Source: https://patents.com/us-10147880.html
Timestamp: 2019-10-18 14:12:49
Document Index: 638420711

Matched Legal Cases: ['Application No. 200910170990', 'Application No. 2009', 'Application No. 10', 'art 17', 'arts 12', 'art 17', 'art 17', 'art 17', 'art 17', 'arts 12', 'art 12', 'art 12', 'art 12', 'art 17', 'art 12', 'art 17', 'art 12', 'art 17', 'art 12', 'arts 12', 'art 12', 'art 12', 'art 12', 'art 17', 'art 12', 'art 17', 'art 12', 'arts 17', 'art 12', 'arts 17']

US Patent # 1,014,7880. Mask for thin film deposition and method of manufacturing oled using the same - Patents.com
United States Patent 10,147,880
Sung; Dong-Young (Yongin-si, KR), Kim; Hong-Ryul (Yongin-si, KR)
Family ID: 1000003688371
15/255,019
US 20160372669 A1 Dec 22, 2016
12359112 Jan 23, 2009 9441288
Sep 1, 2008 [KR] 10-2008-0085738
Current CPC Class: H01L 51/0011 (20130101); B05B 12/20 (20180201); C23C 14/042 (20130101); H01L 51/5012 (20130101); C23C 18/1605 (20130101); C30B 25/04 (20130101); C23C 16/042 (20130101)
Current International Class: H01L 51/00 (20060101); H01L 51/50 (20060101); B05B 12/20 (20180101); C23C 14/04 (20060101); C30B 25/04 (20060101); C23C 16/04 (20060101); C23C 18/16 (20060101)
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Office Action dated Nov. 26, 2010 for Chinese Patent Application No. 200910170990.2. cited by applicant .
Office Action dated Dec. 21, 2011 for Japanese Patent Application No. 2009-007724. cited by applicant .
Chinese Office Action dated Feb. 3, 2012 for Chinese Patent Application No. CN 200910170990.2 which shares priority of Korean Patent Application No. KR 10-2008-0085738 with captioned U.S. Appl. No. 12/359,112. cited by applicant .
Extended European Search Report dated Jun. 29, 2012 for European Patent Application No. EP 09 16 1245.7 which shares priority of Korean Patent Application No. KR 10-2008-0085738 with captioned U.S. Appl. No. 12/359,112. cited by applicant .
Certificate of Patent granted Sep. 5, 2012 for Chinese Patent Application No. CN 200910170990.2 which shares priority of Korean Patent Application No. KR 10-2008-0085738 with captioned U.S. Appl. No. 12/359,112. cited by applicant.
This application is a divisional application of U.S. patent application Ser. No. 12/359,112, filed on Jan. 23, 2009, which claims priority to and the benefit of Korean Patent Application No. 10-2008-0085738, filed on Sep. 1, 2008, in the Korean Intellectual Property Office, the entire content of which is incorporated herein by reference.
1. A method of manufacturing an organic light emitting device, comprising: providing a mask which comprises i) a base member, ii) a plurality of slits penetrating through the base member, and iii) a plurality of ribs each being formed between two adjacent ones of the slits, wherein the plurality of slits comprise an outermost slit positioned in an outermost location, wherein only the outermost slit comprises two sub-slits separated from each other by a rib supporting part, wherein the plurality of ribs comprise an outermost rib adjacent to the outermost slit, and wherein each of the sub-slits is fully enclosed by the outermost rib and the rib supporting part; and depositing an organic light emitting film, through the slits of the mask, between first and second electrodes of the organic light emitting device, wherein the first and second electrodes are formed over a substrate.
2. The method of manufacturing the organic light emitting device as claimed in claim 1, further comprising: applying, with the use of a magnet array, magnetic force to the mask so that the mask is closely adhered to the substrate, wherein the substrate is disposed between the mask and the magnet array, wherein the magnet array comprises a plurality of magnets in a stripe shape, and wherein an extended direction of the magnets have a predetermined angle with the length direction of the plurality of slits of the mask.
3. The method of manufacturing the organic light emitting device as claimed in claim 1, wherein the width of the rib supporting part is about 10 .mu.m to about 100 .mu.m.
4. The method of manufacturing the organic light emitting device as claimed in claim 1, wherein the length of the slits is at least about 2 cm.
Generally, an organic material deposition apparatus is used to form material on a substrate in a film shape by applying current to the material to be deposited under a vacuum of about 10.sup.-7 torr or more. The organic material deposition apparatus uses a mask so as to form an organic film in a desired shape on a substrate. When depositing an organic material on a large substrate of a predetermined size, a metal mask having high durability and strength may be used in order to deposit an organic material in a desired pattern stably.
The width of the rib supporting part may be about 10 .mu.m to 100 .mu.m.
In the above mask, the rib supporting part is integrally formed with the base member. In the above mask, the width of the rib supporting part is about 10 .mu.m to about 100 .mu.m. In the above mask, the length of the slits is about 2 cm. In the above mask, the base member is formed of a metal material.
In the above method, the width of the rib supporting part is about 10 .mu.m to about 100 .mu.m. In the above method, the length of the slits is at least about 2 cm.
Another aspect of the invention is a mask for thin film deposition, comprising: a base member; a plurality of through-slits defined in the base member, wherein the plurality of through-slits have a predetermined length and extend in a first direction, and wherein the plurality of through-slits comprise an outermost slit separated into two sub-slits; a plurality of ribs each being formed between two adjacent ones of the plurality of through-slits, wherein the plurality of ribs comprise an outermost rib adjacent to the outermost slit; and a rib support extending from the outermost rib and between the two sub-slits.
In the above mask, the plurality of through-slits are substantially parallel with each other. In the above mask, the width of the outermost slit is about 50 .mu.m. In the above mask, the width of the outermost rib is about 10 .mu.m to about 100 .mu.m.
FIG. 6B is a cross-sectional view taken along line I-I' of the magnet array of FIG. 6A;
In the following detailed description, only certain exemplary embodiments of the present invention have been shown and described, simply by way of illustration. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention. Accordingly, the drawings and description are to be regarded as illustrative in nature and not restrictive. In addition, when an element is referred to as being "on" another element, it can be directly on the element or be indirectly on the element with one or more intervening elements interposed therebetween. Also, when an element is referred to as being "connected to" another element, it can be directly connected to the element or be indirectly connected to the element with one or more intervening elements interposed therebetween. Hereinafter, like reference numerals refer to like elements.
The mask 10 includes a rib supporting part (or rib support) 17 installed crossing an outermost slit 14 (separated into two sub-slits as shown in FIG. 1) of a group of slits 13, the outermost slit positioned in the outermost in a second direction having a predetermined angle with respect to a first direction, or an X direction. The rib supporting part 17 connects a rib (or outermost rib) adjacent to the outermost slit 14, that is, a rib 15 forming a first surface of the outermost slit 14, to the base member 11 forming a second surface facing the first surface of the outermost slit 14. In another embodiment, at least one other rib supporting part (or rib support) may be formed to support, for example, the second outermost rib 15. In this embodiment, the second outermost slit 13' is separated into two sub-slits.
In one embodiment, in each of the unit masking pattern parts 12, the length L1 of each slit 13 is about 2 cm or more, the width W1 of the slit 13 and the width W3 of the outermost slit 14 are about 50 .mu.m, and the distance between the slits 13, that is the width W2 of the rib 15, is about 10 .mu.m to about 100 .mu.m. The width W2 of the rib 16 adjacent to the outermost slit 14 is also about 10 .mu.m to about 100 .mu.m. If the entire length L1 of the outermost slit 14 including the length L2 of the rib supporting part 17 is about 2 cm and the width W2 of the rib 16 is about 10 .mu.m to about 100 .mu.m, the rib 16 may be bent by magnetic force of the magnet array. However, the rib supporting part 17 may prevent the rib 16 from being bent. In another embodiment, L1, L2 and W1-W3 may have values different from those described above.
The outermost slit 14 may be a dummy slit whose masking effect for the slit 13' adjacent to the outermost slit 14 is the same as the masking effect for other slits 13. In this case, the length L2 of the rib supporting part 17 may be controlled optionally in the range that the length L2 of the rib supporting part 17 has the length capable of supporting the rib 16 adjacent to the outermost slit 14 and does not have a bad influence on the masking effect of the slit 13' adjacent to the outermost slit 14.
Referring to FIGS. 2A and 2B, metal masks 110a, 110b include slits 113a in a stripe shape and a rib 115a installed between the slits. An outermost slit 114a positioned in the outermost in the width direction substantially perpendicular to a longitudinal direction of the slits 113a is installed between a rib adjacent to the outermost slit 114a and a base member 111a, the rib being a rib 116a forming one surface of the outermost slit 114a.
The metal masks 110a and 110b of the comparative example of certain embodiments of the present invention may be closely adhered on a substrate by a magnet array installed in a deposition apparatus. Here, the magnet array may be disposed such that a magnet in a stripe shape is extended in the width direction substantially perpendicular to the length direction of the slits 113a (see FIGS. 5, 6A and 6B). At this time, the rib 116a may be positioned to be adjacent to one end portion of the magnet in a stripe shape. In this case, magnetic force is concentrated on both end portions of the magnet in a stripe shape instead of other portions, so the rib 16 may be bent easily by the strong magnetic force applied to the end portions of the magnet compared to other rib 115a. In other words, the rib 116a may be bent such that the width of the outermost slit 114a becomes narrow as shown in FIG. 2A, or be bent such that the width of the outermost slit 114a becomes wide as shown in FIG. 2B.
As described above, the rib 116a may be bent by the magnetic force of the magnet array. In this case, the defect occurs in an organic light emission layer deposited through the slit 113a adjacent to the outermost slit 114a so that at least one cell may reveal an undesired peculiar color to cause the defect of device, the cell being positioned in the slit region adjacent to the outermost slit through the corresponding slit when lighting the organic light emitting device.
Referring to FIG. 3, a mask assembly a mask 10a and a frame 20a, the mask assembly being an apparatus for mass production.
The mask 10a includes a plurality of unit masking pattern parts 12a formed on a metal thin plate base member 11a so that several unit substrates forming an organic light emitting device can be deposited at a time. The plurality of unit masking pattern part 12a may be arranged in a lattice shape. Each unit masking pattern part 12a includes a plurality of slits 13a patterned in a desired shape and a rib 15a positioned between the adjacent slits, the unit masking pattern part 12a capable of depositing an organic material on one device.
In particular, the mask 10a includes a rib supporting part 17a in the unit masking pattern part 12a positioned in an end portion of a magnet in a stripe shape provided in a magnet array. In consideration of the case when the magnet in a stripe shape is extended in an X axis direction, the rib supporting part 17a is installed inside an outermost slit 14a of the unit masking pattern part 12 positioned on both end portions of the magnet in the X axis. In other words, the rib supporting part 17a is extended crossing each outermost slit 14a of two groups of unit masking patterns positioned in the both outermost in the X direction of the mask 10a, and connects a rib adjacent to the outermost slit 14a, that is, a rib 16a forming one surface of the outermost slit 14a, to a base member 11a positioned on other surface facing the one surface of the outermost slit 14a.
The mask 10a is fixed to a frame 20a such that tensile force is applied, in order to prevent the masking defects for a certain device at the time of mass production. In other words, the mask 10a is fixed to the frame 20a in a rectangular shape so that the width of the slit 13a formed in each unit masking pattern part 12a is maintained within the range of a preset tolerance.
In one embodiment, the frame 20a is formed of a member having stiffness so as to support the mask 10a. The frame 20a includes a pair of first sides 21a substantially parallel to each other, and a pair of second sides 22a each connecting both ends of the pair of the first sides 21a. The first side 21a and second side 22a of the frame 20a are formed integrally with each other, but not are limited thereto. Instead, they may be manufactured separately as first and second sub frames to be coupled to each other.
Referring to FIG. 4, a mask assembly includes a mask 10b and a frame 20b, the mask assembly being an apparatus for mass production.
The mask 10b includes i) a first mask strip 11b installed on one side of the frame 20b, ii) a second mask strip 11c installed on the other side of the frame 20b, and iii) third mask strips 11d installed in the middle of the frame 20b. The mask 10b includes a plurality of unit masking pattern parts 12b formed on a metal thin plate base member 11a so that several unit substrates forming an organic light emitting device can be deposited at a time. The plurality of unit masking pattern part 12b may be arranged in a row in a Y direction having predetermined intervals. Each unit masking pattern part 12b includes a plurality of slits 13b patterned in a desired shape and a rib 15b positioned between the adjacent slits, the unit masking pattern part 12b capable of depositing an organic material on one device.
The first mask strip 11b includes a rib support part 17b inside an outermost slit 14b of each unit masking pattern part 12b positioned farthest from the third mask strip 11d in the X axis direction. Similarly, the second mask strip 11c includes a rib support part 17c inside an outermost slit 14c of each unit masking pattern part 12b positioned farthest from the third mask strip 11d in the X axis direction. In consideration of the case when a magnet in a stripe shape is extended in an X axis direction, the magnet being provided in a magnet array, the rib supporting parts 17b and 17c are installed inside the outermost slit 14b and 14c of the unit masking pattern part 12 positioned on both end portions of the magnet in the X axis. In other words, the rib supporting parts 17b and 17c extend to cross the respective outermost slits 14b and 14c of two groups of unit masking patterns positioned in the both outermost in the X direction of the mask 10b, and connect ribs adjacent to the outermost slits 14b and 14c, that is, ribs 16b and 16c forming one surface of the outermost slits 14b and 14c, to a base member positioned on other surface facing the one surface of the outermost slits 14b and 14c.
The respective mask strips 11b, 11c, and 11d are fixed to a frame 20b such that tensile force is applied in order to prevent the masking defects for a certain device at the time of mass production. In other words, the respective mask strips 11b, 11c, and 11d are fixed to the pair of first sides 21b facing the frame 20b in a rectangular shape so that the length or the width of the slits 13b and 13c formed in each unit masking pattern part remains within the range of a preset tolerance.
The frame 20b may be formed of a member having stiffness so as to support the respective mask strips 11b, 11c, and 11d. The frame 20b includes a pair of first sides 21b parallel to each other, and a pair of second sides 22b each connecting both ends of the pair of the first sides 21b. The first side 21b and second side 22b of the frame 20a may be formed integrally with each other, but not are limited thereto. Instead, they may be manufactured separately as first and second sub frames to be coupled to each other.
Meanwhile, a structure of the frame 20b is not limited to FIG. 4 and the explanation thereof, but may of course be implemented as various modifications. For example, a structure or a separate member for allowing mask strips to be bonded to the frame 20b may be used.
Referring to FIG. 5, the deposition apparatus 30 may use the mask 10b for thin film deposition as described above with reference to FIG. 4.
In order to deposit red R, green G, and blue B organic light emitting films of an organic light emitting display apparatus, the mask 10b is installed on an organic film deposition crucible 60 installed in a vacuum chamber 31, and a substrate 50 on which a thin film is to be formed is mounted on the mask 10b. The mask 10b is then closely adhered to the substrate 50 by driving a magnet array 40. In this state, if the organic film deposition crucible 60 operates, an organic material mounted in the organic film deposition crucible 60 is evaporated to pass through slits of the mask 10b, thereby being deposited on the substrate 50 in a predetermined pattern.
FIG. 6A is a perspective view of a main part of a magnet array which can be adopted to the deposition apparatus of FIG. 5. FIG. 6B is a cross-sectional view taken along line I-I' of the magnet array of FIG. 6A.
As shown in FIGS. 6A and 6B, when an organic material is deposited in an organic deposition apparatus, a magnet array 40 is used so as to closely fix the mask on one surface of a substrate. At this time, the magnet array 40 is formed such that a plurality of rod-shaped magnets 44 are commonly arranged in a row in order to appropriately support the mask 10b having a relatively large size with magnetic force. For example, the magnet array 40 may include a plurality of rod-shaped magnets 44 and bodies 42 having grooves 43 into which the respective magnets 44 are inserted.
In the aforementioned case, when the slit of the mask 10b is extended n the Y axis direction, each rod-shaped magnet 44 of the magnet array 40 is extended in the X axis direction, so the ribs adjacent to the outermost slits positioned on both end portions of the respective magnets 44 receive a large magnetic force. At this time, in the existing metal mask, the rib positioned between the outermost slit and the slit adjacent the outermost slit may be bent by the magnetic force of the magnet. However, the mask 10b according to at least one embodiment of the present embodiment includes the rib supporting part, making it possible to prevent the slit from being bent, the slit being positioned between the outermost slit and the slit adjacent the outermost slit.
The organic layer 226 may use a low or high molecular organic layer. When a low molecular organic layer is used, the organic layer 226 may be formed in a single or complex structure that a first organic layer 223 and a second organic layer 225 are stacked, the first organic layer 223 including a hole injection layer, a hole transport layer, and the like, and the second organic layer 225 including an organic light emission layer 224, a electron transport layer, an electron injection layer (EIL) and the like. The organic layer 226 may use organic materials such as copper phthalocyanine (CuPu), N,N'-Di(naphthalene-1-yl)-N--N'-diphenylbenzidine (NPB), tris-8-hydroxyquinoline aluminum (Alq3) or the like. These low molecular organic layers may be formed using a vacuum deposition method.
The first electrode 221 may include a transparent electrode or a reflective electrode. When using the transparent electrode, the first electrode 221 may be formed of ITO, IZO, ZnO or In.sub.2O.sub.3. When using the reflective electrode, the first electrode 221 may form a reflective film using Ag, Mg, Al, Pt, Pd, Au, Ni, Nd, Ir, Cr, the compound thereof, or the like and then be formed of ITO, IZO, ZnO or In.sub.2O.sub.3 on the reflective film.
The organic semiconductor forming the active layer 231 may include semiconductive organic material whose band gap is 1eV to 4eV, wherein a high molecular organic material may include polythiophen and derivatives thereof, poly-phenylene vinylene and derivatives thereof, poly-paraphenylene and derivatives thereof, polyfluorenes and derivatives thereof, polythiophene vinylene and derivatives thereof, and polythiophen-heterocyclic aromatic copolymer and derivatives thereof, and a low molecular organic material may include pentacene, tetracene, oligocene of naphthalene and derivatives thereof, alpha-6-thiophene, oligothiophene of alpha-5-thiophene and derivatives thereof, phthalocyanine containing or not containing a metal and derivatives thereof, pyromellitic dianhydride or pyromellitic diimides and derivatives thereof, perylene tetracarboxylic acid dianhydride or perylene tetracarboxylic diimides and derivatives thereof.
The gate insulating film 232 may be formed of SiO.sub.2 or the like, and also be formed of SiNx or a double film of SiO.sub.2 and SiNx. A gate electrode 233 formed of a conductive metal film such as MoW, Al, Cr, Al/Cu or the like is formed on a predetermined region on the gate insulating film 232. The material forming the gate electrode 233 is not always limited thereto, but diverse conductive materials such as conductive polymer may be used as the gate electrode 233. The region on which the gate electrode 233 is formed corresponds to the channel region of the active layer 231.
The interlayer insulating film 234 may be formed of SiO.sub.2 or SiNx or the compound thereof, and the source/drain electrodes 235 may be formed of the same material as the gate electrode 233.
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