Organic layer deposition assembly, organic layer deposition device including the same, and method of manufacturing organic light-emitting display device using the organic layer deposition assembly

An organic layer deposition assembly for depositing a deposition material on a substrate includes a deposition source configured to spray the deposition material, a deposition source nozzle arranged in one side of the deposition source and including deposition source nozzles arranged in a first direction, a patterning slit sheet arranged to face the deposition source nozzle and having patterning slits in a second direction that crosses the first direction, and a correction sheet arranged between the deposition source nozzle and the patterning slit sheet and configured to block at least a part of the deposition material sprayed from the deposition source.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority from and the benefit of Korean Patent Application No. 10-2015-0186769, filed on Dec. 24, 2015, which is hereby incorporated by reference for all purposes as if fully set forth herein.

BACKGROUND

Field

Exemplary embodiments relate to an organic layer deposition assembly, an organic layer deposition device including the same, and a method of manufacturing an organic light-emitting display device using the same.

Discussion of the Background

Among display devices, an organic light-emitting display device has been in the spotlight as a next generation display device for its wide viewing angle, excellent contrast, and fast response time.

The organic light-emitting device includes a first electrode, a second electrode opposite the first electrode, and an intermediate layer disposed between the first electrode and the second electrode and including an emission layer. The first electrode, the second electrode, and the intermediate layer are formed by using various methods. One of these various methods is an independent deposition method. In order to manufacture the organic light-emitting display device by using a deposition method, an organic layer of a predetermined pattern is formed by bringing a fine metal mask (FMM) having the same pattern as the pattern of the organic layer or the like into close contact with a substrate over which the organic layer or the like is to be formed and depositing a material of the organic layer or the like.

SUMMARY

Exemplary embodiments include an organic layer deposition assembly, an organic layer deposition device including the same, and a method of manufacturing an organic light-emitting display device using the same.

Additional aspects will be set forth in part in the description which follows and, in part, will be apparent from the disclosure, or may be learned by practice of the inventive concept.

According to one or more exemplary embodiments, an organic layer deposition assembly for depositing a deposition material on a substrate includes a deposition source configured to spray the deposition material, a deposition source nozzle arranged in one side of the deposition source and including deposition source nozzles arranged in a first direction, a patterning slit sheet arranged to face the deposition source nozzle and having patterning slits in a second direction that crosses the first direction, and a correction sheet arranged between the deposition source nozzle and the patterning slit sheet and configured to block at least a part of the deposition material sprayed from the deposition source, wherein the organic layer deposition assembly is configured to perform deposition while the substrate moves in the first direction with respect to the organic layer deposition assembly, wherein the patterning slits include a first patterning slit and a second patterning slit spaced apart from each other by a predetermined distance in the first direction and in the second direction, and wherein a line crossing a center of the first patterning slit in the second direction and a line crossing a center of the second patterning slit in the second direction are spaced apart from each other by a predetermined distance.

According to one or more exemplary embodiments, an organic layer deposition device includes a transfer unit including a moving unit arranged to move along with a substrate fixed to the moving unit, a first transfer unit configured to transfer the moving unit to which the substrate is fixed in a first direction, and a second transfer unit configured to transfer the moving unit from which the substrate is separated when deposition is completed in a direction opposite the first direction, a loading unit configured to fix the substrate to the moving unit, a deposition unit including a chamber configured to maintain a vacuum therein and at least one organic layer deposition assembly configured to deposit an organic layer on the substrate fixed to the moving unit transferred from the loading unit, and an unloading unit configured to separate the substrate on which deposition is completed by passing through the deposition unit from the moving unit, wherein the moving unit is configured to move cyclically between the first transfer unit and the second transfer unit, wherein the substrate fixed to the moving unit is spaced apart from the organic layer deposition assembly by a predetermined degree while the first transfer unit is moving. The organic layer deposition assembly includes a deposition source configured to spray the deposition material, a deposition source nozzle arranged in one side of the deposition source and including deposition source nozzles arranged in a first direction, a patterning slit sheet arranged to face the deposition source nozzle and including patterning slits in a second direction crossing the first direction, and a correction sheet arranged between the deposition source nozzle and the patterning slit sheet and configured to block at least a part of the deposition material sprayed from the deposition source, wherein the organic layer deposition assembly is configured to perform deposition while the substrate moves in the first direction with respect to the organic layer deposition assembly, wherein the patterning slits include a first patterning slit and a second patterning slit spaced apart from each other by a predetermined distance in the first direction and in the second direction, and wherein a line crossing a center of the first patterning slit in the second direction and a line crossing a center of the second patterning slit in the second direction are spaced apart from each other by a predetermined distance.

According to one or more exemplary embodiments, a method of manufacturing an organic light emitting display device including an organic layer deposition device for depositing an organic layer on a substrate includes fixing the substrate to a moving unit wherein the fixing is performed by a loading unit, transferring the moving unit to which the substrate is fixed to a chamber via a first transfer unit installed to penetrate the chamber, forming the organic layer by depositing a deposition material sprayed from the organic layer deposition assembly on the substrate while the substrate relatively moves with respect to the organic layer deposition assembly wherein an organic layer deposition assembly and the substrate that are arranged in the chamber are spaced apart from each other by a predetermined degree, separating the substrate from which deposition is completed from the moving unit wherein the separating is performed by an unloading unit, and transferring the moving unit separated from the substrate to the loading unit via a second transfer unit installed to penetrate the chamber. The organic layer deposition assembly includes a deposition source configured to spray the deposition material, a deposition source nozzle arranged in one side of the deposition source and including deposition source nozzles arranged in a first direction, a patterning slit sheet arranged to face the deposition source nozzle and including patterning slits in a second direction that crosses the first direction, and a correction sheet arranged between the deposition source nozzle and the patterning slit sheet and configured to block at least a part of the deposition material sprayed from the deposition source wherein the organic layer deposition assembly is configured to perform deposition while the substrate moves in the first direction with respect to the organic layer deposition assembly, wherein the patterning slits include a first patterning slit and a second patterning slit spaced apart from each other by a predetermined distance in the first direction and in the second direction, and wherein a line crossing a center of the first patterning slit in the second direction and a line crossing a center of the second patterning slit in the second direction are spaced apart from each other by a predetermined distance.

According to one or more exemplary embodiments, an organic layer deposition assembly for depositing a deposition material on a substrate includes a deposition source, deposition source nozzles, a patterning slit, and a correction sheet. The deposition source nozzles are disposed in one side of the deposition source and are arranged in a first direction. The patterning slit sheet is arranged to face the deposition source nozzle and has patterning slits disposed in a second direction that crosses the first direction. The correction sheet is arranged between the deposition source nozzle and the patterning slit sheet, and is configured to block at least a part of the patterning slit sheet. The correction sheet is further shaped to block a larger portion of central patterning slits than peripheral patterning slits.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

FIG. 1is a schematic plan view of an organic layer deposition device10according to an exemplary embodiment.FIG. 2is a schematic perspective cross-sectional view of a part of a deposition unit100of the organic layer deposition device10shown inFIG. 1.FIG. 3is a schematic cross-sectional view of a part of the deposition unit100of the organic layer deposition device10shown inFIG. 1.

Referring toFIGS. 1, 2, and 3, the organic layer deposition device10may include the deposition unit100, a loading unit200, an unloading unit300, and a transfer unit400.

The loading unit200may include a first rack212, an introduction chamber214, a first inversion chamber218, and a buffer chamber219.

One or more substrates600, over which deposition is to be performed, may be loaded over the first rack212. An introduction robot provided in the introduction chamber214may hold the substrate600over the first rack212, may place the substrate600over a moving unit430moved from a second transfer unit420, and may move, to the first inversion chamber218, the moving unit430over which the substrate600is placed.

The first inversion chamber218may be provided adjacent to the introduction chamber214. A first inversion robot located in the first inversion chamber218may invert the moving unit430and may mount the moving unit430over a first transfer unit410of the deposition unit100.

Referring toFIG. 1, the introduction robot of the introduction chamber214may place the substrate600over an upper surface of the moving unit430. In this state, the moving unit430may be transferred to the inversion chamber218. As the first inversion robot of the inversion chamber218may invert the inversion chamber218, the substrate600may be turned upside down in the deposition unit100.

A configuration of the unloading unit300may be opposite to that of the loading unit200described above. That is, a second inversion robot may invert the substrate600and the moving unit430which pass through the deposition unit100and may transfer the substrate600and the moving unit430to an ejection chamber324. An ejection robot may eject the substrate600and the moving unit430from the ejection chamber324, may separate the substrate600from the moving unit430, and may load the separated substrate600over a second rack322. The moving unit430, separated from the substrate600, may be retransferred to the loading unit200through the second transfer unit420.

However, exemplary embodiments of the disclosure are not necessarily limited thereto. Thus, the substrate600may be directly transferred to the deposition unit100by being fixed to a lower surface of the moving unit430. In this case, for example, the first inversion robot of the first inversion chamber218and the second inversion robot of the second inversion chamber328may be unnecessary.

The deposition unit100may include at least one chamber101for deposition. According to the exemplary embodiment shown inFIGS. 1 and 2, the deposition unit100may include the chamber101in which a plurality of deposition assemblies100-1,100-2, . . .100-nmay be arranged. According to the exemplary embodiment shown inFIG. 1, although the first through eleventh deposition assemblies100-1through100-11are installed in the chamber101, the number of the deposition assemblies may vary according to a deposition material and a deposition condition. The chamber101may maintain a vacuum during deposition.

According to the exemplary embodiment shown inFIG. 1, the moving unit430, to which the substrate600is fixed, may be moved to at least the deposition unit100by the transfer unit410or may be sequentially moved to the loading unit200, the deposition unit100, and the unloading unit300by the first transfer unit410. The moving unit430, separated from the substrate600in the unloading unit300, may be retransferred to the loading unit200by the second transfer unit420.

The first transfer unit410may penetrate the chamber101when passing through the deposition unit100. The second transfer unit420may transfer the moving unit430from which the substrate600is separated.

In the organic layer deposition device10according to the present exemplary embodiment, the first and second transfer units410and420may be respectively arranged in a vertical direction so that the moving unit430, that completes deposition while passing through the first transfer unit410, is separated from the substrate600in the unloading unit300and retransferred to the loading unit200through the second transfer unit420arranged below the moving unit430. Thus, space utilization efficiency in the organic layer deposition device10may be improved.

The deposition unit100ofFIG. 1may further include a deposition source replacement unit190at one side of each of the deposition assemblies100-1through100-n(where n is a natural number from 1 through n, with n being 11 in the present exemplary embodiment). Although not shown in detail inFIG. 1, the deposition source replacement unit190may be formed in a cassette type so as to be ejected to the outside from each of the deposition assemblies100-1through100-n(where n is a natural number from 1 through 11). Thus, a deposition source (see110ofFIG. 3) of the organic layer deposition assembly100-5may be easily replaced.

As shown inFIG. 1, two sets are provided in parallel for constituting the organic layer deposition device10, each including the loading unit200, the deposition unit100, the unloading unit300, and the transfer unit400(shown inFIG. 4). That is, two organic layer deposition devices10may be respectively provided at an upper side and a lower side inFIG. 1.

In this case, a patterning slit sheet replacement unit500may be further disposed between the two organic layer deposition devices10. That is, the patterning slit sheet replacement unit500may be disposed between the two organic layer deposition devices10such that the two organic layer deposition devices10share the patterning slit sheet replacement unit500, thereby improving space utilization efficiency, compared to a case where each of the two organic layer deposition devices10includes the patterning slit sheet replacement unit500.

Referring toFIGS. 2 and 3, the deposition unit100of the organic layer deposition device10may include at least one organic layer deposition assembly100-5and the transfer unit400.

An overall configuration of the deposition unit100will be described below.

The chamber101may be formed as a hollow box shape. The at least one organic layer deposition assembly100-5and the transfer unit400may be accommodated in the chamber101. In more detail, a base102may be formed and fixed to a support surface (such as a floor), a lower housing103may be formed over the base102, and an upper housing104may be formed over the lower housing103. The chamber101may accommodate both of the lower and upper housings103and104therein. In this regard, a connector between the lower housing103and the upper housing104may be sealed to allow an inside of the chamber101to be entirely blocked from the outside.

As described above, the lower and upper housings103and104may be arranged over the base102fixed to the support surface, and thus the lower and upper housings103and104may maintain their fixed positions even though the chamber101repeatedly contracts or expands. Accordingly, the lower and upper housings103and104may function as a kind of a reference frame in the deposition unit100.

The organic layer deposition assembly100-5and the first transfer unit410of the transfer unit400may be arranged in the upper housing104, and the second transfer unit420of the transfer unit400may be arranged in the lower housing103. Deposition may be continuously performed while the moving unit430cyclically moves between the first transfer unit410and the second transfer unit420.

A detailed configuration of the organic layer deposition assembly100-5will be described below.

The organic layer deposition assembly100-5may include a deposition source110, a deposition source nozzle120, source shutters140, a frame sheet assembly150, a first stage160, and a second stage170. In order to ensure that a deposition material115is delivered in a linear manner, all elements ofFIGS. 2 and 3may be arranged in the chamber101in which an appropriate degree of vacuum is maintained.

The substrate600, that is, a deposition target, may be arranged in the chamber101. The substrate600may be a substrate for a flat panel display device. The substrate600may also be a large-sized substrate for manufacturing a flat panel display device having a large screen of about 40 inches or more.

In this regard, deposition may be performed while the substrate600moves relatively with respect to the organic layer deposition assembly100-5.

In more detail, it is required that a fine metal mask (FMM) has the same size as that of a substrate in the exiting FMM deposition method. Thus, if the size of the substrate increases, an FMM with a larger size is required. Accordingly, it is not easy to manufacture an FMM and also it is not easy to manufacture an FMM having tensile properties and align the FMM in a precise pattern.

In order to address these problems, deposition may be performed while the organic layer deposition assembly100-5and the substrate600move relatively with respect to each other. In other words, deposition may be continuously performed while the substrate600facing the organic layer deposition assembly100-5moves in an X-axis direction. That is, deposition may be performed in a scanning manner while the substrate600moves in a direction of an arrow A ofFIG. 2.

In this regard, deposition is performed while the substrate600moves in a Y-axis direction in the chamber101inFIG. 2. However, the present disclosure is not limited thereto. Deposition may be performed while the substrate600is fixed, and the organic layer deposition assembly100-5moves in the Y-axis direction.

Thus, the mask sheet assembly150having a much smaller size than an existing FMM may be manufactured by using the organic layer deposition assembly100-5. That is, the organic layer deposition assembly100-5may continuously perform deposition, i.e., by moving in a scanning manner, while the substrate600moves in the Y-axis direction, and thus a length of the mask sheet assembly150in at least one of the X-axis direction and the Y-axis direction may be much less than a length of the substrate600.

As described above, the mask sheet assembly150may be much smaller than the existing FMM, and thus it is easy to manufacture the mask sheet assembly150. That is, in all processes of the mask sheet assembly150such as an etching process, a subsequent fine tensile and welding process, a transfer and washing process, etc. the mask sheet assembly150having a small size may be advantageous compared to a FMM deposition method. The mask sheet assembly150having a small size may be further advantageous as the organic light-emitting display device becomes larger.

As described above, in order to perform deposition while the organic layer deposition assembly100-5and the substrate600move relatively with respect to each other, the organic layer deposition assembly100-5and the substrate600may be spaced apart from each other. This will be described in detail later.

The deposition source110receiving and heating the deposition material115may be arranged at a side opposite to the substrate600in the chamber101. As the deposition material115received in the deposition source110is evaporated, deposition may be performed over the substrate600.

More specifically, the deposition source110may include a crucible111filled with the deposition material115therein and a heater112for heating the crucible111and evaporating the deposition material115filling the crucible111toward one side of the crucible111, specifically, toward the deposition source nozzle120.

The deposition source nozzle120may be arranged at one side of the deposition source110, specifically, at a side that faces the substrate600in the deposition source110. In this regard, in the organic layer deposition assembly100-5, deposition source nozzles121may be formed differently from each other when a common layer and a pattern layer are deposited.

The mask sheet assembly150may be further provided between the deposition source110and the substrate600. The above-described mask sheet assembly150will be described in detail below.

The deposition material115evaporated in the deposition source110may pass through the deposition source nozzle120and the mask sheet assembly150and face toward the substrate600that is a deposition target. In this regard, the mask sheet assembly150may be manufactured through etching that is the same method as an existing method of manufacturing a FMM, in particular, a stripe type mask. However, the present disclosure is not limited thereto. The mask sheet assembly150may be manufactured by using an electro-forming method, a laser patterning method, or the like.

In this regard, the above-described deposition source110, the deposition source nozzle120coupled to the deposition source110, and the mask sheet assembly150may be spaced apart from each other.

As described above, the deposition may be performed in the organic layer deposition assembly100-5while moving relatively with respect to the substrate600. In order for the organic layer deposition assembly100-5to move relatively with respect to the substrate600, the mask sheet assembly150may be spaced apart from the substrate600by a predetermined distance.

More specifically, an existing FMM deposition method performs a deposition process by bringing a mask into close contact with a substrate in order to prevent a shadow from being formed over the substrate. However, when the mask comes into close contact with the substrate as described above, defects occur due to the contact between the substrate and the mask. Since the mask may not move with respect to the substrate, a size of the mask needs to be the same as that of the substrate. Thus, since the organic light-emitting device becomes larger, the size of the mask needs to increase, which causes a problem in that it is not easy to form such a large-sized mask.

In order to address the problem, in the organic layer deposition assembly100-5according to the present exemplary embodiment, the mask sheet assembly150may be spaced apart from the substrate600, the deposition target, by a predetermined distance.

According to the present disclosure, deposition may be performed while the mask sheet assembly150moves with respect to the substrate600, thereby obtaining an effect of easily manufacturing the mask sheet assembly150. Since exemplary embodiments avoid mask contact with the substrate, defects caused by a contact between the substrate600and the mask sheet assembly150may be prevented. Manufacturing speed may also be increased since the time to bring the substrate600into close contact with the mask sheet assembly150during processing may be unnecessary.

A specific placement of each of configurations of the upper housing104will be described as follows.

The above-described deposition source110and deposition source nozzle120may be arranged over a bottom portion of the upper housing104. A seating unit104-1may protrude from both sides of the deposition source110and the deposition source nozzle units120. The mask sheet assembly150, the first stage160, and the second stage170may be sequentially arranged over the seating unit104-1.

In this regard, the first stage160may be configured to move in the X-axis direction and the Y-axis direction and may function to align the mask sheet assembly150in the X-axis direction and the Y-axis direction. That is, the first stage160may include a plurality of actuators and may move in the X-axis direction and the Y-axis direction with respect to the upper housing104.

The second stage170may be configured to move in a Z-axis direction and may function to align the mask sheet assembly150in the Z-axis direction. That is, the second stage170may include a plurality of actuators and may move in the Z-axis direction with respect to the first stage160.

The mask sheet assembly150may be arranged over the second stage170. As described above, the mask sheet assembly150is arranged over the first and second stages160and170such that the mask sheet assembly150is configured to move in the X-axis direction, the Y-axis-direction, and the Z-axis direction, and thus the substrate600and the mask sheet assembly150may be aligned.

Furthermore, the upper housing104, the first stage160, and the second stage170may simultaneously function to guide a movement path of the deposition material115such that the deposition material115sprayed through the deposition source nozzles121is not dispersed. That is, the movement path of the deposition material115may be closed by the upper housing104, the first stage160, and the second stage170, and thus the upper housing104, the movement of the deposition material115may simultaneously guide a movement of the deposition material115in the X-axis direction and the Y-axis direction.

The source shutters140may be further provided between the mask sheet assembly150and the deposition source110. The source shutters140may function to block the deposition material115sprayed from the deposition source110.

Although not shown inFIG. 1, 2, or3, a blocking member (not shown) for preventing an organic material from being deposited on a non-film forming region of the substrate600may be further provided in the deposition unit100. The blocking member (not shown) may be formed to move together with the substrate600while covering an edge portion of the substrate600, and thus the non-film forming region of the substrate600may be covered, thereby obtaining an effect of conveniently preventing the organic material from being deposited on the non-film forming region of the substrate600without a separate structure.

In addition, although not shown inFIGS. 1, 2 and 3, source shutter drivers (not shown) for moving respectively the source shutters140may be further provided in the deposition unit100. In this regard, each of the source shutter drivers may include a general motor and a gear assembly and may include a cylinder or the like that linearly moves in one direction. However, the above-described source shutter drivers are not limited thereto and may include all of devices that linearly move each of the source shutters140.

The transfer unit400for transferring the substrate600that is a deposition target will be described in detail below. Referring toFIGS. 2 and 3, the transfer unit400may include the first transfer unit410, the second transfer unit420, and the moving unit430.

In order to deposit an organic layer over the substrate600with the organic layer deposition assembly100-5, the first transfer unit410may function to, in-line, transfer the moving unit430including a carrier431and an electrostatic chuck432coupled to the carrier431and the substrate600attached to the moving unit430.

The second transfer unit420may function to retransfer, to the loading unit200, the moving unit430from which the substrate600is separated in the unloading unit300after deposition is performed once while the substrate600passes through the deposition unit100. The above-described second transfer unit420may include a coil421, a roller guide422, and a charging track423.

The moving unit430may include the carrier431that is transferred along with the first and second transfer units410and420and the electrostatic chuck432coupled over one surface of the carrier431and to which the substrate600is attached.

Each of configurations of the transfer unit400will be described in more detail below.

The carrier431of the moving unit430will be described in detail.

The carrier431may include a body portion431a, a linear motion system (LMS) magnet, a contactless power supply (CPS) module431c, a power supply431d, and guide grooves (not shown).

The body portion431amay constitute a base portion of the carrier431and may include a magnetic material such as iron. The carrier431may be maintained to be spaced apart from a guider412by a predetermined distance according to a magnetic force between the body portion431aof the carrier431and a magnetic levitation bearing (not shown).

The guide grooves (not shown) may be formed at both side surfaces of the body portion431a. A guide protrusion (not shown) of the guider412may be accommodated in each of the guide grooves.

A magnetic rail431bmay be arranged along a centerline of a travel direction of the body portion431a. A linear motor may be configured by combining the magnetic rail431bof the body portion431aand a coil421with each other and may transfer the carrier431in the direction of the arrow A.

The CPS module431cand the power supply431dmay be disposed at one side of the magnetic rail431bin the body portion431a. The power supply431dmay be a kind of a rechargeable battery for supplying electric power such that the electrostatic chuck432uses the electric power to clamp the substrate600and maintains the state of clamping the electrostatic chuck432to the substrate600. The CPS module431cmay be a wireless charging module for charging the power supply431d.

More specifically, the charging track423arranged in the second transfer unit420may be connected to an inverter (not shown) and may supply electric power to the CPS module431cwhen the carrier431is transferred in the second transfer unit420, and a magnetic field is generated between the charging track423and the CPS module431c. The electric power supplied to the CPS module431cmay charge the power supply431d.

In the electrostatic chuck432, an electrode to which electric power is applied may be located in a body including ceramic, and the substrate600may be attached to a surface of the body by applying a high voltage to the electrode.

Driving of the moving unit430will be described in detail.

A driver may be configured by combining the magnetic rail431bof the body portion431aand the coil421. In this regard, the driver may be a linear motor. The linear motor may be a device having a very high positioning degree owing to a small friction coefficient and a very low occurrence of errors compared to an existing slide guide system. As described above, the linear motor may include the coil421and the magnetic rail431b. The magnetic rail431bmay be arranged in a line over the carrier431. A plurality of coils421may be spaced apart from each other by a predetermined distance at one side in the chamber101so as to respectively face the magnetic rails431b.

As described above, the magnetic rails431brather than the coils421may be arranged over the carrier431that is a moving object, and thus it may be possible to drive the carrier431although electric power is not applied to the carrier431. In this regard, the coils421may be installed in an atmosphere (ATM) box in an atmospheric condition. The magnetic rails431bmay be attached to the carrier431such that the carrier431travels in the chamber101that maintains vacuum.

The organic layer deposition assembly100-5of the organic layer deposition device10may further include a camera180for aligning. More specifically, the camera180may align marks formed over the frame sheet assembly150and marks formed over the substrate600in real time. In this regard, the camera180may be provided so as to secure a clear view in the vacuum chamber101in which deposition is performed. To this end, the camera180may be installed in a camera accommodator181in an atmospheric condition.

The frame sheet assembly150will be described in detail with reference toFIGS. 4, 5, 6, 7, 8, 9, and 10below.

FIG. 4is a schematic perspective view of the organic layer deposition assembly100-5according to an exemplary embodiment.FIG. 5is a lateral cross-sectional view of the organic layer deposition assembly100-5ofFIG. 4.FIG. 6is a plan cross-sectional view of the organic layer deposition assembly100-5ofFIG. 4.

Referring toFIGS. 4, 5, and 6, the organic layer deposition assembly100-5according to an exemplary embodiment may include the deposition source110, the deposition source nozzle120, and the frame sheet assembly150.

The deposition source110and the deposition source nozzle120were described in detail above, and thus the frame sheet assembly150will be described in detail below.

As described above, the frame sheet assembly150may be disposed between the deposition source110and the substrate600. The frame sheet assembly150may include a patterning slit sheet151, a correction sheet152, and a frame155.

The frame155may have a polygonal shape. The correction sheet152and the patterning slit sheet151may be sequentially stacked over and combined with the frame155. In more detail, the frame155may include a body portion155aand a bonding portion155b. The bonding portion155bmay protrude from the body portion155a. The bonding portion155bof the frame155may be bonded to the correction sheet152via welding. The patterning slit sheet151may also be to the correction sheet152via welding. In this regard, the patterning slit sheet151and the correction sheet152will be described in more detail with reference toFIGS. 7, 8, 9, and10.

The above-described deposition source110and the deposition source nozzle120and the frame sheet assembly150coupled to the deposition source110may be spaced apart from each other by a predetermined distance and connected to each other through a connection member135. That is, the deposition source110, the deposition source nozzle120, and the frame sheet assembly150may be connected to each other through the connection member135and may be integrally formed with each other.

In this regard, the connection member135may guide a movement path of the deposition material115such that the deposition material115sprayed through the deposition source nozzles121is not dispersed. Although the connection members135are formed only in left and right directions of the deposition source110, the deposition source nozzle120, and the frame sheet assembly150and guide the deposition material115in a Y-axis direction (as shown inFIG. 4), this is for convenience of illustration and the present disclosure is not limited thereto. The connection member135may have a closed box shape and may simultaneously guide a movement of the deposition material115in an X-axis direction and in the Y-axis direction.

FIG. 7is a schematic plan view of the frame sheet assembly150ofFIG. 4.FIG. 8is a lateral cross-sectional view of the frame sheet assembly150ofFIG. 7taken along a cut line VII-VII′.FIG. 9is a schematic plan view of the patterning slit sheet151ofFIG. 7.

Referring toFIGS. 7, 8, and 9, the patterning slit sheet151may include a patterning slit151aand a patterning bar151b. The patterning slit151amay be a region penetrating from an upper surface of the patterning slit sheet151to a lower surface thereof. The patterning bar151bmay be a blocking region disposed between patterning slits151athat are adjacent to each other. That is, the deposition material115evaporated in the deposition source110may be blocked by the patterning bar151bor may pass through the patterning slit151aand may be deposited on the substrate600that is a deposition target.

In more detail, the patterning slit151may include a plurality of first patterning slits151a_1and a plurality of second patterning slits151a_2. The plurality of first patterning slits151a_1and the plurality of second patterning slits151a_2may be alternately arranged in a first direction (X-axis direction) or in a second direction (Y-axis direction).

In this regard, a line L1passing through a center of the first patterning slit151a_1in the second direction and a line L2passing through a center of the second patterning slit151a_2in the second direction may be spaced apart from each other by a predetermined distance d. That is, the first patterning slit151a_1and the second patterning slit151a_2may be arranged in a zigzag in the second direction.

In a case where patterning slits (not shown) having the same length, other than the first patterning slit151a_1and the second patterning slit151a_2, are continuously arranged in the first direction and in the second direction, a difference between some regions of each of the patterning slits blocked by the correction sheet152may occur.

That is, the deposition material115of a relatively small amount may pass through a patterning slit of a relatively large region blocked by the correction sheet152, whereas the deposition material115of a relatively great amount may pass through a patterning slit of a relatively small region blocked by the correction sheet152.

Thus, in the case where the patterning slits have the same length, an amount of the deposition material115passing through each of the patterning slits may be different. This means that a film thickness of the deposition material115deposited on the substrate600is not uniform. If the deposition material115is not uniformly deposited, the quality and reliability of a display product may deteriorate.

However, due to an arrangement of the first patterning slit151a_1and the second patterning slit151a_2having the configuration according to an exemplary embodiment, a thickness of the deposition material115deposited on the substrate600through the patterning slit151aadjacent to the correction sheet152may be uniformly deposited and the occurrence of a brightness difference between regions of a display device may be further prevented.

The correction sheet152may be coupled with the frame155. The patterning slit sheet151may be coupled onto the correction sheet152. The correction sheet152may partially cover the patterning slit151aand correct an amount of the deposition material115passing through the patterning slit151asuch that the deposition material115of the same amount passes through a center portion (see C inFIG. 10) of the patterning slit151aarranged at a relatively close to the deposition source nozzle121and an edge region of the patterning slit151aarranged at a relatively far from the deposition source nozzle121. The correction sheet152will be described in detail with reference toFIG. 10below.

FIG. 10is a schematic plan view of the correction sheet152ofFIGS. 7 and 8. Referring toFIG. 10, the correction sheet152may include a through hole152aand blocking parts152band152c. The through hole152amay be a region passing through an upper surface of the correction sheet152and a lower surface thereof. The blocking parts152band152cmay bulge in a length direction of the patterning slit151atoward the center portion C of the through hole152a.

In more detail, the blocking parts152band152cmay include a first member152band a second member152c. The first member152bmay bulge and downwardly extend toward the center portion C of the through hole152a. The second member152cmay bulge and upwardly extend toward the center portion C of the through hole152a. The through hole152aformed by the blocking parts152band152cmay be similar to a cross-section of a concave lens. The first member152band the second member152cmay be symmetrical to each other with respect to the center portion C of the through hole152a.

The patterning slit sheet151may be arranged over the correction sheet152, and thus upper and lower portions of the patterning slit151amay be partially hidden by the blocking parts152band152cof the correction sheet152. Thus, as shown inFIG. 7, the farther from a center of the patterning slit sheet151, the longer the length of the patterning slit151aexposed by the through hole152a. That is, a length of the patterning slit151aof a center portion of the patterning slit sheet151that is exposed by the through hole152amay be smaller than that of the patterning slit151aof both ends of the patterning slit sheet151.

In the organic layer deposition assembly100-5according to an exemplary embodiment, the deposition source nozzle121may be arranged in a length direction (in an X-axis direction) of the patterning slit151a, and thus when the correction sheet152is not present, the deposition material115of the greatest amount may be deposited on a center portion of the substrate600, thereby reducing a deposition uniformity.

However, as described above, the patterning slit151ain a center portion of the patterning slit sheet151may be hidden by the blocking parts152band152cof the correction sheet152relatively more than the patterning bar151bof both ends of the patterning slit sheet151, and accordingly, an amount of the deposition material115passing through the patterning slit151aof the center portion of the patterning slit sheet151may be reduced. Thus, a thickness of a deposition layer deposited on the substrate600may be uniform.

That is, since a deposition layer deposited by an organic layer deposition device may have a bulging portion in a center thereof, a part of a deposition material moving toward the center of the deposition layer needs to be blocked in order to make the bulging portion uniform. Thus, the correction sheet152may be arranged below the patterning slit sheet151to block a part of the deposition material115. In this regard, since the blocking parts152band152cof the correction sheet152bulgingly protrude toward the center portion C of the through hole152a, a greater amount of the deposition material115may collide with the blocking parts152band152cand thus may be blocked from reaching the bulging portion, and a smaller amount of the deposition material115may collide with the blocking parts152band152cand thus may be blocked from reaching an edge portion of the deposition layer. In this case, the correction sheet152may be formed such that a smallest film thickness, in general, a film thickness of both ends of the patterning slit sheet151, is an entire film thickness.

As described above, the correction sheet152may be arranged in a movement path of the deposition material115, and thus, a thickness of the deposition film deposited by the organic layer deposition device may be corrected. That is, a part in which a great amount of the deposition material115is deposited may not receive a great amount of the deposition material115by increasing heights of the blocking parts152band152cof the correction sheet152and a part in which a small amount of the deposition material115is deposited may not receive a small amount of the deposition material115by decreasing heights of the blocking parts152band152cof the correction sheet152. Thus, a deposition amount may be corrected in order to achieve a uniform thickness of the deposition material115. An organic layer deposited on a substrate according to exemplary embodiments may be uniformly formed with a uniformity error in a range from 1% to 2%. Thus, the quality and reliability of products may increase.

The patterning slit sheet151may droop toward the deposition source110due to gravity as a size thereof increases. However, according to an exemplary embodiment, the correction sheet152is arranged over a lower surface of the patterning slit sheet151, thereby supporting the patterning slit sheet151and reducing drooping of the patterning slit sheet151.

FIG. 11is a cross-sectional view of an organic light-emitting display device manufactured as an organic layer deposition device according to the present disclosure.

Referring toFIG. 11, an active matrix type organic light-emitting display device may be formed over a substrate30. The substrate30may include a transparent material, for example, a glass material, a plastic material, or a metallic material. An insulating layer31, such as a buffer layer, may be formed over an entire surface of the substrate30.

A thin film transistor (TFT)40, a capacitor50, and an organic light-emitting diode (OLED)60may be arranged over the insulating layer31as shown inFIG. 11.

A semiconductor active layer41may be formed on an upper surface of the insulating layer31in a predetermined pattern. The semiconductor active layer41may be covered by a gate insulating layer32. The semiconductor active layer41may include a p-type or n-type semiconductor material.

A first capacitor electrode51of the capacitor50may be formed on an upper surface of the gate insulating layer32. A gate electrode42of the TFT40may be formed corresponding to the semiconductor active layer41. An interlayer insulating layer33may be formed to cover the first capacitor electrode51and the gate electrode42. The semiconductor active layer41may be partially exposed by a contact hole formed by etching the gate insulating layer32and the interlayer insulating layer33through an etching process such as dry etching after the interlayer insulating layer33is formed.

Thereafter, a second capacitor electrode52and a source/drain electrode43may be formed over the interlayer insulating layer33. The source/drain electrode43may be formed to contact the semiconductor active layer41exposed through the contact hole. A protection layer34may be formed to cover the second capacitor electrode52and the source/drain electrode43and expose a part of the drain electrode43through the etching process. An insulating layer may be further formed over the protection layer34so as to planarize the protection layer34.

The OLED60may display predetermined image information by emitting red, green, or blue light according to a flow of current. A first electrode61may be formed over the protection layer34. The first electrode61may be electrically connected to the drain electrode43of the TFT40.

A pixel-defining layer35may be formed to cover the first electrode61. An opening64may be formed in the pixel-defining layer35and then an organic emission layer63may be formed in a region defined by the opening64. A second electrode62may be formed over the organic emission layer63.

The pixel-defining layer35may define individual pixels, include an organic material, and planarize a surface of the substrate in which the first electrode61is formed, in particular, a surface of the protection layer34.

The first electrode61and the second electrode62may be insulated from each other and apply voltages of opposite polarities to the organic emission layer63to allow the organic emission layer63to emit light.

The organic emission layer63may include a low-molecular weight organic material or a high-molecular weight organic material. When the organic emission layer63includes the low-molecular weight organic material, the organic emission layer63may have a single or multi-layer structure including a hole injection layer (HIL), a hole transport layer (HTL), the EML, an electron transport layer (ETL), and/or an electron injection layer (EIL). Examples of available organic materials may include copper phthalocyanine (CuPc), N,N′-di(naphthalene-1-yl)-N,N′-diphenyl-benzidine (NPB), and tris-8-hydroxyquinoline aluminum (Alq3). The organic emission layer63including these low-molecular weight organic materials may be formed by using the organic layer deposition assembly100ofFIGS. 1, 2, and 3through a vacuum deposition method.

After the opening64is formed in the pixel-defining layer35, the substrate30may be transferred into a unit100as shown inFIG. 1. A target organic material may be contained in a first deposition source11and a second deposition source12and then deposited. In this regard, when a host and a dopant are simultaneously deposited, a host material and a dopant material may be respectively contained in the first deposition source11and the second deposition source12and then deposited.

After the organic emission layer63is formed, the second electrode62may also be formed through the same deposition process as used in the organic emission layer63.

The first electrode61may function as an anode, and the second electrode62may function as a cathode. Polarities of the first electrode61and the second electrode62may be switched. The first electrode61may be patterned to correspond to a region of each pixel. The second electrode62may be formed to cover all pixels.

The first electrode61may be formed as a transparent electrode or a reflective electrode. When the first electrode61is formed as the transparent electrode, the transparent electrode may include indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO), or indium oxide (In2O3). When the first electrode61is formed as the reflective electrode, the reflective electrode may be formed by forming a reflective layer including silver (Ag), magnesium (Mg), aluminum (Al), platinum (Pt), palladium (Pd), gold (Au), nickel (Ni), neodymium (Nd), iridium (Ir), chromium (Cr) or a compound thereof and forming a transparent layer including ITO, IZO, ZnO, or In2O3on the reflective layer. The first electrode61may be formed by forming a layer by sputtering, etc. and then patterning the layer by photolithography, etc.

The second electrode62may also be formed as a transparent electrode or a reflective electrode. When the second electrode62is formed as the transparent electrode, since the second electrode62may be used as a cathode, the transparent electrode may be formed by depositing a metal having a low work function, such as lithium (Li), calcium (Ca), lithium fluoride/calcium (LiF/Ca), lithium fluoride/aluminum (LiF/Al), aluminum (Al), silver (Ag), magnesium (Mg), or a compound thereof in a direction of the organic emission layer63and forming an auxiliary electrode layer or a bus electrode line including ITO, IZO, ZnO, In2O3, or etc. thereon. When the second electrode62is formed as the reflective electrode, the reflective layer may be formed by entirely depositing Li, Ca, LiF/Ca, LiF/Al, Al, Ag, Mg, or a compound thereof. The second electrode62may be formed by using the same deposition method used in the organic emission layer63described above.

The organic layer deposition device according to the present invention may be applied to deposit an organic layer or an inorganic layer of an organic TFT and to form layers including various materials.

According to the exemplary embodiments of the disclosure described above, an organic layer having a uniform thickness may be deposited on a display substrate, thereby preventing the occurrence of a brightness difference.