Mask for depositing a thin film and a thin film deposition method using the same

A mask for depositing a thin film and a thin film deposition method using the same are disclosed. The mask includes pattern bars disposed on a frame. The pattern bars are moveable and are position to form a deposition pattern. The mask includes a pattern modification mechanism configured to move the pattern pars to a plurality of positions to modify the deposition pattern.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application claims priority under 35 U.S.C. §119 to Korean Patent Application No. 10-2013-0068637, filed in the Korean Intellectual Property Office on Jun. 14, 2013, the disclosure of which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present invention relates to a mask for depositing a thin film and a thin film deposition method using the same and more particularly, to a mask capable of modifying a deposition pattern and a thin film deposition method using the same.

DISCUSSION OF RELATED ART

Organic light-emitting display apparatuses have wide viewing angles, high contrast ratios, and fast response times, for example.

An organic light-emitting display apparatus generates colors by recombining electrons and holes injected from an anode and a cathode in a light-emitting layer to emit light. An organic light-emitting display apparatus has an emission layer disposed between the anode and the cathode. However, high light-emission efficiency may not be achieved with this configuration. Thus, intermediate layers, including an electron injection layer, an electron transport layer, a hole transport layer, and a hole injection layer, may be selectively added and inserted between each of the electrodes (e.g., anode and cathode) and the emission layer.

The electrodes and the intermediate layers, including the emissive layer, may be formed using various methods. One of these methods is a deposition method. To manufacture organic light-emitting display apparatuses by using the deposition method, a mask having the same pattern as that of a thin film to be formed may be aligned on a substrate, and then a raw material of the thin film may be deposited to form the thin film having the desired pattern.

Since organic light-emitting display apparatuses having various standards are developed, a mask for a respective standard is used. However, an existing mask may be fixed in shape and thus may only correspond to one pattern. Thus, if a product standard is changed, the mask may have to be replaced with a mask corresponding to the changed product standard.

As a result, productivity associated with the manufacture of organic light-emitting devices may be reduced and manufacturing costs may be increased.

SUMMARY

Exemplary embodiments of the present invention provide a mask corresponding to various patterns and a thin film deposition method using the same.

An exemplary embodiment of the present invention provides a mask for depositing a thin film. The mask includes a frame. The mask includes pattern bars disposed on the frame to form a deposition pattern. The mask includes a pattern modification mechanism, which moves the pattern bars to modify the deposition pattern.

The pattern modification mechanism may include a rotational support part. The rotational support part may be positioned in the frame. The rotational support part may be coupled to the pattern bars. The pattern modification mechanism may include an actuator. The actuator may rotate each of the pattern bars coupled to the rotational support part to an angle.

The actuator may include a micro electromechanical system (MEMS).

The pattern bars may include first pattern bars disposed on the frame in a first direction. The pattern bars may include second pattern bars disposed on the frame in a second direction. The second direction may be perpendicular to the first direction.

A portion between the pattern bars for forming the deposition pattern may have a square shape.

The pattern modification mechanism may include a sliding support part. The sliding support part may be positioned in the frame. The sliding support part may be coupled to the pattern bars. The pattern modification mechanism may include an actuator, which slides each of the pattern bars coupled to the sliding support part to a position.

The actuator may include a micro electromechanical system (MEMS)

The pattern bars may include first pattern bars disposed on the frame in a first direction. The pattern bars may include second pattern bars disposed on the frame in a second direction. The second direction may be perpendicular to the first direction. The actuator may drive at least one of the first and second pattern bars.

According to an exemplary embodiment of the present invention, there is provided a method of depositing a thin film. The method includes preparing a mask in which pattern bars for forming a deposition pattern are arranged in a frame. The method includes moving the pattern bars to modify the deposition pattern, and performing a deposition process using the modified deposition pattern of the mask.

The pattern bars may be rotated at a plurality of angles to modify the deposition pattern.

The pattern bars may be slid into a plurality of positions to modify the deposition pattern.

DETAILED DESCRIPTION OF THE EMBODIMENTS

Exemplary embodiments of the present invention will be described below in more detail with reference to the accompanying drawings. However, the present invention may be modified in various different ways and should not be construed as limited to the embodiments disclosed herein.

FIG. 1is a perspective view of a mask100for depositing a thin film, according to an exemplary embodiment the present invention, andFIG. 2is a plan view of the mask100.

Referring toFIGS. 1 and 2, the mask100includes a frame120, and a plurality of pattern bars110. Each end of the pattern bars110may be fixed to the frame120.

The frame120may define an outer frame of the mask100. The frame120may have a square or rectangular shape in which an opening is defined in a center thereof. Both ends of each of the pattern bars110are supported by facing sides of the frame120. The frame120and pattern bars110form deposition patterns of the mask100. The pattern bars110include first pattern bars111disposed in a first direction, and second pattern bars112disposed in a second direction. The second direction may be perpendicular to the first direction. The first pattern bars111and second pattern bars112cross each other to form a deposition pattern having a grid shape.

The pattern bars110, including the first and second pattern bars111and112, are not fixed to the frame120. For example, the pattern bars110may be rotated at a plurality of desired angles by a pattern modification mechanism130that will be described below.

In other words, each of the pattern bars110is rotatably supported by the frame120by a rotational supporting part131, for example, a bearing. In addition, each of the pattern bars110is connected to an actuator132. The actuator132may rotate the pattern bars110to a desired angle. The actuator132may be, for example, a micro electromechanical system (MEMS). In addition, all variety of driving sources capable of rotating the pattern bars110may be used as the actuator132.

When the pattern bars110rotate, a distance between openings defined by the pattern bars110, e.g., a pitch, may be changed to modify the deposition pattern. In this way, a plurality of deposition patterns may be fashioned.

A plurality of the pattern bars110may be adjusted simultaneously. The pattern bars110may be adjusted simultaneously by the pattern modification mechanism130.

The pattern bars110may be adjusted individually. The pattern bars may be adjusted individually by the pattern modification mechanism130.

FIGS. 3A and 3Billustrate a process of modifying the deposition pattern of the mask100through the rotation of the pattern bars110, according to an exemplary embodiment of the present invention. Initially, the openings between the pattern bars100may have a square shape. When the pattern bars110are rotated, a distance between the adjacent pattern bars110(e.g., the pitch) may be gradually changed.

FIG. 3Aillustrates, for example, a state in which the pattern bars110are not rotated. Here, the pattern bars110may be maintained at a pitch d1. For example, if a deposition process is performed in this state, a thin film11may be formed to correspond to the deposition pattern having the pitch d1of the mask100on a substrate10.

In the state shown inFIG. 3B, the pattern modification mechanism130is operated to slightly rotate the pattern bars110. For example, the pattern bars110are changed in pitch from the pitch d1to the pitch d2, as shown inFIG. 3B. Then, for example, if a deposition process is performed with the pattern bars110maintained at the pitch d2, a thin film12may be formed on the substrate10to correspond to the deposition pattern having the pitch d2of the mask100.

A thin film deposition process using the mask100having the above-described structure will be described below. With reference toFIG. 3B, a thin film11may be formed on a substrate10by using a deposition pattern having a pitch d1. A mask100is disposed within a deposition chamber. Pattern bars110of the mask100are maintained at the pitch d1. A deposition source400may deposit the thin film11on the substrate10. The thin film11is deposited on the substrate10according to the deposition pattern of the mask100having the pitch d1. The thin film11having the pitch d1may be continuously deposited.

With regard toFIG. 3B, a thin film12may be formed on a substrate10by using a deposition pattern having a pitch d2. A pattern modification mechanism130may rotate the pattern bars110and change the pitch of the pattern bars110from the pitch d1to the pitch d2. A deposition source400may deposit the thin film12on the substrate10. The thin film12may be deposited on the substrate10according to the deposition pattern having the pitch d2. The thin film12having the pitch d2may be continuously deposited. The thin film12may be formed on the thin film11. When the deposition process is performed while changing the deposition pattern as described above, thin films complying with various standards may be deposited by using a single mask, for example, mask100. Thus, the mask100may improve efficiency. Further, use of the mask100may improve productivity.

FIG. 4is a perspective view of a mask200according to an exemplary embodiment of the present invention. The mask200may include pattern bars210. Pattern bars210may include first pattern bars211and second pattern bars212. The first pattern bars211and the second pattern bars212may perpendicularly cross each other to form openings. The pattern bars210may linearly slide to change the size of the openings and thus change the deposition pattern. To accomplish this, the mask200may include a pattern modification mechanism230. The pattern modification mechanism230may include a sliding support part231and an actuator232. The sliding support part231may support the patterning bars210to the frame220of the mask200, yet be large enough so that the bars can be slid therein. The sliding support part231and the actuator232may be disposed in the frame220. The actuator232may slide each of the patterning bars210supported by the sliding support part231into a plurality of positions. For example, the actuator232may be a micro electromechanical system (MEMS). In addition, a variety of driving sources capable of moving the pattern bars210may be used as the actuator232.

When the pattern bars210slidingly move, a distance between openings defined by the pattern bars210, e.g. a pitch, may be changed to modify the deposition pattern.

FIGS. 5A and 5Billustrate a process of modifying the deposition pattern of the mask200through the movement of the pattern bars210, according to an embodiment of the present inventive concept.

FIG. 5Aillustrates a process of moving the first pattern bars211while the pattern modification mechanism230operates. According to the process ofFIG. 5A, a thin film may be formed to correspond to a modified deposition pattern while a pitch between the first pattern bars211is changed.

In addition,FIG. 5Billustrates a process of moving the second pattern bars212while the pattern modification mechanism230operates. According to the process ofFIG. 5B, a thin film may be formed to correspond to a modified deposition pattern while a pitch between the second pattern bars212is changed.

Alternatively, the first and second pattern bars211and212may slide at the same time to modify the pattern.

A plurality of the pattern bars210may be adjusted simultaneously. The pattern bars210may be adjusted simultaneously by the pattern modification mechanism230.

The pattern bars210may be adjusted individually. The pattern bars may be adjusted individually by the pattern modification mechanism230.

A thin film deposition process using the mask200having the above-described structure will be described below.

For example, with reference toFIG. 5A, the mask200with the first pattern bars211adjusted in pitch may be placed in a deposition chamber. In this state, a deposition process may be performed and a thin film may be deposited corresponding to the deposition pattern of the mask220.

With reference toFIG. 5B, the mask200with the second pattern bars212adjusted in pitch may be placed in the deposition chamber. A deposition process may be performed and a thin film may be deposited corresponding to the deposition pattern of the mask200. The thin film may be formed on the thin film. Therefore, when a deposition process is performed while changing the deposition pattern as described above with reference toFIGS. 5A and 5B, thin films complying with various standards may be deposited by using a single mask200. Thus, the mask200may improve efficiency. Further, use of the mask200may improve productivity.

According to an exemplary embodiment of the present invention, the masks100and200may be used for depositing various thin films in addition to a process of patterning an organic light-emitting layer.

According to an exemplary embodiment of the present invention, a mask for depositing a thin film and a method of depositing the thin film by using the same are provided. In using the mask and methods, various patterns may be formed using a single mask, and thus, products having various characteristics may be produced using one mask. Thus, the loads in the manufacture, management, and replacement of the mask may be reduced and thereby lead to improved productivity.

While the present invention has been shown and described with reference to the exemplary embodiments thereof, it will be apparent to those of ordinary skill in the art that various changes in form and detail may be made thereto without departing from the spirit and scope of the invention as defined by the claims.