Vapor deposition method

A vapor deposition apparatus, which is capable of performing a thin film deposition process and improving characteristics of a formed thin film, includes: a chamber having an exhaust opening; a stage disposed in the chamber, and comprising a mounting surface on which the substrate may be mounted; an injection unit having at least one injection opening for injecting a gas into the chamber in a direction parallel with a surface of the substrate, on which the thin film is to be formed; a guide member facing the substrate to provide a set or predetermined space between the substrate and the guide member; and a driving unit conveying the stage and the guide member.

CROSS-REFERENCE TO RELATED PATENT APPLICATION

This application claims priority to and the benefit of Korean Patent Application No. 10-2011-0069488, filed on Jul. 13, 2011, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference.

BACKGROUND

1.Field of the Invention

The present invention relates to a vapor deposition apparatus, a vapor deposition method, and a method of manufacturing an organic light emitting display apparatus.

2.Description of Related Art

Semiconductor devices, display apparatuses, and other electronic devices include a plurality of thin films. The plurality of thin films may be formed using various methods, one of which is a vapor deposition method.

According to the vapor deposition method, one or more gases are used as a source for forming thin films. The vapor deposition method may include a chemical vapor deposition (CVD) method, an atomic layer deposition (ALD) method, and various other methods.

Among display apparatuses, organic light emitting display apparatuses are considered to be next generation display apparatuses due to their wide viewing angles, excellent contrast, and fast response speeds.

Organic light emitting display apparatuses include an intermediate layer having an organic emission layer between a first electrode and a second electrode that face each other, and one or more thin films. Here, a deposition process may be used to form thin films of the organic light emitting display apparatus.

However, since the organic light emitting display apparatus increases in size and requires high resolution, it is difficult to form a large sized thin film having desired properties. In addition, there is a limitation in improving efficiency of processes for forming thin films.

SUMMARY

An aspect of an embodiment of the present invention is directed toward a vapor deposition apparatus capable of performing a deposition process efficiently and improving characteristics of thin films, a vapor deposition method, and a method of manufacturing an organic light emitting display apparatus.

According to an embodiment of the present invention, there is provided a vapor deposition apparatus for forming a thin film on a substrate, the apparatus including: a chamber having an exhaust opening; a stage disposed in the chamber, and comprising a mounting surface on which the substrate may be mounted; an injection unit having at least one injection opening for injecting a gas into the chamber in a direction parallel with a surface of the substrate, on which the thin film is to be formed; a guide member facing the substrate to provide a predetermined space between the substrate and the guide member; and a driving unit conveying the stage and the guide member.

The guide member may be disposed in parallel with the substrate.

The guide member may be equal to or greater in size than that of the substrate.

The guide member may have an irregular surface comprising a plurality of convex portions and a plurality of concave portions and facing the substrate.

The convex portions and the concave portions may be extended in a direction in which the gravity acts.

The space disposed between the guide member and the substrate may have a shape corresponding to the pattern of the thin film that is to be formed on the substrate, and the guide member may include a path to the space, and through which the gas injected from the injection unit passes.

The path may include at least a first penetration portion formed on an upper end of the guide member and a second penetration portion formed on a lower end of the guide member.

The first penetration portion or the second penetration portion may be elongated so as to correspond to the space.

The first penetration portion or the second penetration portion may include a plurality of penetration openings corresponding to the space.

The space may correspond in shape to a groove formed in a surface of the guide member, which faces the substrate.

The guide member may include a cover that covers the space.

The driving unit may convey the stage and the guide member in a direction perpendicular to the surface of the substrate, on which the thin film will be formed, in a state where the substrate is mounted on the stage.

The driving unit may move reciprocately.

The driving unit may convey the stage and the guide member simultaneously.

The driving unit may include a first driving unit that moves the stage and a second driving unit that moves the guide member.

The mounting surface may be disposed in parallel with the direction in which the gravity acts.

The injection unit may be disposed above the stage.

The exhaust opening may be connected to a pump.

A source gas and a reaction gas may be sequentially injected through the injection opening.

The injection unit may include a plurality of injection openings through which a source gas and a reaction gas are independently injected.

The exhaust opening may be closer to ground than the substrate is.

The apparatus may further include a mask having a mask opening for forming a thin film on the substrate in a desired pattern, wherein the mask is disposed on the substrate.

The injection unit may include a plurality of injection openings that are arranged in a direction perpendicular to the surface of the substrate on which the thin film will be formed, and are separated from each other so as to perform a deposition process for a plurality of times on the substrate.

According to another aspect of the present invention, there is provided a vapor deposition method for forming thin films on a substrate, the method including: mounting the substrate on a mounting surface of a stage that is disposed in a chamber; injecting a source gas toward a space between the substrate and a guide member that is in parallel with the substrate through an injection unit in a direction parallel with a surface of the substrate, on which thin films are to be formed; performing exhaustion through an exhaust opening of the chamber; injecting a reaction gas into the chamber through the injection unit in a direction parallel with the surface of the substrate; and performing an exhaustion through the exhaust opening of the chamber.

The exhaustion may be performed by a pump.

The injection unit may have an injection opening, and the source gas and the reaction gas may be sequentially injected through the injection opening.

The injection unit may have a plurality of injection openings, and the source gas and the reaction gas may be respectively injected through different ones of injection openings.

The mounting of the substrate may include placing a mask having an opening for forming the thin films of desired pattern on the substrate.

The thin film deposition may be performed while moving the substrate in a direction perpendicular to the surface of the substrate, on which the thin film is formed, in a state where the substrate is mounted on the stage in the chamber.

According to another aspect of the present invention, there is provided a method of manufacturing an organic light emitting display apparatus which may include a plurality of thin films including at least a first electrode, an intermediate layer including an organic emission layer, and a second electrode on a substrate, wherein the forming of the thin film includes: mounting the substrate on a mounting surface of a stage that is disposed in a chamber; injecting a source gas toward a space between a guide member facing the substrate and the substrate through an injection unit in a direction parallel with a surface of the substrate, on which the thin films are to be formed; performing exhaustion through an exhaust opening of the chamber; injecting a reaction gas into the chamber through the injection unit in a direction parallel with the surface of the substrate; and performing exhaustion through the exhaust opening of the chamber.

The forming of the thin film may include forming an encapsulation layer on the second electrode.

The forming of the thin film may include forming an insulating layer.

The forming of the thin film may include forming a conductive layer.

DETAILED DESCRIPTION

Hereinafter, embodiments of the present invention will now be described with reference to accompanying drawings.

FIG. 1is a schematic cross-sectional view of a vapor deposition apparatus100according to an embodiment of the present invention.

Referring toFIG. 1, the vapor deposition apparatus100includes a chamber110, a stage120, an injection unit130, a guide member140, and first and second driving units151and152.

The chamber110includes an exhaust opening (e.g., a hole)111on a lower portion thereof. The exhaust opening111is an outlet for exhausting gas, and may be connected to a pump so as to perform the exhaustion process easily.

Although not shown inFIG. 1, the chamber110is controlled by a pump so as to maintain a suitable pressure (e.g., a predetermined pressure). In addition, a heating unit (not shown) for heating inside of the chamber110may be disposed on an inner or outer portion of the chamber110so as to improve efficiency of a thin film deposition process.

The stage120is disposed in the chamber110. The stage120includes a mounting surface121. The mounting surface121is disposed in parallel with a direction in which gravity acts. That is, the mounting surface121is disposed perpendicularly to ground. To do this, the stage120is disposed perpendicularly to the ground.

A substrate101is disposed on the stage120. In more detail, the substrate101is mounted on the mounting surface121of the stage120.

A fixing unit (not shown) may be disposed on the mounting surface121so that the substrate101may be fixed after being mounted on the mounting surface121. The fixing unit (not shown) may be a clamp, a compressing unit, an adhesive material, or other suitable materials or devices.

The guide member140is disposed to face the substrate101. Thus, a space (e.g., a gap) G is formed between the substrate101and the guide member140. The guide member140may be disposed in parallel with the substrate. In addition, the guide member140is formed as a flat plate having a size that is equal to or greater than that of the substrate101.

The first and second driving units151and152are connected to the stage120and the guide member140. In more detail, the first driving unit151is connected to the stage120, and the second driving unit152is connected to the guide member140. InFIG. 1, the first and second driving units151and152are separately formed from each other; however, the present invention is not limited thereto. That is, one driving unit that moves both the stage120and the guide member140concurrently or simultaneously may be used.

The first driving unit151conveys the stage120in a direction denoted by an arrow M shown inFIG. 1, or an opposite direction to the direction denoted by the arrow M. That is, the first driving unit151conveys the stage120in an X-axis direction ofFIG. 1. Thus, the substrate101may be moved in a direction perpendicular to a surface of the substrate101, that is, a surface on which a thin film will be formed.

In addition, the second driving unit152conveys the guide member140in the direction denoted by the arrow M shown inFIG. 1, or an opposite direction to the direction denoted by the arrow M. That is, the second driving unit152conveys the guide member140in an X-axis direction ofFIG. 1. Thus, the guide member140may be moved in a direction perpendicular to a surface of the substrate101, that is, a surface on which a thin film will be formed.

The first and second driving units151and152are controlled to maintain the space G between the substrate101and the guide member140.

The injection unit130is connected to the chamber110. One or more gases are injected toward the substrate101through the injection unit130. In more detail, the injection unit130includes a first injection opening (e.g., a hole)131, a second injection opening132, a third injection opening133, a fourth injection opening134, a fifth injection opening135, and a sixth injection opening136.

In addition, the first through sixth injection openings131through136are arranged along a moving direction of the substrate101. That is, the first through sixth injection openings131through136are arranged in the X-axis direction ofFIG. 1and separated from each other.

In addition, the first through sixth injection openings131through136may be formed to have various shapes, for example, may be formed as dots or lines corresponding to a width of the substrate101.

A gas is injected into the chamber110through the first through sixth injection openings131through136in parallel with a surface direction of the substrate101. That is, the gas is injected through the first through sixth injection openings131through136in parallel with a direction in which gravity acts.

In more detail, a source gas S is injected through the first, third, and fifth injection openings131,133, and135, and a reaction gas is injected through the second, fourth, and sixth injection openings132,134, and136.

While the source gas S is being injected through the first, third, and fifth injection openings131,133, and135, the reaction gas is not injected through the second, fourth, and sixth injection openings132,134, and136. After injecting the source gas S through the first, third, and fifth injection openings131,133, and135, the reaction gas is injected through the second, fourth, and sixth injection openings132,134, and136.

In addition, the source gas S may be sequentially, concurrently, or simultaneously injected through the first, third, and fifth injection openings131,133, and135. Likewise, the reaction gas may be injected sequentially, concurrently, or simultaneously injected through the second, fourth, and sixth injection openings132,134, and136.

However, the present invention is not limited to the above example. That is, the source gas S and the reaction gas may be injected through the same injection openings of the injection unit130. For example, the injection unit130may include only the first, third, and fifth injection openings131,133, and135, and the source gas S is sequentially injected through the first, third, and fifth injection openings131,133, and135, and then the reaction gas may be injected through the first, third, and fifth injection opening231,233, and235.

Although not shown inFIG. 1, the first through sixth injection openings131through136may be separated at regular intervals from each other. That is, after injecting the source gas S, the reaction gas may be injected after moving the substrate101by using the driving units151and152.

In addition, six injection openings are formed in the injection unit130as shown inFIG. 1; however, the present invention is not limited thereto, that is, two or more injection openings may be formed in the injection unit130.

Operations of the vapor deposition apparatus100according to the present embodiment will now be described.

The substrate101is mounted on the mounting surface121of the stage120. After that, the source gas S is injected through the first injection opening131of the injection unit130. Here, the source gas S is injected toward the space G between the substrate101and the guide member140.

In more detail, the source gas S may include aluminum (Al) atoms.

The source gas S is adsorbed on an upper surface (e.g., a surface opposite the surface facing the stage120) of the substrate101. After that, an exhaustion process is performed through the exhaust opening111, and then an atom layer of a single-layered structure or multi-layered structure formed of the source gas S is formed on the upper surface of the substrate101. That is, a single layer or multiple layers of Al atoms are formed.

After that, the reaction gas is injected through the second injection opening132of the injection unit130. As described above, when the injection openings131through136of the injection unit130are arranged at regular intervals, after injecting the source gas S through the first injection opening131, the stage120and the guide member140are moved in the X-axis direction ofFIG. 1, that is, the direction denoted by the arrow M, by using the driving units151and152so that the reaction gas may be injected through the second injection opening132.

The reaction gas may be injected toward the space G between the substrate101and the guide member140. In more detail, the reaction gas may include oxygen (O) atoms. The reaction gas is adsorbed on the upper surface of the substrate101. Then, an exhaustion process is performed through the exhaust opening111, and then, an atom layer of the single-layered structure or multi-layered structure formed of the reaction gas is formed on the upper surface of the substrate101. That is, a single layer or multi-layers of oxygen atoms are formed.

Therefore, the atom layers of the single-layered structure or the multi-layered structure formed of the source gas S and the reaction gas components are formed on the upper surface of the substrate101. That is, an aluminum oxide layer (AlxOy, where x and y may be variable according to processing conditions) is formed. In the present embodiment, the aluminum oxide layer is formed; however, the present invention is not limited thereto. That is, embodiments of the present invention may be applied to processes of forming various insulating layers and conductive layers including oxide layers.

After that, the stage120and the guide member140are moved in the X-axis direction ofFIG. 1, that is, the direction denoted by the arrow M, by using the first and second driving units151and152. Therefore, the space G between the substrate101and the guide member140may be maintained.

The source gas S is injected through the third injection opening133of the injection unit130toward the space G between the substrate101and the guide member140. The source gas S is adsorbed on the upper surface of the substrate101. After that, an exhaustion process is performed by using the exhaust opening111, and then, an atom layer of a single-layered structure or multi-layered structure formed of the source gas S is formed on the upper surface of the substrate101.

The reaction gas may be injected toward the space G between the substrate101and the guide member140through the fourth injection opening134of the injection unit130. The reaction gas is adsorbed on the upper surface of the substrate101. Then, an exhaustion process is performed through the exhaust opening111, and then, an atom layer of the single-layered structure or multi-layered structure formed of the reaction gas is formed on the upper surface of the substrate101.

Therefore, the single-layered atom layer or the multi-layered atom layers including the source gas S and the reaction gas components are additionally formed on the thin film that is formed on the upper surface of the substrate101through the first and second injection openings131and132.

After that, the stage120and the guide member140are moved in the X-axis direction ofFIG. 1, that is, the direction denoted by the arrow M, by using the first and second driving units151and152.

The source gas S and the reaction gas are injected toward the space G between the substrate101and the guide member140through the fifth and sixth injection openings135and136so that additional thin films may be formed on the substrate101, like the thin films formed through the first and second injection openings131and132.

Through the above processes, the thin film of desired thickness may be easily formed on the substrate101in one chamber110. That is, moving distance of the stage120and the guide member140may be controlled according to the desired thickness of the thin film.

According to the present embodiment, the gas is injected from the injection unit130in a direction parallel with the upper surface of the substrate101. In particular, the substrate101is disposed in a direction perpendicular to the ground, that is, a direction in which gravity acts. Therefore, when the gas is injected through the injection unit130and adsorbed on the substrate101, an unnecessarily adsorbed amount on the substrate101may be reduced. That is, unnecessary adsorbed components on the substrate101and other unevenly lumped components fall down due to the gravity, and thus, the unnecessary amount is reduced. In addition, the unnecessary gas component may be easily removed by the exhaustion process through the exhaust opening111disposed on a lower portion of the substrate101. Therefore, after injecting the source gas S through the first injection opening131of the injection unit130, the exhaustion process is performed without performing a purging process using an additional purge gas. After that, the reaction gas is injected through the second injection opening132, the exhaustion process is performed without performing the purging process using an additional purge gas, and then, the deposition process is finished.

In addition, the guide member140is disposed to face the substrate101according to the present embodiment. Thus, impurities may be blocked by the guide member140. For example, when the source gas S is injected through the third injection opening133, remaining impurity gas that remains after forming the thin film on the substrate101among the source gas or the reaction gas that is injected through the first and second injection openings131and132in the previous process may not be exhausted completely through the exhaust opening111. In this case, the process of forming the thin film by using the source gas S injected through the third injection opening133is affected by the impurity gas, and thereby degrading characteristics of the thin film formed on the substrate101. However, according to the present embodiment, the space G is formed between the substrate101and the guide member140, and the source gas S is injected toward the space through the third injection opening133so that the guide member140may prevent or block the impurity away from the substrate101.

In addition, the source gas S injected through the third injection opening133is not as dispersed, and is effectively adsorbed on the substrate101between the substrate101and the guide member140, and thereby improving the thin film deposition efficiency.

As a result, efficiency of the deposition process for forming desired thin films may be greatly improved. In addition, adsorption of the unnecessary gas components may be reduced or prevented, and mixture of purge gas impurities into the thin films formed on the substrate101may be reduced or prevented. Therefore, the thin films may be evenly formed, and have excellent physical and chemical characteristics.

In addition, according to the present embodiment, the deposition processes are performed while moving the stage120and the guide member140by using the driving units151and152. As such, the deposition processes can be sequentially performed through the first through sixth injection openings131through136, and thus, time that is needed for forming the thin film of desired thickness may be greatly reduced and the convenience of deposition processes is improved.

FIG. 2is a schematic cross-sectional view of a vapor deposition apparatus200according to another embodiment of the present invention, andFIG. 3is a diagram of the vapor deposition apparatus seen from a direction A ofFIG. 2.

Referring toFIGS. 2 and 3, a vapor deposition apparatus200includes a chamber210, a stage220, an injection unit230, a guide member240, first and second driving units251and252, and a mask260.

The chamber210includes an exhaust opening211on a lower portion thereof. The exhaust opening211is an outlet that exhausts gas, and may be connected to a pump so as to perform the exhaustion sufficiently.

Although not shown inFIGS. 2 and 3, the chamber210is controlled by a pump so as to maintain a suitable pressure (e.g., a predetermined pressure). In addition, a heating unit (not shown) for heating inside of the chamber210may be disposed on an inner or outer portion of the chamber210so as to improve efficiency of a thin film deposition process.

The stage220is disposed in the chamber210. The stage220includes a mounting surface221. The mounting surface221is disposed in parallel with a direction in which gravity is applied. That is, the mounting surface221is disposed perpendicularly to ground. To do this, the stage220is disposed perpendicularly to the ground.

A substrate201is disposed on the stage220. In more detail, the substrate201is mounted on the mounting surface221of the stage220.

A fixing unit (not shown) may be disposed on the mounting surface221so that the substrate201may be fixed after being mounted on the mounting surface221. The fixing unit (not shown) may be a clamp, a compressing unit, an adhesive material, or other materials.

The mask260is disposed on the substrate201. Referring toFIG. 3, the mask260includes a mask opening260ahaving a suitable shape (e.g., a predetermined shape), which is a rectangular shape inFIG. 3, but is limited thereto. The mask opening260acorresponds to a pattern of the thin film that will be formed on the substrate201.

FIG. 3shows six mask openings260a;however, the present invention is not limited thereto. That is, the number and shape of the mask openings260amay be determined according to the number of patterns that are wanted to be formed on the substrate201. for example, the mask260may be an open mask having one mask opening260a.

The guide member240is disposed to face the substrate201. Thus, a space G is formed between the substrate201and the guide member240. The guide member240may be disposed in parallel with the substrate. In addition, the guide member240is formed as a flat plate having a size that is equal to or greater than that of the substrate201.

The first and second driving units251and252are connected to the stage220and the guide member240. In more detail, the first driving unit251is connected to the stage220, and the second driving unit252is connected to the guide member240.

The first driving unit251conveys the stage220in a direction denoted by an arrow M shown inFIG. 2, or an opposite direction to the direction denoted by the arrow M. That is, the first driving unit251conveys the stage220in an X-axis direction ofFIG. 2. Thus, the substrate201may be moved in a direction perpendicular to a surface of the substrate201, that is, a surface on which a thin film will be formed.

In addition, the second driving unit252conveys the guide member240in the direction denoted by the arrow M shown inFIG. 2, or an opposite direction to the direction denoted by the arrow M. That is, the second driving unit252conveys the guide member240in an X-axis direction ofFIG. 1. Thus, the guide member240may be moved in a direction perpendicular to a surface of the substrate201, that is, a surface on which a thin film will be formed.

The first and second driving units251and252are controlled to maintain the space G between the substrate201and the guide member240.

The injection unit230is connected to the chamber210. One or more gases are injected toward the substrate201through the injection unit230. In more detail, the injection unit230includes a first injection opening231, a second injection opening232, a third injection opening233, a fourth injection opening234, a fifth injection opening235, and a sixth injection opening236.

In addition, the first through sixth injection openings231through236are arranged along a moving direction of the substrate201. That is, the first through sixth injection openings231through236are arranged in the X-axis direction ofFIG. 2and separated from each other.

In addition, the first through sixth injection openings231through236may be formed to have various shapes, for example, may be formed as dots or lines corresponding to a width of the substrate201.

A gas is injected into the chamber210through the first through sixth injection openings231through236in parallel with a surface direction of the substrate201. That is, the gas is injected through the first through sixth injection openings231through236in parallel with a direction in which gravity acts.

In more detail, a source gas S is injected through the first, third, and fifth injection openings231,233, and235, and a reaction gas is injected through the second, fourth, and sixth injection openings232,234, and236.

While the source gas S is injected through the first, third, and fifth injection openings231,233, and235, the reaction gas is not injected through the second, fourth, and sixth injection openings232,234, and236. After injecting the source gas S through the first, third, and fifth injection openings231,233, and235, the reaction gas is injected through the second, fourth, and sixth injection openings232,234, and236.

In addition, the source gas S may be sequentially, concurrently, or simultaneously injected through the first, third, and fifth injection openings231,233, and235. Likewise, the reaction gas may be injected sequentially, concurrently, or simultaneously injected through the second, fourth, and sixth injection openings232,234, and236.

However, the present invention is not limited to the above example. That is, the source gas S and the reaction gas may be injected through the same injection openings of the injection unit230. For example, the injection unit230may include only the first, third, and fifth injection openings231,233, and235, and the source gas S is sequentially injected through the first, third, and fifth injection openings231,233, and235, and then the reaction gas may be injected through the first, third, and fifth injection openings231,233, and235.

Although not shown inFIG. 2, the first through sixth injection openings231through236may be separated at regular intervals from each other. That is, after injecting the source gas S, the reaction gas may be injected after moving the substrate201by using the driving units251and252.

Operations of the vapor deposition apparatus200according to the present embodiment will now be described.

The substrate201is mounted on the mounting surface221of the stage220. The mask260having an opening260athat corresponds to a pattern of a thin film that will be formed on the substrate201is disposed on the substrate201.

After that, the source gas S is injected through the first injection opening231of the injection unit230. Here, the source gas S is injected toward the space G between the substrate201and the guide member240.

The source gas S is adsorbed on an upper surface of the substrate201. In particular, the source gas S is adsorbed on a portion of the upper surface of the substrate201, which corresponds to the opening260aof the mask260.

After that, an exhaustion process is performed through the exhaust opening211, and then an atom layer of a single-layered structure or multi-layered structure formed of the source gas S is formed on the upper surface of the substrate201.

After that, the reaction gas is injected through the second injection opening232of the injection unit230. Here, the reaction gas is injected toward the space G between the substrate201and the guide member240. The reaction gas is adsorbed on the upper surface of the substrate201, in particular, on a portion corresponding to the opening260aof the mask260.

Then, an exhaustion process is performed through the exhaust opening211, and then, an atom layer of the single-layered structure or multi-layered structure formed of the reaction gas is formed on the upper surface of the substrate201.

Thus, the atom layers of single-layered structure or multi-layered structure formed of the source gas S and the reaction gas are formed on the upper surface of the substrate201so as to correspond to the opening260aof the mask260.

After that, the stage220and the guide member240are moved in the X-axis direction ofFIG. 2, that is, the direction denoted by the arrow M, by using the first and second driving units251and252. After moving the stage220and the guide member240, the space G between the substrate201and the guide member240may be maintained.

The source gas S is injected through the third injection opening233of the injection unit230toward the space G between the substrate201and the guide member240. The source gas S is adsorbed on the upper surface of the substrate201, in particular, on a portion corresponding to the opening260aof the mask260. Then, an exhaustion process is performed through the exhaust opening211, and the single-layered atom layer or the multi-layered atom layer including the source gas S is formed on the upper surface of the substrate201.

Then, the reaction gas is injected toward the space G between the substrate201and the guide member240through the fourth injection opening234of the injection unit230. The reaction gas is adsorbed on the portion of the upper surface of the substrate201, which corresponds to the opening260aof the mask260. After that, the exhaustion is performed through the exhaust opening211, and then, the atom layer having the single-layered or multi-layered structure of the reaction gas is formed on the upper surface of the substrate201.

Therefore, the single-layered atom layer or the multi-layered atom layers including the source gas S and the reaction gas components are additionally formed on the thin film that is formed on the upper surface of the substrate201through the first and second injection openings231and232.

After that, the stage220and the guide member240are moved in the X-axis direction ofFIG. 2, that is, the direction denoted by the arrow M, by using the first and second driving units251and252.

The source gas S and the reaction gas are injected toward the space G between the substrate201and the guide member240through the fifth and sixth injection openings235and236so that additional thin films may be formed on the substrate201, like the thin films formed through the first and second injection openings231and232.

Through the above processes, the thin film of desired thickness may be easily formed on the substrate201in one chamber210. That is, moving distance of the stage220and the guide member240may be controlled according to the desired thickness of the thin film.

In the present embodiment, the mask260is disposed on the substrate201so as to easily form the thin film of the desired pattern on the substrate201.

According to the present embodiment, the gas is injected from the injection unit230in a direction parallel with the upper surface of the substrate201. In particular, the substrate201is disposed in a direction perpendicular to the ground, that is, a direction in which gravity acts. Therefore, when the gas is injected through the injection unit230and adsorbed on the substrate201, an unnecessarily adsorbed amount on the substrate201may be reduced. That is, unnecessary adsorbed components on the substrate201and other unevenly lumped components fall down due to the gravity, and thus, the unnecessary amount is reduced. In addition, the unnecessary gas component may be easily removed by the exhaustion process through the exhaust opening211disposed on a lower portion of the substrate201. Therefore, after injecting the source gas S through the first injection opening231of the injection unit230, the exhaustion process is performed without performing a purging process using an additional purge gas. After that, the reaction gas is injected through the second injection opening232, the exhaustion process is performed without performing the purging process using an additional purge gas, and then, the deposition process is finished.

In addition, the guide member240is disposed to face the substrate201according to the present embodiment. Thus, impurities may be blocked by the guide member240. In addition, the source gas S injected through the injection unit230is not as dispersed, and is effectively adsorbed on the substrate201between the substrate201and the guide member240, and thereby improving the thin film deposition efficiency.

As a result, efficiency of the deposition process for forming desired thin films may be greatly improved. In addition, adsorption of the unnecessary gas components may be reduced or prevented, and mixture of purge gas impurities into the thin films formed on the substrate201may be reduced or prevented. Therefore, the thin films may be evenly formed, and have excellent physical and chemical characteristics.

In addition, according to the present embodiment, the deposition processes are sequentially performed while moving the stage220and the guide member240by using the driving units251and252. Therefore, time that is taken for forming the thin film of desired thickness may be greatly reduced and the convenience of deposition processes is improved.

FIG. 4is a front view of a vapor deposition apparatus300according to another embodiment of the present invention.FIG. 5is a schematic perspective view of a substrate and a guide member shown inFIG. 4, andFIG. 6is a cross-sectional view of the substrate and the guide member taken along line VI-VI ofFIG. 5.

The vapor deposition apparatus300includes a chamber310, a stage320, an injection unit330, a guide member340, and first and second driving units351and352.

The chamber310includes an exhaust opening311on a lower portion thereof. The exhaust opening311is an outlet that exhausts gas, and may be connected to a pump so as to perform the exhaustion sufficiently.

Although not shown inFIG. 4, the chamber310is controlled by a pump so as to maintain a suitable pressure (e.g., a predetermined pressure). In addition, a heating unit (not shown) for heating inside of the chamber310may be disposed on an inner or outer portion of the chamber310so as to improve efficiency of a thin film deposition process.

The stage320is disposed in the chamber310. The stage320includes a mounting surface321. The mounting surface321is disposed in parallel with a direction in which gravity is applied. That is, the mounting surface321is disposed perpendicularly to ground. To do this, the stage320is disposed perpendicularly to the ground.

A substrate301is disposed on the stage320. In more detail, the substrate301is mounted on the mounting surface321of the stage320.

A fixing unit (not shown) may be disposed on the mounting surface321so that the substrate301may be fixed after being mounted on the mounting surface321. The fixing unit (not shown) may be a clamp, a compressing unit, an adhesive material, or other materials.

The guide member340is disposed to face the substrate301. Thus, a space G is formed between the substrate301and the guide member340. The guide member340may be disposed in parallel with the substrate.

In addition, the guide member340is formed to have a size that is equal to or greater than that of the substrate301so as to correspond to the substrate301.

The guide member340has an irregular surface that faces the substrate301. That is, the guide member340includes convex portions341and concave portions342facing the substrate301. The concave portions342are disposed between two adjacent convex portions341. In addition, the convex and concave portions341and342are extended from an upper portion toward a lower portion along a direction, in which gravity acts.

The first and second driving units351and352are connected to the stage320and the guide member340. In more detail, the first driving unit351is connected to the stage320, and the second driving unit352is connected to the guide member340.

The first driving unit351conveys the stage320in a direction denoted by an arrow M shown inFIG. 4, or an opposite direction to the direction denoted by the arrow M. That is, the first driving unit351conveys the stage320in an X-axis direction ofFIG. 4. Thus, the substrate301may be moved in a direction perpendicular to a surface of the substrate301, that is, a surface on which a thin film will be formed.

In addition, the second driving unit352conveys the guide member340in the direction denoted by the arrow M shown inFIG. 4, or an opposite direction to the direction denoted by the arrow M. That is, the second driving unit352conveys the guide member340in an X-axis direction ofFIG. 4. Thus, the guide member340may be moved in a direction perpendicular to a surface of the substrate301, that is, a surface on which a thin film will be formed.

The first and second driving units351and352are controlled to maintain the space G between the substrate301and the guide member340.

The injection unit330is connected to the chamber310. One or more gases are injected toward the substrate301through the injection unit330. In more detail, the injection unit330includes a first injection opening331, a second injection opening332, a third injection opening333, a fourth injection opening334, a fifth injection opening335, and a sixth injection opening336.

In addition, the first through sixth injection openings331through336are arranged along a moving direction of the substrate301. That is, the first through sixth injection openings331through336are arranged in the X-axis direction ofFIG. 4and separated from each other.

In addition, the first through sixth injection openings331through336may be formed to have various shapes, for example, may be formed as dots or lines corresponding to a width of the substrate301. That is, inFIG. 5, the first injection opening331is formed as a line; however, the present invention is not limited thereto, that is, the first injection opening331may be formed as a dot.

A gas is injected into the chamber210through the first through sixth injection openings231through236in parallel with a surface direction of the substrate201. That is, the gas is injected through the first through sixth injection openings231through236in parallel with a direction in which gravity acts.

In more detail, a source gas S is injected through the first, third, and fifth injection openings331,333, and335, and a reaction gas is injected through the second, fourth, and sixth injection openings332,334, and336.

While the source gas S is injected through the first, third, and fifth injection openings331,333, and335, the reaction gas is not injected through the second, fourth, and sixth injection openings332,334, and336. After injecting the source gas S through the first, third, and fifth injection openings331,333, and335, the reaction gas is injected through the second, fourth, and sixth injection openings332,334, and336.

In addition, the source gas S may be sequentially, concurrently, or simultaneously injected through the first, third, and fifth injection openings331,333, and335. Likewise, the reaction gas may be injected sequentially, concurrently, or simultaneously injected through the second, fourth, and sixth injection openings332,334, and336.

However, the present invention is not limited to the above example. That is, the source gas S and the reaction gas may be injected through the same injection openings of the injection unit330. For example, the injection unit330may include only the first, third, and fifth injection openings331,333, and335, and the source gas S is sequentially injected through the first, third, and fifth injection openings331,333, and335, and then the reaction gas may be injected through the first, third, and fifth injection openings331,333, and335.

Although not shown in the drawings, the first through sixth injection openings331through336may be separated at regular intervals from each other. That is, after injecting the source gas S, the reaction gas may be injected after moving the substrate301by using the driving units351and352.

Operations of the vapor deposition apparatus300according to the present embodiment will now be described.

The substrate301is mounted on the mounting surface321of the stage320. After that, the source gas S is injected through the first injection opening331of the injection unit330. Here, the source gas S is injected toward the space G between the substrate301and the guide member340.

The source gas S is adsorbed on an upper surface of the substrate301. After that, an exhaustion process is performed through the exhaust opening311, and then an atom layer of a single-layered structure or multi-layered structure formed of the source gas S is formed on the upper surface of the substrate301.

After that, the reaction gas is injected through the second injection opening332of the injection unit330. Here, the reaction gas is injected toward the space G between the substrate301and the guide member340.

The reaction gas is adsorbed on the upper surface of the substrate301. Then, an exhaustion process is performed through the exhaust opening311, and then, an atom layer of the single-layered structure or multi-layered structure formed of the reaction gas is formed on the upper surface of the substrate301. That is, a single layer or multi-layers of oxygen atoms are formed on the substrate301.

Through the above processes, the atom layers of single-layered structure or multi-layered structure formed of the source gas S and the reaction gas are formed on the upper surface of the substrate301.

After that, the stage320and the guide member340are moved in the X-axis direction ofFIG. 4, that is, the direction denoted by the arrow M, by using the first and second driving units351and352. After moving the stage320and the guide member340, the space G between the substrate301and the guide member340may be maintained.

The source gas S and the reaction gas are injected through the third and fourth injection openings333and334of the injection unit330toward the space G between the substrate301and the guide member340so as to form an additional thin film on the substrate301like the thin film formed by using the first and second injection openings331and332.

After that, the stage320and the guide member340are moved in the X-axis direction ofFIG. 4, that is, the direction denoted by the arrow M, by using the first and second driving units351and352. The source gas S and the reaction gas are injected through the fifth and sixth injection openings335and336of the injection unit330toward the space G between the substrate301and the guide member340so as to form an additional thin film on the substrate301like the thin film formed by using the first and second injection openings331and332.

Through the above processes, the thin film of desired thickness may be easily formed on the substrate301in one chamber310.

According to the present embodiment, the gas is injected from the injection unit330in a direction parallel with the upper surface of the substrate301. In particular, the substrate301is disposed in a direction perpendicular to the ground, that is, a direction in which gravity acts. Therefore, when the gas is injected through the injection unit330and adsorbed on the substrate301, an unnecessarily adsorbed amount on the substrate301may be reduced. Therefore, after injecting the source gas S through the first injection opening331of the injection unit330, the exhaustion process is performed without performing a purging process using an additional purge gas. After that, the reaction gas is injected through the second injection opening332, the exhaustion process is performed without performing the purging process using an additional purge gas, and then, the deposition process is finished.

In addition, adsorption of the unnecessary gas components may be prevented, and mixture of purge gas impurities into the thin films formed on the substrate301may be prevented. Therefore, the thin films may be evenly formed, and have excellent physical and chemical characteristics.

In addition, the guide member340is disposed to face the substrate301according to the present embodiment. Thus, impurities may be blocked by the guide member340. In addition, the source gas S injected through the injection unit330is not as dispersed, and is effectively adsorbed on the substrate301between the substrate301and the guide member340, and thereby improving the thin film deposition efficiency. For example, when the source gas S is injected through the third injection opening333, remaining impurity gas that remains after forming the thin film on the substrate301among the source gas or the reaction gas that is injected through the first and second injection openings331and332in the previous process may not be exhausted completely through the exhaust opening311. In this case, the process of forming the thin film by using the source gas S injected through the third injection opening333is affected by the impurity gas, and thereby degrading characteristics of the thin film formed on the substrate301. However, according to the present embodiment, the space G is formed between the substrate301and the guide member340, and the source gas S is injected toward the space through the third injection opening333so that the guide member340may prevent or block the impurity away from the substrate301.

In addition, the source gas S injected through the third injection opening333is not as dispersed, and is effectively adsorbed on the substrate301between the substrate301and the guide member340, and thereby improving the thin film deposition efficiency.

Moreover, the guide member340of the present embodiment further includes the irregular surface having the convex portions341and the concave portions342, and facing the substrate301. In more detail, the convex portions341and the concave portions342are elongated in the direction in which gravity acts, that is, the longitudinal direction. The convex portions341and the concave portions342perform as paths in which the gas injected from the injection unit330may proceed toward the substrate301without being as dispersed. That is, inFIGS. 5 and 6, the convex portions341and the concave portions342make the injected gases move straight downward in a Z-axis direction without overly dispersing in a Y-axis direction, so that reaction efficiency between the injected gases and the substrate301may be improved.

Therefore, the efficiency of the deposition process for forming the thin film of desired thickness is greatly improved, and thereby improving thin film characteristics.

In addition, according to the present embodiment, the deposition processes are sequentially performed while moving the stage320and the guide member340by using the driving units351and352. Therefore, time that is taken for forming the thin film of desired thickness may be greatly reduced and the convenience of deposition processes is improved by performing the deposition processes sequentially through the first through sixth injection openings331through336.

FIG. 7is a schematic cross-sectional view of a vapor deposition apparatus400according to another embodiment of the present invention,FIG. 8is a projecting perspective view of a guide member460shown inFIG. 7, andFIG. 9is a cross-sectional view of the guide member taken along line IX-IX ofFIG. 8.

Referring toFIGS. 7 through 9, the vapor deposition apparatus400includes a chamber410, a stage420, an injection unit430, a guide member460, and a driving unit451.

The chamber410includes an exhaust opening411on a lower portion thereof. The exhaust opening311is an outlet that exhausts gas, and may be connected to a pump so as to perform the exhaustion sufficiently.

Although not shown inFIGS. 7 through 9, the chamber410is controlled by a pump so as to maintain a suitable pressure (e.g., a predetermined pressure). In addition, a heating unit (not shown) for heating inside of the chamber410may be disposed on an inner or outer portion of the chamber410so as to improve efficiency of a thin film deposition process.

The stage420is disposed in the chamber410. The stage420includes a mounting surface421. The mounting surface421is disposed in parallel with a direction in which gravity is applied. That is, the mounting surface421is disposed perpendicularly to ground. To do this, the stage420is disposed perpendicularly to the ground.

A substrate401is disposed on the stage420. In more detail, the substrate401is mounted on the mounting surface421of the stage420.

A fixing unit (not shown) may be disposed on the mounting surface421so that the substrate401may be fixed after being mounted on the mounting surface421. The fixing unit (not shown) may be a clamp, a compressing unit, an adhesive material, or other suitable materials or devices.

The guide member460is disposed to face the substrate401. The guide member460may be coupled to the stage420. That is, edges of the guide member460may be coupled to the stage420.

The guide member460is disposed on the substrate401. In addition, the guide member460has a size that is equal to or greater than that of the substrate401so as to correspond to the substrate401.

The guide member460includes paths461through which the gases injected from the injection unit430may pass. The path461includes a first penetration portion (e.g., a channel)461aand a second penetration portion461c.In more detail, the first penetration portion461ais formed on an upper end of the guide member460, and the second penetration portion461c is formed on a lower end of the guide member460. A connecting penetration portion461bis formed between the first and second penetration portions461aand461c.

In addition, the guide member460includes a space G formed as a suitable shape (e.g., a predetermined shape). The space G may be a groove formed by removing a surface of the guide member460to a suitable depth (e.g., a predetermined depth). The space G has a shape corresponding to a pattern of a thin film that will be formed on the substrate401. In addition, the space G contacts an upper surface of the substrate401.

That is, the space G is formed between the substrate401and the guide member460. The gases injected through the path461react with the substrate401in the space G.

In particular, the guide member460includes a cover462disposed on the space G so as not to expose the space G out of the cover462. InFIGS. 8 and 9, the cover462is formed as a part of the guide member460; however, the present invention is not limited thereto. That is, the cover462may be separately formed with the guide member460.

FIG. 8shows six spaces G; however, the present invention is not limited thereto. That is, the number and shapes of the spaces G may be determined according to the number of patterns that are to be formed on the substrate401. For example, the guide member460may be formed as an open mask having one space G.

The space G is connected to the path461. Thus, the gas is injected into the space G through the injection unit430so as to form the thin film having the pattern corresponding to the space G.

The first and second penetration portions461aand461cmay be formed to have various shapes. That is, as shown inFIG. 8, the first and second penetration portions461aand461cmay be elongated to correspond to the space G, or may include a plurality of penetrating openings. Both of the above shapes are shown inFIG. 8; however, the present invention is not limited thereto. That is, the first and second penetration portions461aand461cmay be formed to have only one shape.

The driving unit451is connected to the stage420. The driving unit451conveys the stage420in a direction denoted by an arrow M shown inFIG. 7, or an opposite direction to the direction denoted by the arrow M. That is, the driving unit451conveys the stage420in an X-axis direction ofFIG. 7. Thus, the substrate401may be moved in a direction perpendicular to a surface of the substrate401, that is, a surface on which a thin film will be formed. Accordingly, the guide member460and the stage420are moved concurrently or simultaneously.

The injection unit430is connected to the chamber410. One or more gases are injected toward the substrate401through the injection unit430. In more detail, the injection unit430includes a first injection opening431, a second injection opening432, a third injection opening433, a fourth injection opening434, a fifth injection opening435, and a sixth injection opening436.

In addition, the first through sixth injection openings431through436are arranged along a moving direction of the substrate401. That is, the first through sixth injection openings431through436are arranged in the X-axis direction ofFIG. 7to be separated from each other.

In addition, the first through sixth injection openings431through436may be formed to have various shapes, for example, may be formed as dots or lines corresponding to a width of the substrate401. That is, inFIG. 8, the first injection opening431is formed as a line; however, the present invention is not limited thereto, that is, the first injection opening431may be formed as a dot.

A gas is injected into the chamber410through the first through sixth injection openings431through436in parallel with a surface direction of the substrate401. That is, the gas is injected through the first through sixth injection openings431through436in parallel with a direction in which gravity acts.

In more detail, a source gas S is injected through the first, third, and fifth injection openings431,433, and435, and a reaction gas is injected through the second, fourth, and sixth injection openings432,434, and436.

While the source gas S is injected through the first, third, and fifth injection openings431,433, and435, the reaction gas is not injected through the second, fourth, and sixth injection openings432,434, and436. After injecting the source gas S through the first, third, and fifth injection openings431,433, and435, the reaction gas is injected through the second, fourth, and sixth injection openings432,434, and436.

In addition, the source gas S may be sequentially or simultaneously injected through the first, third, and fifth injection openings431,433, and435. Likewise, the reaction gas may be injected sequentially or simultaneously injected through the second, fourth, and sixth injection openings432,434, and436.

However, the present invention is not limited to the above example. That is, the source gas S and the reaction gas may be injected through the same injection openings of the injection unit430. For example, the injection unit430may include the first, third, and fifth injection openings431,433, and435, and the source gas S is sequentially injected through the first, third, and fifth injection openings431,433, and435, and then the reaction gas may be injected through the first, third, and fifth injection openings431,433, and435.

Although not shown in the drawings, the first through sixth injection openings431through436may be separated at regular intervals from each other. That is, after injecting the source gas S, the reaction gas may be injected after moving the substrate401by using the driving unit451.

Operations of the vapor deposition apparatus400according to the present embodiment will now be described.

The substrate401is mounted on the mounting surface421of the stage420. The guide member460having the space G that corresponds to the pattern of the thin film to be formed on the substrate401is disposed on the substrate401.

After that, the source gas S is injected through the first injection opening431of the injection unit430. Here, the source gas S is injected toward the space G between the substrate401and the guide member460. In more detail, the source gas S is injected through the first penetration portion461aso as to proceed in the path461.

The source gas S is adsorbed on an upper surface of the substrate401, in particular, to a portion corresponding to the space G.

After that, an exhaustion process is performed through the exhaust opening411, and then an atom layer of a single-layered structure or multi-layered structure formed of the source gas S is formed on the upper surface of the substrate401.

In addition, the reaction gas is injected through the second injection opening432of the injection unit430. Here, the reaction gas is injected toward the space G between the substrate401and the guide member460. In more detail, the reaction gas is injected through the first penetration portion461aso as to proceed in the path461.

The reaction gas is adsorbed on the upper surface of the substrate401, in particular, on a portion corresponding to the space G.

Then, an exhaustion process is performed through the exhaust opening411, and then, an atom layer of the single-layered structure or multi-layered structure formed of the reaction gas is formed on the upper surface of the substrate401.

Through the above processes, the atom layer of single-layered structure or multi-layered structure formed of the source gas S and the reaction gas is formed on the upper surface of the substrate401.

After that, the stage420and the guide member460are moved in the X-axis direction ofFIG. 7, that is, the direction denoted by the arrow M, by using the driving unit451. After moving the stage420and the guide member460, the space G between the substrate401and the guide member460may be maintained.

The source gas S and the reaction gas are injected through the third injection opening433of the injection unit430toward the space G between the substrate401and the guide member460. In more detail, the source gas S is injected through the first penetration portion461aso as to proceed in the path461.

The source gas S is adsorbed on an upper surface of the substrate401, and in particular, a portion corresponding to the space G. After that, an exhaustion process is performed through the exhaust opening411, and then an atom layer of a single-layered structure or multi-layered structure formed of the source gas S is formed on the upper surface of the substrate401.

After that, the reaction gas is injected through the fourth injection opening434of the injection unit430toward the space G that is between the substrate401and the guide member460. In more detail, the reaction gas is injected through the first penetration portion461aso as to proceed in the path461.

The reaction gas is adsorbed on the upper surface of the substrate401, in particular, the portion corresponding to the space G. Then, an exhaustion process is performed through the exhaust opening411, and then, an atom layer of the single-layered structure or multi-layered structure formed of the reaction gas is formed on the upper surface of the substrate401.

Through the above processes, the atom layers of single-layered structure or multi-layered structure formed of the source gas S and the reaction gas are additionally formed on the thin film formed by the gases injected through the first and second injection openings431and432on the upper surface of the substrate401.

After that, the stage420and the guide member460are moved in the X-axis direction ofFIG. 7, that is, the direction denoted by the arrow M, by using the driving unit451.

The source gas S and the reaction gas are injected through the fifth and sixth injection openings435and436of the injection unit430toward the space G between the substrate401and the guide member460so as to form an additional thin film on the substrate401like the thin film formed by using the first and second injection openings431and432.

Through the above processes, the thin film of desired thickness may be easily formed on the substrate401in one chamber410. That is, the moving distance of the stage420and the guide member460may be controlled according to the desired thickness of the thin film.

According to the present embodiment, the gas is injected from the injection unit430in a direction parallel with the upper surface of the substrate401. In particular, the substrate401is disposed in a direction perpendicularly to the ground, that is, a direction in which gravity acts. Therefore, when the gas is injected through the injection unit430and adsorbed on the substrate401, an unnecessarily adsorbed amount on the substrate401may be reduced. Therefore, after injecting the source gas S through the first injection opening431of the injection unit430, the exhaustion process is performed without performing a purging process using an additional purge gas. After that, the reaction gas is injected through the second injection opening432, the exhaustion process is performed without performing the purging process using an additional purge gas, and then, the deposition process is finished.

In particular, according to the present embodiment, the guide member460is disposed to face the substrate401according to the present embodiment. Thus, impurities may be blocked by the guide member460. In addition, the source gas S injected through the injection unit430is not as dispersed, and effectively adsorbed on the substrate401between the substrate401and the guide member460, and thereby reducing or improving the thin film deposition efficiency.

In addition, the gas injected from the injection unit430passes through the first penetration portion461aof the path461in the guide member460, and the gas reacts with the substrate401in the space G that is connected to the path461. Then, the gas is exhausted from the guide member460through the second penetration portion461c, and after that, the gas is exhausted through the exhaust opening411, and thereby preventing the impurities from interfering with the thin film deposition processes.

In addition, the guide member460having the space G corresponding to the desired pattern of the thin film is disposed on the substrate401, and thus, the desired pattern may be easily formed.

Consequently, efficiency of the thin film deposition process for forming the thin film of desired patterns may be greatly improved. In addition, adsorption of the unnecessary gas components may be reduced or prevented, and mixture of purge gas impurities into the thin films formed on the substrate401may be reduced or prevented. Therefore, the thin films may be evenly formed, and have excellent physical and chemical characteristics.

In addition, according to the present embodiment, the deposition processes are sequentially performed while moving the stage420and the guide member460by using the driving unit451. Therefore, time that is taken for forming the thin film of desired thickness may be greatly reduced and the convenience of deposition processes is improved.

FIG. 10is a schematic cross-sectional view of an organic light emitting display apparatus10manufactured by an organic light emitting display apparatus manufacturing method according to an embodiment of the present invention. In more detail, the organic light emitting display apparatus10ofFIG. 10is manufactured by using the vapor deposition apparatus100,200,300, or400according to an embodiment of the present invention.

Referring toFIG. 10, the organic light emitting display apparatus10is formed on a substrate30. The substrate30may be formed of a glass material, a plastic material, or a metal material. A buffer layer31that forms a flat surface on an upper portion of the substrate30and includes an insulating material for preventing moisture and impurities from infiltrating into the substrate30is formed on the substrate30.

A thin film transistor (TFT)40, a capacitor50, and an organic light emitting device60are formed on the buffer layer31. The TFT40includes an active layer41, a gate electrode42, and source/drain electrodes43. The organic light emitting device60includes a first electrode61, a second electrode62, and an intermediate layer63.

In more detail, the active layer41having a suitable pattern (e.g., a predetermined pattern) is formed on the buffer layer31. The active layer41may be a p-type or an n-type semiconductor. A gate insulating layer32is formed on the active layer41. The gate electrode42is formed on the gate insulating layer32to correspond to the active layer41. An interlayer dielectric33is formed to cover the gate electrode42. The source/drain electrodes43are formed on the interlayer dielectric33so as to contact a suitable region (e.g., a predetermined region) of the active layer41. A passivation layer34is formed to cover the source/drain electrodes43, and an insulating layer may be additionally formed on the passivation layer34for planarizing the passivation layer34.

The first electrode61is formed on the passivation layer34. The first electrode61is electrically connected to the drain electrode43. In addition, a pixel defining layer35is formed to cover the first electrode61. A set or predetermined opening64is formed in the pixel defining layer35, and the intermediate layer63including an organic emission layer is formed on a portion defined by the opening64. The second electrode62is formed on the intermediate layer63.

An encapsulation layer70is formed on the second electrode62. The encapsulation layer70may include an organic or an inorganic material, or may include the organic and inorganic materials stacked alternately.

The encapsulation layer70may be formed by using the vapor deposition apparatus100,200,300, or400. That is, the substrate30on which the second electrode62is formed is conveyed to the chamber, and the vapor deposition process is performed to form the encapsulation layer70.

However, the present invention is not limited thereto. That is, other insulating layers of the organic light emitting display apparatus10such as the buffer layer31, the gate insulating layer32, the interlayer dielectric33, the passivation layer34, and the pixel defining layer35may be formed by using the vapor deposition apparatus according to embodiments of the present invention.

Also, various conductive thin films such as the active layer41, the gate electrode42, the source/drain electrodes43, the first electrode61, the intermediate layer63, and the second electrode62may be formed by using the vapor deposition apparatus according to embodiments of the present invention.

According to the vapor deposition apparatus, the vapor deposition method, and the method of manufacturing the organic light emitting display apparatus of embodiments of the present invention, a deposition process may be performed efficiently and characteristics of formed thin films may be improved.