Abstract:
A packaging apparatus is provided for packaging one or more deposition masks. The apparatus comprises a base comprising a first surface and a first recess; a cover disposed over the base and comprising a second surface facing the first surface and a second recess; a first film placed over the first surface to cover the first recess; a second film placed over the second surface to cover the second recess; and a plurality of insertion sheets interposed between the first film and the second film. The one or more deposition masks comprise a first mask interposed between first and second insertion sheets, the first mask having a width defining a width direction. Each of the first and second insertion sheets comprises a plurality of openings, each extending along the width direction when viewed in a viewing direction perpendicular to the first surface.

Description:
RELATED APPLICATION 
       [0001]    This application claims the benefit of Korean Patent Application No. 10-2014-0135963, filed on Oct. 8, 2014, in the Korean Intellectual Property Office, the disclosure of which is incorporated herein in its entirety by reference. 
       BACKGROUND 
       [0002]    1. Field 
         [0003]    One or more embodiments relate to a packaging apparatus for deposition masks. 
         [0004]    2. Description of the Related Art 
         [0005]    An organic light-emitting display device generates an image as light emission occurs due to recombination of holes and electrons injected from an anode and a cathode in an emission layer. The organic light-emitting display device has a stack structure in which the emission layer is interposed between the anode and the cathode. However, light emission achieved by using this structure has low efficiency, and thus, a structure including an emission layer between the anode and cathode, and an electron injection layer, an electron transport layer, a hole transport layer, or a hole injection layer selectively added on the emission layer has been proposed. 
         [0006]    The electrodes (anode and cathode) and the intermediate (emission) layer of the organic light-emitting display device may be formed by various methods, one of which is a deposition method. In this case, a deposition mask having the same pattern as a thin-film pattern to be formed on a substrate is aligned on the substrate, and a thin film having a desired pattern is formed by depositing an original material of the thin film on the substrate through the deposition mask. 
         [0007]    Information disclosed in this Background section had been already known to the inventors before achieving the present inventive concept or is technical information acquired in the process of achieving the present inventive concept. Therefore, this information may not include the prior art that had been already known to the public in this country. 
       SUMMARY 
       [0008]    One or more embodiments include a mask packaging apparatus. 
         [0009]    Additional aspects will be set forth in part in the description which follows and, in part, will be apparent from the description, or may be learned by practice of the presented embodiments. 
         [0010]    One aspect of the invention provides a packaging apparatus for packaging one or more deposition masks having slits through which a deposition material passes, the apparatus comprising: a base comprising a first surface and a first recess recessed from the first surface; a cover disposed over the base and comprising a second surface facing the first surface and a second recess recessed from the second surface; a first film placed over the first surface to cover the first recess; a second film placed over the second surface to cover the second recess; and a plurality of insertion sheets interposed between the first film and the second film, wherein the one or more deposition masks comprises a first mask interposed between a first one and a second one of the plurality of insertion sheets, the first mask having a width defining a width direction, wherein each of the first and second insertion sheets comprising a plurality of openings, each extending along the width direction when viewed in a viewing direction perpendicular to the first surface. 
         [0011]    In the foregoing apparatus, the first film may have a predetermined elastic force and supports the one or more masks to inhibit the one or more masks from being at least partly inserted in the first recess. The second film may have a predetermined elastic force and supports the one or more masks to inhibit the one or more masks from being at least partly inserted in the second recess. The apparatus may further comprise a connection member which connects the base and the cover, wherein the connection member is hingedly attached to the base and the cover such that the base, the connection member and the cover together form a folder. The plurality of insertion sheets may be formed of polyethylene (PE), polypropylene (PP), or polyethylene terephthalate (PET). Each of the plurality of openings of the first and second insertion sheets may comprise one end that does not overlap the first mask when viewed in the viewing direction. 
         [0012]    Still in the foregoing apparatus, the plurality of openings may be arranged along a length of the first mask, and each of the plurality of openings may have a width of about 0.1 mm to about 10 mm measured in a direction along the length of the first mask. Each of the plurality of openings may have a polygonal shape when viewed in the viewing direction. Each of the plurality of openings may have a round end when viewed in the viewing direction. Each of the plurality of openings may have an oval shape. 
         [0013]    Yet in the foregoing apparatus, the plurality of openings may comprise a plurality of pairs of openings which are arranged along a length of the first mask, each pair comprises a first opening and a second opening aligned along an imaginary line extending along the width direction, wherein each of the plurality of openings comprises a first end overlapping the first mask when viewed in the viewing direction and a second end not overlapping the first mask when viewed in the viewing direction. The first opening and the second opening are separated by a partition part having a width of about 0.1 mm to about 10 mm. When viewed in the viewing direction, the partition part may comprise an edge slanted with respect to the width direction with an angle greater than 0° and less than 90°. 
         [0014]    Further in the foregoing apparatus, a length of the plurality of openings may be equal to or greater than the width of the first mask. The plurality of openings may be arranged along a length of the first mask by a substantially constant distance. The first mask may comprise a plurality of deposition patterns and at least one bridge disposed between immediately neighboring two of the plurality of deposition patterns, wherein the at least one bridge overlaps at least one of the plurality of openings when viewed in the viewing direction. The first mask may comprise a plurality of deposition patterns and at least one bridge disposed between immediately neighboring two of the plurality of deposition patterns, wherein each deposition pattern overlaps at least one of the plurality of openings when viewed in the viewing direction. The first mask may contact the first and second insertion sheets. 
         [0015]    Another aspect of the invention provides a method of making an organic light emitting display device, the method comprising: providing the foregoing packaging apparatus; retrieving the first mask from the packaging apparatus; placing the first mask between a substrate and a deposition source containing a deposition material; and depositing the deposition material over the substrate through the slits of the first mask, thereby making an organic light emitting display device. In the foregoing method, each of the plurality of openings of the first and second insertion sheets may comprise one end that does not overlap the first mask when viewed in the viewing direction. 
         [0016]    According to one or more embodiments, a packaging apparatus for packaging one or more deposition masks having slits through which a deposition material passes includes: a bottom part having a first groove; a cover part having a second groove and covering the bottom part; a first film covering the first groove; a second film covering the second groove; a connection part connecting the bottom part and the cover part; and a plurality of intermediate members interposed between the first film and the second film and having a plurality of openings extending in a width direction of the one or more masks. 
         [0017]    The first film may have a predetermined elastic force and support the one or more masks to prevent deformation thereof in a height direction thereof. 
         [0018]    The second film may have a predetermined elastic force and may support the one or more masks to prevent deformation of the one or more masks. 
         [0019]    The connection part may have a hinge shape. 
         [0020]    The plurality of intermediate members may be formed of polyethylene (PE), polypropylene (PP), or polyethylene terephthalate (PET). 
         [0021]    The one or more masks may be interposed between the plurality of intermediate members. 
         [0022]    The plurality of openings may have a width of about 0.1 mm to about 10 mm. 
         [0023]    The plurality of openings may be formed to have a polygonal shape. 
         [0024]    One or more edges of the plurality of openings may have a predetermined curvature. 
         [0025]    The plurality of openings may have an oval shape. 
         [0026]    Each of the plurality of openings may include one or more partition parts in a width direction thereof. 
         [0027]    The one or more partition parts may have a width of about 0.1 mm to about 10 mm. 
         [0028]    The plurality of openings and the one or more partition parts may make an angle greater than 0° and less than 90°. 
         [0029]    A length of the plurality of openings may be equal to or greater than a width of the one or more masks. 
         [0030]    The plurality of openings may be spaced from each other by a constant distance. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0031]    These and/or other aspects will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings in which: 
           [0032]      FIG. 1  is a schematic exploded perspective view of a packaging apparatus according to an embodiment of the inventive concept; 
           [0033]      FIGS. 2A to 2D  are top views of examples of an intermediate member of the packaging apparatus of  FIG. 1 , according to embodiments of the inventive concept; 
           [0034]      FIGS. 3A and 3B  are top views of examples of an intermediate member of the packaging apparatus of  FIG. 1 , according to other embodiments of the inventive concept; 
           [0035]      FIG. 4  is a partial magnified view of the intermediate member of  FIG. 3A ; 
           [0036]      FIG. 5  is a top view of a mask and an intermediate member of the packaging apparatus of  FIG. 1 , according to an embodiment of the inventive concept; and 
           [0037]      FIG. 6  is a side view and a partial magnified view of the packaging apparatus of  FIG. 1 , according to an embodiment of the inventive concept. 
       
    
    
     DETAILED DESCRIPTION 
       [0038]    Reference will now be made in detail to embodiments, examples of which are illustrated in the accompanying drawings, wherein like reference numerals refer to like elements throughout. In this regard, the present embodiments may have different forms and should not be construed as being limited to the descriptions set forth herein. Accordingly, the embodiments are merely described below, by referring to the figures, to explain aspects of the present description. It will be understood that although the terms “first”, “second”, etc. may be used herein to describe various components, these components should not be limited by these terms. These components are only used to distinguish one component from another. As used herein, the singular forms “a,” “an” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. It will be further understood that the terms “comprises” and/or “comprising” used herein specify the presence of stated features or components, but do not preclude the presence or addition of one or more other features or components. 
         [0039]    Sizes of elements in the drawings may be exaggerated for convenience of explanation. In other words, since sizes and thicknesses of components in the drawings are arbitrarily illustrated for convenience of explanation, the following embodiments are not limited thereto. When a certain embodiment may be implemented differently, a specific process order may be performed differently from the described order. For example, two consecutively described processes may be performed substantially at the same time or performed in an order opposite to the described order. 
         [0040]    The inventive concept will now be described more fully with reference to the accompanying drawings, in which embodiments of the inventive concept are shown. Like reference numerals in the drawings denote like elements, and thus their repetitive description will be omitted. 
         [0041]    To deposit a precise pattern on a substrate during the manufacturing process of a display device, for example, an organic light emitting display device, it is important to minimize or avoid contamination or deformation of a deposition mask by foreign substances or an external shock during manufacturing, transportation, and storage of the deposition mask. In addition, in view of the small thickness of the deposition mask, it is desirable to protect the deposition mask from heat deflection due to temperature changes. 
         [0042]      FIG. 1  is a schematic exploded perspective view of a packaging apparatus  10  for deposition masks, according to an embodiment of the inventive concept. 
         [0043]    Referring to  FIG. 1 , the packaging apparatus  10  includes a bottom part or base  100 , a cover part  200 , a first film  300 , a second film  400 , a connection part  500 , and intermediate members or insertion sheets  600 . 
         [0044]    In detail, the bottom part  100  includes a first groove or recess  110  and supports the first film  300 , a plurality of intermediate members or insertion sheets  600 , and a plurality of masks M sequentially disposed over the first groove  110 . The first groove  110  can minimize or reduce deformation of the plurality of masks M due to a shock applied to the packaging apparatus  10  during transportation of the plurality of masks M and has a shorter length than the plurality of masks M. Accordingly, the first film  300  may be seated around the first groove  110 , and the plurality of masks M and the plurality of intermediate members  600  may be sequentially disposed on the first film  300 . 
         [0045]    The first film  300  is seated on the first groove  110  to cover the first groove  110  and has a predetermined elastic force so as to minimize or reduce deformation of each mask M in a thickness direction thereof. In general, a length of the first groove  110  is less than a length of the mask M, and thus, if the mask M is bent due to a force applied in the thickness direction of the mask M, the mask M may fall in the first groove  110 . 
         [0046]    If the mask M falls in the first groove  110 , since the length of the mask M is greater than the length of the first groove  110 , the mask M fallen in the first groove  110  is stuck in the first groove  110 , and thus, permanent deformation of the mask M may occur if the mask M is stuck in the first groove  110  for a long time. 
         [0047]    As the first film  300  has the predetermined elastic force and is interposed between the first groove  110  and the mask M, the first film  300  may provide a restoring force to the mask M so that the original shape of the mask M remains the same even though the mask M is bent due to a force applied in the thickness direction thereof. Therefore, by disposing the first film  300  to cover the first groove  110  and to support the mask M, the mask M may be protected from falling in the first groove  110  and having a permanently deformed shape. 
         [0048]    Next, the cover part  200  includes a second groove or recess  210  and covers the bottom part  100 , and the first film  300 , the plurality of intermediate members  600 , the plurality of masks M, and the second film  400  sequentially disposed on the bottom part  100 . Like the first groove  110 , the second groove  210  can minimize or reduce deformation of the plurality of masks M due to a shock applied to the packaging apparatus  10  during transportation of the plurality of masks M. 
         [0049]    In addition, the second groove  210  has a shorter length than each mask M such that the second film  400  is seated around the second groove  210 , and the second film  400  covers the uppermost intermediate member  600  when the cover part  200  covers the bottom part  100 , the first film  300  and a stack structure of one or more masks M and intermediate members  600 . 
         [0050]    The second film  400  is seated in contact with the second groove  210  to cover the second groove  210  and has a predetermined elastic force so as to minimize or reduce deformation of each mask M in the thickness direction thereof. In this case, when the cover part  200  covers the bottom part  100 , the cover part  200  and the bottom part  100  are disposed such that the cover part  200  and the bottom part  100  face each other, and thus, the second film  400  is disposed below the second groove  210  and is interposed between the second groove  210  and the uppermost intermediate member  600 . 
         [0051]    In general, a length of the second groove  210  is less than the length of the mask M, and thus, if the mask M is bent due to a force in the thickness direction thereof, the mask M may fall in the second groove  210 . 
         [0052]    If the mask M falls in the second groove  210 , since the length of the mask M is greater than the length of the second groove  210 , the mask M fallen in the second groove  210  is stuck into the second groove  210 , and thus, a permanent deformation of the mask M may occur if the mask M remains stuck in the groove  210  for a long time. 
         [0053]    The second film  400  has the predetermined elastic force and is interposed between the second groove  210  and the mask M, and thus, the second film  400  may provide a restoring force to the mask M so that the original shape of the mask M is maintained even though the mask M is bent due to a force applied in the thickness direction thereof. Therefore, by disposing the second film  400  to cover the second groove  210  and to support the mask M, the mask M may be prevented from falling in the second groove  210  and having a permanently deformed shape. 
         [0054]    The packaging apparatus  10  also includes the connection part  500  connecting the bottom part  100  and the cover part  200 . The connection part  500  connects the bottom part  100  and the cover part  200  so that the bottom part  100  and the cover part  200  rotatably move around the connection part  500  between an area where the first groove  110  and the second groove  210  respectively formed in the bottom part  100  and the cover part  200  face each other (refer to  FIG. 6 ) and an area where the first groove  110  and the second groove  210  do not face each other (refer to  FIG. 1 ). 
         [0055]    According to  FIGS. 1 and 6 , the connection part  500  has a trapezoidal cross-section, but this is merely for corresponding to shapes of the bottom part  100  and the cover part  200 . For example, the connection part  500  may have a hinge shape like a hinge connecting a door and a door frame or have any shape as long as the connection part  500  holds and connects the bottom part  100  and the cover part  200  such that the bottom part  100  and the cover part  200  rotatably move with respect to each other. In embodiments, the connecting part, base part and cover part form a folder-shaped packaging device. 
         [0056]    Next, the packaging apparatus  10  also includes the plurality of intermediate members  600 . The plurality of intermediate members  600  may be formed of polyethylene (PE), polypropylene (PP), or polyethylene terephthalate (PET). 
         [0057]    PE, PP, and PET used as a material for the plurality of intermediate members  600  are thermoplastic materials and have a thermal expansion coefficient  60  times greater than that of an invar alloy, which is a general material for forming the plurality of masks M. Therefore, when the plurality of intermediate members  600  and the plurality of masks M are packed in a contact state at a normal temperature and are exposed thereafter in a low-temperature environment, the plurality of masks M manufactured in a thin-plate shape contract along with the plurality of intermediate members  600  which easily contract due to a temperature drop. 
         [0058]    This phenomenon usually occurs when the plurality of masks M are packed and transported in winter when the air temperature is low. When the packaging apparatus  10  exposed to external air at a low temperature is stored again in a warehouse at a normal temperature, the plurality of intermediate members  600  made of thermoplastic having a large thermal expansion coefficient are plastic-deformed again and expand to the shape before contraction. However, the plurality of masks M made of an invar alloy are not plastic-deformed and continuously remain in the contracted shape due to the previous temperature drop, and as a result, wrinkles are generated on the plurality of masks M, thereby causing defective masks M. 
         [0059]    To address this problem, in the present embodiment, an opening  610  is formed in each intermediate member  600  to compensate for thermal deformation of the intermediate member  600 . The opening  610  will be described in detail below. 
         [0060]    Referring back to  FIG. 1 , a mask M is interposed between a plurality of intermediate members  600 , and a stack body including the mask M and the plurality of intermediate members  600  is repeatedly stacked several times. Therefore, a plurality of masks M may be disposed between the bottom part  100  and the cover part  200  of the mask packaging apparatus  10 , but the present embodiment is not limited thereto, and only one mask M may be packed in the mask packaging apparatus  10 . 
         [0061]    In addition, although  FIG. 1  shows that two intermediate members  600  are disposed between the plurality of masks M interposed between the first film  300  and the second film  400 , the present embodiment is not limited thereto, and one intermediate member  600  or three or more intermediate members  600  may be disposed between the plurality of masks M, between the first film  300  and one mask M, and between the second film  400  and one mask M. 
         [0062]    Next, the opening  610  and a partition part  620  formed in each intermediate member  600  will be described with reference to  FIGS. 2A to 2D, 3A, and 3B . 
         [0063]      FIGS. 2A to 2D  are top views of modification examples of the intermediate member  600  of  FIG. 1 , according to embodiments of the inventive concept, and  FIGS. 3A and 3B  are top views of modification examples of the intermediate member  600  of  FIG. 1 , according to other embodiments of the inventive concept. 
         [0064]    The intermediate member  600  may include a plurality of openings  610  extending in a width direction of the mask M. Herein, the plurality of openings  610  may be formed in a polygonal shape or an oval shape. For example, the plurality of openings  610  may be formed in a rectangular shape as shown by reference numeral  610   a  in  FIG. 2A , in a hexagonal shape as shown by reference numeral  610   b  in  FIG. 2B , or in an oval shape as shown as reference numeral  610   c  in  FIG. 2C . Alternatively, one or more of edges of the plurality of openings  610  may be formed to have a predetermined curvature. For example,  FIG. 2D  shows that both ends of each of the plurality of openings  610  are curved. 
         [0065]    In detail, the plurality of openings  610  may be formed to be spaced apart from each other by a predetermined distance as shown in  FIGS. 2A to 2D , but the present embodiment is not limited thereto, and the plurality of openings  610  may be formed to be spaced apart from each other by different distances. 
         [0066]    Each opening  610  is formed to have a width of about 0.1 mm to about 10 mm. Reference L 1  denotes the width of the opening  610 . The reason why the opening  610  is formed to have a width of about 0.1 mm to about 10 mm is presented below. 
         [0067]    As described above, the plurality of openings  610  are formed in the intermediate member  600  to minimize or reduce the occurrence of wrinkles in the mask M due to thermal deformation of the intermediate member  600 . To achieve this purpose, the width of the opening  610  may be adjusted. If the width of the opening  610  is unnecessarily large, a rib R between pattern areas PA formed on the mask M may be inserted into the opening  610 , and accordingly, the mask M may be permanently deformed. On the contrary, if the width of the opening  610  is unnecessarily small, the opening  610  cannot sufficiently compensate for thermal deformation of the intermediate member  600 . Therefore, the opening  610  may be formed to have a width of about 0.1 mm to about 10 mm in order to minimize or reduce the formation of wrinkles in the mask M due to thermal deformation of the intermediate member  600 , by sufficiently compensating for the thermal deformation of the intermediate member  600 . 
         [0068]    In more detail, the plurality of openings  610  may include one or more partition parts  620  formed in a length direction of the plurality of openings  610 . As shown in  FIG. 3A , one partition part  620  is formed in each opening  610 , and as shown in  FIG. 3B , two partition parts  620  are formed in each opening  610 . 
         [0069]      FIG. 4  is a partial magnified view of the intermediate member  600  of  FIG. 3A . 
         [0070]    Referring to  FIG. 4 , reference L 1  denotes the width of the opening  610 , and reference L 2  denotes a width of the partition part  620 . As described above, the width L 1  of the opening  610  may be about 0.1 mm to about 10 mm, and the width L 2  of the partition part  620  may also be about 0.1 mm to about 10 mm. 
         [0071]    Next, reference α denotes an angle between the opening  610  and the partition part  620 . The opening  610  and the partition part  620  may be formed to make an angle greater than 0° and less than 90°. In one embodiment, the angle may be about 10°, about 20°, about 25°, about 30°, about 35°, about 40°, about 45°, about 55° or about 70°. In another embodiment, the angle may be a value between two of above angle values. 
         [0072]      FIG. 5  is a top view of the mask M and the intermediate member  600  of  FIG. 1 , according to an embodiment of the inventive concept. 
         [0073]    Referring to  FIG. 5 , a length L 3  of the opening  610  is equal to or greater than a width L 4  of the mask M.  FIG. 5  shows that the length L 3  of the opening  610  is greater than the width L 4  of the mask M. 
         [0074]    The reason why the length L 3  of the opening  610  is formed to be equal to or greater than the width L 4  of the mask M is to further minimize or reduce the occurrence of wrinkles in the mask M due to thermal deformation of the intermediate member  600  by sufficiently compensating for thermal deformation of the intermediate member  600 . If the length L 3  of the opening  610  is less than the width L 4  of the mask M, when the intermediate member  600  contracts or expands due to thermal deformation, wrinkles may occur in the mask M in an edge of the mask M, i.e., a region where the opening  610  does not exist. 
         [0075]    Therefore, to further minimize or reduce the occurrence of wrinkles due to a residual stress applied to the mask M while the intermediate member  600  contracts or expands due to thermal deformation, the length L 3  of the opening  610  may be at least equal to or greater than the width L 4  of the mask M. 
         [0076]    A state where a plurality of masks M are packed along with a plurality of intermediate members  600 , the first film  300 , and the second film  400  in the packaging apparatus  10  of  FIG. 1  and the bottom part  100  is covered with the cover part  200  will now be described with reference to  FIG. 6 . 
         [0077]      FIG. 6  is a side view and a partial magnified view of the packaging apparatus  10  of  FIG. 1 , according to an embodiment of the inventive concept. 
         [0078]    The bottom part  100  is disposed at the lowest side. The first film  300  is disposed on the bottom part  100  such that the first film  300  covers the first groove  110  formed in the bottom part  100 , and a plurality of intermediate members  600  (two in  FIG. 6 ) are disposed on the first film  300 . Herein each of the intermediate members  600  includes the openings  610  as shown in  FIGS. 1 to 5  and the partition part(s)  620  as shown in  FIGS. 3A to 4 . After the plurality of intermediate members  600  are disposed on the first film  300 , a mask M is disposed on the plurality of intermediate members  600 . A plurality of intermediate members  600  (two in  FIG. 6 ) are disposed on the mask M again, and a mask M and a plurality of intermediate members  600  are disposed thereon again, such that the intermediate members  600  covers each mask M from the top and bottom of the mask M and protects the mask M from an external shock. 
         [0079]    The mask M is interposed between the intermediate members  600  according to the arrangement described above, and up to ten masks M may be sequentially disposed and packed in the mask packaging apparatus  10 . 
         [0080]    As described above, according to the one or more of the above embodiments, a packaging apparatus for deposition masks may minimize heat deflection of the deposition masks which may occur during transportation and storage of the deposition masks. 
         [0081]    It should be understood that the embodiments described therein should be considered in a descriptive sense only and not for purposes of limitation. Descriptions of features or aspects within each embodiment should typically be considered as available for other similar features or aspects in other embodiments. 
         [0082]    While one or more embodiments have been described with reference to the appended figures, it will be understood by those of ordinary skill in the art that various changes in form and details may be made therein without departing from the spirit and scope as defined by the following claims.