Patent Description:
In electronic devices such as smartphones and tablet PCs, high-definition display devices are demanded from the market. A display device has a pixel density of, for example, <NUM> ppi or more or <NUM> ppi or more.

Attention has been paid to the organic EL display device because of its excellent responsibility and/or high contrast. A known method for forming pixels of the organic EL display device is attaching a material that constitutes pixels on a substrate by vapor deposition. In this case, first, a deposition mask apparatus including a deposition mask having holes and a frame that supports the deposition mask is prepared. Next, the deposition mask of the deposition mask apparatus is placed in contact with a substrate in the deposition apparatus. Then, an organic material and/or inorganic material or the like is deposited on the substrate, thereby forming an organic material and/or inorganic material or the like on the substrate.

During the vapor deposition step, the dimensional accuracy of the organic material on the substrate and/or the accuracy of the position of the organic material on the substrate may be reduced due to the presence of a gap between the deposition mask and the substrate. The cause of the gap is that the deposition mask warps by its own weight. In order to solve such a problem, it is known that a deposition mask, a substrate, and a magnet are arranged in that order, thereby drawing the deposition mask toward the substrate using magnetic force.

Patent Document D1: <CIT> is directed at a mask frame assembly that includes a frame having an opening, a support bar extended in a first direction crossing the opening of the frame and having distal ends installed over the frame, and a mask having extended in a second direction crossing the first direction, having distal ends installed over the frame, and having a pattern unit extended along the second direction and configured to pass a deposition material. The support bar includes a first opening disposed on one side of the support bar and having a first width in the second direction, and a second opening disposed on the other side of the support bar opposite to the one side of the support bar and having a second width greater than the first width in the second direction.

Patent Document D2: <CIT> is directed at a mask for evaporation and a preparation method. The mask for evaporation includes a frame, a transverse support bar, a sheltering bar, a mask substrate and a vertical supportbar; a first mounting groove, a second mounting groove, a third mounting groove and a fourth mounting groove are formed in the frame, the first mounting groove and the second mounting groove both extend in the horizontal direction of the frame, and both the third mounting groove and the fourth mounting groove extend in the vertical direction of the frame; the two ends of the transverse support bar are located in the first mounting groove and the second mounting groove respectively; the two ends of the sheltering bar are located in the third mounting groove and the fourth mounting groove respectively, and the transverse support bar is connected with the sheltering bar in a lap joint mode; the vertical support bar and the mask substrate jointly bear the pressing gravity of a substrate, thus, the deformation of the mask substrate which is caused by the extrusion of the substrate is alleviated, the service life of the mask is prolonged, and the problem is avoided that because opening patterns of an effective area of the mask substrate deform due to the deformation of the mask substrate, colour cast and even colour mixture occur.

Patent Document D3: <CIT> is directed at a mask frame assembly for thin-film deposition. The mask frame assembly including a mask frame having an opening defined therethrough, the mask frame configured to retain a mask, at least one supporter configured to contact the mask for supporting the mask, and a fixing unit coupled to the supporter and the mask frame.

Depending on the form of warping generated in the deposition mask, the gap between the deposition mask and the substrate may not be sufficiently reduced even when a magnet or the like is used.

An object of an embodiment of the present disclosure is to reduce a gap between a deposition mask and a substrate.

The invention provides a deposition mask apparatus set forth in claim <NUM>, a mask support mechanism as set forth in claim <NUM>, and a production method for a deposition mask apparatus. Particular embodiments are defined in claims <NUM>-<NUM> and <NUM>-<NUM>, respectively.

A deposition mask apparatus in one embodiment of the present disclosure includes:.

According to the deposition mask apparatus of the embodiment of the present disclosure, the gap between the deposition mask and the substrate can be reduced.

In the present specification and the drawings, unless otherwise specified, terms each meaning a substance that is the basis of a certain structure, e.g., "substrate", "base member", "plate", "sheet", and "film" are not distinguished from each other based solely on the difference in designation.

In the present specification and the drawings, unless otherwise specified, terms specifying shapes, geometric conditions, and their degrees, e.g., "parallel" and "perpendicular" and values of lengths, angles, and the like are not limited to their strict definitions, but construed to include a range of capable of exerting a similar function.

In the present specification and the drawings, unless otherwise specified, when a certain structure of a certain member, a certain region, or the like is "above" or "below", "on the upper side of" or "on the lower side of", or "upward toward" or "downward toward" another structure of another member, another region, or the like, it includes a case in which a certain structure is in direct contact with another structure. Further, this also includes a case in which further structure is included between a certain structure and another structure, which means a case in which they are indirectly in contact with each other. Unless otherwise specified, the terms "above," "upper side", or "upward" and "below", "lower side", or "downward" may be interchangeable when the vertical direction is reversed.

In the present specification and the drawings, unless otherwise specified, the same portions or portions including similar functions are denoted by the same reference numerals or similar reference numerals, and repeated description thereof may be omitted. In addition, the dimensional ratios in the drawings may be different from actual ratios for convenience of description, or some of the components may be omitted from the drawings.

In the present specification and the drawings, unless otherwise specified, the embodiments and examples may be combined with other embodiments and modified examples unless there is contradiction. Further, the other embodiments, or other embodiments and modified examples may be combined unless there is contradiction. Further, the modified examples may be combined with each other unless there is contradiction.

In the present specification and the drawings, unless otherwise specified, when a plurality of steps are disclosed in relation to a method such as a production method, other steps that are not disclosed may be performed between the disclosed steps. In addition, the order of the disclosed steps is appropriately modified unless there is contradiction.

In the present specification and the drawings, unless otherwise specified, the numerical ranges expressed by the sign "-" include numerical values placed before and after the sign "-". For example, the numerical range defined by the expression "<NUM>%-<NUM>% by mass" is the same as the numerical range defined by the expression "<NUM>% or more and <NUM>% or less by mass".

In one embodiment described herein, an example relating to a deposition mask used for patterning an organic material on a substrate in a desired pattern when producing an organic EL display device and a method for producing the same will be described. However, without being limited to such an application, the present embodiment can be applied to a deposition mask used for various uses. For example, the mask of the embodiment may be used to produce an apparatus for displaying or projecting an image or video for expressing virtual reality, so-called VR, or augmented reality, so-called AR.

A first aspect of the present disclosure is a deposition mask apparatus which includes:.

According to a second aspect of the present disclosure, in the deposition mask apparatus in the first aspect described above,.

According to a third aspect of the present disclosure, in the deposition mask apparatus in the second aspect described above,.

According to a fourth aspect of the present disclosure, in the deposition mask apparatus of each of the first to third aspects described above,
the supporting members may have a thickness that is larger than a thickness of the deposition mask at a position where the deposition mask overlaps the supporting member in plan view.

According to a fifth aspect of the present disclosure, in the deposition mask apparatus of each of the first to third aspects described above,
the supporting members may have a thickness that is twice or more of a thickness of the deposition mask at a position where the deposition mask overlaps the supporting member in plan view.

According to a sixth aspect of the present disclosure, in the deposition mask apparatus of each of the first to fifth aspects described above,
the supporting members may have a thickness of <NUM> or more.

According to a seventh aspect of the present disclosure, in the deposition mask apparatus of each of the first to sixth aspects described above,
the supporting members may have a thickness that is <NUM> times or less a thickness of the deposition mask at a position where the deposition mask overlaps the supporting member in plan view.

According to an eighth aspect of the present disclosure, in the deposition mask apparatus of each of the first to seventh aspects described above,
the supporting members may have a thickness of <NUM> or less.

According to a ninth aspect of the present disclosure, in the deposition mask apparatus of each of the first to eighth aspects described above,.

According to a tenth aspect of the present disclosure, in the deposition mask apparatus of each of the first to ninth aspects described above,
the first portion and the second portion of the frame may be shorter than the third portion and the fourth portion of the frame.

According to an eleventh aspect of the present disclosure, in the deposition mask apparatus of each of the first to tenth aspects described above,
a ratio of a length of the third portion and the fourth portion to a length of the first portion and the second portion may be <NUM> or more.

A twelfth aspect of the present disclosure is a mask support mechanism for supporting a deposition mask which includes:.

According to a thirteenth aspect of the present disclosure, in the mask support mechanism of the twelfth aspect described above,.

According to a fourteenth aspect of the present disclosure, in the mask support mechanism of the thirteenth aspect described above,.

According to a fifteenth aspect of the present disclosure, in the mask support mechanism of each of the twelfth to fourteenth aspects described above,
each of the supporting members may have a thickness of <NUM> or more.

According to a sixteenth aspect of the present disclosure, in the mask support mechanism of each of the twelfth to fifteenth aspects described above,
each of the supporting members may have a thickness of <NUM> or less.

According to a seventeenth aspect of the present disclosure, in the mask support mechanism of each of the twelfth to sixteenth aspects described above,.

According to an eighteenth aspect of the present disclosure, in the mask support mechanism of each of the twelfth to seventeenth aspects described above,
the first portion and the second portion of the frame may be shorter than the third portion and the fourth portion of the frame.

According to a nineteenth aspect of the present disclosure, in the mask support mechanism of each of the twelfth to eighteenth aspects described above,
a ratio of a length of the third portion and the fourth portion to a length of the first portion and the second portion may be <NUM> or more.

A twentieth aspect of the present disclosure is a production method for a deposition mask apparatus which comprises:.

Hereinafter, an embodiment of the present disclosure will be described in detail with reference to the drawings. The embodiment described below is an example of an embodiment of the present disclosure, and the present disclosure is not construed as being limited to only such an embodiment.

Firstly, a deposition apparatus <NUM> for performing a deposition process for depositing a deposition material on an object is explained with reference to <FIG>. As shown in <FIG>, the deposition apparatus <NUM> may include therein a deposition source <NUM>, a heater <NUM>, and a deposition mask apparatus <NUM>. In addition, the deposition apparatus <NUM> may further include exhaust means to create a vacuum atmosphere inside of the deposition apparatus <NUM>. An example of the deposition source <NUM> is a crucible that accommodates a deposition material <NUM> such as an organic luminescent material. The heater <NUM> is configured to heat the deposition source <NUM> to evaporate the deposition material <NUM> in the vacuum atmosphere. The deposition mask apparatus <NUM> is placed opposite to the deposition source <NUM>.

Hereinafter, the deposition mask apparatus <NUM> is described. As shown in <FIG>, the deposition mask apparatus <NUM> includes a frame <NUM> and a deposition mask <NUM> fixed to the frame <NUM>. The frame <NUM> is configured to hold the deposition mask <NUM> in a taut state in the planar direction in order to restrain the deposition mask <NUM> from warping.

The deposition mask apparatus <NUM> is disposed in a deposition apparatus <NUM> such that the deposition mask <NUM> faces a substrate <NUM> as an object, onto which the deposition material <NUM> is to be deposited as shown in <FIG>. The deposition mask <NUM> has a plurality of holes <NUM> through which the deposition material <NUM> incoming from the deposition source <NUM> passes. In the following description, a surface of the deposition mask <NUM> located on the side of the substrate <NUM> is referred to as "first surface <NUM>", and a surface of the deposition mask <NUM> opposite to the first surface <NUM> is referred to as "second surface <NUM>". The incoming deposition material <NUM> adheres to the substrate <NUM>.

The deposition mask apparatus <NUM> may include a cooling plate <NUM> disposed on a surface of the substrate <NUM>, which is opposite to the other surface of the substrate <NUM> facing the deposition mask <NUM>, as shown in <FIG>. The cooling plate <NUM> may have a flow path for circulating a refrigerant inside the cooling plate <NUM>. The deposition mask apparatus <NUM> includes the cooling plate <NUM>, which makes it possible to suppress an increase in the temperature of the substrate <NUM> during the vapor deposition step.

Although not shown, the deposition mask apparatus <NUM> may include a magnet disposed on the surface of the substrate <NUM>, which is opposite to the other surface of the substrate <NUM> facing the deposition mask <NUM>. The magnet may be arranged on a surface of the cooling plate <NUM>, which is opposite to the other surface of the cooling plate <NUM> facing the deposition mask <NUM>. By providing the magnet, the deposition mask can be attracted to the substrate <NUM> by magnetic force, and the deposition mask <NUM> can be brought into close contact with the substrate <NUM>. Thus, it is possible to suppress the occurrence of shadow in the vapor deposition step thereby improving the dimensional accuracy and positional accuracy of a deposition layer formed on the substrate <NUM> with the deposition material <NUM> attached to the substrate <NUM>. The term "shadow" used herein refers to a phenomenon in which the deposition material <NUM> enters a gap between the deposition mask <NUM> and the substrate <NUM>, thereby causing the thickness of the deposition layer to be uneven. Alternatively, the deposition mask <NUM> may be brought into close contact with the substrate <NUM> by using an electrostatic chuck that utilizes electrostatic force.

<FIG> is a plan view of the deposition mask apparatus <NUM> when viewed from the first surface <NUM> side of the deposition mask <NUM>. As shown in <FIG>, the deposition mask apparatus <NUM> may include a plurality of deposition masks <NUM> arranged in a first direction D1. In this embodiment, each deposition mask <NUM> has a rectangular shape extending in a second direction D2 crossing the first direction D1. Each deposition mask <NUM> is fixed via both end portions in the longitudinal direction of the deposition mask <NUM> to the frame <NUM> by being welded, for example.

As shown in <FIG>, the deposition mask apparatus <NUM> may include a supporter <NUM> located between the frame <NUM> and the deposition mask <NUM>. The supporter <NUM> may be fixed to the frame <NUM>. <FIG> is a plan view showing a state in which the deposition mask <NUM> has been removed from the deposition mask apparatus <NUM> in <FIG> in order to clearly show the supporter <NUM>. The component including the frame <NUM> and the supporter <NUM> may be also referred to as "mask support mechanism <NUM>".

Hereinafter, the frame <NUM>, the deposition mask <NUM>, and the supporter <NUM> of the deposition mask apparatus <NUM> will be described in detail.

Firstly, the frame <NUM> will be described. As shown in <FIG>, the frame <NUM> has a frame member including a first portion <NUM>, a second portion <NUM>, a third portion <NUM>, and a fourth portion <NUM>, and an opening <NUM> inside the frame member. The first portion <NUM> and the second portion <NUM> face each other across the opening <NUM> in the first direction D1. The third portion <NUM> and the fourth portion <NUM> face each other across the opening <NUM> in a second direction D2 different from the first direction D1.

As shown in <FIG>, the first direction D1 and the second direction D2 may be orthogonal to each other. The first portion <NUM> and the second portion <NUM> may extend in the second direction D2. The third portion <NUM> and the fourth portion <NUM> may extend in the first direction D1.

As shown in <FIG>, the first portion <NUM> and the second portion <NUM> of the frame <NUM> may be shorter than the third portion <NUM> and the fourth portion <NUM>. As shown in <FIG>, on the first surface <NUM> side of the frame <NUM>, the end portions of the supporter <NUM> may be fixed to the first portion <NUM> and the second portion <NUM>. On the first surface <NUM> side of the frame <NUM>, the end portions of the deposition mask <NUM> may be fixed to the third portion <NUM> and the fourth portion <NUM>. In this case, as shown in <FIG>, the supporter <NUM> is longer than the deposition mask <NUM>.

The ratio of the length of the third portion <NUM> and the fourth portion <NUM> to the length of the first portion <NUM> and the second portion <NUM> may be, for example, <NUM> or more, <NUM> or more, or <NUM> or more. The ratio of the length of the third portion <NUM> and the fourth portion <NUM> to the length of the first portion <NUM> and the second portion <NUM> may be, for example, <NUM> or less, <NUM> or less, or <NUM> or less. The ratio of the length of the third portion <NUM> and the fourth portion <NUM> to the length of the first portion <NUM> and the second portion <NUM> may be in a range defined by a first group consisting of <NUM>, <NUM>, and <NUM> and/or a second group consisting of <NUM>, <NUM>, and <NUM>. The ratio of the length of the third portion <NUM> and the fourth portion <NUM> to the length of the first portion <NUM> and the second portion <NUM> may be in a range determined by a combination of any one of the values included in the first group and any one of the values included in the second group. The ratio of the length of the third portion <NUM> and the fourth portion <NUM> to the length of the first portion <NUM> and the second portion <NUM> may be in a range determined by a combination of any two of the values included in the first group. The ratio of the length of the third portion <NUM> and the fourth portion <NUM> to the length of the first portion <NUM> and the second portion <NUM> may be in a range determined by a combination of any two of the values included in the second group. For example, the ratio may be <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, or <NUM> or more and <NUM> or less.

As a material forming the frame <NUM>, the same material as a material of a metal plate for the deposition mask <NUM> described later can be used. For example, an iron alloy containing nickel can be used.

Next, the deposition mask <NUM> will be described. As shown in <FIG>, the deposition mask <NUM> may have a pair of end parts <NUM> fixed to the frame <NUM>, and an intermediate part <NUM> located between the end parts <NUM>. In the following description, one of the pair of end parts <NUM>, which is fixed to the third portion <NUM> of the frame <NUM>, is also referred to as "third end <NUM>", and the other of the pair of end parts <NUM>, which is fixed to the fourth portion <NUM> of the frame <NUM>, is also referred to as "fourth end <NUM>".

The intermediate part <NUM> of the deposition mask <NUM> may have at least one effective area <NUM> and a peripheral area <NUM> located around the effective area <NUM>. In the example shown in <FIG>, the intermediate part <NUM> includes a plurality of effective areas <NUM> arranged at predetermined intervals along the second direction D2. The peripheral area <NUM> surrounds a plurality of effective areas <NUM>.

In a case in which a display device such as an organic EL display device is produced using the deposition mask <NUM>, one effective area <NUM> corresponds to a display area of one organic EL display device. Therefore, the deposition mask apparatus <NUM> shown in <FIG> can form the deposition layer constituting the organic EL display devices on one substrate. A single effective area <NUM> may also correspond to a plurality of display areas. Although not shown, a plurality of effective areas <NUM> may be arranged at predetermined intervals in the width direction of the deposition mask <NUM>.

Each effective area <NUM> has an outline of, for example, a substantially quadrangular shape in plan view, more precisely, a substantially rectangular shape in plan view. Although not shown, each effective area <NUM> can have an outline of a different shape in accordance with the shape of the display area of the organic EL display device. For example, each effective area <NUM> may have a circular outline. The plan view means that the deposition mask apparatus <NUM> is viewed along the normal direction of the first surface <NUM> of the frame <NUM>.

Next, the supporter <NUM> will be described. As shown in <FIG>, the supporter <NUM> may include a plurality of supporting members arranged in the second direction D2. In the examples shown in <FIG>, the supporter <NUM> includes seven supporting members. Each supporting member may include an end portion fixed to the first portion <NUM> on the first surface <NUM> side of the frame <NUM> and an end portion fixed to the second portion <NUM> on the first surface <NUM> side of the frame <NUM>. In the following description, the end portion of the supporting member fixed to the first portion <NUM> is also referred to as "first end <NUM>", and the end portion of the supporting member fixed to the second portion <NUM> is also referred to as "second end <NUM>".

The plurality of supporting members include at least a first supporting member <NUM> and a second supporting member <NUM>. The first supporting member <NUM> is closest to an intermediate position between the third portion <NUM> and the fourth portion <NUM> of the frame <NUM>. The second supporting member <NUM> is located closer to the third portion <NUM> than the first supporting member <NUM>. The "intermediate position between the third portion <NUM> and the fourth portion <NUM>" is a position where the distance to the third portion <NUM> and the distance to the fourth portion <NUM> in the second direction D2 are equal. In <FIG>, an alternate long and short dash line denoted by a reference sign M indicates an intermediate position between the third portion <NUM> and the fourth portion <NUM>. When there is a supporting member overlapping the intermediate position in plan view, the supporting member overlapping the intermediate position is the first supporting member <NUM> closest to the intermediate position. In the example shown in <FIG>, the first supporting member <NUM> overlaps an intermediate position between the third portion <NUM> and the fourth portion <NUM>. When there is not a supporting member overlapping the intermediate position in plan view, the supporting member having a minimum distance from the intermediate position is the first supporting member <NUM> closest to the intermediate position. In <FIG>, a reference sign Z2 denotes a distance between the intermediate position and the second supporting member <NUM>. A reference sign Z3 denotes a distance between the intermediate position and the third supporting member <NUM>. The plurality of supporting members may further include a third supporting member <NUM> located closer to the fourth portion <NUM> than the first supporting member <NUM>. Further, the plurality of supporting members may further include a fourth supporting member <NUM> located closer to the third portion <NUM> than the second supporting member <NUM>. The plurality of supporting members may further include a fifth supporting member <NUM> located closer to the fourth portion <NUM> than the third supporting member <NUM>. The plurality of supporting members may further include a sixth supporting member <NUM> located closer to the third portion <NUM> than the fourth supporting member <NUM>. Further, the plurality of supporting members may further include a seventh supporting member <NUM> located closer to the fourth portion <NUM> than the fifth supporting member <NUM>.

As shown in <FIG>, the plurality of supporting members of the supporter <NUM> may overlap a peripheral area <NUM> of the deposition mask <NUM> in plan view. Thus, the deposition material that has passed through the holes in the effective area <NUM> of the deposition mask <NUM> can be restrained from adhering to the supporter <NUM>.

As a material forming each supporting member of the supporter <NUM>, the same material as a material of a metal plate for the deposition mask <NUM> described later can be used. For example, an iron alloy containing nickel can be used.

Next, a cross-sectional structure of the deposition mask apparatus <NUM> will be described with reference to <FIG> is a cross-sectional view taken along the line A-A of <FIG> passing through the first supporting member <NUM>. <FIG> is a cross-sectional view taken along the line B-B of <FIG> through the deposition mask <NUM> at an intermediate position between the first portion <NUM> and the second portion <NUM>.

As shown in <FIG>, the frame <NUM> includes a first surface <NUM>, a second surface <NUM>, a third surface <NUM>, and a fourth surface <NUM>. The first surface <NUM> is located on the side where the deposition mask <NUM> and the supporter <NUM> are fixed to the frame <NUM>. The second surface <NUM> is located opposite side of the first surface <NUM>. The third surface <NUM> is located between the first surface <NUM> and the second surface <NUM> and faces the opening <NUM>. The fourth surface <NUM> is located on the opposite side of the third surface <NUM> in the horizontal direction.

As shown in <FIG>, the first surface <NUM> may include a fifth surface <NUM> and a sixth surface <NUM> located closer to the second surface <NUM> than the fifth surface <NUM>. The fifth surface <NUM> may be located on the same plane as the first surface <NUM> of the third portion <NUM> and the fourth portion <NUM> to which the deposition mask <NUM> is fixed. The sixth surface <NUM> may be connected to the third surface <NUM>. Supporting members such as the first supporting member <NUM> may be fixed to the sixth surface <NUM>. The sixth surface <NUM> may be formed by cutting a part of the fifth surface <NUM>.

Supporting members such as the first supporting member <NUM> of the supporter <NUM> are located between the frame <NUM> and the deposition mask <NUM> on the first surface <NUM> side. Supporting members such as the first supporting member <NUM> function to support the deposition mask <NUM> that warps downward by its own weight from below. Note that supporting members such as the first supporting member <NUM> also warps downward due to its own weight and the force received from the deposition mask <NUM>.

The downward warping amount of a supporting member when the first surface <NUM> of the frame <NUM> is located above the second surface <NUM> will be described. In the cross-sectional views such as <FIG>, an arrow Y1 represents an upper side and an arrow Y2 represents a lower side.

In <FIG>, a reference sign a1 denotes the downward warping amount of the first supporting member <NUM>. The warping amount is a vertical distance between a portion of the first supporting member <NUM> fixed to the frame <NUM> and a lowermost portion of the first supporting member <NUM>. In the example illustrated in <FIG>, a portion of the first supporting member <NUM> at an intermediate position between the first portion <NUM> and the second portion <NUM> is located at the lowest position. As a measuring instrument for measuring the warping amount, a laser displacement meter such as LK-G85 manufactured by KEYENCE CORPORATION can be used. In the following description, the warping amount of the first supporting member <NUM> is also referred to as "first warping amount a1". A horizontal plane passing through a portion of the first supporting member <NUM> fixed to the frame <NUM> is also referred to as "first reference plane P1".

As shown in <FIG>, other supporting members such as the second supporting member <NUM> and the third supporting member <NUM> may warp downward. In <FIG>, a reference sign a2 denotes a downward warping amount of the second supporting member <NUM>, and a reference sign a3 denotes a downward warping amount of the third supporting member <NUM>. In the following description, the warping amount of the second supporting member <NUM> is also referred to as "second warping amount a2", and the warping amount of the third supporting member <NUM> is also referred to as "third warping amount a3". Although not shown, regarding the supporting members subsequent to the fourth supporting member <NUM> the warping amount of the n-th supporting member is also referred to as "n-th warping amount", and is denoted by a reference sign "an". "n is a natural number. The method for measuring the warping amount of each supporting member is the same as the method for measuring the first warping amount a1 of the first supporting member <NUM>.

The plurality of supporting members of the supporter <NUM> are fixed to the frame <NUM> such that the supporting member located closer to the third portion <NUM> or the fourth portion <NUM> of the frame <NUM> has a smaller warping amount. For example, the second warping amount a2 of the second supporting member <NUM> and the third warping amount a3 of the third supporting member <NUM> are smaller than the first warping amount a1 of the first supporting member <NUM>. The fourth warping amount a4 of the fourth supporting member <NUM> is smaller than the second warping amount a2 of the second supporting member <NUM>. The fifth warping amount a5 of the fifth supporting member <NUM> is smaller than the third warping amount of deflection a3 of the third supporting member <NUM>. The sixth warping amount a6 of the sixth supporting member <NUM> is smaller than the fourth warping amount a4 of the fourth supporting member <NUM>. The seventh warping amount a7 of the seventh supporting member <NUM> is smaller than the fifth warping amount a5 of the fifth supporting member <NUM>. Such a relationship is represented by the following relational expressions. <MAT> <MAT>.

By adjusting the warping amounts of the plurality of supporting members of the supporter <NUM> as described above, the downward warping amount of the deposition mask <NUM> can be maximized at an intermediate position between the third portion <NUM> and the fourth portion <NUM> as shown in <FIG>. In addition, the supporter <NUM> can support the deposition mask <NUM> such that the downward warping amount of the deposition mask <NUM> decreases from the intermediate position between the third portion <NUM> and the fourth portion <NUM> to the third portion <NUM> or the fourth portion <NUM>.

In <FIG>, a reference sign b1 denotes the downward warping amount of the deposition mask <NUM>. As in the case of supporting members such as the first supporting member <NUM>, the warping amount b1 of the deposition mask <NUM> corresponds to a vertical distance between the portion of the deposition mask <NUM> fixed to the frame <NUM> and the lowermost portion of the deposition mask <NUM>. A horizontal plane passing through a portion of the deposition mask <NUM> fixed to the frame <NUM> is also referred to as "second reference plane P2".

In <FIG>, a reference sign L1 denotes a distance between the third portion <NUM> and the fourth portion <NUM> of the frame <NUM>. b1/L1 is preferably <NUM> or less. b1/L1 may be <NUM> or less, or may be <NUM> or less. Accordingly, it is possible to reduce the generation of a gap between the deposition mask <NUM> and the substrate <NUM>. b1/ L1 is preferably <NUM> or more. b1/L1 may be <NUM> or more, and may be <NUM> or more.

The range of b1/L1 may be determined based on a combination of any of a plurality of upper limit candidate values and any of a plurality of lower limit candidate values. For example, b1/L1 may be <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, or <NUM> or more and <NUM> or less. In addition, the range of the b1/L1 may be determined based on a combination of any two of a plurality of upper limit candidate values. For example, b1/L1 may be <NUM> or more and <NUM> or less. The range of the b1/L1 may be determined based on a combination of any two of a plurality of lower limit candidate values. For example, b1/L1 may be <NUM> or more and <NUM> or less.

<FIG> is a sectional view along the C-C line of <FIG>. As shown in <FIG>, the supporter <NUM> in a state of not supporting the deposition mask <NUM> may also warp due to its weight. The warping amount in the n-th supporting member of the supporter <NUM> in a state of not supporting the deposition mask <NUM> is also referred to as "preliminary n-th warping amount", and is denoted by a reference sign "cn". "n" is a natural number. The method for measuring the preliminary warping amount of each supporting member is the same as the method for measuring the first warping amount a1 of the first supporting member <NUM>. Regarding the preliminary warping amount cn, as in the case of the above-described warping amount an, the following relational expressions may be satisfied. <MAT> <MAT>.

The thickness of each supporting member of the supporter <NUM> is determined to satisfy the above-described relationship of the warping amount. The thickness of each supporting member of the supporter <NUM> is preferably <NUM> or more. The thickness of each supporting member of the supporter <NUM> may be <NUM> or more, or <NUM> or more. Thus, it is possible to restrain the warping amount of each supporting member of the supporter <NUM> from becoming too large. In addition, the thickness of each supporting member of the supporter <NUM> is preferably <NUM> or less. The thickness of each supporting member of the supporter <NUM> may be <NUM> or less, or <NUM> or less. Thus, the deposition material that has passed through the holes in the effective area <NUM> of the deposition mask <NUM> can be restrained from adhering to the supporter <NUM>. The thickness of each supporting member of the supporter <NUM> is, for example, <NUM>.

The range of thickness of each supporting member of the supporter <NUM> may be determined based on a combination of any of a plurality of upper limit candidate values and any of a plurality of lower limit candidate values. For example, the thickness of each supporting member of the supporter <NUM> may be <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, or <NUM> or more and <NUM> or less. In addition, the range of the thickness of each supporting member of the supporter <NUM> may be determined based on a combination of any two of a plurality of upper limit candidate values. For example, the thickness of each supporting member of the supporter <NUM> may be <NUM> or more and <NUM> or less. The range of the thickness of each supporting member of the supporter <NUM> may be determined based on a combination of any two of a plurality of lower limit candidate values. For example, the thickness of each supporting member of the supporter <NUM> may be <NUM> or more and <NUM> or less. By setting the thickness of the supporting member to <NUM> or less, the number of steps required to cut the fifth surface <NUM> of the frame <NUM> to form the sixth surface <NUM> can be reduced.

A preferable range of thickness of each supporting member of the supporter <NUM> may be determined to be a relative value with respect to thickness of the deposition mask <NUM> at a position where the deposition mask overlaps the supporter <NUM> in plan view. The deposition mask <NUM> is supported by the supporter <NUM> from below at a position where the deposition mask overlaps the supporter <NUM> in plan view. Preferably, the thickness of each supporting member of the supporter <NUM> is larger than the thickness of the deposition mask <NUM> at a position where the deposition mask overlaps the supporter <NUM> in plan view. For example, the ratio of the thickness of each supporting member to the thickness of the deposition mask <NUM> is preferably <NUM> or more. The ratio may be <NUM> or higher, or <NUM> or higher. In addition, the ratio of the thickness of each supporting member to the thickness of the deposition mask <NUM> is preferably <NUM> or less. The ratio may be <NUM> or less, or <NUM> or less.

Further, the range of the thickness of each supporting member to the thickness of the deposition mask <NUM> may be determined based on a combination of any of the plurality of upper limit candidate values described above and any of the plurality of lower limit candidate values described above. For example, the ratio may be <NUM> or more and <NUM> or less, or <NUM> or more and <NUM> or less. In addition, the range of the ratio may be determined based on a combination of any two of a plurality of upper limit candidate values. For example, the ratio may be <NUM> or more and <NUM> or less. The range of the ratio may be determined based on a combination of any two of a plurality of lower limit candidate values. For example, the ratio may be <NUM> or more and <NUM> or less.

Next, an example of the structure of the deposition mask <NUM> will be described. <FIG> is a plan view showing the enlarged effective area <NUM> when viewed from the second surface <NUM> side of deposition mask <NUM>. As shown in <FIG>, a plurality of holes <NUM> formed in each effective area <NUM> are arranged at predetermined pitches along two directions perpendicular to each other.

<FIG> is a sectional view along the D-D line of the effective area <NUM> of <FIG>. As shown in <FIG>, the plurality of holes <NUM> extend from the first surface <NUM> of the deposition mask <NUM> to the second surface <NUM>. The holes <NUM> have a first recess <NUM> located on the first surface <NUM> of the metal plate <NUM> constituting the deposition mask <NUM> and a second recess <NUM> located on the second surface <NUM> on the opposite side of the first surface <NUM>, which is connected to the first recess <NUM>. The first recess <NUM> and the second recess <NUM> are formed by etching the metal plate <NUM> from the first surface <NUM> side and the second surface <NUM> side, respectively.

As shown in <FIG>, a wall surface <NUM> of the first recess <NUM> and a wall surface <NUM> of the second recess <NUM> may be connected via a circumferential connection portion <NUM>. The connection portion <NUM> may define an passing portion <NUM> where an opening area of each hole <NUM> is minimum in plan view of the deposition mask <NUM>.

As shown in <FIG>, the adjacent two holes <NUM> on the first surface <NUM> side of the deposition mask <NUM> are spaced from each other on the first surface <NUM> of the metal plate <NUM>. The adjacent two second recesses <NUM> may be also spaced from each other on the second surface <NUM> of the metal plate <NUM> on the second surface <NUM> side of the deposition mask <NUM>. Namely, the second surface <NUM> of the metal plate <NUM> may remain between the two adjacent second recesses <NUM>. In the description below, a portion of the effective area <NUM> of the second surface <NUM> of the meal plate <NUM>, which is not etched and thus remains, is also referred to as "top portion <NUM>". By producing the deposition mask <NUM> such that such a top portion <NUM> remains, the deposition mask <NUM> can have a sufficient strength. Thus, it can be restrained that the deposition mask <NUM> is damaged during transport, for example. In a case in which the width of the top portion <NUM> is too large, adhesion of a deposition material to a region overlapping the holes of the deposition mask <NUM> on a deposition object such as the substrate <NUM> is inhibited by the second surface <NUM> and/or the wall surface of the deposition mask <NUM>. As a result, the utilization efficiency of the deposition material <NUM> may decrease. Thus, the deposition mask <NUM> is preferably produced such that the width β of the top portion <NUM> is excessively large.

In the vapor deposition step, the first surface <NUM> of the deposition mask <NUM> faces the substrate <NUM>, and the second surface <NUM> of the deposition mask <NUM> is located toward a crucible <NUM> holding the deposition material <NUM>. The deposition material <NUM> adheres to the substrate <NUM> through the second recess <NUM> whose opening area gradually decreases. As shown by the arrow in <FIG> extending from the second surface <NUM> toward the first surface <NUM>, the deposition material <NUM> not only moves from the crucible <NUM> toward the substrate <NUM> along the normal direction N of the substrate <NUM>, but also sometimes moves along a direction largely inclined with respect to the normal direction N of the substrate <NUM>. At this time, when the thickness of the deposition mask <NUM> is large, the deposition material <NUM> moving diagonally tends to be stuck on the top portion <NUM>, the wall surface <NUM> of the second recess <NUM>, or the wall surface <NUM> of the first recess <NUM>. As a result, the proportion of the deposition material <NUM> that cannot pass through the holes <NUM> increases. Thus, in order to improve a utilization efficiency of the deposition material <NUM>, it is considered to be preferable that the thickness T of the deposition mask <NUM> is reduced so that heights of the wall surface <NUM> of the second recess <NUM> and the wall surface <NUM> of the first recess <NUM> are reduced. Namely, it can be said that it is preferable that a metal plate <NUM>, which has the thickness T as small as possible as long as the strength of the deposition mask <NUM> is ensured, is used as the metal plate <NUM> for constituting the deposition mask <NUM>. In consideration of this point, in the present embodiment, the thickness T of the deposition mask <NUM> is preferably <NUM> or less. The thickness T of the deposition mask <NUM> may be <NUM> or less, <NUM> or less, <NUM> or less, <NUM> or less, <NUM> or less, or <NUM> or less. Meanwhile, when the thickness of the deposition mask <NUM> is excessively small, strength of the deposition mask <NUM> is reduced, which is likely to cause damage or deformation of the deposition mask <NUM>. In consideration of this point, the thickness T of the deposition mask <NUM> is preferably <NUM> or more. The thickness T of the deposition mask <NUM> may be <NUM> or more, <NUM> or more, <NUM> or more, <NUM> or more, or <NUM> or more.

The range of the thickness T of the deposition mask <NUM> may be determined based on a combination of any of the plurality of upper limit candidate values described above and any of the plurality of lower limit candidate values described above. For example, the thickness T of the deposition mask <NUM> may be in a range of <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, <NUM> or more and <NUM> or less, or <NUM> or more and <NUM> or less. In addition, the range of the thickness T of the deposition mask <NUM> may be determined based on a combination of any two of the plurality of upper limit candidate values described above. For example, the thickness T of the deposition mask <NUM> may be in a range of <NUM> or more and <NUM> or less. In addition, the range of the thickness T of the deposition mask <NUM> may be determined based on a combination of any two of the plurality of lower limit candidate values described above. For example, the thickness T of the deposition mask <NUM> may be in a range of <NUM> or more and <NUM> or less.

The thickness T is a thickness of the peripheral area <NUM>, i.e., a thickness of a part of the deposition mask <NUM> where the first recess <NUM> and the second recess <NUM> are not formed. Therefore, the thickness T can be said as a thickness of the metal plate <NUM>.

As a method for measuring the thickness of the metal plate <NUM>, the deposition mask <NUM>, and the above-described supporter <NUM>, a contact-type measurement method is employed. For a contact-type measuring method, "MT1271", a HEIDENHAIM-METRO length gauge manufactured by HEIDENHAIN and equipped with a guide ball bushing-type plunger is used.

In <FIG>, the reference sign a represents a width of a portion (hereinafter also referred to as "rib portion") of the effective area <NUM> of the first surface <NUM> of the metal plate <NUM>, which is not etched and thus remains. A width a of the rib portion and a size r of the passing portion <NUM> are suitably determined depending on a size of an organic EL display device and its display pixels.

Although not shown, etching may be performed such that two adjacent second recesses <NUM> are connected to each other. Namely, there may be a part where no second surface <NUM> of the metal plate <NUM> remains between two adjacent second recesses <NUM>. Although not shown, etching may be performed such that two adjacent second recesses <NUM> are connected to each other over the entire second surface <NUM>.

As a material of the metal plate <NUM>, for example, an iron alloy containing nickel can be used. The iron alloy may further contain cobalt as well as nickel. For example, it is possible to use, as a material for the metal plate <NUM>, an iron alloy containing nickel and cobalt at a total content of <NUM>% or more and <NUM>% or less by mass in which the cobalt content is <NUM>% or more and <NUM>% or less by mass. Concrete examples of an iron alloy containing nickel or nickel and cobalt may be an invar material containing nickel of <NUM>% or more and <NUM>% or less by mass, a super invar material containing cobalt in addition to nickel of <NUM>% or more and <NUM>% or less by mass, or a low thermal expansion Fe-Ni based plated alloy containing nickel of <NUM>% or more and <NUM>% or less by mass. By using such an iron alloy, the thermal expansion coefficient of the metal plate <NUM> can be reduced. For example, when a glass substrate is used as the substrate <NUM>, the thermal expansion coefficient of the metal plate <NUM> can be set to a low value equal or proximate to that of the glass substrate. Accordingly, during the vapor deposition step, the dimensional accuracy and the positional accuracy of the deposition layer formed on the substrate <NUM> can be suppressed from being reduced due to the difference in thermal expansion coefficient between the deposition mask <NUM> including the metal plate <NUM> and the substrate <NUM>.

Next, a method for manufacturing the deposition mask apparatus <NUM> described above will be described.

First, as shown in <FIG>, a frame <NUM> provided with an opening <NUM> is prepared. The method for producing the frame <NUM> is appropriately determined. For example, the frame <NUM> can be manufactured by cutting a block of a material such as the above-described invar material forming the frame <NUM>.

Next, as shown in <FIG>, a supporter fixing step of fixing the first end <NUM> and the second end <NUM> of the plurality of supporting members of the supporter <NUM> to the first portion <NUM> and the second portion <NUM> of the frame <NUM> is performed. The first end <NUM> and the second end <NUM> are fixed by being welded, for example. At this time, as shown in <FIG>, a plurality of supporting members may be fixed to the frame <NUM> so that the preliminary warping amount increases as a supporting member is positioned closer to the intermediate position between the third portion <NUM> and the fourth portion <NUM>.

In the supporter fixing step, the supporter may be fixed to the frame <NUM> in order from the supporting member located near the intermediate position between the third portion <NUM> and the fourth portion <NUM>. For example, first, the first supporting member <NUM> may be fixed to the frame <NUM>, and then, the second supporting member <NUM> and the third supporting member <NUM> may be fixed to the frame <NUM>. Thereafter, the fourth supporting member <NUM> and the 5th supporting member <NUM> may be fixed to the frame <NUM>, and then the sixth supporting member <NUM> and the seventh supporting member <NUM> may be fixed to the frame <NUM>.

Alternatively, in the supporter fixing step, the supporting members located far from the intermediate position between the third portion <NUM> and the fourth portion <NUM> may be fixed to the frame <NUM> in order. For example, first, the sixth supporting member <NUM> and the seventh supporting member <NUM> may be fixed to the frame <NUM>, and then, the fourth supporting member <NUM> and the fifth supporting member <NUM> may be fixed to the frame <NUM>. Thereafter, the second supporting member <NUM> and the third supporting member <NUM> may be fixed to the frame <NUM>, and then the first supporting member <NUM> may be fixed to the frame <NUM>.

When fixing the supporting members of the supporter <NUM> to the frame <NUM>, a force may be applied to the frame <NUM> such that the first portion <NUM> and the second portion <NUM> are elastically deformed inward as shown in <FIG>. By elastically deforming the first portion <NUM> and the second portion <NUM> inward, it is possible to apply a force due to restoring force of the first portion <NUM> and the second portion <NUM> to the supporting members of the supporter <NUM> fixed to the first portion <NUM> and the second portion <NUM>. In this case, by adjusting the restoring force generated in the first portion <NUM> and the second portion <NUM>, the preliminary warping amount of each supporting member of the supporter <NUM> can satisfy the above-described relational expression.

In a case in which a force is applied to the frame <NUM> such that the first portion <NUM> and the second portion <NUM> are elastically deformed inward, the third surface <NUM> of the first portion <NUM> at a position where the third surface overlaps the first supporting member <NUM> in plan view may be located closer to the second portion <NUM> than the third surface <NUM> of the first portion <NUM> at a position where the third surface overlaps the second supporting member <NUM> in plan view. In this case, a portion of the first portion <NUM> to which the first end <NUM> of the first supporting member <NUM> is welded may be located closer to the second portion <NUM> than a portion of the first portion <NUM> to which the first end <NUM> of the second supporting member <NUM> is welded. Such a positional relationship may occur when the length of the first supporting member <NUM> is the same as the length of the second supporting member <NUM>.

The third surface <NUM> of the second portion <NUM> at a position where the second portion overlaps the first supporting member <NUM> in plan view may be located closer to the first portion <NUM> than the third surface <NUM> of the second portion <NUM> at a position where the second portion overlaps the second supporting member <NUM> in plan view. In this case, a portion of the first portion <NUM> to which the second end <NUM> of the first supporting member <NUM> is welded may be located closer to the first portion <NUM> than a portion of the second portion <NUM> to which the second end <NUM> of the second supporting member <NUM> is welded. Such a positional relationship may occur when the length of the first supporting member <NUM> is the same as the length of the second supporting member <NUM>.

In <FIG>, a third surface <NUM> of each of the first portion <NUM> and the second portion <NUM> at a position where each of the first portion <NUM> and the second portion <NUM> overlaps the first supporting member <NUM> in plan view is denoted by reference numeral <NUM>. A third surface <NUM> of each of the first portion <NUM> and the second portion <NUM> at a position where each of the first portion <NUM> and the second portion <NUM> overlaps the second supporting member <NUM> in plan view is denoted by reference numeral <NUM>.

Subsequently, as shown in <FIG>, a mask fixing step of fixing the third end <NUM> and the fourth end <NUM> of the deposition mask <NUM> to the third portion <NUM> and the fourth portion <NUM> of the frame <NUM> is performed. The third end <NUM> and the fourth end <NUM> are fixed by being welded, for example. In the mask fixing step, the deposition mask <NUM> is fixed to the frame <NUM> while applying tension to the deposition mask <NUM> such that the holes <NUM> are appropriately arranged with respect to the substrate <NUM>. Thus, a deposition mask apparatus <NUM> including the frame <NUM>, the supporter <NUM>, and the deposition mask <NUM> can be obtained.

In the mask fixing step, a force may be applied to the frame <NUM> such that the third portion <NUM> and the fourth portion <NUM> are elastically deformed inward. Thus, a force due to restoring force of the third portion <NUM> and the fourth portion <NUM> can be applied to the deposition mask <NUM> fixed to the third portion <NUM> and the fourth portion <NUM> thereby making it possible to restrain the deposition mask <NUM> from warping.

Here, when the force applied to the deposition mask <NUM> becomes too large, wrinkles may be generated in the deposition mask <NUM>, and the positions of some holes <NUM> may deviate from the design. In this embodiment, the deposition mask apparatus <NUM> includes the supporter <NUM> that supports the deposition mask <NUM> from below. Thus, it is possible to reduce the occurrence of looseness in the deposition mask <NUM> while reducing the generation of wrinkles in the deposition mask <NUM>.

Next, a deposition method for performing the vapor deposition of the deposition material <NUM> on the substrate <NUM> using the deposition mask apparatus <NUM> will be described. First, a step of combining the deposition mask apparatus <NUM> and the substrate <NUM> is performed. For examples, as shown by an arrow Q1 in <FIG>, the substrate <NUM> is relatively moved toward the deposition mask <NUM> of the deposition mask apparatus <NUM>, and the substrate <NUM> is brought into contact with the deposition mask <NUM>.

In this embodiment, the first supporting member <NUM>, which is closest to the intermediate position of the third portion <NUM> and the fourth portion <NUM>, supports the deposition mask <NUM> from below in a state of warping with a first warping amount a1. The second supporting member <NUM>, which is located closer to the third portion <NUM> than the first supporting member <NUM>, supports the deposition mask <NUM> from below in a state of warping with a second warping amount a2 smaller than a first warping amount a1. The third supporting member <NUM>, which is located closer to the fourth portion <NUM> than the first supporting member <NUM>, supports the deposition mask <NUM> from below in a state of warping with a third warping amount a3 smaller than a first warping amount a1. In addition, the other supporting members also support the deposition mask <NUM> from below in a state where the tension of the supporting members is adjusted such that the warping amount decreases as the distance from the first supporting member <NUM> to the third portion <NUM> side or the fourth portion <NUM> side decreases. Therefore, the downward warping amount of the deposition mask <NUM> can be maximized at an intermediate position between the third portion <NUM> and the fourth portion <NUM> as shown in <FIG>. In addition, the downward warping amount of the deposition mask <NUM> can be decreased from the intermediate position between the third portion <NUM> and the fourth portion <NUM> to the third portion <NUM> or the fourth portion <NUM>.

As described above, by monotonously changing the warping amount of the deposition mask <NUM>, it is possible to causing a contact between the substrate <NUM> and the deposition mask <NUM> in order in the second direction D2 when bringing the substrate <NUM> into contact with the deposition mask <NUM>. For example, it is possible to first cause a contact between the substrate <NUM> and the deposition mask <NUM> at the intermediate position between the third portion <NUM> and the fourth portion <NUM>, and then, change a contact position in order from the intermediate position toward the third portion <NUM> and from the intermediate position toward the fourth portion <NUM>. Alternatively, it is possible to first cause a contact between the substrate <NUM> and the deposition mask <NUM> near the third portion <NUM> and the fourth portion <NUM>, and then, change a contact position in order toward the intermediate position between the third portion <NUM> and the fourth portion <NUM>. As described above, by causing a contact between the substrate <NUM> and the deposition mask <NUM> in order in the second direction D2, it is possible to reduce the generation of a gap between the substrate <NUM> and the deposition mask <NUM> as compared with a case in which a contact is made simultaneously at a plurality of positions on the second direction D2.

Preferably, the warping amount d1 of the substrate <NUM> is larger than the warping amount b1 of the deposition mask <NUM>. In other words, it is preferable to adjust the tension applied to each supporting member of the supporter <NUM> such that the warping amount b1 of the deposition mask <NUM> is smaller than the warping amount d1 of the substrate <NUM>. Thus, it is possible to first cause a contact between the substrate <NUM> and the deposition mask <NUM> at the intermediate position between the third portion <NUM> and the fourth portion <NUM>, and then, change a contact position in order from the intermediate position toward the third portion <NUM> and from the intermediate position toward the fourth portion <NUM>.

Then, as shown by arrow Q2 in <FIG>, a step of relatively moving the cooling plate <NUM> toward the substrate <NUM> so as to bring the cooling plate <NUM> into contact with the substrate <NUM> may be performed. The warping amount e1 of the cooling plate <NUM> is larger than the warping amount b1 of the deposition mask <NUM>. The warping amount e1 of the cooling plate <NUM> may be larger than the warping amount d1' of the substrate <NUM>. The warping amount d1' means the warping amount of the substrate <NUM> in a state of being in contact with the deposition mask <NUM>. By making the warping amount e1 of the cooling plate <NUM> larger than the warping amount d1' of the substrate <NUM>, it is possible to first cause a contact between the substrate <NUM> and the substrate <NUM> at the intermediate position between the third portion <NUM> and the fourth portion <NUM>, and then, change a contact position in order from the intermediate position toward the third portion <NUM> and from the intermediate position toward the fourth portion <NUM>.

The cooling plate <NUM> may have a curved surface that forms a protrusion toward the substrate <NUM> as shown in <FIG>. In this case, the protrusion amount e2 of the surface of the cooling plate <NUM> with respect to the surface of the substrate <NUM> is larger than the warping amount b1 of the deposition mask <NUM>. The protrusion amount e2 may be larger than the warping amount d1 of the substrate <NUM>. Thus, even in a case in which the cooling plate <NUM> does not warp or slightly warps, it is possible to first cause a contact between the cooling plate <NUM> and the substrate <NUM> at the intermediate position between the third portion <NUM> and the fourth portion <NUM>, and then, change a contact position in order from the intermediate position toward the third portion <NUM> and from the intermediate position toward the fourth portion <NUM>.

Thereafter, although not shown, a magnet may be disposed on the surface of the cooling plate <NUM>, which is opposite to the other surface of the cooling plate <NUM> facing the deposition mask <NUM>. Accordingly, the deposition mask can be attracted toward the substrate <NUM> by the magnetic force.

Next, the deposition material <NUM> is evaporated to fly to the substrate <NUM>. It is possible for the deposition material <NUM> to adhere to the substrate <NUM> in a pattern corresponding to the holes <NUM> of the deposition mask <NUM>. <FIG> is a cross-sectional view showing a deposition substrate <NUM> including a substrate <NUM> and a deposition layer <NUM> made of a deposition material <NUM> adhering to the substrate <NUM>. Although not shown, the deposition substrate <NUM> may further include an electrode that overlaps the deposition layer <NUM>.

According to this embodiment, it is possible to reduce the generation of a gap between the deposition mask <NUM> and the substrate <NUM>. Therefore, it is possible to restrain the deposition material <NUM> from adhering to the substrate <NUM> in the gap between the deposition mask <NUM> and the substrate <NUM>, thereby improving and the dimensional accuracy and position accuracy of the deposition layer <NUM>. Accordingly, it is possible to reduce a margin provided in the design of the deposition substrate <NUM> in consideration of interference between adjacent pixels.

By reducing a margin in the design of the deposition substrate <NUM> in consideration of interference between adjacent pixels, it is possible to increase the pixel density of the deposition substrate <NUM>. In a case in which the pixel density in the deposition substrate <NUM> is constant, the area of the electrode can be increased while restraining interference between adjacent pixels by reducing the margin. Thus, the luminance of the deposition layer <NUM> can be increased. The drive voltage required to obtain a certain luminance can also be reduced. This makes it possible to extend the life of an organic EL display device and reduce power consumption.

The aforementioned embodiment can be variously modified. Hereinafter, modification examples are described with reference to the drawings according to need. In the below description and the drawings used in the below description, a part that can be similarly constituted to the above embodiment has the same reference sign as that of corresponding part the above embodiment, and overlapped description is omitted. In addition, when the effect obtained by the aforementioned embodiment is apparently obtained in the modification examples, description thereof is possibly omitted.

In the above-described embodiment, an example in which one of the supporting members of the frame <NUM> is located at the intermediate position between the third portion <NUM> and the fourth portion <NUM> of the frame <NUM> and this supporting member is referred to as "first supporting member <NUM>" is shown. In this modified example, as shown in <FIG>, an example in which the supporting member is not located at the intermediate position between the third portion <NUM> and the fourth portion <NUM> of the frame <NUM> will be described.

In <FIG>, an alternate long and short dash line M indicating the intermediate position between the third portion <NUM> and the fourth portion <NUM> of the frame <NUM> does not overlap the supporting member. In this case, a pair of supporting members facing each other in the second direction D2 across the straight line M may be referred to as "first supporting member <NUM>". In such a case, the warping amount of the two first supporting members <NUM> is determined to be the above-described first warping amount a1. The warping amount of two first supporting members <NUM> may be the same or different.

In <FIG>, a reference sign Z1 denotes a distance between the intermediate position and the first supporting member <NUM>. A reference sign Z2 denotes a distance between the intermediate position and the second supporting member <NUM>. A reference sign Z3 denotes a distance between the intermediate position and the third supporting member <NUM>. The distance Z1 is smaller than both the distance Z2 and the distance Z3.

In this modified example, the second warping amount a2 of the second supporting member <NUM> located closer to the third portion <NUM> than the first supporting member <NUM> is also larger than the first warping amount a1 of the first supporting member <NUM>. The third warping amount a3 of the third supporting member <NUM> located closer to the fourth portion <NUM> than first supporting member <NUM> is also larger than the first warping amount a1 of the first supporting member <NUM>. Accordingly, the downward warping amount of the deposition mask <NUM> can be maximized at an intermediate position between the third portion <NUM> and the fourth portion <NUM>.

<FIG> is a plan view illustrating another modified example of the deposition mask apparatus <NUM>. <FIG> is a plan view showing a state in which the deposition mask <NUM> has been removed from the deposition mask apparatus <NUM> in <FIG> in order to clearly show the covering member <NUM>. As shown in <FIG>, the deposition mask apparatus <NUM> may further include a plurality of covering members <NUM> extending in the second direction D2 which are fixed to the third portion <NUM> and the fourth portion <NUM> of the frame <NUM>.

<FIG> is a cross-sectional view taken along the line E-E of <FIG> passing through the first supporting member <NUM>. As shown in <FIG>, the covering members <NUM> may be located closer to the second surface <NUM> of the frame <NUM> than the deposition mask <NUM> and the supporter <NUM>. In addition, as shown in <FIG> and <FIG>, the covering members <NUM> may be located such that each covering member <NUM> overlaps a gap G between each two deposition masks <NUM> arranged in the first direction D1 when viewed along the normal direction of the surface of the deposition masks <NUM>. Thus, the deposition material <NUM> can be restrained from passing through the gap G between the plurality of deposition masks <NUM> and adhering to the substrate <NUM> in the vapor deposition step.

<FIG> is a plan view illustrating another modified example of the supporter <NUM> fixed to the frame <NUM>. The supporter <NUM> may further include a plurality of covering members <NUM> extending in the second direction D2 which are arranged in the first direction D1, as well as a plurality of supporting members <NUM> to <NUM> extending in the first direction D1 which are arranged in the second direction D2. The plurality of supporting members <NUM> to <NUM> and the plurality of covering members <NUM> may be integrally formed with the same material. The covering members <NUM> can function as with the above-described covering members <NUM> such that the deposition material <NUM> can be restrained from passing through each gap G between each two deposition masks <NUM> and adhering to the substrate <NUM> in the vapor deposition step.

<FIG> is a plan view illustrating another modified example of the deposition mask apparatus <NUM>. As shown in <FIG>, a plurality of effective areas <NUM> may be arranged not only in the second direction D2 but also in the first direction D1 on the deposition mask <NUM>.

Next, with reference to <FIG>, <FIG>, an example of a method for measuring the preliminary warping amount of the supporting members that do not support the deposition mask <NUM> will be described.

First, as shown in <FIG>, a deposition mask apparatus <NUM> including a frame <NUM>, a supporter <NUM>, and a deposition mask <NUM> fixed to frame <NUM> is prepared. Next, as shown in <FIG>, the deposition mask <NUM> located at a position where it overlaps the supporter <NUM> in plan view is removed. For example, the deposition mask <NUM> is cut at a position between a sixth supporting member <NUM> and a third portion <NUM>, and the deposition mask <NUM> is also cut at a position between a seventh supporting member <NUM> and a fourth portion <NUM>. Thus, a mask support mechanism <NUM> including the frame <NUM> and the supporter <NUM> in a state of not supporting the deposition mask <NUM> can be obtained.

<FIG> is a sectional view along the F-F line of <FIG>. In the mask support mechanism <NUM>, a supporting member located closer to the third portion <NUM> or the fourth portion <NUM> of the frame <NUM> may have a smaller preliminary warping amount. For example, the second preliminary warping amount c2 of the second supporting member <NUM> and the third preliminary warping amount c3 of the third supporting member <NUM> are smaller than the first preliminary warping amount c1 of the first supporting member <NUM>. The fourth preliminary warping amount c4 of the fourth supporting member <NUM> is smaller than the second preliminary warping amount c2 of the second supporting member <NUM>. The fifth preliminary warping amount c5 of the fifth supporting member <NUM> is smaller than the third preliminary warping amount of deflection c3 of the third supporting member <NUM>. The sixth preliminary warping amount c6 of the sixth supporting member <NUM> is smaller than the fourth preliminary warping amount c4 of the fourth supporting member <NUM>. The seventh preliminary warping amount c7 of the seventh supporting member <NUM> is smaller than the fifth preliminary warping amount c5 of the fifth supporting member <NUM>. As a measuring instrument for measuring the preliminary warping amount, a laser displacement meter such as LK-G85 manufactured by KEYENCE CORPORATION can be used.

Although some modified examples of the above-described embodiment have been described, it is needless to say that a plurality of modified examples may be appropriately combined and applied.

Next, the embodiment of the disclosure is described in more detail based on examples, and the embodiment of the disclosure is not limited to the below description of the examples unless the present invention departs from its thought.

First, as in the case of the example shown in <FIG>, a frame <NUM> including a first portion <NUM>, a second portion <NUM>, a third portion <NUM>, and a fourth portion <NUM> was prepared. The distance between the first portion <NUM> and the second portion <NUM> was <NUM>, and the distance between the third portion <NUM> and the fourth portion <NUM> was <NUM>.

Subsequently, while applying tension to seven supporting members <NUM> to <NUM>, a first end <NUM> and a second end <NUM> of each of the supporting members <NUM> to <NUM> were fixed to the first portion <NUM> and the second portion <NUM>, respectively, by being welded. Each of the supporting members <NUM> to <NUM> had a thickness of <NUM> and a width of <NUM>.

Subsequently, in a state where a first surface <NUM> of the frame <NUM> was located above a second surface <NUM>, the preliminary warping amounts of the supporting members <NUM> to <NUM> were measured using a laser displacement meter LK-G85 manufactured by KEYENCE CORPORATION. The results are shown below.

Subsequently, while applying tension to a deposition mask <NUM>, a third end <NUM> and a fourth end <NUM> of the deposition mask <NUM> were fixed to the third portion <NUM> and the fourth portion <NUM>, respectively, by being welded. The number of deposition masks <NUM> fixed to the frame <NUM> was <NUM>. Each deposition mask <NUM> had a thickness of <NUM> and a width of <NUM>. The nineteen deposition masks <NUM> arranged from the first portion <NUM> side to the second portion <NUM> side are also referred to as "first deposition mask", "second deposition mask",. and "19th deposition mask" respectively.

Subsequently, in a state where the first surface <NUM> of the frame <NUM> was located above the second surface <NUM>, the warping amounts of the 10th deposition mask at positions where the 10th deposition mask overlapped the supporting members <NUM> to <NUM> were measured using a laser displacement meter LK-G85 manufactured by KEYENCE CORPORATION. Namely, the warping amounts of the supporting members <NUM> to <NUM> were measured. The results are shown below. In this Example, the position of the upper surface of the portion of the supporting members <NUM> to <NUM> fixed to the frame <NUM> is equal to the position of the upper surface of the frame <NUM>. In addition, each deposition mask is fixed on the upper surface of the frame <NUM>. Further, the 10th deposition mask is located at an intermediate position between the first portion <NUM> and the second portion <NUM> of the frame <NUM>. Therefore, the warping amounts of the 10th deposition mask at positions where the 10th deposition mask overlaps the supporting members <NUM> to <NUM> are equal to the warping amounts a1 to a7 of the supporting members <NUM> to <NUM>. The warping amounts of the supporting members <NUM> to <NUM> calculated based on the warping amounts of the 10th deposition mask are as follows.

In addition, in a state where the first surface <NUM> of the frame <NUM> was located above the second surface <NUM>, the warping amounts of the first to 19th deposition masks in a state of being supported by the supporting member <NUM> to <NUM> were measured using a laser displacement meter LK-G85 manufactured by KEYENCE CORPORATION. The results are shown below.

Subsequently, the substrate <NUM> was brought into contact with the first to 19th deposition masks to perform the vapor deposition step. <FIG> shows a deposition layer <NUM> formed on an electrode <NUM> on the substrate <NUM>. The deposition layer <NUM> includes a uniform thickness portion 92a and a shadow portion 92b. The uniform thickness portion 92a is a portion of the deposition layer <NUM> which has a thickness within a range of ± <NUM>% of the average thickness of the deposition layer <NUM>. The shadow portion 92b is a portion having a thickness smaller than the average thickness of the deposition layer <NUM> by <NUM>% or more. The average thickness of the deposition layer <NUM> is an average value of the thickness of a portion of the deposition layer <NUM> which overlaps the electrode <NUM>. Thereafter, the dimensional accuracy and positional accuracy of the deposition layer <NUM> were evaluated. Specifically, for each of the deposition layers <NUM> formed using the first to 19th deposition masks, a distance W1 between the position of the end portion of the electrode <NUM> and the position of the end portion of the uniform thickness portion 92a of the deposition layer <NUM> was measured. In addition, it was determined whether the maximum value of the distance W1 in each deposition layer <NUM> was equal to or less than the first threshold. The first threshold is, for example, <NUM>. As a result, the maximum value of the distance W1 was equal to or less than the first threshold. In addition, a width W2 of the shadow portion 92b was measured for each of the deposition layers <NUM> formed using the first to 19th deposition masks. Further, it was determined whether the width W2 of the shadow portion 92b was less than or equal to the second threshold. The second threshold is, for example, <NUM>. As a result, the width W2 of the shadow portion 92b was equal to or smaller than the second threshold.

A first end <NUM> and a second end <NUM> of each of the supporting members <NUM> to <NUM> were fixed to the first portion <NUM> and the second portion <NUM> of the frame <NUM>, respectively, by being welded such that the preliminary warping amounts of the support members <NUM> to <NUM> became equal. Subsequently, as in the case of Example <NUM>, the preliminary warping amounts of the supporting members <NUM> to <NUM> were measured. The results are shown below.

Subsequently, as in the case of Example <NUM>, while applying tension to the deposition mask <NUM>, a third end <NUM> and a fourth end <NUM> of the deposition mask <NUM> were fixed to the third portion <NUM> and the fourth portion <NUM>, respectively, by being welded. Next, the warping amounts of the first to 19th deposition masks in a state of being supported by the supporting member <NUM> to <NUM> were measured. The results are shown below.

Subsequently, as in the case of Example <NUM>, the vapor deposition step was performed using the first to 19th deposition masks, thereby forming a deposition layer <NUM> on the electrode <NUM> on the substrate <NUM>. In addition, the distance W1 between the position of the end portion of the electrode <NUM> and the position of the end portion of the uniform thickness portion 92a of the deposition layer <NUM> was measured. As a result, the maximum value of the distance W1 exceeded the first threshold. In addition, the width W2 of the shadow portion 92b was measured. As a result, the width W2 of the shadow portion 92b exceeded the second threshold.

Claim 1:
A deposition mask apparatus (<NUM>), comprising:
a frame (<NUM>) including a first portion (<NUM>), a second portion (<NUM>) facing the first portion (<NUM>) across an opening (<NUM>) in a first direction (D1), a third portion (<NUM>), and a fourth portion (<NUM>) facing the third portion (<NUM>) across the opening (<NUM>) in a second direction (D2) different from the first direction (D1), and including a first surface (<NUM>) and a second surface (<NUM>) that is located opposite to the first surface (<NUM>);
a supporter (<NUM>) including a plurality of supporting members that are arranged in the second direction, the supporting member including a first end (<NUM>) that is fixed to the first portion (<NUM>) on the first surface (<NUM>) side and a second end (<NUM>) that is fixed to the second portion (<NUM>) on the first surface (<NUM>) side; and
a deposition mask (<NUM>) including a third end (<NUM>) that is fixed to the third portion (<NUM>) on the first surface (<NUM>) side and a fourth end (<NUM>) that is fixed to the fourth portion (<NUM>) on the first surface (<NUM>) side, and including a plurality of holes (<NUM>) that are located between the third end (<NUM>) and the fourth end (<NUM>),
wherein the plurality of supporting members include at least a first supporting member (<NUM>) that is closest to an intermediate position between the third portion (<NUM>) and the fourth portion (<NUM>) of the frame (<NUM>) and a second supporting member (<NUM>) that is located closer to the third portion (<NUM>) of the frame (<NUM>) than the first supporting member (<NUM>), and
when the first surface (<NUM>) of the frame (<NUM>) is located above the second surface (<NUM>), the first supporting member (<NUM>) in a state of warping downward from the frame (<NUM>) with a first warping amount (a1) supports the deposition mask (<NUM>) from below, and the second supporting member (<NUM>) in a state of warping downward from the frame (<NUM>) with a second warping amount (a2) that is smaller than the first warping amount (a1) supports the deposition mask (<NUM>) from below.