VAPOR DEPOSITION DEVICE AND VAPOR DEPOSITION METHOD

A vapor deposition device (1) includes: a vapor deposition source (30); a vapor deposition mask (10) having a plurality of mask openings (12); and a limiting plate unit (20) having a plurality of limiting plates (22). The limiting plate unit is configured such that, in a cross section parallel to an X axis direction, (i) the limiting plate unit includes at least one limiting plate opening (23), each of which is formed between the limiting plates and opposite to a respective one of at least one target region (202) of a target substrate (200) such that the at least one limiting plate opening and the at least one target region are in one-to-one correspondence and (ii) the limiting plate unit prevents entry into the mask openings by vapor deposition particles (310) whose angle of entry is less than a shadow critical angle.

TECHNICAL FIELD

The present invention relates to a vapor deposition device and a vapor deposition method each of which are for forming, on a vapor deposition target substrate having at least one vapor deposition target region, a vapor-deposited film having a predetermined pattern, the vapor-deposited film being formed in the at least one vapor deposition target region.

BACKGROUND ART

Recent years have witnessed practical use of flat-panel displays in various products and fields. This has led to a demand for a flat-panel display that is larger in size, that achieves higher image quality, and that consumes less power.

Under such circumstances, great attention has been drawn to an EL display device that (i) includes an EL element which uses electroluminescence (hereinafter abbreviated to “EL”) of an organic or inorganic material and that (ii) is an all-solid-state flat-panel display which is excellent in, for example, low-voltage driving, high-speed response, and light-emitting characteristics.

In order to achieve a full-color display, an EL display device includes a luminescent layer which outputs light of a desired color in correspondence with a plurality of sub-pixels constituting a pixel.

A luminescent layer is formed as a vapor-deposited film on a film formation target substrate (this substrate hereinafter also referred to simply as a “target substrate”). Specifically, in a vapor deposition process, a fine metal mask (FMM) having high-precision openings is used as a vapor deposition mask, and differing vapor deposition particles are vapor deposited to each region of the target substrate.

Typically used in a mass production process is a method in which vapor deposition is carried out while a vapor deposition mask is caused to be in close contact with the target substrate, the vapor deposition mask having a size equivalent to that of the target substrate.

However, in recent years, the size of target substrates has been progressively increasing, in view of improving productivity. In a case where a large target substrate is used, it is difficult to ensure uniform close contact between the target substrate and a vapor deposition mask having a size equivalent to that of the target substrate.

In order to address this issue, there have been proposed methods in which a vapor deposition region of a large target substrate is divided into a plurality of sections, and vapor deposition is carried out while the target substrate is caused to move, with use of a vapor deposition mask smaller than the target substrate (see, for example, Patent Literature 1).

CITATION LIST

Patent Literature

SUMMARY OF INVENTION

Technical Problem

However, a mask opening of a vapor deposition mask is typically formed by use of etching, lasers, or the like. This causes the mask opening to have a specific cross-sectional shape. In Patent Literature 1 as well, etching is used to form slits as mask openings in a vapor deposition mask.

In a case where a vapor-deposited film pattern is formed by causing vapor deposition particles to enter such mask openings, depending on the shape and position of openings in the vapor deposition mask, the vapor-deposited film may not be formed in the correct pattern.

A problematic issue in such cases is the presence of vapor deposition particles which enter mask openings obliquely. Depending on the angle of entry, such vapor deposition particles may not be able to pass through the mask openings and reach the target substrate. This results in a problem typically known as a shadow, in which film thickness gradually decreases from the center of a mask opening toward the edges thereof. This can cause, for example, an indistinctly formed outline and a failure to form part of a pixel.

With a typical vapor deposition device, there are vapor deposition particles which enter mask openings obliquely, and, therefore, a shadow and patterning defects will occur. This places significant limitations on processes and devices.

With the techniques of Patent Literature 1, the direction of vapor deposition particles which reach the target substrate is not limited, and as a result, there are vapor deposition particles which enter mask openings at a small angle. This unfortunately causes a shadow to occur and prevents accurate patterning. In particular, with a mass production device, it is desirable to use a line source as a vapor deposition source in order to increase throughput, but doing so causes a particularly prominent shadow.

The present invention has been made in view of the above problem. An object of the present invention is to provide a vapor deposition device and a vapor deposition method, each of which prevents indistinct outlines and pixel defects caused by a shadow.

Solution to Problem

In order to solve the above problems, a vapor deposition device in accordance with an aspect of the present invention is a vapor deposition device for forming, on a target substrate having at least one target region, a plurality of vapor-deposited films having a predetermined pattern which are spaced from each other in at least a first direction, the plurality of vapor-deposited films being formed in the at least one target region, the vapor deposition device including: a vapor deposition source having a plurality of vapor deposition source openings for emitting vapor deposition particles; a vapor deposition mask provided opposite to the at least one target region, the vapor deposition mask having a mask opening region constituted by a plurality of mask openings provided along at least the first direction in correspondence with the predetermined pattern of the plurality of vapor-deposited films, each of the plurality of mask openings having a cross-sectional shape which is tapered toward the target substrate; and a limiting plate unit provided between the vapor deposition source and the vapor deposition mask, the limiting plate unit having a plurality of limiting plates which are provided along at least the first direction so as to be spaced from each other, the limiting plate unit being configured such that, in a cross section of the limiting plate unit which cross section is parallel to the first direction, (i) the limiting plate unit includes at least one limiting plate opening, each of which is formed between a respective pair of mutually adjacent ones of the plurality of limiting plates and opposite to a respective one of the at least one target region such that the at least one limiting plate opening and the at least one target region are in one-to-one correspondence, (ii) a central axis of each of the at least one limiting plate opening is aligned with a central axis of a respective one of the at least one target region, and (iii) the following Formula (1) is satisfied:

where Wp is a width, as measured in the first direction, of each of the at least one target region; Wr is a width of each of the at least one limiting plate opening as measured in the first direction at a face of each of the at least one limiting plate opening which face is on a side toward a surface of the limiting plate unit which surface faces the vapor deposition source; Db is a distance from (a) a target surface of the target substrate to (b) a surface of each of the limiting plates which surface faces the vapor deposition source; and a is an angle of inclination of an opening wall of each of the plurality of mask openings as observed in a cross section of the vapor deposition mask which cross section is parallel to the first direction.

In order to solve the above problems, a method of vapor deposition in accordance with an aspect of the present invention includes forming, on a target substrate having at least one target region, a plurality of vapor-deposited films having a predetermined pattern which are spaced from each other in at least a first direction, the plurality of vapor-deposited films being formed in the at least one target region, the forming being carried out with use of a vapor deposition device in accordance with an aspect of the present invention.

Advantageous Effects of Invention

An embodiment of the present invention makes it possible to provide a vapor deposition device and a vapor deposition method, each of which prevents indistinct outlines and pixel defects caused by a shadow.

DESCRIPTION OF EMBODIMENTS

The following description will discuss, in detail, embodiments of the present invention.

FIG. 1is a cross-sectional view illustrating a basic configuration of a vapor deposition device1in accordance with Embodiment 1.FIG. 2is a perspective view illustrating a basic configuration of the vapor deposition device1in accordance with Embodiment 1.FIG. 3is a cross-sectional view schematically illustrating an example configuration of main parts of the vapor deposition device1in accordance with Embodiment 1.

The vapor deposition device1in accordance with Embodiment 1 and a vapor deposition method in accordance with Embodiment 1 are each particularly useful for vapor deposition of an EL layer such as a luminescent layer included in an EL element, the EL element being in an EL display device such as an organic EL display device.

The following description will discuss an example in which the vapor deposition device1and the vapor deposition method in accordance with Embodiment 1 are applied to production of an organic EL display device for RGB full-color display, in which organic EL display device organic EL elements of the colors red (R), green (G), and blue (B) have been formed as sub-pixels in an array on a substrate. The following description will exemplarily discuss a case where an RGB selective method is used for film formation of a luminescent layer of an organic EL element.

In other words, the following description will exemplarily discuss a case where vapor-deposited films300formed by use of the vapor deposition device1serve as luminescent layers of the colors R, G, and B in an organic EL display device. Note, however, that Embodiment 1 is not limited to such an example. The vapor deposition device1and vapor deposition method in accordance with Embodiment 1 can be applied in general to production of devices which production utilizes a vapor deposition technique, including the production of organic EL display devices and inorganic EL display devices.

In Embodiment 1, as illustrated inFIG. 1, the vapor-deposited films300constituting luminescent layers of the colors R, G, and B in an organic EL display device will be denoted as vapor-deposited film300R, vapor-deposited film300G, and vapor-deposited film300B, respectively. However, in cases where it is not particularly necessary to distinguish between the vapor-deposited films300R,300G, and300B, the vapor-deposited films300R,300G, and300B are simply referred to collectively as vapor-deposited films300.

Note that the following description assumes that (i) a Y axis is a horizontal axis extending in a scanning direction (along a scanning axis) of a target substrate200, (ii) an X axis is a horizontal axis extending in a direction perpendicular to the scanning direction of the target substrate200, and (iii) a Z axis is a vertical axis which is perpendicular to each of the X axis and the Y axis, which is a direction normal to a film formation target surface (hereinafter also referred to as a “target surface”)201of the target substrate200. The following description assumes that an X axis direction is a “row” direction (first direction) and a Y axis direction is a “column” direction (second direction). Note also that, for convenience, the following description assumes that a side to which the upward arrow of the Z axis points inFIG. 1is up (an upper side), unless mentioned otherwise.

<Main Configuration of Vapor Deposition Device1>

As illustrated inFIGS. 1 and 3, the vapor deposition device1is a device for forming the vapor-deposited films300in a film formation target region202(vapor-deposited film patterning region; hereinafter also referred to as a “target region”) of the target surface201of the target substrate200.

The vapor deposition device1in accordance with Embodiment 1 includes, as essential components thereof, a vapor deposition mask10, a limiting plate unit20, and a vapor deposition source30.

The limiting plate unit20and the vapor deposition source30are rendered a unit by being positionally fixed with respect to each other. The limiting plate unit20and the vapor deposition source30can, for example, be fixed to each other by a rigid member. The limiting plate unit20and the vapor deposition source30can have independent respective configurations and be controlled to operate as a single unit. The limiting plate unit20and the vapor deposition source30move, as a single unit, in the scanning direction as illustrated inFIG. 2. This allows the formation of the vapor-deposited films300in, ultimately, all target regions202of the target substrate200.

The following description will exemplarily discuss a case where the limiting plate unit20and the vapor deposition source30are rendered a unit, namely a vapor deposition unit40, by each being held by the same holder41(limiting plate holding member), as illustrated inFIG. 3.

In one example, the vapor deposition device1of Embodiment 1 includes, for example, a film formation chamber2, a mask holder3, a magnet plate4, a substrate moving device5, the vapor deposition mask10, the vapor deposition unit40, a vapor deposition unit moving device6, a deposition preventing plate (not illustrated), a shutter (not illustrated), and a control device (not illustrated).

In the film formation chamber2, a vacuum pump (not illustrated) is provided for vacuum-pumping the film formation chamber2via an exhaust port (not illustrated) thereof to keep a vacuum in the film formation chamber2during vapor deposition. The vacuum pump is provided externally to the film formation chamber2. The control device for controlling operations of the vapor deposition device1is also provided externally to the film formation chamber2. Note that the mask holder3, the magnet plate4, the substrate moving device5, the vapor deposition mask10, the vapor deposition unit40, the vapor deposition unit moving device6, the deposition preventing plate (not illustrated), and the shutter (not illustrated) are provided within the film formation chamber2.

The mask holder3in accordance with Embodiment 1 serves as both a substrate holding member and a mask holding member.

As illustrated inFIG. 3, the mask holder3includes, for example, a mask mount3aonto which the vapor deposition mask10is mounted. Mounting the vapor deposition mask10and the target substrate200onto the mask mount3acauses the vapor deposition mask10and the target substrate200to be held in contact (close contact) with each other.

In Embodiment 1, the target substrate200and the vapor deposition mask10are subjected to alignment before vapor deposition so as to be in contact with each other or within adequate proximity to each other.

Note that in a case where the target substrate200and the vapor deposition mask10are provided in a state of non-contact with each other, the mask holder3need only to allow the vapor deposition mask10to be mounted thereto. In such a case, the vapor deposition device1may include a substrate holder (not illustrated) as a substrate holding member separate from the mask holder3.

In a case where the target substrate200and the vapor deposition mask10are provided in a state of non-contact with each other, the substrate holder can be a substrate holding member which holds the target substrate200such that the target surface201of the target substrate200is opposite from and a certain distance away from the vapor deposition mask10. For example, a substrate attracting device such as an electrostatic chuck can be suitably used as the substrate holder. The target substrate200, being attracted and held by an electrostatic chuck, is fixed to the substrate holder without being bent by its own weight.

Note that a deposition preventing plate (shielding plate; not illustrated), a shutter (not illustrated), and/or the like can be provided below the mask holder3in order to prevent unnecessary vapor deposition particles310from adhering to the vapor deposition mask10, target substrate200, and/or the like.

In a case where (i) the target substrate200and the vapor deposition mask10are provided in a state of contact with each other and (ii) a mask having a metallic layer is used as the vapor deposition mask10, the vapor deposition device1may include the magnet plate4as a magnetic attracting member, as illustrated inFIG. 3.

By providing the magnet plate4opposite the vapor deposition mask10so as to sandwich the target substrate200and magnetically attracting the metallic layer of the vapor deposition mask10, it is possible to improve close contact between the vapor deposition mask10and the target substrate200.

The vapor deposition device1in accordance with Embodiment 1 includes, for example, at least one of the substrate moving device5and the vapor deposition unit moving device6. With such a configuration, Embodiment 1 is arranged to carry out scan vapor deposition by using at least one of the substrate moving device5and the vapor deposition unit moving device6to move the target substrate200and the vapor deposition unit40relative to each other such that the scanning direction corresponds to the Y axis direction.

As described above,FIG. 2exemplarily illustrates a case where the limiting plate unit20and the vapor deposition source30are moved, as a single unit, in the scanning direction.

The substrate moving device5and the vapor deposition unit moving device6are not particularly limited and may each be any of a variety of known moving devices, such as a roller moving device or a hydraulic moving device.

The target substrate200and the vapor deposition unit40need only be provided in a manner such that at least one can move with respect to the other. As such, it is possible to employ a configuration in which only one from the group consisting of the substrate moving device5and the vapor deposition unit moving device6is provided. One from the group consisting of the target substrate200and the vapor deposition unit40may be fixed to an inner wall of the film formation chamber2.

As illustrated inFIG. 2, the target surface201of the target substrate200is provided with a plurality of target regions202, which are partitioned from each other as vapor-deposited film patterning regions. Each of the target regions202is provided in a matrix. A film-non-formation region204is provided so as to surround each of the target regions202.

In the example illustrated inFIG. 2, the target substrate200includes eight target regions202which are rectangular and which are provided in four rows and four columns.

The vapor deposition mask10has a size such that it is large enough to cover all of the target regions202of the target substrate200. The vapor deposition mask10therefore has a size which is, for example, identical to the size of the target substrate200in a planar view, as illustrated inFIG. 2. Note that the “planar view” refers to a case where the vapor deposition mask10is viewed from a direction orthogonal to a main surface thereof (that is, from a direction parallel to the Z axis).

The vapor deposition mask10may be used as is, or may be fixed, in a tensioned state, to a mask frame (not illustrated) in order to prevent the vapor deposition mask10from bending due to its own weight. The mask frame is formed so as to have a rectangular contour that, in a planar view, is identical to that of vapor deposition mask10or is somewhat larger than that of the vapor deposition mask10.

The vapor deposition mask10is plate-like and has a mask surface, which is a main surface thereof and which is parallel to the XY plane, similarly to the target surface201of the target substrate200. The vapor deposition mask10and the target substrate200are positionally fixed with respect to each other.

Note that it is desirable for the vapor deposition mask10to be provided so as to be in close contact with the target surface201of the target substrate200. However, it is not necessary for the vapor deposition mask10to be in close contact with the target surface201, as long as the vapor deposition mask10is provided so as to be within adequate proximity to the target surface201.

In other words, the vapor deposition mask10is provided opposite to the target surface201of the target substrate200so as to be in contact therewith, and it is desirable for the vapor deposition mask10to be provided so as to be in close contact with the target surface201. However, the vapor deposition mask10may be partially in contact with the target surface201, and it is not necessary for the entirety of the vapor deposition mask10to be in contact with the target surface201, as long as the vapor deposition mask10is provided so as to be within adequate proximity to the target surface201.

In Embodiment 1, formed in advance in each of the target regions202are (i) driving circuitry (not illustrated) for an organic EL display device and (ii) one electrode (not illustrated) out of a pair of electrodes which will sandwich a luminescent layer of an organic EL element.

For convenience of explanation, Embodiment 1 exemplarily discusses a case where an organic EL element includes a luminescent layer as an organic EL layer between a pair of electrodes. Note, however, that the organic EL layer may include an organic layer other than the luminescent layer. As such, after formation of the one electrode, the vapor deposition device1and the vapor deposition method in accordance with Embodiment 1 may be used to form, as the vapor-deposited films300, an organic layer other than the luminescent layer. The vapor deposition device1and the vapor deposition method in accordance with Embodiment 1 may also be used to form, as the vapor-deposited films300, a luminescent layer in each of the target regions202of the target substrate200after the one electrode and the organic layer other than the luminescent layer have already been formed in each of the target regions202.

Provided in each of the target regions202are sub-pixels of the colors R, G, and B, which are constituted by organic EL elements of each respective color. In each sub-pixel, the vapor-deposited films300are formed in a fine pattern. The pattern is constituted by the vapor-deposited films300R,300G, and300B for each color, which films are used as luminescent layers of each organic EL element.

As such, each of the target regions202includes film formation target pattern regions (hereinafter also referred to as “target pattern regions”)203R,203G, and203B in which patterns of the vapor-deposited films300R,300G, and300B, respectively, are formed in correspondence with each sub-pixel, as illustrated inFIG. 1. The vapor-deposited film300R for the color red is formed in the target pattern region203R. The vapor-deposited film300G for the color green is formed in the target pattern region203G. The vapor-deposited film300B for the color blue is formed in the target pattern region203B. Note that in the following descriptions, in cases where it is not particularly necessary to distinguish between the target pattern regions203R,203G, and203B, the target pattern regions203R,203G, and203B are simply referred to collectively as target pattern regions203.

The main surface of the vapor deposition mask10includes a plurality of mask opening regions11. Each of the mask opening regions11includes a group of mask openings12in correspondence with the respective patterns of the vapor-deposited films300R,300G, and300B, as illustrated inFIGS. 1 and 2.

In other words, as illustrated inFIG. 2, the vapor deposition mask10includes the plurality of mask opening regions11, each of which is positioned opposite one of the target regions202of the target substrate200when the vapor deposition mask10is positioned opposite the target substrate200. Each of the mask opening regions11has a plurality of openings (through holes) which are provided as the mask openings12. The plurality of openings function as passages through which the vapor deposition particles310(vapor deposition material) pass during vapor deposition. Regions of the vapor deposition mask10other than the mask openings12are non-opening regions13which serve as blocking sections that block the flow of vapor deposition particles310during vapor deposition.

Each of the mask openings12is arranged so as to correspond to a pattern of the vapor-deposited films300which are is formed by use of the vapor deposition mask10. Furthermore, each of the mask openings12is arranged so that vapor deposition particles310do not adhere to regions of the target substrate200other than desired ones of the target pattern regions203(that is, other than ones of the target pattern regions203for the color of the film to be formed by use of the vapor deposition mask10).

As described above, luminescent layers of an organic EL display device that are made of the vapor deposition material are vapor-deposited for each color of the luminescent layers during an organic EL vapor deposition process.

A vapor deposition mask10for forming a red luminescent layer is used to form the vapor-deposited film300R, which is a luminescent layer of the color red. A vapor deposition mask10for forming a green luminescent layer is used to form the vapor-deposited film300G, which is a luminescent layer of the color green. Similarly, a vapor deposition mask10for forming a blue luminescent layer is used to form the vapor-deposited film300B, which is a luminescent layer of the color blue.

Only the vapor deposition particles310that have passed through the mask openings12reach the target substrate200, so that a vapor-deposited film300having a pattern corresponding to each of the mask openings12is formed on the target substrate200.

In the example illustrated inFIG. 2, each of the mask opening regions11has a plurality of mask openings12which have a long and narrow slit-like shape. The plurality of mask openings12extend in the column direction and are spaced from each other in the row direction. However, the mask openings12can be, for example, slot-like. The shape of the mask openings12and the mask opening regions11as seen in a planar view, and the number of the mask openings12and the mask opening regions11are not limited to the exemplary shapes and numbers illustrated inFIG. 2. A cross-sectional shape of the mask openings12will be discussed later.

In Embodiment 1, a fine metal mask (FMM) is used as the vapor deposition mask10. The vapor deposition mask10is typically made from, for example, invar (an iron-nickel alloy) which has a low thermal expansion coefficient. The vapor deposition mask10has a thickness which is typically in a range from several tens to several hundreds of pmm. Invar can be used suitably because it exhibits little heat-induced deformation.

A material from which the vapor deposition mask10is made is not limited to metals such as invar. The material from which the vapor deposition mask10is made can be (i) organic matter (resin) such as polyimide, (ii) an oxide such as Al2O3, (iii) ceramic, or (iv) a combination of any of these.

As discussed above, the vapor deposition unit40is configured so as to be a unit which includes the limiting plate unit20and the vapor deposition source30. In Embodiment 1, the limiting plate unit20and the vapor deposition source30are rendered a unit by each being held by the same holder41, as illustrated inFIG. 3. As such, the vapor deposition unit40in accordance with Embodiment 1 includes the limiting plate unit20, the vapor deposition source30, and the holder41.

The holder41holds the limiting plate unit20and the vapor deposition source30such that the limiting plate unit20and the vapor deposition source30are positionally fixed with respect to each other.

The vapor deposition unit40is provided so as to be directly below the vapor deposition mask10and spaced from the vapor deposition mask10. The following description will discuss the limiting plate unit20and the vapor deposition source30in more detail.

As illustrated inFIG. 2, the vapor deposition source30has, for example, a rectangular shape. The vapor deposition source30has a top surface (that is, a surface facing the limiting plate unit20) having a plurality of vapor deposition source openings31(through holes, nozzles) which serve as emission holes from which vapor deposition particles310are emitted. The vapor deposition source openings31are arranged in a line in the X axis direction, at a predetermined pitch.

The vapor deposition source30generates vapor deposition particles310in the form of a gas by heating a vapor deposition material so that the vapor deposition material is evaporated (in a case where the vapor deposition material is a liquid material) or sublimated (in a case where the vapor deposition material is a solid material). The vapor deposition source30emits, from the vapor deposition source openings31and toward the limiting plate unit20, the gaseous vapor deposition material as vapor deposition particles310.

In this way, in Embodiment 1, it is possible to use a line-type vapor deposition source having a plurality of vapor deposition source openings31as the vapor deposition source30. Furthermore, by causing the vapor deposition source30to move in the Y axis direction, it is possible to achieve uniform film formation on the target substrate200, which has a large surface area. This is greatly advantageous, as it prevents the occurrence of a reduction of throughput during mass production.

The limiting plate unit20is provided so as to be (i) between the vapor deposition mask10and the vapor deposition source30and (ii) spaced from the vapor deposition mask10and the vapor deposition source30.

The limiting plate unit20includes a limiting plate row21which is constituted by a plurality of limiting plates22. The limiting plates22are provided such that, in a planar view, the limiting plates22are parallel to each other and spaced from each other in the X axis direction. As such, limiting plate openings23are formed as openings between ones of the limiting plates22which ones are mutually adjacent in the X axis direction.

Note that in Embodiment 1, as illustrated inFIG. 2, the limiting plate unit20is a block-like unit. Specifically, the limiting plate unit20is a single block which has a main surface in the XY plane and a rectangular shape whose long axis is the X axis direction. The single block has the plurality of limiting plate openings23(openings), which are provided in the X axis direction at a predetermined pitch. With this configuration, the limiting plate unit20as illustrated inFIG. 2is configured such that a plurality of limiting plates22are arranged in the X axis direction at a predetermined pitch such that each of the limiting plates22is between mutually adjacent ones of the limiting plate openings23.

In the single block constituting the limiting plate unit20as illustrated inFIG. 2, the plurality of limiting plates22and holding sections24which hold and connect the limiting plates22are integrally formed by portions other than the limiting plate openings23(that is, by portions which are non-opening regions).

Note, however, that the limiting plate unit20in accordance with Embodiment 1 is not limited to the configuration illustrated inFIG. 2. The limiting plate unit20can be configured such that the limiting plates22, which are arranged so as to have limiting plate openings23therebetween, are fixed by screws, welding, or the like to holding sections which hold and connect the limiting plates22.

In other words, each of the limiting plates22may be formed integrally with each other and integrally with the holding sections24as illustrated inFIG. 2, or the limiting plates22may be separately from each other and separately from the holding sections24.

The method for holding the limiting plates22is not limited to the above method, and may be any method that allows relative positions and orientations of the limiting plates22to be fixed.

The limiting plate unit20may have any shape that satisfies the conditions described later. However, the limiting plate unit20preferably has a block-like shape as illustrated inFIG. 2. Forming the limiting plate unit20so as to have a block-like shape makes it possible for the limiting plate unit20to be compact in size. Forming the limiting plate unit20so as to have a block-like shape is also advantageous in that, for example, doing so makes it easy to align each of the limiting plates22and easy to replace the limiting plate unit20.

The limiting plate openings23and the target regions202are provided so as to have a one-to-one relationship.

In Embodiment 1, in a planar view, each of the limiting plate unit20and the vapor deposition source30has a size (width), as measured in the Y axis direction, which is smaller than that of each of the vapor deposition mask10and the target substrate200. Vapor deposition is carried out while moving (i) the vapor deposition mask10and the target substrate200as a unit and (ii) the limiting plate unit20and the vapor deposition source30(specifically, the vapor deposition unit40) as a unit with respect to each other, so as to vapor deposit one column at a time in the Y axis direction. This forms the patterns of the vapor-deposited films300in each of the target regions202of the target substrate200.

The limiting plate unit20therefore has one row (put otherwise, one column in the X axis direction) of limiting plate openings23which correspond to the target regions202of the target substrate200.

The limiting plate openings23are arranged at a pitch larger than that of the mask openings12such that, in a planar view, a plurality of mask openings12are positioned between two limiting plates22adjacent to each other in the X axis direction.

Furthermore the limiting plate openings23are arranged at a pitch larger than that of the vapor deposition source openings31such that, in a planar view, a plurality of limiting plate openings23are positioned between two limiting plates22adjacent to each other in the X axis direction. In other words, there are at least two vapor deposition source openings31corresponding to each one of the limiting plate openings23of the limiting plate unit20. As such, the vapor deposition source openings31and the limiting plate openings23do not have a one-to-one relationship. Therefore, with Embodiment 1, it is possible to greatly increase a vapor deposition rate in comparison to a configuration where the vapor deposition source openings31and the limiting plate openings23have a one-to-one relationship. This brings about device-related advantages in that (i) it makes it possible to enhance mass production efficiency and (ii) it makes it easy to design a vapor deposition source.

Vapor deposition particles310emitted from the vapor deposition source openings31initially spread in a substantially isotropic manner, as illustrated inFIG. 3. Note that inFIG. 3, arrows provide a simplified indication of the flow of vapor deposition particles310from each of the vapor deposition source openings31. The length of each arrow corresponds to the number of vapor deposition particles. As such, for each of the limiting plate openings23, it is vapor deposition particles310emitted from a vapor deposition source opening31positioned directly therebeneath which travel toward the limiting plate opening23in the greatest number. However, in addition, vapor deposition particles310emitted from a vapor deposition source opening31positioned obliquely beneath a limiting plate opening23will also travel toward that limiting plate opening23.

Vapor deposition particles310emitted from the vapor deposition source openings31pass through the limiting plate openings23and therefore reach the vapor deposition mask10while being limited as to their angle of entry β into the mask openings12. Vapor deposition particles310that pass through the mask openings12adhere to the target substrate200, thereby forming, on the target substrate200, a film formation pattern constituted by the vapor-deposited films300.

The limiting plate unit20partitions a space between the vapor deposition mask10and the vapor deposition source30into a plurality of vapor deposition spaces, that is, the limiting plate openings23, with use of each of the limiting plates22. As described above, the limiting plate unit20has one limiting plate opening23for each one of the mask opening regions11.

The limiting plate unit20limits the angle of entry β of the vapor deposition particles310into the mask openings12in each of the mask opening regions11such that the angle of entry β is not less than a shadow critical angle a. The shadow critical angle α is a critical angle α at which a shadow does not occur. Note that dotted and dashed lines L1inFIG. 1,FIG. 3, and (a) and (b) ofFIG. 4indicate the shadow critical angle α for each of the target regions202.

The following description will discuss the shadow critical angle with reference toFIG. 1and (a) and (b) ofFIG. 4.

(a) and (b) ofFIG. 4are each a cross-sectional view illustrating a relationship between the angle of entry β of vapor deposition particles310into the mask openings12and a pattern of the vapor-deposited films300. (a) ofFIG. 4illustrates a case where the angle of entry β of vapor deposition particles310into the mask openings12is not less than the shadow critical angle α (β≥α). (b) ofFIG. 4illustrates a case where there are vapor deposition particles310whose angle of entry β into the mask openings12is less than the shadow critical angle α (β<α).

A mask opening of a vapor deposition mask is typically formed by use of etching, lasers, or the like. In Embodiment 1 as well, the mask openings12of the vapor deposition mask10are formed by use of etching, such as wet etching, lasers, or the like.

The vapor deposition mask10is provided such that the cross-sectional shape of the mask openings12is tapered toward a side away from a surface14which faces the limiting plate unit20, as illustrated inFIG. 1and (a) and (b) ofFIG. 4. In other words, the vapor deposition mask10is provided such that a pair of opposing opening walls12a(inner walls) of each mask opening12are angled so that an area of each mask opening12decreases as proximity to a surface15increases, the surface15being a surface of the vapor deposition mask10which faces the target substrate200.

This is equivalent to the vapor deposition mask10being provided such that opening walls12aof each non-opening region13in each mask opening region11of the vapor deposition mask10have an inverse taper so as to be tapered toward the surface14which faces the limiting plate unit20. Here, having an inverse taper means that, in a cross section of the vapor deposition mask10, an angle of inclination formed by (i) the surface14and (ii) an opening wall12aof each non-opening region13in each mask opening region11is greater than 90°.

A shadow is dependent on the shape of the mask openings12. As illustrated in (a) ofFIG. 4, in a case where the mask openings12are tapered toward the target substrate200, the shadow critical angle α is, in a cross section of the vapor deposition mask10which cross section extends parallel to the

X axis direction, an angle formed by (i) an opening wall12aof a mask opening12and (ii) a face of the mask openings12which face is on a side toward the surface14. In other words, the angle of inclination of each of the opening walls12aof the mask openings12in the cross section is the shadow critical angle α.

In a case where the mask openings12are tapered toward the target substrate200, as illustrated in (b) ofFIG. 4, out of vapor deposition particles310emitted obliquely toward the mask openings12, those vapor deposition particles310having an angle of entry β into the mask openings12which is smaller than the shadow critical angle α cannot pass through the mask openings12and thus cannot reach the target substrate200. Such vapor deposition particles310cause what is known as a shadow, in which film thickness gradually decreases from the center of a mask opening12toward the edges thereof, as illustrated in (b) ofFIG. 4. This can cause, for example, an indistinctly formed outline and a failure to form part of a pixel.

<Limitation of Angle of Entry of Vapor Deposition Particles310into Mask Openings12by Limiting Plate Unit20>

In Embodiment 1, vapor deposition particles310which enter the limiting plate openings23are selectively blocked (caught) according to the angle of entry β thereof, in order to prevent entry into the mask openings12by vapor deposition particles310whose angle of entry β into the limiting plate openings23is less than the shadow critical angle α, as illustrated inFIG. 1and (a) ofFIG. 4. This makes it possible to achieve accurate vapor deposition patterning without a shadow.

In other words, in a case where vapor deposition particles310enter the mask openings12only at angles not less than the shadow critical angle α, a shadow will not occur, and thus the above-described patterning defects will not occur.

As such, in Embodiment 1, the limiting plates22are provided such that the angle of entry β of vapor deposition particles310into the mask openings12of each mask opening region11are controlled to be not less than the angle of inclination of the opening walls12aof the mask openings12.

Therefore, in Embodiment 1, the limiting plates22are provided such that (i) a central axis of each of the limiting plate openings23is aligned with a central axis of a respective one of the target regions202and (ii) the following Formula (1) is satisfied:

where Wp is a width, as measured in the X axis direction, of each of the target regions202; Wr is a width of each of the limiting plate openings23as measured in the X axis direction at a face of each of the limiting plate openings23which face is on a side toward a surface22aof the limiting plate unit20which surface22afaces the vapor deposition source30; and Db is a distance from (a) the target surface201of the target substrate200to (b) a surface22aof each of the limiting plates22which surface22afaces the vapor deposition source30.

In other words, as described above, it is necessary for the angle of entry β at which vapor deposition particles310enter each of the target regions202to be not less than the shadow critical angle α (i.e., not less than the angle of inclination of opening walls12aof the mask openings12as observed in a cross section of the vapor deposition mask10which cross section extends parallel to the X axis direction).

Thus, in the above cross section, in a case where the angle of entry β at which the vapor deposition particles310enter each of the target regions202is a minimum, vapor deposition particles310will enter the limiting plate openings23in a manner so as to graze a lower end of a respective limiting plate22before reaching an opposing one of the target regions202(that is, the vapor deposition particles310will reach the target regions202by travelling along the dotted and dashed lines L1ofFIG. 1).

As such, the angle of entry β of vapor deposition particles310(incident particles) which travel along the dotted and dashed lines L1inFIG. 1and reach the target regions202must be not less than α.

As such, in a case where the angle of entry β of vapor deposition particles310(incident particles) which travel along the dotted and dashed lines L1and reach the target regions202as illustrated inFIG. 1is represented as β′, the following formula stands:

Solving this formula provides the following:

Since β′ is greater than or equal to α, tanβ′ is greater than or equal to tanα.

As such, the following formula stands:

Solving this formula provides the Formula (1) above.

Note that in Embodiment 1, the following dimensions are not particularly limited provided that they are set so as to satisfy the conditions described above: the height of each of the limiting plates22(thickness along the Z axis, i.e., length of limiting plate openings23as measured in the Z axis direction); the width of each of the limiting plates22(thickness as measured in the X axis direction); the width of each of the limiting plate openings23as measured in the X axis direction at the surface22aof the limiting plate unit20which surface22afaces the vapor deposition source30; the width of each of the limiting plate openings23as measured in the X axis direction at a surface22bof the limiting plate unit20which surface22bfaces the vapor deposition mask10; and the like.

Thus, with Embodiment 1, the limiting plate unit20has the limiting plate openings23each of which (i) is opposite to a respective one of the target regions202so as to form a pair with the respective one of the target regions202and (ii) has a central axis that is aligned with a central axis of the respective one of the target regions202. Furthermore, the limiting plate unit20is designed/provided so as to satisfy Formula (1). As such, it is possible to prevent vapor deposition particles310whose angle of entry β into the limiting plate openings23is less than the shadow critical angle α from entering the mask openings12.

Furthermore, in order to prevent vapor deposition particles310which, as with vapor deposition particles314(described in later examples), have been emitted from vapor deposition source openings31corresponding to (i) a respective one of the target regions202and (ii) a respective one of the limiting plate openings23from passing through the respective one of the limiting plate openings23and entering a target region202which is adjacent to the respective one of the target regions202(such an adjacent target region202hereinafter referred to as an “adjacent target region202”), the limiting plates22can be provided so as to satisfy the following Formula (2):

where S is a width, as measured in the X axis direction, of a film-non-formation region204between mutually adjacent ones of the target regions202; and θ is an angle of inclination of a line L2(bold dotted and dashed line inFIGS. 1, 6, and 7) which line L2connects, in each of the limiting plate openings23, (i) a lower end (opening wall lower end) of a first limiting plate22of an mutually opposed pair of the limiting plates22(opening walls12a) and (ii) an upper end (opening wall upper end) of a second limiting plate22of the mutually opposed pair of the limiting plates22, the mutually opposed pair of the limiting plates22being opposed in the X axis direction. In other words, θ is an angle of inclination formed by the line L2and a horizontal plane.

In other words, vapor deposition particles which reach a position closest to an adjacent target region202of the target substrate200are vapor deposition particles310which pass through one of the limiting plate openings23in a manner so as to (i) pass by an lower end of a specific one of the limiting plates22and (ii) graze an upper end of one of the limiting plates22which one is opposite to the specific one of the limiting plates22with respect to the limiting plate opening23, as indicated by the line L2.

As such, in a planar view, in a case where a lower end of one of the limiting plates22is used as a reference position, the position at which a vapor deposition particle310reaches target substrate200is a position at which the vapor deposition particle310has neared the adjacent target region202by a distance of (Db/tanθ) from the lower end of the one of the limiting plates22.

Similarly, in a planar view, in a case where a lower end of one of the limiting plates22is used as a reference position, a position of an edge of an adjacent target region202can be expressed as Wr/2+Wp/2+S.

As such, when Formula (2) is satisfied, the left side of Formula (2) is shorter than the right side of Formula (2). The left side of Formula (2) is, in the planar view in a case where a lower end of one of the limiting plates22is used as a reference position, a distance from (i) the reference position to (ii) a position of a vapor deposition particle which reaches a position closest to the adjacent target region202of the target substrate200. The right side of Formula (2) is a distance from (iii) the reference position to (iv) a position at an end of the adjacent target region202.

Note that Formula (2) is not an essential condition from the viewpoint of preventing vapor deposition particles310whose angle of entry β is less than the shadow critical angle α from entering the mask openings12. A path of entry into the adjacent target region202occurs at a low angle which is less than the shadow critical angle α.

The following description will discuss effects of the vapor deposition device1in accordance with Embodiment 1 by discussing, as examples of the vapor deposition particles310, vapor deposition particles311to314which have differing angles of entry β into the limiting plate openings23as illustrated inFIG. 1. These differing angles of entry β are indicated as β1through β4.

For example, in the case of the vapor deposition particles311, the angle of entry β1into the limiting plate openings23is not less than the shadow critical angle α. The vapor deposition particles311therefore reach a position within the target regions202without any problems.

In the case of the vapor deposition particles312, while the vapor deposition particles312do pass through the vicinity of a corner part of one of the limiting plates22which corner part is on a side toward the surface22afacing the vapor deposition source30, the vapor deposition particles312successfully reach a position within the target regions202because the angle of entry β2into the limiting plate openings23is not less than the shadow critical angle α.

In the case of the vapor deposition particles313, the angle of entry β3into the limiting plate openings23is smaller than the shadow critical angle α. The vapor deposition particles313pass through the limiting plate openings23but reach an area outside of the target regions202. As such, the vapor deposition particles313do not enter the mask openings12and therefore do not require consideration as a factor causing a shadow in the target regions202.

In the case of the vapor deposition particles314, the angle of entry β3into the limiting plate openings23is smaller than the shadow critical angle α. If a path of entry (direction of entry) of the vapor deposition particles314were extended further, the path would reach a target region202which is adjacent to a target region202entered by particles whose angle is not less than the shadow critical angle α. The vapor deposition particles314would therefore become a factor causing a shadow. However, in Embodiment 1, the limiting plates22block the vapor deposition particles314as illustrated inFIG. 1. This prevents vapor deposition particles310such as the vapor deposition particles314, which would otherwise be a factor causing a shadow, from reaching the target regions202.

Note that the example illustrated inFIG. 1is configured so that vapor deposition particles310emitted from a single one of the vapor deposition source openings31will enter the following target regions202: (i) out of pairs of the target regions202which are, in a planar view, separated from each other so as to sandwich the single one of the vapor deposition source openings31(i.e., target regions202other than a target region202which is directly above the single one of the vapor deposition source openings31), whichever one of the pairs is closest to the single one of the vapor deposition source openings31; and (ii) a target region202positioned directly above the single one of the vapor deposition source openings31, in a case where such a target regions202exists.

As such, for example, vapor deposition particles310emitted from a vapor deposition source opening31A, which also emits vapor deposition particles314, will enter (i) a first target region202which is directly above the vapor deposition source opening31A and (ii) second and third target regions202which are adjacent to the first target region202on either side thereof. However, as is shown with the vapor deposition particles314, vapor deposition particles310will not reach other ones of the target regions202which are adjacent to the second and third target regions202so as to sandwich the second and third target regions202.

Note, however, that the configuration discussed above is an example. The target regions202which are entered by vapor deposition particles310emitted from a single one of the vapor deposition source openings31can be set/altered as necessary by altering, for example, each parameter of Formulas (1) and (2), the shape of the limiting plates22, and the distance between the limiting plate unit20and the vapor deposition source30, provided that Formulas (1) and (2) are satisfied. In other words, the correspondence between (i) the target regions202and (ii) the limiting plate openings23and the vapor deposition source openings31can be set/altered as necessary.

As described above, with Embodiment 1, all vapor deposition particles310whose angle of entry β into the limiting plate openings23is less than the shadow critical angle α are blocked, by the limiting plates22, from entering the target regions202. As such, the limiting plate unit20limits the vapor deposition particles310such that all vapor deposition particles310which reach the mask openings12are vapor deposition particles310whose angle of entry is not less than the shadow critical angle α. This makes it possible to achieve accurate vapor deposition patterning without a shadow.

The present technology is particularly efficacious for high-definition patterning over a large surface area. As such, the present technology is particularly efficacious for vapor deposition carried out on a large target substrate divided into a plurality of vapor deposition regions, an example thereof being the target surface201provided with the plurality of target regions202.

As illustrated inFIG. 2, the vapor deposition source30and the limiting plate unit20are rendered a unit by being positionally fixed with respect to each other, and a film is formed in all vapor deposition regions of the target substrate200(that is, in all target regions202) by moving the unit back and forth. This configuration makes it possible, even for the target substrate200having a large surface area, to achieve high-precision patterning without a shadow occurring. This configuration also makes it possible to achieve high-definition patterning over a large surface area even when using the vapor deposition source30and the limiting plate unit20which are both relatively small. As such, the configuration enables enhanced mass production efficiency.

Furthermore, conventionally, achieving a uniform distribution of film thickness has required, for example, significant configurational adjustments to mask openings and/or providing a plurality of stages of limiting plates.

However, with Embodiment 1, it is possible to achieve a uniform distribution of film thickness simply by, for example, controlling a vapor deposition rate of vapor deposition particles310emitted from the vapor deposition source30, as indicated by the arrows inFIG. 3. As such, the vapor deposition device1can be easily designed. The vapor deposition rate of vapor deposition particles310emitted from the vapor deposition source30will be discussed in Embodiment 2.

The limiting plates22desirably have a temperature which is lower than a temperature at which vapor deposition particles are generated, i.e., lower than a temperature at which the vapor deposition material becomes a gas. As such, it is preferable to cool the limiting plates22. A cooling mechanism28which cools the limiting plates22may therefore be provided to the limiting plate unit20, as indicated by a chain double-dashed line inFIG. 3. This makes it possible to (i) solidify and catch vapor deposition particles310which have collided into the limiting plates22, (ii) prevent collisions between and scattering of vapor deposition particles310, and (iii) prevent the limiting plates22from causing revaporization. This configuration therefore makes it possible to reliably limit vapor deposition flow from the vapor deposition source30.

Furthermore, cooling the limiting plates22inhibits radiant heat given off by the vapor deposition source30, thereby making it possible to prevent a rise in temperature of the target substrate200and of the vapor deposition mask10. Cooling the limiting plates22therefore makes it possible to prevent thermal expansion of the target substrate200and of the vapor deposition mask10. This makes it possible to maintain high precision. Furthermore, the above effects make it possible to bring the vapor deposition source30and the target substrate200relatively closer to each other. This enables an improved rate of film formation.

(Cross-Sectional Shape of Limiting Plate Openings23)

FIGS. 1 and 3exemplarily illustrate a case where the limiting plates22have a cross-sectional shape which is tapered toward the target substrate200such that (i) an area of the surface22aof each of the limiting plates22, which surface22afaces the vapor deposition mask10, is greater than (ii) an area of the surface22bof each of the limiting plates22, which surface22bfaces the vapor deposition mask10. This gives the limiting plate openings23a cross-sectional shape which is tapered toward the vapor deposition source30. However, the limiting plates22are not limited to having such a shape, provided that the above-described conditions are satisfied. As such, the cross-sectional shape of the limiting plates22and the shape of the limiting plate openings23can be rectangular, or a combination of other shapes can be used. Note that in a case where (i) the limiting plates22have a cross-sectional shape which is tapered toward the vapor deposition source30and (ii) this gives the limiting plate openings23a cross-sectional shape which is tapered toward the target substrate200, Formula (1) will not be satisfied.

Exemplarily discussed in Embodiment 1 was a case where scanning vapor deposition is carried out by, for example, causing the vapor deposition unit40to move in the Y axis direction, as illustrated inFIG. 2. However, Embodiment 1 is not limited to such a configuration. It is possible to employ a configuration in which, out of the vapor deposition source30and the limiting plate unit20, at least the limiting plate unit20is provided so as to be opposite to the entirety of the target substrate200and the entirety of the vapor deposition mask10in a planar view. In such a case as well, it is possible to achieve high-precision patterning without a shadow occurring, even if the target substrate200has a large surface area.

Exemplarily discussed in Embodiment 1 was a case where the target substrate200has a plurality of target regions202. However, the target substrate200need only have at least one target region202.

As such, the vapor deposition mask10need only have at least one mask opening region11in correspondence with the at least one target region202, and the limiting plate unit20need only have at least one limiting plate opening23.

As described above, the present technology is particularly useful for vapor deposition of, for example, an EL layer of an organic EL display device. However, the present technology is not limited to this. The present technology can be applied to film formation technologies in general, such as production of various devices which production utilizes vapor deposition, an example being production of EL display devices such as organic EL display devices or inorganic EL display devices.

The following description will discuss another embodiment of the present invention, primarily with reference toFIG. 5. The description below will deal mainly with how the present embodiment differs from Embodiment 1. Any member of the present embodiment that is identical in function to a corresponding member of Embodiment 1 is assigned a common reference numeral, and is not described here.

Discussed in Embodiment 2 is a vapor deposition rate (film formation rate; film formation speed) of vapor deposition particles310emitted from a vapor deposition source30.

FIG. 5is a cross-sectional view illustrating a basic configuration of a vapor deposition device1in accordance with Embodiment 2.

As illustrated inFIG. 5, the vapor deposition device1of Embodiment 2 is configurationally identical to the vapor deposition device1of Embodiment 1. As described in Embodiment 1, with the vapor deposition device1, it is possible to achieve a uniform distribution of film thickness simply by, for example, controlling the vapor deposition rate of vapor deposition particles310emitted from the vapor deposition source30.

As such, in Embodiment 2, the vapor deposition rate of vapor deposition particles310emitted from the vapor deposition source30has a distribution.

The amount of flying vapor deposition particles310which are emitted from each of the vapor deposition source openings31has a distribution. For example, as indicated by arrows inFIG. 3, generally, the maximum value is that for vapor deposition particles310directly above the vapor deposition source openings31, and the amount decreases progressively toward outward areas.

In normal vapor deposition, vapor deposition particles emitted from a single vapor deposition source opening have the above distribution. However, in a vapor deposition device used for mass production of a typical organic EL display device, a plurality of such single vapor deposition source openings are provided such that their distributions intentionally overlap. This results in a uniform distribution of film thickness on the target substrate.

However, with the vapor deposition device1, as described above, vapor deposition particles310which travel toward a single one of the target regions202are limited, and vapor deposition source openings31which emit vapor deposition particles310travelling toward a single one of the target regions202are also limited.

As such, in a case where control of the vapor deposition rate etc. is not carried out, while problems such as indistinct outlines at edges of the mask openings12and failure to form part of a pixel will be remedied, there will be an increase in film thickness of the vapor-deposited films300particularly in a portion of each of the target regions202which portion corresponds to a central portion of a respective one of the limiting plate openings23in a planar view. This results in a non-uniform distribution of film thickness in each of the target regions202.

In Embodiment 2, a uniform distribution of film thickness is achieved in each of the target regions202by causing a relative decrease in the vapor deposition rate of vapor deposition particles310emitted from those of the vapor deposition source openings31which are directly below limiting plate openings23, as indicated by a dashed line R inFIG. 5.

<Method for Adjusting Vapor Deposition Rate Distribution>

A vapor deposition rate distribution is adjusted by (i) an arrangement of the limiting plates22with respect to the target regions202, (ii) the shape of the limiting plates22, and (iii) emission characteristics of each of the vapor deposition source openings31.

A method for adjusting the vapor deposition rate distribution is not particularly limited. Methods which can be employed include: a method in which vapor deposition source openings31are provided directly under the limiting plate openings23at a period (i.e., at a nozzle density) which differs from that of vapor deposition source openings31in other regions; a method in which vapor deposition source openings31provided directly under the limiting plate openings23have a shape which differs from that of vapor deposition source openings31in other regions; and a method in which vapor deposition source30has temperatures which differ between regions directly under the limiting plate openings and other regions.

For example,FIG. 5exemplarily illustrates a case where the vapor deposition source openings31are provided so as to be uniformly spaced. However, it is possible to decrease the vapor deposition rate in regions directly below limiting plate openings23relative to the vapor deposition rate in other areas by configuring the vapor deposition source30such that vapor deposition source openings31in a region opposite to one of the limiting plate openings23are provided at a density which is less than that of vapor deposition source openings31provided in other regions.

Note that the alteration of intervals between vapor deposition source openings in order to achieve uniform thickness of a vapor-deposited film in normal vapor deposition has been disclosed in, for example, Patent Literature 2.

Patent Literature 2 does not involve using the limiting plate unit20, nor does it involve causing vapor deposition particles310emitted from a single vapor deposition source opening31to enter a plurality of target regions202which correspond to the single vapor deposition source opening31. As such, the arrangement of holes formed in a vapor deposition source as disclosed in Patent Literature2cannot be applied as-is to the vapor deposition device1in accordance with Embodiment 2. However, with Embodiment 2, for example, in a case where the vapor deposition source openings31are configured to be provided at uniform intervals, a uniform thin film of the vapor-deposited films300can be achieved in each of the target regions202by altering the configuration so as to provide a relatively greater number of vapor deposition source openings31which will deposit vapor deposition particles310in portions of the target regions202where the vapor-deposited films300would otherwise be relatively thinly deposited.

Furthermore, it is possible to increase the vapor deposition rate by increasing the area of a vapor deposition source opening31. As such, it is possible to relatively decrease the vapor deposition rate in regions directly below the limiting plate openings23as described above by decreasing an area of each of the vapor deposition source openings31which are directly below limiting plate openings23, relative to an area of each of the vapor deposition source openings31in other regions (or, in other words, by relatively increasing the area of each of the vapor deposition source openings31in regions other than regions directly below the limiting plate openings23).

Furthermore, a vapor deposition rate tends to increase as temperature increases. As such, the same effect as above can be achieved by employing a temperature distribution that follows the vapor deposition rate distribution indicated by the dashed line R inFIG. 5, so that a vapor deposition temperature of each of the vapor deposition source openings31which are opposite to limiting plate openings23is lower that a vapor deposition temperature of each of the vapor deposition source openings31which are opposite to the limiting plates22.

In this way, with Embodiment 2 it is possible to achieve a uniform distribution of film thickness by controlling a vapor deposition rate in accordance with a vapor deposition material and the like so as to obtain a desired vapor deposition rate.

The following description will discuss another embodiment of the present invention, primarily with reference toFIGS. 6 and 7. The description below will deal mainly with how the present embodiment differs from Embodiments 1 and 2. Any member of the present embodiment that is identical in function to a corresponding member of Embodiment 1 or 2 is assigned a common reference numeral, and is not described here.

FIG. 6is a cross-sectional view illustrating a basic configuration of a vapor deposition device1in accordance with Embodiment 3.

As described above, in Embodiments 1 and 2, vapor deposition particles310emitted from a single one of the vapor deposition source openings31enter a plurality of target regions202.

As a point of difference from the vapor deposition device1of each of Embodiments 1 and 2 (see, for example,FIG. 1), a vapor deposition device1in accordance with Embodiment 3 is configured such that there is a one-to-one correspondence between each of the target regions202and a respective one of vapor deposition source opening formation regions (hereinafter, “source opening formation regions”)32, each of the source opening formation regions32corresponding to a respective one of the target regions202as indicated by bold dashed lines L3inFIG. 6.

A source opening formation region32corresponding to a respective one of the target regions202refers to a region in which it is possible to form vapor deposition source openings31which will emit vapor deposition particles310that will pass through the same mask opening region11and enter the respective one of the target regions202.

In the vapor deposition device1in accordance with Embodiment 3, the limiting plates22are formed so as to have a height (length as measured in the Z axis direction) which is greater than in Embodiment 1 such that vapor deposition particles310which enter a specific one of the target regions202are limited to vapor deposition particles310from a specific, opposing one of the source opening formation regions32.

As such, in Embodiment 3, a film thickness and distribution of film thickness of the vapor-deposited films300in each of the target regions202can be controlled independently from the other target regions202. Embodiment 3 can therefore be expected to allow both improved controllability and improved mass production efficiency.

The following description will discuss design conditions for the source opening formation regions32.

A width of each of the source opening formation regions32can be expressed by the following Formula (3);

where: We is the width, as measured in the X axis direction, of each of the source opening formation regions32; Wp is a width, as measured in the X axis direction, of each of the target regions202; Wr is a width of each of the limiting plate openings23as measured at a face of each of the limiting plate openings23which face is on a side toward the surface22aof the limiting plate unit20, the surface22afacing the vapor deposition source30; Da is a distance from (a) the target surface201of the target substrate200to (b) a surface of the vapor deposition source30on which surface the vapor deposition source openings31are formed; and Db is a distance from (a) the target surface201of the target substrate200to (b) the surface22aof each of the limiting plates22which surface22afaces the vapor deposition source30.

In a case where the width We of mutually adjacent ones of the source opening formation regions32is increased such that the mutually adjacent ones of the source opening formation regions32completely overlap, source opening formation regions32will not be independent, and vapor deposition particles310which can enter a specific one of the target regions202will not be limited to vapor deposition particles310from a specific, opposing one of the source opening formation regions32.

Overlapping of mutually adjacent ones of the source opening formation regions32refers to overlapping of a first source opening formation region and a second source opening formation region, where (i) the first source opening formation region is one of the source opening formation regions32in which one it is possible to form vapor deposition source openings31which emit vapor deposition particles310that enter a first one of the target regions202and (ii) the second source opening formation region is one of the source opening formation regions32in which one it is possible to form vapor deposition source openings31which emit vapor deposition particles310that enter a second one of the target regions202, the second one of the target regions being adjacent to the first one of the target regions202.

Note that, as described above, each of the source opening formation regions32is a region of the vapor deposition source30in which it is possible to form vapor deposition source openings31which emit vapor deposition particles310that pass through the same one of the mask opening regions11and enter a respective one of the target regions202. As such, the source opening formation regions32do not indicate which regions the vapor deposition source openings31are actually formed in. In other words, the source opening formation regions32are each a region in which, no matter where vapor deposition source openings31are formed within the region, the vapor deposition source openings31in the same source opening formation region32will emit vapor deposition particles310that pass through the same one of the mask opening regions11and enter one of the target regions202which one corresponds to the source opening formation region32.

As such, even in a case where source opening formation regions32overlap, as long as vapor deposition source openings are not provided in overlapping portions of the source opening formation regions32, it is possible for the target regions202and the source opening formation regions32to be in one-to-one correspondence. In other words, as long as each of the source opening formation regions32includes at least a portion which does not overlap with other source opening formation regions32, it is possible to achieve one-to-one correspondence between the target regions202and the source opening formation regions32by providing the vapor deposition source openings31only in such portions of no overlap.

However, in a case where mutually adjacent ones of the source opening formation regions32overlap completely, there will be an absence of portions of no overlap.

Therefore, in order to prevent mutually adjacent ones of the source opening formation regions32from overlapping completely, We can be set so as to satisfy the following Formula (4):

This makes it possible to limit vapor deposition particles310which enter a specific one of the target regions202to being vapor deposition particles310emitted from vapor deposition source openings31within a specific, opposing one of the source opening formation regions32.

A region in which source opening formation regions32overlap is preferably small, as being small enables more efficient use of the length of the vapor deposition source30as measured in the X axis direction.

In other words, as described above, in a case where vapor deposition source openings31are provided in a region where mutually adjacent ones of the source opening formation regions32overlap, the target regions202and the source opening formation regions32will not be in one-to-one correspondence. As such, an absence of regions where mutually adjacent ones of the source opening formation regions32overlap allows for more efficient use of the length of the entire region of the vapor deposition source30in which vapor deposition source openings31can be provided.

As such, it is preferable to set We so as to satisfy the following Formula (5):

In such a case, mutually adjacent ones of the source opening formation regions32will not overlap, and it is possible to, for example, provide mutually adjacent ones of the source opening formation regions32so as to be spaced from each other. In other words, as illustrated inFIG. 6, it is possible set (i) a distance between mutually adjacent vapor deposition source openings31which sandwich a boundary between mutually adjacent ones of the source opening formation regions32so as to be greater than (ii) a distance between mutually adjacent vapor deposition openings31within each of the source opening formation regions32. This provides a space between groups of vapor deposition source openings31, each group emitting vapor deposition particles310which enter a respective one of the target regions202. Such a configuration makes it possible to form the source opening formation regions32so as to be completely independent from each other.

However, it is not preferable to set We to be excessively small, since doing so means that within We, a group of vapor deposition source openings31which emit vapor deposition particles310that enter the same one of the target regions202may (depending on a ratio of (i) the length of the vapor deposition source30as measured in the X axis direction to (ii) the width of each of the vapor deposition source openings31as measured in the X axis direction) be packed tightly, with little space between mutually adjacent ones of the vapor deposition source openings31. It is therefore preferable to set We in accordance with (i) the length of the vapor deposition source30as measured in the X axis direction and (ii) the width of each of the vapor deposition source openings31as measured in the X axis direction, such that We falls within a range that is feasible from a design standpoint.

Other than the above-described point, the vapor deposition device1of Embodiment 3 is identical to the vapor deposition device1of Embodiment 1.

InFIG. 6, the limiting plates22are configured to have a height (length as measured in the Z axis direction) which is greater than in Embodiment 1, thereby increasing a space limited by the limiting plates22so as to prevent partial overlap (for example, as illustrated inFIG. 1) of (i) a group of vapor deposition source openings31which emit vapor deposition particles310that enter a specific one of the target regions202and (ii) another group of vapor deposition source openings31which emit vapor deposition particles310that enter one of the target regions202adjacent to the specific one of the target regions202. However, Embodiment 3 is not limited to this.

Furthermore, in Embodiment 3 it is of course preferable to employ a rate distribution within each of the source opening formation regions32, similarly to Embodiment 2, in order to achieve a uniform distribution of film thickness.

FIG. 7is a cross-sectional view illustrating another configuration of the vapor deposition device1in accordance with Embodiment 3.

Note that inFIG. 7, the bold dashed lines L3overlap with the dotted and dashed lines L1. As such, for convenience, the bold dashed lines L3are shown only in some regions.

With Embodiment 3, the one-to-one correspondence between the target regions202and the source opening formation regions32can also be achieved by bringing the vapor deposition source30closer, as illustrated inFIG. 7.

In the vapor deposition device1in accordance with Embodiment 3, the limiting plates22are formed so as to have a height (length as measured in the Z axis direction) which is greater than in Embodiment 1 such that vapor deposition particles310which enter a specific one of the target regions202are limited to vapor deposition particles310from a specific, opposing one of the source opening formation regions32.

Other methods for achieving the one-to-one correspondence between the target regions202and the source opening formation regions32include, for example, (i) decreasing the width Wr and (ii) increasing the distance Db with respect to the distance Da.

Decreasing the width Wr limits (i.e., decreases) a width of a region of the vapor deposition mask10which region is opposite a target region202with respect to a limiting plate opening23. As such, the one-to-one correspondence between the target regions202and the source opening formation regions32can be achieved by, for example, decreasing the width Wr such that mutually adjacent ones of the source opening formation regions32are spaced from each other.

Increasing the distance Db with respect to the distance Da (in other words, decreasing Da/Db) is equivalent to increasing the height of the limiting plates22.

Note that Da/Db is not particularly limited and is set or altered in accordance with, for example, the type of the vapor deposition material and the shape of the limiting plates22. For example, Da/Db can be set qualitatively such that Da/Db<2.

Thus, as described above, Embodiment 3 can be altered in various ways in accordance with the descriptions above while still achieving the effects of Embodiment 3.

The following description will discuss yet another embodiment of the present invention, primarily with reference toFIG. 8. The description below will deal mainly with how the present embodiment differs from Embodiments 1, 2, and 3. Any member of the present embodiment that is identical in function to a corresponding member of Embodiments 1, 2, or 3 is assigned a common reference numeral, and is not described here.

FIG. 8is a cross-sectional view illustrating a basic configuration of a vapor deposition device1in accordance with Embodiment 4.

In the vapor deposition device1in accordance with Embodiment 4, a limiting plate unit20has limiting plates22each having a T-shaped cross-section. Other than this point, the vapor deposition device1in accordance with Embodiment 4 is identical to the vapor deposition device1in accordance with each of Embodiments 1 to 3.

The limiting plates22in accordance with Embodiment 4 each include (i) a blocking wall section25constituted by a plate-like member whose main surface is in a YZ plane and (ii) a flange section26constituted by a plate-like member whose main surface is in an XY plane, the flange section26being provided at a lower end surface (that is, bottom surface) of the blocking wall section25so as to protrude in an eaves-like manner toward adjacent ones of the limiting plates22.

Note that the design parameters of Embodiments 1 to 3 remain the same in Embodiment 4 so that the vapor deposition device1of Embodiment 4 is designed such that the above formulas are satisfied.

Embodiment 4 enables a reduction in the volume of the limiting plates22. This makes it possible to increase the volume of space in which the vapor deposition particles310fly. As such, it is possible to prevent a problem where decreased space between the vapor deposition source30and the vapor deposition mask10causes a steep rise in pressure occurring between the vapor deposition source30and limiting plates22and in the limiting plate openings23. Furthermore, by decreasing the volume of the limiting plates22, Embodiment 4 also enables a reduction in the weight of the limiting plate unit20. This can be advantageous in terms of device design by enabling, for example, a decrease in the load borne by the holding member which holds the limiting plate unit20.

Furthermore, by configuring the limiting plates22to include the flange section26, it becomes possible to catch, with the flange section26, vapor deposition material which has come off the blocking wall section25. This advantageously prevents the vapor deposition material which has come off from falling onto the vapor deposition source30.

InFIG. 8, the blocking wall section25is planar so as to be substantially parallel to the Z axis. Note, however, that this is a non-limiting example, and the blocking wall section25may have any shape. For example, the blocking wall section25may be planar so as to be inclined with respect to the Z axis, or the blocking wall section25may alternatively have a curved shape. Furthermore, inFIG. 8, the blocking wall section25is a thin plate which has a substantially constant thickness, but this is a non-limiting example. For example, the blocking wall section25may have a wedge-like cross section so as to become thinner towards a tip thereof.

A vapor deposition device1in accordance with Aspect 1 of the present invention is a vapor deposition device for forming, on a target substrate200having at least one target region202, a plurality of vapor-deposited films300having a predetermined pattern which are spaced from each other in at least a first direction (a direction along a side of the at least one target region202; an X axis direction), the plurality of vapor-deposited films300being formed in the at least one target region202, the vapor deposition device including: a vapor deposition source30having a plurality of vapor deposition source openings31for emitting vapor deposition particles310; a vapor deposition mask10provided opposite to the at least one target region202, the vapor deposition mask10having a mask opening region11constituted by a plurality of mask openings12provided along at least the first direction in correspondence with the predetermined pattern of the plurality of vapor-deposited films300, each of the plurality of mask openings12having a cross-sectional shape which is tapered toward the target substrate; and a limiting plate unit20provided between the vapor deposition source30and the vapor deposition mask10, the limiting plate unit20having a plurality of limiting plates22which are provided along at least the first direction so as to be spaced from each other, the limiting plate unit20being configured such that, in a cross section of the limiting plate unit20which cross section is parallel to the first direction, (i) the limiting plate unit20includes at least one limiting plate opening23, each of which is formed between a respective pair of mutually adjacent ones of the plurality of limiting plates22and opposite to a respective one of the at least one target region202such that the at least one limiting plate opening23and the at least one target region202are in one-to-one correspondence, (ii) a central axis of each of the at least one limiting plate opening23is aligned with a central axis of a respective one of the at least one target region202, and (iii) the following Formula (1) is satisfied:

where Wp is a width, as measured in the first direction, of each of the at least one target region202; Wr is a width of each of the at least one limiting plate opening23as measured in the first direction at a face of each of the at least one limiting plate opening which face is on a side toward a surface of the limiting plate unit20which surface faces the vapor deposition source30; Db is a distance from (a) a target surface201of the target substrate200to (b) a surface22aof each of the limiting plates22which surface22afaces the vapor deposition source30; and α is an angle of inclination of an opening wall12aof each of the plurality of mask openings12as observed in a cross section of the vapor deposition mask10which cross section is parallel to the first direction.

In other words, a vapor deposition device1in accordance with Aspect 1 is a vapor deposition device for forming, on a target substrate200having at least one target region202, a plurality of vapor-deposited films300having a predetermined pattern which are spaced from each other in at least a first direction, the plurality of vapor-deposited films300being formed in the at least one target region202, the vapor deposition device including: a vapor deposition source30having a plurality of vapor deposition source openings31for emitting vapor deposition particles310; a vapor deposition mask10provided opposite to the at least one target region202, the vapor deposition mask10having a mask opening region11constituted by a plurality of mask openings12provided along at least the first direction in correspondence with the predetermined pattern of the plurality of vapor-deposited films300, each of the plurality of mask openings12having a cross-sectional shape which is tapered toward the target substrate; and a limiting plate unit20provided between the vapor deposition source30and the vapor deposition mask10, the limiting plate unit20having a plurality of limiting plates22which are provided along at least the first direction so as to be spaced from each other, the limiting plate unit20being configured such that in a cross section of the limiting plate unit20which cross section is parallel to the first direction, (i) the limiting plate unit20includes at least one limiting plate opening23, each of which is formed between a respective pair of mutually adjacent ones of the plurality of limiting plates22and opposite to a respective one of the at least one target region202such that the at least one limiting plate opening23and the at least one target region202are in one-to-one correspondence, and (ii) the limiting plate unit20prevents entry into the plurality of mask openings12by vapor deposition particles310flying at an angle which is less than an angle of inclination (shadow critical angle α) of an opening wall12aof each of the plurality of mask openings12as observed in a cross section of the vapor deposition mask10which cross section is parallel to the first direction.

With the vapor deposition device1, entry into the at least one target region202is prevented for all vapor deposition particles310whose angle of entry into the at least one limiting plate opening23is less than an angle of inclination of an opening wall12aof each of the plurality of mask openings12as observed in a cross section of the vapor deposition mask10which cross section is parallel to the first direction. As such, the limiting plate unit20limits vapor deposition particles310which reach the mask openings12to being only those vapor deposition particles310whose angle of entry is not less than an angle of inclination of an opening wall12aof each of the plurality of mask openings12as observed in a cross section of the vapor deposition mask10which cross section is parallel to the first direction, which angle of inclination is a shadow critical angle. This makes it possible to achieve accurate vapor deposition patterning without a shadow.

In Aspect 2 of the present invention, the vapor deposition device1in accordance with Aspect 1 is preferably arranged such that the plurality of vapor deposition source openings31are formed such that two or more vapor deposition source openings from among the plurality of vapor deposition source openings31are opposite to each one of the at least one target region202.

With the above configuration, it is possible to greatly increase a vapor deposition rate in comparison to a configuration where the vapor deposition source openings31and the at least one limiting plate opening23have a one-to-one relationship. This makes it possible to enhance mass production efficiency and makes it easy to design a vapor deposition source.

In Aspect 3 of the present invention, the vapor deposition device1in accordance with Aspect 1 or 2 is preferably arranged such that: the at least one target region202includes a plurality of target regions which are provided along at least the first direction and separated by a film-non-formation region204provided between each of the plurality of target regions; and the limiting plate unit20satisfies the following Formula (2):

where S is a width, as measured in the first direction, of the film-non-formation region204; and θ is an angle of inclination of a line (L2) which connects, in each of the at least one limiting plate opening23, (i) a lower end of a first limiting plate22of a mutually opposed pair of the plurality of limiting plates22and (ii) an upper end of a second limiting plate22of the mutually opposed pair of the plurality of limiting plates22, the mutually opposed pair of the plurality of limiting plates22being opposed in the first direction.

With the above configuration, in a case where a lower end of one of the limiting plates22is used as a reference position, the following holds true in a planar view: a distance from (i) the reference position to (ii) a position of a vapor deposition particle which reaches a position closest to the adjacent target region202of the target substrate200is shorter than a distance from (iii) the reference position to (iv) a position at an end of the adjacent target region202.

The above configuration therefore makes it possible to prevent vapor deposition particles310which have been emitted from vapor deposition source openings31corresponding to (i) a respective one of the at least one target region202and (ii) a respective one of the at least one limiting plate opening23from passing through the respective one of the at least one limiting plate opening23and entering an adjacent target region202which is adjacent to the respective one of the at least one target region202.

In Aspect 4 of the present invention, the vapor deposition device1in accordance with any one of Aspects 1 to 3 is preferably arranged such that: the at least one target region202includes a plurality of target regions which are provided along at least the first direction; and the following Formula (4) is satisfied:

where We is a width, as measured in the first direction, of each of a plurality of formation regions (source opening formation regions32) of the vapor deposition source30, the plurality of formation regions each being for formation of the plurality of vapor deposition source openings31, the plurality of formation regions each corresponding to a respective one of the plurality of target regions202.

With the above configuration, mutually adjacent ones of the source opening formation regions32are prevented from overlapping completely. As long as each of the source opening formation regions32includes, as in the above configuration, at least a portion which does not overlap with other source opening formation regions32, it is possible to achieve one-to-one correspondence between the target regions202and the source opening formation regions32by providing the vapor deposition source openings31only in such portions of no overlap. As such, the above configuration makes it possible to limit vapor deposition particles310which enter a specific one of the target regions202to being vapor deposition particles310emitted from vapor deposition source openings31within a specific, opposing one of the source opening formation regions32.

In Aspect 5 of the present invention, the vapor deposition device1in accordance with Aspect 4 is preferably arranged such that the following Formula (5) is satisfied:

With the above configuration, mutually adjacent ones of the source opening formation regions32will not overlap, and it is possible to form the source opening formation regions32so as to be completely independent from each other.

In Aspect 6 of the present invention, the vapor deposition device1in accordance with any one of Aspects 1 to 5 is preferably arranged such that a vapor deposition rate of vapor deposition particles310emitted by the vapor deposition source from ones of the plurality of vapor deposition source openings31which ones are provided in a region opposite to the at least one limiting plate opening23is lower than a vapor deposition rate of vapor deposition particles310emitted by the vapor deposition source30from ones of the plurality of vapor deposition source openings31which ones are provided in a region other than the region opposite to the at least one limiting plate opening23.

The above configuration makes it possible to achieve a uniform distribution of film thickness of the vapor-deposited films300in each of the at least one target region202.

In Aspect 7 of the present invention, the vapor deposition device1in accordance with any one of Aspects 1 to 6 is preferably arranged such that each of the plurality of limiting plates22has a cross-sectional shape which is tapered toward the target substrate.

In a case where each of the limiting plates22has a cross-sectional shape which is tapered toward the vapor deposition source, the limiting plate unit20will not satisfy the above Formulas (1) and (2). However, in a case where each of the limiting plates22has a cross-sectional shape which is tapered toward the target substrate, it is possible to form the limiting plate unit20in a manner so as to satisfy the above Formulas (1) and (2).

In Aspect 8 of the present invention, the vapor deposition device1in accordance with any one of Aspects 1 to 6 is preferably arranged such that each of the plurality of limiting plates22has a T-shaped cross section and includes: a blocking wall section25constituted by a plate-like member; and a flange section26constituted by a plate-like member provided at a bottom surface of the blocking wall section25so as to protrude in an eaves-like manner toward adjacent ones of the plurality of limiting plates22.

The above configuration enables a reduction in the volume of the plurality of the limiting plates22. This makes it possible to increase the volume of space in which the vapor deposition particles310fly. As such, the above configuration makes possible to prevent a steep rise in pressure from occurring (i) between the vapor deposition source30and the plurality of limiting plates22and (ii) in the at least one limiting plate opening23. The above configuration also makes it possible to reduce the weight of the limiting plate unit20. Furthermore, with the above configuration, each of the plurality of limiting plates22includes a flange section26. This makes it possible to prevent vapor deposition material which has come off from the blocking wall section25from falling onto the vapor deposition source30.

In Aspect 9 of the present invention, the vapor deposition device1in accordance with any one of Aspects 1 to 8 is preferably arranged such that: the at least one target region202includes a plurality of target regions202which are (i) provided along the first direction (X axis direction) and a second direction (Y axis direction) orthogonal to the first direction and (ii) separated by a film-non-formation region204provided between each of the plurality of target regions202; the vapor deposition mask10has a size so as to be large enough to cover the plurality of target regions202of the target substrate200; the vapor deposition mask10and the target substrate200are positionally fixed with respect to each other; the limiting plate unit20and the vapor deposition source30are positionally fixed with respect to each other; each of the plurality of limiting plates22has a width, as measured in the second direction, which is less than that of the target substrate200and less than that of the vapor deposition mask10; the vapor deposition device1further includes a moving device (at least one of the substrate moving device5and the vapor deposition unit moving device6) configured to move (i) one of (a) a combination of the target substrate200and the vapor deposition mask10and (b) a combination of the limiting plate unit20and the vapor deposition source30with respect to the other or (ii) both (a) the combination of the target substrate200and the vapor deposition mask10and (b) the combination of the limiting plate unit20and the vapor deposition source30with respect to each other, such that a scanning direction is the second direction; and the vapor deposition device1, while carrying out scanning in the scanning direction, causes the vapor deposition particles310emitted by the vapor deposition source30to be vapor-deposited onto the target substrate200through the limiting plate unit20and the vapor deposition mask10.

The above configuration makes it possible, even for the target substrate200having a large surface area, to achieve high-precision patterning without a shadow occurring. This configuration also makes it possible to achieve high-definition patterning over a large surface area even when using the vapor deposition source30and the limiting plate unit20which are both relatively small. As such, the configuration enables enhanced mass production efficiency.

A method of vapor deposition in accordance with Aspect of the present invention includes forming, on a target substrate200having at least one target region202, a plurality of vapor-deposited films300having a predetermined pattern which are spaced from each other in at least a first direction, the plurality of vapor-deposited films300being formed in the at least one target region202, the forming being carried out with use of a vapor deposition device1in accordance with any one of Aspects 1 to 9.

The above method brings about effects similar to those of Aspect 1.

The present invention is not limited to the embodiments, but can be altered by a skilled person in the art within the scope of the claims. The present invention also encompasses, in its technical scope, any embodiment derived by combining technical means disclosed in differing embodiments. Further, it is possible to form a new technical feature by combining the technical means disclosed in the respective embodiments.

INDUSTRIAL APPLICABILITY

A vapor deposition device and a vapor deposition method in accordance with an embodiment of the present invention can each be suitably applied to, for example, production of various devices which production utilizes vapor deposition, an example being production of EL display devices such as organic EL display devices or inorganic EL display devices.

Reference Signs List

2Film formation chamber

11Mask opening region

14Surface (surface of vapor deposition mask which faces limiting plate unit)

15Surface (surface of vapor deposition mask which faces target substrate)

20Limiting plate unit

21Limiting plate row

22aSurface (surface of limiting plate unit which faces vapor deposition source)

22bSurface (surface of limiting plate unit which faces vapor deposition mask)

23Limiting plate opening

25Blocking wall section

30Vapor deposition source

31,31A Vapor deposition source opening

32Source opening formation regions

40Vapor deposition unit

203,203R,203G,203B Target pattern region

α Shadow critical angle