of protrusions of identical height are provided only outside the opening group formation region of the substrate in an arrangement that can support the entire substrate from one side, it is possible to realize a vapor deposition mask capable of forming a uniform vapor deposition film on an active matrix substrate.

In order to solve the above problems, a method for manufacturing a vapor deposition mask of the present disclosure relates to a method for manufacturing a vapor deposition mask provided with a plurality of openings to pass vapor deposition particles, wherein at least a portion of the plurality of openings are structured by one or more opening groups, the plurality of openings being repeatedly arranged in accordance with a constant rule, and an opening group formation region is a region in the substrate including at least a plurality of openings belonging to each of the opening groups and a region between adjacent openings of the plurality of openings belonging to each of the opening groups; the method including forming, only outside the opening group formation region, a plurality of protrusions of identical height with an arrangement to support the entire substrate from one side.

According to the above method, as a process is included for forming a plurality of protrusions of identical height only outside the opening group forming region of the substrate in an arrangement that can support the entire substrate from one side, it is possible to realize a vapor deposition mask manufacturing method capable of forming a uniform vapor deposition film on an active matrix substrate.

Advantageous Effects of Disclosure

According to one aspect of the present disclosure, it is possible to provide a vapor deposition mask capable of forming a uniform vapor deposition film on an active matrix substrate, and a method for manufacturing the vapor deposition mask.

DESCRIPTION OF EMBODIMENTS

Embodiments of the present disclosure will be described with reference toFIG. 1toFIGS. 17A to 17C. In the following, for convenience of description, components having the same function as components described in specific embodiments will be denoted by the same reference numerals, and the description thereof may be omitted.

First Embodiment

A first embodiment of the present disclosure will be described with reference toFIG. 1toFIGS. 9A to 9C.

FIG. 1is a diagram illustrating a vapor deposition mask1in which a plurality of protrusions5are provided outside an opening group formation region3.

In the present embodiment, although description is provided of an example of a case where the vapor deposition mask1is a metallic mask which does not experience deformation or the like at the temperature of the vapor deposition film formation step, the material of the mask is not particularly limited.

As illustrated inFIG. 1, the vapor deposition mask1may include a metallic substrate2provided with a plurality of openings4(also referred to as through-holes) to pass vapor deposition particles. The plurality of openings4in the opening group formation region3may be arranged in accordance with a constant rule, and a plurality of opening group formation regions3may be formed in the metal substrate2.

In addition, when manufacturing organic EL display devices, in order to manufacture at a lower cost, there are cases where a method is used in which a plurality of sub-substrates (for example, 5 inches) are simultaneously formed on a large base substrate, and cut out to form the individual sub-substrates. The opening group formation region3is a mask region corresponding to these sub-substrates.

In the present embodiment, although an example is provided of a case where30opening group formation regions3are formed, the number of the opening group formation regions3can be appropriately set in accordance with the size of one opening group formation region3and the size of the vapor deposition mask1, and may be one.

It should be noted that the size of one opening group formation region3may correspond to the size of a display region of one of the30organic EL display devices of the30organic EL display devices obtained by dividing the active matrix substrate including the vapor deposition film deposited using the vapor deposition mask1.

In addition, in the present embodiment, as description is provided of an example of a case where the evaporation mask1is a red light-emitting layer, the arrangement of the plurality of openings4in each opening group formation region3of the vapor deposition mask1is arranged in accordance with the shape of the red light-emitting layer of the30organic EL display devices obtained by dividing the active matrix substrate including the vapor deposition film deposited using the vapor deposition mask1.

In the present embodiment, as described below, the red pixels of the red light-emitting layer, the green pixels of the green light-emitting layer, and the blue pixels of the blue light-emitting layer are vapor deposition masks used for manufacturing an organic EL display device that forms one pixel. As such, although an example is described of a case where the arrangement of the plurality of openings4in the opening group formation region3is arranged is based on the arrangement of the pixels in accordance with a constant rule, it goes without saying that the arrangement of the plurality of openings4in the opening group formation region3may be arranged accordingly in cases where each color pixel is in a Pentile arrangement, another arrangement, or the size of each color pixel is different.

As illustrated inFIG. 1, in the vapor deposition mask1, a plurality of protrusions5are formed on a surface2aopposed to the active matrix substrate (not shown) outside the opening group formation region3. In the case of the vapor deposition mask1, although the protrusions5are provided at the four corner portions of the opening group formation region3, as described later, provided the arrangement can support the entire vapor deposition mask from one side, the present disclosure is not limited herein.

FIGS. 2A to 2Cis a diagram for describing a case where a vapor deposition film is formed on the active matrix substrate100ausing the vapor deposition mask1depicted inFIG. 1.

As illustrated inFIG. 2A, in the vapor deposition mask1, each of the plurality of protrusions5may be arranged on a surface2aopposed to the active matrix substrate100aand outside the opening group formation region3with a height of 4 μm so as to support the entire vapor deposition mask1from one side (the active matrix substrate100aside).

Accordingly, a 4 μm distance can be secured between the surface2aopposed to the active matrix substrate100aof the vapor deposition mask1and the surface of the active matrix substrate100opposed to the vapor deposition mask1. Note thatFIG. 2Adoes not depict the entire vapor deposition mask1and the active matrix substrate100a, but only depicts a portion corresponding to one opening group formation region3.

In the present embodiment, although a case in which the protrusions5are formed with a height of 4 μm was described as an example, it may be preferable that the height of the protrusions5be formed to be more than 2 μm and less than 5 μm for the reasons described below. In the case that the height of the protrusions5are formed to be 2 μm or less, the risk of contact between the vapor deposition mask1and the active matrix substrate100aincreases, and in the case that the height of the protrusions5are formed to be 5 μm or more, blurring may occur in the actual vapor deposition pattern, such that the vapor deposition accuracy is lowered.

As illustrated inFIG. 2A, a constant distance can be maintained by the protrusions5such that the active matrix substrate100aand the vapor deposition mask1do not completely adhere to each other.

Next, in a state where the active matrix substrate100aand the vapor deposition mask1are maintained at a constant distance, the vapor deposition particles emitted from the vapor deposition source (not shown) may be formed in a predetermined shape on the active matrix substrate100avia the openings4of the vapor deposition mask1, such that a uniform vapor deposition film can be formed on the active matrix substrate100a.

In a case where a vapor deposition mask1provided with the protrusions5is used, as the active matrix substrate100aand the vapor deposition mask1can be maintained at a constant distance by the projections5of the vapor deposition mask1, as illustrated inFIG. 2B, for example, only edge covers108awith a height of 1 μm may be provided on the active matrix substrate100a.

In addition, as illustrated inFIG. 2C, the active region of the active matrix substrate100awhich overlaps with the opening group formation region3of the vapor deposition mask in a plan view may be a region including an electrode107and the edge cover108a.

In the vapor deposition mask1, as the plurality of projections5are provided outside the opening group formation region3, the projections5of the vapor deposition mask1do not come into contact with the active region of the active matrix substrate100a, and are in contact with the upper surface of the interlayer insulating film106, which is a flattening film of the active matrix substrate100a.

Accordingly, by using the vapor deposition mask1, the active matrix substrate100aand the vapor deposition mask1can be maintained at a constant distance with high accuracy.

FIG. 3is a partially enlarged view of an opening group formation region3of the vapor deposition mask1.

As illustrated inFIG. 3, in the vapor deposition mask1, as the red pixels of the red light-emitting layer, the green pixels of the green light-emitting layer, and the blue pixels of the blue light-emitting layer are vapor deposition masks used for manufacturing an organic EL display device that forms one pixel, the plurality of openings4of the opening group formation region3may be formed with a first opening pitch in the horizontal direction of the figures and with a second opening pitch in the vertical direction of the figures.

Note that the opening4′ indicated by the dotted line in the figures is an opening present in the vapor deposition mask of the green light-emitting layer used for manufacturing the organic EL display device in which the red pixels of the red light-emitting layer, the green pixels of the green light-emitting layer, and the blue pixels of the blue light-emitting layer form one pixel, and is an imaginary opening that does not exist in the vapor deposition mask1. In addition, the opening4″ indicated by the dotted light in the figures is also an opening present in the vapor deposition mask of the blue light-emitting layer used for manufacturing the organic EL display device in which the red pixels of the red light-emitting layer, the green pixels of the green light-emitting layer, and the blue pixels of the blue light-emitting layer form one pixel, and is an imaginary opening that does not exist in the vapor deposition mask1.

As illustrated inFIG. 3, the opening group formation region3may be a region including at least a plurality of openings4, a region between each of the openings4in the horizontal direction of the figures, and a region between each of the openings4in the vertical direction of the figures. In the present embodiment, however, in order to prevent the protrusions5from coming into contact with the edge covers of active matrix substrates with more diverse shapes, the right end of the opening group formation region3may be widened by a width A from the right end of the opening4located at the right end within the opening group formation region3, the upper end of the opening group formation region3may be widened by a width B from the upper end of the opening4located at the upper end within the opening group formation region3, the left end of the opening group formation region3may be widened by a width C from the left end of the opening4located at the left end within the opening group formation region3, and the lower end of the opening group formation region3may be widened by a width D from the lower end of the opening4located at the lower end within the opening group formation region3. No protrusions5are provided within the expanded opening group formation region3.

As described above, when considering the edge covers108aarranged at the upper, lower, left, and right end portions, by establishing the opening group formation3, contact between the edge covers108arranged at the upper, lower, left, and right end portions and the plurality of protrusions5arranged outside the opening group formation region3may be prevented, and the protrusions5can be brought into contact with the upper surface of the interlayer insulating film106, which is a flattening film of the active matrix substrate100a.

FIG. 4is a diagram for describing an interface region of the protrusions5of the vapor deposition mask1depicted inFIG. 3in the active matrix substrate100b.

As illustrated inFIG. 4A, the active matrix substrate100bmay have a configuration in which an inorganic film109, an interlayer insulating film106which is a flattening film included in a formation layer of a TFT element (not shown) which is an active element, edge cover108a, and the projections108a′,108a″,108c, and108dare formed on the substrate104.

In particular, the edge cover108amay be provided on the interlayer insulating film106, which is a flattening film, in the active area (display region), the projection108a′ may be provided outside the active area adjacent to the edge cover108aon the interlayer insulating film106, which is a flattening film, the projection108a″ may be provided on the interlayer insulating film106, which is a flattening film, adjacent to the protrusion108a′, the projection108cmay be provided in the opening formed by the interlayer insulating film106, which is a flattening film, provided on the inorganic film109, and the projection108dmay be provided on the interlayer insulating film106, which is a flattening film.

As illustrated in the figures, the protrusions5of the vapor deposition mask1may be interfaced with the interlayer insulating film106in the interface region of the protrusions in the figure of the active matrix substrate100b.

As the interface region of the protrusions5depicted inFIG. 4Aare nearby to the opening group formation region3of the vapor deposition mask1depicted inFIG. 3, the gap between the vapor deposition mask1and the active matrix substrate100bcan be reliably secured.

Note that although the protrusions5of the vapor deposition mask1may be interfaced with the active matrix substrate100bin the interface region of the protrusions5depicted inFIG. 4A, the present disclosure is not limited herein, and the protrusions5may be interfaced with the active matrix substrate100bin the interface region of the protrusions5illustrated inFIG. 4B.

The interface region of the protrusions5depicted inFIG. 4Bmay be a region regulated by the projection108cand the interlayer insulating film106, which is a flattening film, within the opening formed by the interlayer insulating film106, which is a flattening film. In this interface region of the protrusions5, the protrusions5of the vapor deposition mask1may interface with the inorganic film109as an insulating film formed below the interlayer insulating film106, which is a flattening film, included in the formation layer of the TFT element (not shown) in the active matrix substrate100b.

In this way, when the protrusions5of the vapor deposition mask1are interfaced with the inorganic film109on the active matrix substrate100b, the gap between the vapor deposition mask1and the active matrix substrate100bcan be made smaller.

In addition, as the height of the protrusions5increase, since the size of the vapor deposition film formed on the active matrix substrate100aside is larger than the size of the openings4, the opening group formation region3in cases where the height of the protrusions5is tall may preferably be set wider than the opening group formation region3when the height of the protrusions5is short.

As illustrated inFIG. 1andFIG. 3, the plurality of openings4in the vapor deposition mask1may be structured from 30 groups of openings in which the openings4are repeatedly arranged in accordance with a constant rule, and as the region that includes each of the30opening groups is the opening group formation region3, there are 30 opening group formation region3in the vapor deposition mask1.

Each of the opening group formation regions3is a region corresponding to an active region, which is a display area of each of the30organic EL display devices obtained by dividing the active matrix substrate that includes the vapor deposition film deposited using the vapor deposition mask1. In particular, as illustrated inFIG. 2C, each of the opening group formation regions3is a region including a region where the electrode107and the edge cover108aare formed in the active matrix substrate100a.

In the present embodiment, as described below, although an example is described of a case in which a plurality of protrusions5are formed on a surface2aof a metal substrate2opposed to the active matrix substrate100aand outside the opening group formation region3using a resin material different from the metal substrate2, the present disclosure is not limited herein, and, for example, the protrusions5may be formed of the same material as the metal substrate2or a metal material different from the metal substrate2, by electroforming or the like.

FIGS. 5A to 5Dare diagrams illustrating a method of manufacturing a vapor deposition mask1provided with protrusions5formed by performing an exposure process after dripping a photo-curable resin material6using an ink-jet dripping device7.

First, as illustrated inFIG. 5A, in a metal substrate2provided with a plurality of openings4to pass vapor deposition particles, the photo-curable resin material6may be dripped using the ink-jet dripping device7onto a predetermined position on the surface2aopposed to the active matrix substrate and outside the opening group formation region3.

In the present embodiment, for example, a photo-curable resin material formed by dissolving an acrylic resin (acrylic polymer) including polymethyl methacrylate or the like and a photoinitiator in a predetermined solvent and adjusted to have a viscosity which can be used in the ink-jet dripping device7and that is also a viscosity that allows for film thickness adjustment on the metal substrate2in accordance with the drip amount was used as the photo-curable resin material6.

As illustrated inFIG. 5B, as the photo-curable resin material6is adjusted to have a viscosity that allows for film thickness adjustment, it can be formed to a constant film thickness in accordance with the drip amount, without widely spreading on the metal substrate2. Note that, in the present embodiment, after the photo-curable resin material6is formed to have a constant film thickness, pre-baking (heat treatment) was performed at a relatively low temperature in order to remove the solvent, but this pre-bake need not be performed.

Then, as illustrated inFIG. 5C, exposure may be performed using light in a wavelength region where the photoinitiator initiates a reaction, and the photo-curable resin material6may be photocured. As illustrated inFIG. 5D, protrusions5with a height of 4 μm may be formed on the outer side of the opening group formation region3on the surface2aof the metal substrate2opposite to the active matrix substrate.

Note that, in addition to the acrylic resin and the photoinitiator, it is preferable that the photo-curable resin material6further includes, for example, at least one of an epoxy resin (epoxy polymer) which is a thermosetting resin or a siloxane polymer as well as a thermal acid generator as a polymerization initiator in order to increase the strength and the like of the protrusions5. In such a case, post-baking (heat treatment) performed at a relatively high temperature may be performed in order to thermally cure the thermosetting resin.

In addition, considering that the vapor deposition mask1is a mask used in the vapor deposition process, even when a thermosetting resin is not included in the photo-curable resin material6, it is preferable for post-baking (heat treatment) at a relatively high temperature to be performed. The temperature of the post-baking (heat treatment) may preferably be set higher than the temperature at which the vapor deposition mask1is used in the vapor deposition process. This is because, in the case of organic films which do not undergo post-baking (heat treatment) performed at a relatively high temperature, there is a risk that the film thickness changes in the vapor deposition step.

Note that the temperature of the post-baking (heat treatment) may be configured to change in stages. In this case, in at least one stage of the multiple stages, it is preferable to set the temperature higher than the temperature at which the vapor deposition mask1is used in the vapor deposition process.

In addition, before dripping the photo-curable resin material6onto the surface2aof the metal substrate2opposed to the active matrix substrate, the surface2aof the metal substrate2, which opposes the active matrix substrate, may be treated with a silane coupling agent or the like to improve adhesion between the metal and the organic film, for example.

FIGS. 6A and 6Bare diagrams illustrating vapor deposition masks1aand1bin which the protrusions5are arranged at different positions from the vapor deposition mask1depicted inFIG. 1.

In the vapor deposition mask1depicted inFIG. 1, the protrusions5are provided at the four corner portions of the opening group formation region3, but as illustrated inFIG. 6A, the protrusions5may be provided outside the opening group formation region3and nearby an intermediate position between the four sides of the opening group formation region3. Further, as illustrated inFIG. 6B, when the 15 opening group formation regions3on the left side of the figure are regarded as large first opening group formation regions and the 15 opening group formation regions3on the right side of the figure are regarded as large second opening group formation regions, the protrusions5may be provided at each of the four corner portions of each of the first opening group formation region and the second opening group formation region, as well as both ends of the intermediate portion in the vertical direction.

As described above, the arrangement of the protrusions5is not particularly limited, provided it is outside the opening group formation region3and can support the entire vapor deposition mask1,1a, and1bfrom one side.

Although an example was described of a case where the protrusions5are formed through an exposure process after dripping the photo-curable resin material6using the ink-jet dripping device7, the protrusions5of the vapor deposition mask1may be formed through a heat treatment process after a thermosetting resin material8is dripped using the ink-jet dripping device7.

FIGS. 7A to 7Dare diagrams illustrating a method of manufacturing a vapor deposition mask10provided with projections9formed by a heat treatment process after a thermosetting resin material8is dripped using the ink-jet dripping device7.

First, as illustrated inFIGS. 7A to 7D, in a metal substrate2provided with a plurality of openings4to pass vapor deposition particles, the thermosetting resin8may be dripped using the ink-jet dripping device7onto a predetermined position on the surface2aopposed to the active matrix substrate and outside the opening group formation region3.

In the present embodiment, for example, a thermosetting resin material formed by dissolving at least one of an epoxy resin (epoxy polymer) and a thermal acid generator as a polymerization initiator in a predetermined solvent and adjusted to have a viscosity which can be used in the ink-jet dripping device7and that is also a viscosity that allows for film thickness adjustment on the metal substrate2in accordance with the drip amount was used as the thermosetting resin material8.

As illustrated inFIG. 7B, as the thermosetting resin material8is adjusted to have a viscosity that allows for film thickness adjustment, it can be formed to a constant film thickness in accordance with the drip amount, without widely spreading on the metal substrate2.

Then, as illustrated inFIG. 7C, heat treatment is performed at or above the temperature in which the thermal acid generator starts polymerization in order to remove the solvent and heat-cure the thermosetting resin material8, and as illustrated inFIG. 7D, a vapor deposition mask10having protrusions9with a height of 4 μm is completed on the outer side of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate.

In addition, considering that the vapor deposition mask10is a mask used in the vapor deposition process, the temperature of the heat treatment illustrated inFIG. 7Cmay preferably be set higher than the temperature at which the vapor deposition mask10is used in the vapor deposition process. This is because, in the case of films which do not undergo heat treatment performed at a relatively high temperature, there is a risk that the film thickness changes in the vapor deposition step.

Note that the temperature of the heat treatment illustrated inFIG. 7Cmay be configured to change in stages. In this case, in at least one stage of the multiple stages, it is preferable to set the temperature higher than the temperature at which the vapor deposition mask10is used in the vapor deposition process.

In addition, before dripping the thermosetting resin material6onto the surface2aof the metal substrate2opposed to the active matrix substrate, the surface2aof the metal substrate2, which opposes the active matrix substrate, may be treated with a silane coupling agent or the like to improve adhesion between the metal and the organic film, for example.

In addition, in cases where it is anticipated that the deposition mask10will be used at a relatively high temperature in the vapor deposition process, in the thermosetting resin material8, it is preferable to increase the content of the siloxane polymer, which is an organic-inorganic hybrid material that forms a film having a high heat-resistance after heat-curing.

In the following, a case will be described with reference toFIGS. 8A to 8Cin which protrusions12of a vapor deposition mask13are formed without using the ink-jet dripping device7.

FIGS. 8A to 8Care diagram illustrating a method of using a slit coater to manufacture a vapor deposition mask13provided with protrusions12formed through an exposure/development process after applying a photo-curable resin material11to the surface2aof the metal substrate2opposing the active matrix substrate.

First, as illustrated inFIG. 8A, the photo-curable resin material11may be applied using a slit coater (not shown) to the entire surface of the surface2aopposed to the active matrix substrate of the metal substrate2, with the exception of the opening4portion.

As a slit coater is used in place of the ink-jet dripping device7, since it is not necessary to adjust the viscosity according to the drip amount such that the film thickness can be adjusted on the metal substrate2as in the case of using the ink-jet dripping device7, the range of viscosity adjustment of the photo-curable resin material11may increase.

In the present embodiment, although a negative type photo-curable resin material formed by dissolving an acrylic resin (acrylic polymer) including polymethyl methacrylate or the like and a photoinitiator in a predetermined solvent and photo-curing an exposed portion was used as the photo-curable resin material11, the present disclosure is not limited thereto, and a positive photo-curable resin material may be used.

In addition, in the present embodiment, although an example was described of a case in which a slit coater was used, the present disclosure is not limited thereto. In consideration of the size of the openings4, the arrangement of the openings4, and the like, a method capable of uniformly coating the photo-curable resin material11on the entire surface with the exception of the opening4portion of the surface2aopposed to the active matrix substrate of the metal substrate2can be appropriately selected. For example, a screen printing method, a spin coater, or the like may be used.

As illustrated inFIG. 8C, a vapor deposition mask13provided with protrusions12having a height of 4 μm may be completed outside the opening group formation region3on the surface2aopposed to the active matrix substrate of the metal substrate2by performing exposure, development, and heat treatment using a mask32having an opening32aas illustrated inFIG. 8B.

Although the above-mentioned heat treatment can be omitted, considering that the vapor deposition mask13is a mask used in the vapor deposition process, it is preferable to perform the above-mentioned heat treatment, and it may be preferable that the temperature of the heat treatment is set higher than the temperature at which the vapor deposition mask13is used in the vapor deposition process. In addition, the temperature of the heat treatment may be configured to change in stages. In this case, in at least one stage of the multiple stages, it is preferable to set the temperature higher than the temperature at which the vapor deposition mask13is used in the vapor deposition process.

In addition, before applying the photo-curable resin material11on the surface2aof the metal substrate2opposed to the active matrix substrate, the surface2aof the metal substrate2, which opposes the active matrix substrate, may be treated with a silane coupling agent or the like to improve adhesion between the metal and the organic film, for example.

FIGS. 9A to 9Care diagram illustrating vapor deposition masks14,20, and20a, which include a plurality of divided masks16and are provided with projections5.

In the vapor deposition masks14,20, and20adepicted inFIG. 9A,FIG. 9B, andFIG. 9C, a plurality of divided masks16are fixed (stretched) in a state in which tension is applied to a frame15having a large opening15ain a center portion, and the opening group formation region18in each of the plurality of divided masks16is arranged so as to overlap with the large opening15ain the central portion of the frame15in a plan view.

Each of the plurality of divided masks16is composed of a metal plate17such as an Invar material, for example, and a surface16aon one side of the divided mask16is a surface opposed to the active matrix substrate.

Each of the plurality of divided masks16may include a plurality of opening group formation regions18similar to the opening group formation regions3illustrated inFIG. 3, and in the metal plate17, a region other than the opening group formation region18may be a surrounding region19.

In the vapor deposition mask14depicted inFIG. 9A, protrusions5with a height of 4 μm are provided at the four corner portions of the frame15outside the opening group formation region18. It should be noted that the arrangement positions of the protrusions5are not limited thereto. For example, the protrusions5may be arranged at regular intervals along the shape of the frame15with the exception of the portion where the divided masks16are fixed.

Note that, in the vapor deposition mask14, as the protrusions5are provided on the frame15, the distance between the frame15and the active matrix substrate is maintained at 4 μm, but in the case that it is desirable to maintain the distance between the divided masks16and the active matrix substrate at 4 μm, protrusions5having a height of 4 μm may be provided on the divided masks16, or projections5having a height obtained by adding the thickness of the divided mask16may be provided on the frame15, as depicted inFIG. 9BandFIG. 9Cto be described later.

In addition with respect to the protrusions5, before the plurality of divided masks16are fixed to the frame15; that is, after first providing the protrusions5on the frame15alone, the plurality of divided masks16may be fixed to the frame15, or the protrusions5may be provided on the frame15after fixing the plurality of divided masks16to the frame15.

In the vapor deposition mask14depicted inFIG. 9A, although the protrusions5were formed using the same method as the method illustrated inFIGS. 5A to 5D, the present disclosure is not limited thereto, and an appropriate selection can be made in consideration of the material of the frame15and the material of the protrusions5.

In the vapor deposition mask20depicted in theFIG. 9B, the protrusions5are provided near both ends each of the plurality of divided masks16in the vertical direction of the figure. In the case of the vapor deposition mask20, as the protrusions5are provided on the divided masks16, the distance between the divided masks16and the active matrix substrate can be maintained at a predetermined distance.

In addition with respect to the protrusions5, in the case of the vapor deposition mask20, before the plurality of divided masks16are fixed to the frame15; that is, after first providing the protrusions5to the divided masks16alone, the plurality of divided masks16may be fixed to the frame15, or the protrusions5may be provided on the divided masks16after the plurality of divided masks16are fixed to the frame15.

In the vapor deposition mask20adepicted inFIG. 9C, the protrusions5may be provided on the surface16aopposed to the active matrix substrate of the divided mask16and in the surrounding region19, which is a region other than the opening group formation region18. In the case of the vapor deposition mask20a, as the protrusions5are also provided in the center portion of the divided masks16in the vertical direction of the figure, the distance between the divided masks16and the active matrix substrate can be maintained at a predetermined distance with a higher accuracy.

In addition with respect to the protrusion5, also in the case of the vapor deposition mask20a, before the plurality of divided masks16are fixed to the frame15; that is, after first providing the protrusions5to the divided masks16alone, a plurality of divided masks16may be fixed to the frame15, and the projections5may be provided on the divided masks16after the plurality of divided masks16are fixed to the frame15.

In addition, although not depicted in the figures, the protrusions5may be provided on both the frame15and the divided masks16.

In this case, considering the thickness of the divided masks16, it may be desirable to set the height of the protrusions5provided on the divided masks16to be lower than the height of the protrusions5provided on the frame15by the thickness of the divided masks16.

In addition, in the vapor deposition masks14,20, and20adepicted inFIG. 9A,FIG. 9B, andFIG. 9C, an example was described of a case in which the divided masks16are fixed to the front side of the frame15, that is, the surface side of the frame15that opposes the active matrix substrate, but the present disclosure is not limited thereto. If the opening group formation region18in each of the plurality of divided masks16is arranged so as to overlap with the large opening15ain the center portion of the frame15in a plan view, the divided masks16may be fixed to the rear surface, that is, the surface of the frame15opposite to the surface facing the active matrix substrate.

Note that in the present embodiment, although an example has been described of a case in which the protrusions5are formed using a material that does not include beads, the protrusions5may be formed of a material including beads as in the third embodiment to be described later.

It should also be noted that in the present embodiment, although an example has been described of a case in which the protrusions5are formed in a dot shape, the shape is not particularly limited thereto provided it is one that can be provided outside the opening group formation region3on the surface2aof the metal substrate2which opposes the active matrix substrate. For example, the shape may be formed in a linear shape or the like.

Second Embodiment

Next, a second embodiment of the present disclosure will be described to reference toFIGS. 10A to 10FandFIGS. 11A to 11F. The present embodiment differs from the first embodiment in that first resin layers23,23ahaving recesses are formed on the surface2aof the metal substrate2which opposes the active matrix substrate, and the protrusions5are formed in the recesses. The other aspects are substantially similar to the description of the first embodiment. For convenience of description, components having the same function as components illustrated in the figures of the first embodiment will be denoted by the same reference numerals, and the description thereof may be omitted.

FIGS. 10A to 10Fare diagrams illustrating a method of manufacturing a vapor deposition mask10bin which a first resin layer23having a recess that exposes the surface2aof the metal substrate2opposed to the active matrix substrate (an opening in which the surface2aof the metal substrate opposed to the active matrix substrate is exposed) is formed on the entire outer surface of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate, and the protrusions5are formed in the recess.

First, as illustrated inFIG. 10A, a photo-curable resin material21may be applied using a slit coater (not shown) to the entire surface of the surface2aof the metal substrate2facing the active matrix substrate with the exception of the opening4portion.

In the present embodiment, for example, a negative photo-curable resin material formed by dissolving an acrylic resin (acrylic polymer) including polymethyl methacrylate or the like and a photoinitiator in a predetermined solvent and having a photo-cured exposed portion was used as the photo-curable resin material21, but the present disclosure is not limited herein, and a positive photo-curable resin material may also be used.

Then, after performing exposure using a mask22having a light blocking portion22aand an opening22cas illustrated inFIG. 10B, it is possible to form the first resin layer23having the recess that exposes the surface2aof the metal substrate2opposed to the active matrix substrate by developing, as illustrated inFIG. 10C.

It should be noted that the shape of the recess is not particularly limited, provided that it is formed on the outside of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate and is surrounded by the first resin layer23.

Then, as illustrated inFIG. 10D, the photo-curable resin material6may be dripped using the ink-jet dripping device7into the recess surrounded by the first resin layer23.

Then, as illustrated inFIG. 10E, as the photo-curable resin material6is adjusted to have a viscosity that allows for film thickness adjustment, it can be formed to a constant film thickness in accordance with the drip amount, without widely spreading on the metal substrate2. Note that, in the present embodiment, after the photo-curable resin material6is formed to have a constant film thickness, pre-baking (heat treatment) was performed at a relatively low temperature in order to remove the solvent, and exposure was subsequently performed to photo-cure the photo-curable resin material6. Then, post-baking was carried out at a relatively high temperature, and a vapor deposition mask10aprovided with protrusions5with a height of 4 μm in the recess surrounded by the first resin layer23was completed as illustrated inFIG. 10F.

In the manufacturing process of the vapor deposition mask10a, as the photo-curable resin material6is dripped into the recess surrounded by the first resin layer23, it is no longer necessary to consider spreading of the photo-curable resin material6on the metal substrate2, such that it is possible to widen the viscosity range of the photo-curable resin materials6that can be used.

In addition, in the case that the height of the protrusions5is 4 μm, the thickness of the first resin layer23surrounding the recess is not particularly limited provided that it is less than 4 μm. However, considering that the spreading of the photo-curable resin material6can be more effectively suppressed and that the active matrix substrate may have a configuration where it is also supported by the first resin layer23when the protrusions5are pushed in due to the load of the active matrix substrate or the like, it may be preferable that the thickness of the first resin layer23is greater than or equal to 50% and less than 100% of the height of the protrusions5, and even more preferably greater than or equal to 80% and less than or equal to 100% of the height of the protrusions5.

Note that in the present embodiment, the thickness of the first resin layer23was formed to be 2 μm, which is 50% of the height of the protrusions5.

FIGS. 11A to 11Fare diagrams illustrating a method of manufacturing a vapor deposition mask10bin which a first resin layer23ahaving a recess that does not expose the surface2aof the metal substrate2opposed to the active matrix substrate is formed on the entire outer surface of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate, and the protrusions5are formed in the recess.

First, as illustrated inFIG. 11A, a photo-curable resin material21may be applied using a slit coater (not shown) to the entire surface of the surface2aof the metal substrate2facing the active matrix substrate with the exception of the opening4portion.

Then, after performing exposure using a mask22having a light blocking portion22a, a slit opening22bthat transmits 30% of the exposure light, and an opening22cthat transmits 100% of the exposure light as illustrated inFIG. 11B, it is possible to form a first resin layer23ahaving a recess that does not expose the surface2aof the metal substrate2opposed to the active matrix substrate by developing, as illustrated inFIG. 11C. That is, the first resin layer23aremains in the recess with a constant film thickness.

As described above, although the manufacturing process of the vapor deposition mask10bmay include a half-exposure step, the present disclosure is not particularly limited thereto, provided that the first resin layer23ahaving the recess formed in this half exposure step is a film formed on the entire outer surface of the opening group formation region3on the surface2aopposed to the active matrix substrate of the metal substrate2, the size and shape of the recess are also formed on the outside of the opening group formation region3on the surface2aopposed to the active matrix substrate of the metal substrate2and it is surrounded by the first resin layer23a.

Then, as illustrated inFIG. 11D, the photo-curable resin material6may be dripped using the ink-jet dripping device7into the recess surrounded by the first resin layer23a.

Then, as illustrated inFIG. 11E, as the photo-curable resin material6is adjusted to have a viscosity that allows for film thickness adjustment, it can be formed to a constant film thickness in accordance with the drip amount, without widely spreading. Note that, in the present embodiment, after the photo-curable resin material6is formed to have a constant film thickness, pre-baking (heat treatment) was performed at a relatively low temperature in order to remove the solvent, and exposure was subsequently performed to photo-cure the photo-curable resin material6. Then, post-baking was carried out at a relatively high temperature, and a vapor deposition mask10bprovided with protrusions5in the recess surrounded by the first resin layer23awas completed as illustrated inFIG. 11F.

Note that the height of the protrusions5was set so that the total film thickness of the first resin layer23aremaining in the recess together with the height of the protrusion5was 4 μm.

In the case of the vapor deposition mask10b, as the protrusions5are formed on the first resin layer23aremaining in the recess, peeling of the protrusions5from the vapor deposition mask10bcan be suppressed.

In addition, in the case that the film thickness of the first resin layer23aremaining in the recess and the height of the protrusion5are 4 μm in total, the thickness of the first resin layer23asurrounding the recess is not particularly limited provided that it is less than 4 μm. However, considering that the spreading of the photo-curable resin material6can be more effectively suppressed and that the active matrix substrate may have a configuration where it is also supported by the first resin layer23awhen the protrusions5are pushed in due to the load of the active matrix substrate or the like, it may be preferable that the thickness of the first resin layer23ais greater than or equal to 50% and less than 100% of the combined value of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions5, and even more preferably greater than or equal to 80% and less than or equal to 100% of the combined value of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions5.

Note that in the present embodiment, the thickness of the first resin layer23awas formed to be 2 μm, which is 50% of the combined value of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions5.

In addition, in the present embodiment, although an example was described of a case in which a photo-curable resin material6was used inFIG. 10DandFIG. 11D, the present disclosure is not limited thereto, and a thermosetting resin material8may also be used.

Third Embodiment

Next, a third embodiment of the present disclosure will be described to reference toFIGS. 12A to 12FandFIGS. 13A to 13F. The present embodiment differs from the second embodiment in that first resin layers23,23ahaving recesses are formed on the surface2aof the metal substrate2which opposes the active matrix substrate, and the protrusions5are formed in the recesses using a photocurable resin material25including beads24. The other aspects are substantially similar to the description of the second embodiment. For convenience of description, components having the same function as components illustrated in the figures of the second embodiment will be denoted by the same reference numerals, and the description thereof may be omitted.

FIGS. 12A to 12Fis a diagram illustrating a method of manufacturing a vapor deposition mask27in which a first resin layer23having a recess that exposes the surface2aof the metal substrate2opposed to the active matrix substrate (an opening in which the surface2aof the metal substrate opposed to the active matrix substrate is exposed) is formed on the entire outer surface of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate, and protrusions26including beads24are formed in the recess.

First, as illustrated inFIG. 12A, a photo-curable resin material21may be applied using a slit coater (not shown) to the entire surface of the surface2aof the metal substrate2facing the active matrix substrate with the exception of the opening4portion.

Then, after performing exposure using a mask22having a light blocking portion22aand an opening22cas illustrated inFIG. 12B, it is possible to form the first resin layer23having the recess that exposes the surface2aof the metal substrate2opposed to the active matrix substrate by developing, as illustrated inFIG. 12C.

It should be noted that the shape of the recess is not particularly limited, provided that it is formed on the outside of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate and is surrounded by the first resin layer23.

Then, as illustrated inFIG. 12D, a photo-curable resin material25including beads24may be dripped using the ink-jet dripping device7into the recess surrounded by the first resin layer23.

Note that the average particle size and shape of the beads24can be appropriately selected based on consideration of the height of the protrusions26.

Then, as illustrated inFIG. 12E, as the photo-curable resin material25including beads24is adjusted to have a viscosity that allows for film thickness adjustment, it can be formed to a constant film thickness in accordance with the drip amount, without widely spreading on the metal substrate2. Note that, in the present embodiment, after the photo-curable resin material25including beads24is formed to have a constant film thickness, pre-baking (heat treatment) was performed at a relatively low temperature in order to remove the solvent, and exposure was subsequently performed to photo-cure the photo-curable resin material25including beads24. Then, post-baking was carried out at a relatively high temperature, and a vapor deposition mask27provided with protrusions26included the beads24and having a height of 4 μm was completed in the recess surrounded by the first resin layer23as illustrated inFIG. 12F.

In the manufacturing process of the vapor deposition mask27, as the photo-curable resin material25including beads24is dripped into the recess surrounded by the first resin layer23, it is no longer necessary to consider spreading of the photo-curable resin material25including beads24on the metal substrate2, such that it is possible to widen the viscosity range of the photo-curable resin material25including beads24that can be used.

In addition, in the case that the height of the protrusions26is 4 μm, the thickness of the first resin layer23surrounding the recess is not particularly limited provided that it is less than 4 μm. However, considering that the spreading of the photo-curable resin material25including beads24can be more effectively suppressed and that the active matrix substrate may have a configuration where it is also supported by the first resin layer23when the protrusions26are pushed in due to the load of the active matrix substrate or the like, it may be preferable that the thickness of the first resin layer23is greater than or equal to 50% and less than 100% of the height of the protrusions26, and even more preferably greater than or equal to 80% and less than or equal to 100% of the height of the protrusions26.

Note that in the present embodiment, the thickness of the first resin layer23was formed to be 2 μm, which is 50% of the height of the protrusions26.

As described above, in the vapor deposition mask27, as the protrusions26include beads24, it is possible to improve the precision of the height of the protrusions26and also improve the strength of the protrusions26.

FIGS. 13A to 13Fare diagrams illustrating a method of manufacturing a vapor deposition mask27a

in which a first resin layer23ahaving a recess that does not expose the surface2aof the metal substrate2opposed to the active matrix substrate is formed on the entire outer surface of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate, and protrusions26including beads24are formed in the recess.

First, as illustrated inFIG. 13A, a photo-curable resin material21may be applied using a slit coater (not shown) to the entire surface of the surface2aof the metal substrate2facing the active matrix substrate with the exception of the opening4portion.

Then, after performing exposure using a mask22having a light blocking portion22a, a slit opening22bthat transmits 30% of the exposure light, and an opening22cthat transmits 100% of the exposure light as illustrated inFIG. 13B, it is possible to form a first resin layer23ahaving a recess that does not expose the surface2aof the metal substrate2opposed to the active matrix substrate by developing, as illustrated inFIG. 13C. That is, the first resin layer23aremains in the recess with a constant film thickness.

Then, as illustrated inFIG. 13D, a photo-curable resin material25including beads24may be dripped using the ink-jet dripping device7into the recess surrounded by the first resin layer23a.

Then, as illustrated inFIG. 13E, as the photo-curable resin material25including beads24is adjusted to have a viscosity that allows for film thickness adjustment, it can be formed to a constant film thickness in accordance with the drip amount, without widely spreading. Note that, in the present embodiment, after the photo-curable resin material25including beads24is formed to have a constant film thickness, pre-baking (heat treatment) was performed at a relatively low temperature in order to remove the solvent, and exposure was subsequently performed to photo-cure the photo-curable resin material25including beads24. Then, post-baking was carried out at a relatively high temperature, and a vapor deposition mask27aprovided with protrusions26including the beads24was completed in the recess surrounded by the first resin layer23aas illustrated inFIG. 13F.

Note that the height of the protrusions26including the beads24was set so that the total film thickness of the first resin layer23aremaining in the recess together with the height of the protrusions26including the beads24was 4 μm.

In the case of the vapor deposition mask27a, as the protrusions26including the beads24are formed on the first resin layer23aremaining in the recess, peeling of the protrusions26including the beads24from the vapor deposition mask27acan be suppressed.

In addition, in the case that the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions26including the beads24are 4 μm in total, the thickness of the first resin layer23asurrounding the recess is not particularly limited provided that it is less than 4 μm. However, considering that the spreading of the photo-curable resin material25including the beads24can be more effectively suppressed and that the active matrix substrate may have a configuration where it is also supported by the first resin layer23awhen the protrusions26including the beads24are pushed in due to the load of the active matrix substrate or the like, it may be preferable that the thickness of the first resin layer23ais greater than or equal to 50% and less than 100% of the combined value of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions26including the beads24, and even more preferably greater than or equal to 80% and less than or equal to 100% of the combined value of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions26including the beads24.

Note that in the present embodiment, the thickness of the first resin layer23awas formed to be 2 μm, which is 50% of the combined value of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions26including the beads24.

In addition, in the present embodiment, although an example was described of a case in which a photo-curable resin material25including the beads24was used inFIG. 12DandFIG. 13D, the present disclosure is not limited thereto, and a thermosetting resin material including beads may also be used.

Fourth Embodiment

Next, a fourth embodiment of the present disclosure will be described with reference toFIGS. 14A to 14EandFIG. 15. The present embodiment differs from the third embodiment in that first resin layers23,23ahaving recesses are formed on the surface2aof the metal substrate2which opposes the active matrix substrate, and protrusions29are formed in the recess by using the photo-curable resin material25including the beads24and the thermosetting resin material28. The other aspects are substantially similar to the description of the second embodiment. For convenience of description, components having the same function as components illustrated in the figures of the third embodiment will be denoted by the same reference numerals, and the description thereof may be omitted.

FIGS. 14A to 14Eare diagrams illustrating a method of manufacturing a vapor deposition mask30in which a first resin layer23having a recess that exposes the surface2aof the metal substrate2opposed to the active matrix substrate (an opening in which the surface2aof the metal substrate opposed to the active matrix substrate is exposed) is formed on the entire outer surface of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate, and protrusions29are formed in the recess using the photo-curable resin material25including the beads24and the thermosetting resin material28.

As illustrated inFIG. 14A, a photo-curable resin material25including beads24may be dripped using the ink-jet dripping device7into the recess surrounded by the first resin layer23.

Note that, as the process of forming the first resin layer23having a recess that exposes the surface2aof the metal substrate2opposed to the active matrix substrate has already been described in the third embodiment, the description thereof will be omitted here.

Then, as illustrated inFIG. 14B, as the photo-curable resin material25including the beads24is adjusted to have a viscosity that allows for film thickness adjustment, it can be formed to a constant film thickness in accordance with the drip amount, without widely spreading on the metal substrate2. Note that, in the present embodiment, after the photo-curable resin material25including beads24is formed to have a constant film thickness, pre-baking (heat treatment) was performed at a relatively low temperature in order to remove the solvent, and exposure was subsequently performed to photo-cure the photo-curable resin material25including the beads24.

Subsequently, as illustrated inFIG. 14C, the thermosetting resin material28is dripped using the ink-jet dripping device7so as to cover the photo-curable resin material25including the cured beads24. Note that, at this time, the thermosetting resin material28is dripped so as to also cover a part of the upper surface of the first resin layer23.

Then, as illustrated inFIG. 14D, post-baking was carried out at a relatively high temperature, and a vapor deposition mask30formed with protrusions29with a height of 4 μm in the recess surrounded by the first resin layer23was completed using the photo-curable resin material25including the beads24and the thermosetting resin material28, as illustrated inFIG. 14E. It should be noted that, due to the thermosetting resin material28, the protrusions29are formed with a wider upper surface, and they are in contact with the upper surface of the first resin layer23.

Accordingly, in the case that the vapor deposition mask30is used, as the active matrix substrate comes into contact with the protrusions29, scratches are unlikely to occur, and the protrusions29are unlikely to be peeled off from the vapor deposition mask30.

In addition, in the case that the height of the protrusions29is 4 μm, the thickness of the first resin layer23surrounding the recess is not particularly limited provided that it is less than 4 μm. However, considering that the spreading of the photo-curable resin material25including beads24can be more effectively suppressed and that the active matrix substrate may have a configuration where it is also supported by the first resin layer23when the protrusions29are pushed in due to the load of the active matrix substrate or the like, it may be preferable that the thickness of the first resin layer23is greater than or equal to 50% and less than 100% of the height of the protrusions29, and even more preferably greater than or equal to 80% and less than or equal to 100% of the height of the protrusions29.

Note that in the present embodiment, the thickness of the first resin layer23was formed to be 2 μm, which is 50% of the height of the protrusions29.

Note that in the present embodiment, as illustrated inFIG. 14B, although an example was described of a case in which the formation width of the photo-curable resin material25including the beads24is formed to be narrower than the width of the recess surrounded by the first resin layer23, the formation width of the photo-curable resin material25including the beads24may be the same as the width of the recess surrounded by the first resin layer23.

In addition, in the present embodiment, although an example was described of a case in which the protrusions29are formed using photo-curable resin material25including the beads24and the thermosetting resin material28, the present disclosure is not limited thereto, and the protrusions29may be formed only using a photo-curable resin material including beads, only a thermosetting resin material including beads, or a thermosetting resin material including beads and a photo-curable resin material.

FIG. 15is a diagram illustrating a method of manufacturing a vapor deposition mask30ain which a first resin layer23ahaving a recess that does not expose the surface2aof the metal substrate2opposed to the active matrix substrate is formed on the entire outer surface of the opening group formation region3on the surface2aof the metal substrate2opposed to the active matrix substrate, and protrusions29are formed in the recess using the photo-curable resin material25including the beads24and the thermosetting resin material28.

As illustrated inFIG. 15A, a photo-curable resin material25including beads24may be dripped using the ink-jet dripping device7into the recess surrounded by the first resin layer23a.

Note that, as the process of forming the first resin layer23ahaving a recess that does not expose the surface2aof the metal substrate2opposed to the active matrix substrate has already been described in the third embodiment, the description thereof will be omitted here.

Then, as illustrated inFIG. 15B, as the photo-curable resin material25including beads24is adjusted to have a viscosity that allows for film thickness adjustment, it can be formed to a constant film thickness in accordance with the drip amount, without widely spreading on the metal substrate2. Note that, in the present embodiment, after the photo-curable resin material25including beads24is formed to have a constant film thickness, pre-baking (heat treatment) was performed at a relatively low temperature in order to remove the solvent, and exposure was subsequently performed to photo-cure the photo-curable resin material25including beads24.

Subsequently, as illustrated inFIG. 15C, the thermosetting resin material28is dripped using the ink-jet dripping device7so as to cover the photo-curable resin material25including the cured beads24. Note that, at this time, the thermosetting resin material28is dripped so as to also cover a part of the upper surface of the first resin layer23a.

Then, as illustrated inFIG. 15D, post-baking was carried out at a relatively high temperature, and a vapor deposition mask30aformed with protrusions29with a height of 4 μm in the recess surrounded by the first resin layer23awas completed using the photo-curable resin material25including the beads24and the thermosetting resin material28, as illustrated inFIG. 15E. It should be noted that, due to the thermosetting resin material28, the protrusions29are formed with a wider upper surface, and they are in contact with the upper surface of the first resin layer23a.

Accordingly, in the case that the vapor deposition mask30ais used, as the active matrix substrate comes into contact with the protrusions29, scratches are unlikely to occur, and the protrusions29are unlikely to be peeled off from the vapor deposition mask30a.

In addition, in the case that the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions29including the beads24are 4 μm in total, the thickness of the first resin layer23asurrounding the recess is not particularly limited provided that it is less than 4 μm. However, considering that the spreading of the photo-curable resin material25including the beads24can be more effectively suppressed and that the active matrix substrate may have a configuration where it is also supported by the first resin layer23awhen the protrusions29are pushed in due to the load of the active matrix substrate or the like, it may be preferable that the thickness of the first resin layer23ais greater than or equal to 50% and less than 100% of the combined height of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions29including the beads24, and even more preferably greater than or equal to 80% and less than or equal to 100% of the combined height of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions29including the beads24.

Note that in the present embodiment, the thickness of the first resin layer23awas formed to be 2 μm, which is 50% of the combined height of the film thickness of the first resin layer23aremaining in the recess and the height of the protrusions9including the beads24.

Note that in the present embodiment, as illustrated inFIG. 15B, although an example was described of a case in which the formation width of the photo-curable resin material25including the beads24is formed to be narrower than the width of the recess surrounded by the first resin layer23a, the formation width of the photo-curable resin material25including the beads24may be the same as the width of the recess surrounded by the first resin layer23a.

In addition, in the present embodiment, although an example was described of a case in which the protrusions29are formed using photo-curable resin material25including the beads24and the thermosetting resin material28, the present disclosure is not limited thereto, and the protrusions29may be formed only using a photo-curable resin material including beads, only a thermosetting resin material including beads, or a thermosetting resin material including beads and a photo-curable resin material.

In the case of the vapor deposition mask30a, as the protrusions29including the beads24are formed on the first resin layer23aremaining in the recess, peeling of the protrusions29including the beads24from the vapor deposition mask30acan be suppressed.

Fifth Embodiment

Next, a fifth embodiment of the present disclosure will be described with reference toFIG. 16andFIG. 17. In the present embodiment, a method of manufacturing an organic EL display device using the vapor deposition mask1will be described. For convenience of description, components having the same function as components illustrated in the figures of the first through fourth embodiments will be denoted by the same reference numerals, and the description thereof may be omitted.

FIG. 16is a diagram for describing each step of a method of manufacturing an organic EL display device using the vapor deposition mask1, andFIGS. 17A to 17Care diagram corresponding to each step of the method of manufacturing the organic EL display device using the vapor deposition mask depicted inFIG. 16.

In the method of manufacturing the organic EL display device using the vapor deposition mask1, as illustrated inFIG. 17A, a step (S1) is first performed in which the protrusions5of the vapor deposition mask1and a dummy substrate (planar substrate)110are interfaced with each other, and the position of the openings4of the vapor deposition mask1are aligned with respect to the dummy substrate110. Note that the dummy substrate110is a substrate on which a vapor deposition film used for manufacturing the active matrix substrate100ais not formed.

In the above step (S1), as the dummy substrate110is used, the protrusions5of the vapor deposition mask1and the dummy substrate110can be interfaced with each other so that the position of the openings4of the vapor deposition mask1can be aligned with respect to the dummy substrate110. That is, in a state where the protrusion5of the vapor deposition mask1and the dummy substrate110are interfaced with each other, it is possible to perform position alignment while moving the vapor deposition mask1with respect to the dummy substrate110. As there is no projection such as the edge cover108aon the dummy substrate110, it is not necessary to take into account contact between the vapor deposition mask1and the protrusions5during movement of the vapor deposition mask1.

It should be noted that, although not depicted inFIG. 17A, the vapor deposition mask1may be supported by a movable mask holder, and the dummy substrate110may be supported by a fixed substrate holder.

As described above, as the openings4of the vapor deposition mask1are aligned in advance in a state where the protrusions5of the vapor deposition mask1and the dummy substrate110are interfaced with each other, in a state described later where the active matrix substrate100aand the vapor deposition mask1are interfaced with each other, it is possible to suppress deviation in the position of the openings4of the vapor deposition mask1in a step (S3) of forming a vapor deposition film on the active matrix substrate100aby using the vapor deposition mask1.

Next, as illustrated inFIG. 17B, in a state where the vapor deposition mask1is fixed, a step (S2) is performed of replacing the dummy substrate110supported by the fixed substrate holder with the active matrix substrate100a.

Next, as illustrated inFIG. 17C, a step (S3) of forming a vapor deposition film on the active matrix substrate100ais performed using the vapor deposition mask1.

In the above step (S3), in a state where the active matrix substrate100aand the vapor deposition mask1are interfaced with each other, the vapor deposition particles emitted from the vapor deposition source (not shown) are formed in a predetermined shape on the active matrix substrate100avia the vapor deposition mask1.

It should be noted that, in the present embodiment, although an example was described of a case in which the openings4of the vapor deposition mask1are aligned in advance by using the dummy substrate110, the present disclosure is not limited thereto. For example, as illustrated inFIG. 17B, in a state where the protrusions5of the vapor deposition mask1and the interlayer insulating film106, which is a flattening film, of the active matrix substrate100aare interfaced with each other, position alignment may be performed while moving one of the active matrix substrate100aor the vapor deposition mask1with respect to the other. In this case, it is necessary to take into account the contact between the edge cover108aof the active matrix substrate100aand the protrusions5of the vapor deposition mask1during movement.

Supplement

A vapor deposition mask according to a first aspect of the present disclosure includes a vapor deposition mask including a substrate provided with a plurality of openings to pass vapor deposition particles, wherein at least a portion of the plurality of openings are structured by one or more opening groups, the plurality of openings being repeatedly arranged in accordance with a constant rule, an opening group formation region is a region in the substrate including at least a plurality of openings belonging to each of the opening groups and a region between adjacent openings of the plurality of openings belonging to each of the opening groups, and a plurality of protrusions of identical height are arranged to support the entire substrate from one side, and are provided only outside the opening group formation region.

According to the above configuration, as the plurality of protrusions of identical height are arranged to support the entire substrate from one side and are provided only outside the opening group formation region, it is possible to realize a vapor deposition mask capable of forming a uniform vapor deposition film on an active matrix substrate.

In the vapor deposition mask according to a second aspect of the present disclosure, in the first aspect, the plurality of protrusions may be formed of a resin containing a photo-curable resin material.

According to the above configuration, the protrusions can be formed using photo-curing.

In the vapor deposition mask according to a third aspect of the present disclosure, in the first aspect, the plurality of protrusions may be formed of a resin containing a thermosetting resin material.

According to the above configuration, the protrusions can be formed using thermal-curing.

In the vapor deposition mask according to a fourth aspect of the present disclosure, in the second or third aspects, the plurality of protrusions may be formed of a resin including beads.

According to the above configuration, it is possible to improve the height accuracy of the protrusions and the strength of the protrusions.

The vapor deposition mask according to a fifth aspect of the present disclosure, in any one of the first through fourth aspects, may include a plurality of divided substrates which are substrates provided with a plurality of openings to pass vapor deposition particles and a border-shaped frame, wherein each of the plurality of divided substrates may be fixed on the frame such that the plurality of openings to pass the vapor deposition particles in each of the plurality of divided substrates and an opening of the frame overlap in a plan view.

According to the above configuration, it is possible to realize a vapor deposition mask in which each of the plurality of divided substrates is fixed to the frame.

In the vapor deposition mask according to a sixth aspect of the present disclosure, in any one of the first through fifth aspects, a first resin layer provided with a recess that exposes the substrate may be formed outside the opening group formation region of the substrate, and the plurality of protrusions may be provided in the recess with a height such that the protrusions project from the recess.

According to the above configuration, as the protrusions are provided in the recess, it is easy to control the width of the protrusions.

In the vapor deposition mask according to a seventh aspect of the present disclosure, in any one of the first through fifth aspects, a first resin layer having a recess of identical depth may be formed outside the opening group formation region of the substrate, and the plurality of protrusions may be provided in the recess of the first resin layer with a height such that the protrusions project from the recess.

According to the above configuration, as the protrusions are provided in the recess, the width of the protrusions can be easily controlled and the protrusions are formed on the first resin layer, such that the protrusions are less likely to peel off from the vapor deposition mask.

In the vapor deposition mask according to an eighth aspect of the present disclosure, in the sixth aspect, a height of the first resin layer surrounding the recess may be greater than or equal to 50% and less than 100% of the height of the plurality of protrusions.

According to the above configuration, in the case that the protrusions are pushed in due to the load of the active matrix substrate or the like, the active matrix substrate may also be supported by the first resin layer.

In the vapor deposition mask according to a ninth aspect of the present disclosure, in the seventh aspect, a height of the first resin layer surrounding the recess may be greater than or equal to 50% and less than 100% of a value obtained by combining a thickness of the first resin layer and the height of the plurality of protrusions in the recess.

According to the above configuration, in the case that the protrusions are pushed in due to the load of the active matrix substrate or the like, the active matrix substrate may also be supported by the first resin layer.

In the vapor deposition mask according to a tenth aspect of the present disclosure, in any of the sixth through ninth aspects, the plurality of protrusions may be formed in the recess and a part of an upper surface of the first resin layer surrounding the recess.

According to the above configuration, scratches are unlikely to occur on the active matrix substrate contacting the protrusions, and the protrusions are unlikely to be peeled off from the vapor deposition mask.

In the vapor deposition mask according to an eleventh aspect of the present disclosure, in any of the first through tenth aspects, the plurality of protrusions may be formed in a dot-shape.

According to the above configuration, as the protrusions are formed in a dot-shape, contact with the edge cover of the active matrix substrate can be suppressed in comparison with the case where the protrusions are formed in a linear shape, or the like.

A method for manufacturing a vapor deposition mask according to a twelfth aspect of the present disclosure includes a method for manufacturing a vapor deposition mask provided with a plurality of openings to pass vapor deposition particles, wherein at least a portion of the plurality of openings are structured by one or more opening groups, the plurality of openings being repeatedly arranged in accordance with a constant rule, and an opening group formation region is a region in the substrate including at least a plurality of openings belonging to each of the opening groups and a region between adjacent openings of the plurality of openings belonging to each of the opening groups, the method including forming, only outside the opening group formation region, a plurality of protrusions of identical height with an arrangement to support the entire substrate from one side.

According to the above method, as a protrusion forming step is included for forming a plurality of protrusions of identical height only outside the opening group formation region of the substrate with an arrangement capable of supporting the entire substrate from one side, it is possible to realize a manufacturing method of a vapor deposition mask capable of forming a uniform vapor deposition film on an active matrix substrate.

In the method for manufacturing the vapor deposition mask according to a thirteenth aspect of the present disclosure, in the twelfth aspect, in the forming of the plurality of protrusions, the plurality of protrusions may be formed by dripping a liquid resin material including a photo-curable resin material on a predetermined location and photo-curing the liquid resin material.

According to the above method, the protrusions can be formed using a liquid resin material dripping method and light curing.

In the method for manufacturing the vapor deposition mask according to a fourteenth aspect of the present disclosure, in the twelfth aspect, in the forming of the plurality of protrusions, the plurality of protrusions may be formed by dripping a liquid resin material including a thermo-setting resin material on a predetermined location, and thermo-setting the liquid resin material.

According to the above method, the protrusions can be formed using a liquid resin material dripping method and thermal curing.

In the method for manufacturing the vapor deposition mask according to a fifteenth aspect of the present disclosure, in the thirteenth or fourteenth aspects, a liquid resin material including beads may be used in the forming of the plurality of protrusions.

According to the above method, it is possible to improve the height accuracy of the protrusions and the strength of the protrusions.

In the method for manufacturing the vapor deposition mask according to a sixteenth aspect of the present disclosure, in any of the twelfth through the fifteenth aspects, the vapor deposition mask sheet may further include a plurality of divided substrates which are substrates provided with a plurality of openings to pass vapor deposition particles, and a border-shaped frame, and the method may further include fixing, before forming of the plurality of protrusions, each of the plurality of divided substrates on the frame such that the plurality of openings to pass the vapor deposition particles in each of the plurality of divided substrates and an opening of the frame overlap in a plan view.

According to the above method, it is possible to realize a vapor deposition mask provided with the protrusions where each of the plurality of divided substrates are fixed to the frame.

In the method for manufacturing the vapor deposition mask according to a seventeenth aspect of the present disclosure, in any of the twelfth through the fifteenth aspects, the vapor deposition mask sheet may further include a plurality of divided substrates which are substrates provided with a plurality of openings to pass vapor deposition particles, and a border-shaped frame, and the method may further include fixing, after forming of the plurality of protrusions, each of the plurality of divided substrates on the frame such that the plurality of openings to pass the vapor deposition particles in each of the plurality of divided substrates and an opening of the frame overlap in a plan view.

According to the above method, it is possible to realize a vapor deposition mask provided with the protrusions where each of the plurality of divided substrates are fixed to the frame.

The method for manufacturing the vapor deposition mask according to an eighteenth aspect of the present disclosure, in any of the twelfth through the seventeenth aspects, may include forming, outside the opening group formation region of the substrate, a first resin layer provided with a recess that exposes the substrate, and forming, in the recess, the plurality of protrusions with a height so as to project from the recess, wherein, in the forming of the plurality of protrusions in the recess with a height so as to project from the recess, the plurality of protrusions are formed by dripping a liquid resin material on a predetermined portion of the recess, and curing the liquid resin material.

According to the above method, as the protrusions are formed by dripping a liquid resin material onto a predetermined location of the recess and curing it, it is easy to control the width of the protrusions.

The method for manufacturing the vapor deposition mask according to a nineteenth aspect of the present disclosure, in any of the twelfth through the seventeenth aspects, may include forming, outside the opening group formation region of the substrate, a first resin layer provided with a recess of identical depth, and forming, in the recess on the first resin layer, the plurality of protrusions with a height such that the protrusions project from the recess, wherein, in the forming of the plurality of protrusions in the recess on the first resin layer with a height such that the protrusions project from the recess, the plurality of protrusions are formed by dripping a liquid resin material on a predetermined portion of the recess, and curing the liquid resin material.

According to the above method, as the protrusions are formed by dripping a liquid resin material onto a predetermined location of the recess on the first resin layer and curing it, it is easy to control the width of the protrusions, and the protrusions are unlikely to peel off from the vapor deposition mask.

In the method for manufacturing the vapor deposition mask according to a twentieth aspect of the present disclosure, in the eighteenth aspect, in the forming of the first resin layer, a height of the first resin layer surrounding the recess may be greater than or equal to 50% and less than 100% of the height of the plurality of protrusions.

According to the above configuration, it is possible to realize a vapor deposition mask in which the active matrix substrate is also supported by the first resin layer in the case that the protrusions are pushed in due to the load of the active matrix substrate.

In the method for manufacturing the vapor deposition mask according to a twenty-first aspect of the present disclosure, in the nineteenth aspect, in the forming of the first resin layer, a height of the first resin layer surrounding the recess may be greater than or equal to 50% and less than 100% of a value obtained by combining a thickness of the first resin layer and the height of the plurality of protrusions in the recess.

According to the above configuration, it is possible to realize a vapor deposition mask in which the active matrix substrate is also supported by the first resin layer in the case that the protrusions are pushed in due to the load of the active matrix substrate.

In the method for manufacturing the vapor deposition mask according to a twenty-second aspect of the present disclosure, in any one of the eighteenth aspect through the twenty-first aspect, the plurality of protrusions may be formed in the recess and on a part of an upper surface of the first resin layer surrounding the recess.

According to the above method, it is possible to realize a vapor deposition mask in which scratches are unlikely to occur on the active matrix substrate contacting the protrusions, and the protrusions are unlikely to be peeled off from the vapor deposition mask.

In the method for manufacturing the vapor deposition mask according to a twenty-third aspect of the present disclosure, in any of the twelfth aspect through the twenty-second aspect, in the forming of the plurality of protrusions, the plurality of protrusions may be formed in a dot-shape.

According to the above configuration, it is possible to realize a vapor deposition mask in which contact with the edge cover of the active matrix substrate can be suppressed in comparison with the case where the protrusions are formed in a linear shape, or the like.

A method for manufacturing an organic EL display device according to a twenty-fourth aspect of the present disclosure, in any one of the first aspect through the eleventh aspect, includes interfacing a plurality of protrusions of the vapor deposition mask according to any one of embodiments 1 to 11 with a planar substrate to align a position of openings of the vapor deposition mask with respect to the planar substrate.

According to the above method, as the protrusions of the vapor deposition mask and the planar substrate are interfaced with each other and position alignment of the openings of the vapor deposition mask is performed with respect to the planar substrate, it is possible to suppress the occurrence of misalignment of the openings of the vapor deposition mask in the vapor deposition step, which is a subsequent step.

In the method for manufacturing the organic EL display device according to a twenty-fifth aspect of the present disclosure, in the twenty-fourth aspect, may include replacing the planar substrate with an active matrix substrate, and forming, in a state where the plurality of protrusions of the vapor deposition mask and the active matrix substrate are interfaced with each other, a vapor deposition film on the active matrix substrate using the vapor deposition mask.

According to the above method, in a state where the protrusions of the vapor deposition mask and the active matrix substrate are interfaced with each other, in the step of forming the vapor deposition film on the active matrix substrate using the vapor deposition mask, it is possible to suppress the occurrence of misalignment of the openings of the vapor deposition mask.

A method for manufacturing an organic EL display device according to a twenty-sixth aspect of the present disclosure includes interfacing a plurality of protrusions of the vapor deposition mask according to any one of embodiments 1 to 11 with an active matrix substrate.

According to the above method, it is possible to realize a manufacturing method of an organic EL display device capable of forming a uniform vapor deposition film on an active matrix substrate.

The method for manufacturing the organic EL display device according to a twenty-seventh aspect of the present disclosure, in the twenty-sixth aspect, may include interfacing, in interfacing of the plurality of protrusions of a vapor deposition mask with an active matrix substrate, the plurality of protrusions of the vapor deposition mask with a lower insulating film than an interlayer insulating film included in a formation layer of an active element provided on the active matrix substrate.

According to the above method, the gap between the vapor deposition mask and the active matrix substrate can be further reduced.

A method for manufacturing an organic EL display device according to a twenty-eighth aspect of the present disclosure, in the twenty-sixth aspect, includes interfacing, in interfacing of the plurality of protrusions of a vapor deposition mask with an active matrix substrate, the plurality of protrusions of the vapor deposition mask with an interlayer insulating film formed near a display region of the active matrix substrate and included in a formation layer of an active element provided on the active matrix substrate.

According to the above method, the gap between the vapor deposition mask and the active matrix substrate can be reliably secured.

Additional Notes

The present disclosure is not limited to each of the embodiments stated above, and various modifications may be implemented within a range not departing from the scope of the claims. Embodiments obtained by appropriately combining technical approaches stated in each of the different embodiments also fall within the scope of the technology of the present disclosure. Moreover, novel technical features may be formed by combining the technical approaches stated in each of the embodiments.

INDUSTRIAL APPLICABILITY

The present disclosure can be applied to vapor deposition masks, methods for manufacturing vapor deposition masks, and methods of manufacturing organic EL display devices.

REFERENCE SIGNS LIST