CN114574908B - Method for manufacturing fine metal mask - Google Patents
Method for manufacturing fine metal mask Download PDFInfo
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- CN114574908B CN114574908B CN202210194698.XA CN202210194698A CN114574908B CN 114574908 B CN114574908 B CN 114574908B CN 202210194698 A CN202210194698 A CN 202210194698A CN 114574908 B CN114574908 B CN 114574908B
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- C—CHEMISTRY; METALLURGY
- C25—ELECTROLYTIC OR ELECTROPHORETIC PROCESSES; APPARATUS THEREFOR
- C25D—PROCESSES FOR THE ELECTROLYTIC OR ELECTROPHORETIC PRODUCTION OF COATINGS; ELECTROFORMING; APPARATUS THEREFOR
- C25D1/00—Electroforming
- C25D1/10—Moulds; Masks; Masterforms
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- C—CHEMISTRY; METALLURGY
- C21—METALLURGY OF IRON
- C21D—MODIFYING THE PHYSICAL STRUCTURE OF FERROUS METALS; GENERAL DEVICES FOR HEAT TREATMENT OF FERROUS OR NON-FERROUS METALS OR ALLOYS; MAKING METAL MALLEABLE, e.g. BY DECARBURISATION OR TEMPERING
- C21D9/00—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor
- C21D9/0068—Heat treatment, e.g. annealing, hardening, quenching or tempering, adapted for particular articles; Furnaces therefor for particular articles not mentioned below
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- C—CHEMISTRY; METALLURGY
- C22—METALLURGY; FERROUS OR NON-FERROUS ALLOYS; TREATMENT OF ALLOYS OR NON-FERROUS METALS
- C22F—CHANGING THE PHYSICAL STRUCTURE OF NON-FERROUS METALS AND NON-FERROUS ALLOYS
- C22F1/00—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working
- C22F1/10—Changing the physical structure of non-ferrous metals or alloys by heat treatment or by hot or cold working of nickel or cobalt or alloys based thereon
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/04—Coating on selected surface areas, e.g. using masks
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/04—Coating on selected surface areas, e.g. using masks
- C23C14/042—Coating on selected surface areas, e.g. using masks using masks
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- C—CHEMISTRY; METALLURGY
- C23—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; CHEMICAL SURFACE TREATMENT; DIFFUSION TREATMENT OF METALLIC MATERIAL; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL; INHIBITING CORROSION OF METALLIC MATERIAL OR INCRUSTATION IN GENERAL
- C23C—COATING METALLIC MATERIAL; COATING MATERIAL WITH METALLIC MATERIAL; SURFACE TREATMENT OF METALLIC MATERIAL BY DIFFUSION INTO THE SURFACE, BY CHEMICAL CONVERSION OR SUBSTITUTION; COATING BY VACUUM EVAPORATION, BY SPUTTERING, BY ION IMPLANTATION OR BY CHEMICAL VAPOUR DEPOSITION, IN GENERAL
- C23C14/00—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material
- C23C14/22—Coating by vacuum evaporation, by sputtering or by ion implantation of the coating forming material characterised by the process of coating
- C23C14/24—Vacuum evaporation
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K99/00—Subject matter not provided for in other groups of this subclass
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
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- Moulds For Moulding Plastics Or The Like (AREA)
Abstract
Provided are a mold manufacturing method for manufacturing a fine metal mask and a fine metal mask manufacturing method, by which a mold capable of manufacturing a fine metal mask that can be used permanently, can save material costs, and can improve productivity can be obtained, and by which a large-area fine metal mask can be manufactured, and by which a yield can be improved by reducing a process defective rate. The method for manufacturing a mold for manufacturing a fine metal mask according to the present invention comprises the steps of: forming an insulating part corresponding to a slit shape of the fine metal mask on the manufacturing substrate; forming a conductive layer on the surface of the insulating part; forming a first metal layer on a manufacturing substrate by an electroforming plating process and separating to form a preliminary mold; and forming a second metal layer on the preliminary mold by an electroforming plating process and separating to form a mold for fine metal mask manufacturing.
Description
The present application is a divisional application of a patent application entitled "method for manufacturing a mold for manufacturing a fine metal mask and method for manufacturing a fine metal mask" filed on 13/05/2020 and having an application number of 202080051095.3.
Technical Field
The present invention relates to a method for manufacturing a mold for manufacturing a fine metal mask and a method for manufacturing a fine metal mask, and more particularly, to a method for manufacturing a mold for manufacturing a fine metal mask and a method for manufacturing a fine metal mask, which can manufacture a fine metal mask having a large area and a high yield by reducing process defects while saving material costs and improving productivity.
Background
Organic Light Emitting Diode (OLED) devices have been attracting attention in the display field and the lighting field because they have not only the characteristics of realizing touch-sensitive screens, high response speed, self-luminescence, being manufactured to be thin, low power, wide viewing angle, etc., but also the characteristics of using Flexible (Flexible) substrates.
The OLED element uses an organic substance as a light-emitting layer, forms organic layers of respective layers between a lower electrode and an upper electrode, and utilizes a principle that when a voltage is applied between the lower electrode and the upper electrode, electrons and holes are injected from a cathode and an anode and recombine in the organic layers to emit light.
When depositing an organic multilayer film on a transparent insulating substrate in order to manufacture an OLED element, a Fine Metal Mask (FMM), i.e., a Shadow mask, is generally used in order to deposit the organic multilayer film only on an element forming region of the substrate and not on other regions of the substrate. Such a shadow mask greatly affects the quality and the overall yield of OLED elements, and thus the importance of the shadow mask is further increasing.
For the fine metal mask, an INVAR (INVAR) alloy having almost no thermal deformation in an organic multilayer film deposition process or the like is rolled for use. Such a fine metal mask is mainly used in the manufacture of a small OLED display device, but in the case of glass for manufacturing a large display, a central portion thereof is sagged toward a bottom portion when the size thereof is increased, and thus alignment with the fine metal mask is problematic, and the fine metal mask cannot be applied.
Also, as the resolution is gradually increased, the thickness of the fine metal mask should be relatively thin, but there is a technical limitation in thinning to a predetermined thickness or more in the existing rolling process. Recently, the manufacture of a fine metal mask using an electroforming plating process has been underway, but it cannot be commercialized due to various difficulties in the manufacturing process caused by the thinning of the thickness of the fine metal mask.
Disclosure of Invention
Technical problem
The present invention has been made to solve the above-described problems, and an object of the present invention is to provide a mold manufacturing method and a fine metal mask manufacturing method capable of manufacturing a fine metal mask which can be used permanently, can save material costs, and can improve productivity, and capable of manufacturing a fine metal mask having a large area, and can improve a yield by reducing a process defective rate.
Technical scheme
The mold manufacturing method for manufacturing a fine metal mask according to an embodiment of the present invention for achieving the above object includes the steps of: forming an insulating part corresponding to a slit shape of the fine metal mask on the manufacturing substrate; forming a conductive layer on the surface of the insulating part; forming a first metal layer on a manufacturing substrate by an electroforming plating process and separating to form a preliminary mold; and forming a second metal layer on the preliminary mold by an electroforming plating process and separating to form a mold for fine metal mask manufacturing.
The insulating portion may include any one of a Dry Film Resist (DFR) and a Photoresist (PR).
The insulating portion may be formed obliquely from the upper surface toward the manufacturing substrate.
The thickness of the first metal layer and the second metal layer may be 50 μm to 500 μm.
The first and second metal layers may include at least one of nickel (Ni), iron (Fe), and copper (Cu).
According to another aspect, there is provided a fine metal mask manufacturing method including the steps of: forming an insulating part corresponding to a slit shape of a fine metal mask on a manufacturing substrate; forming a conductive layer on the surface of the insulating part; forming a first metal layer on a production substrate by an electroforming plating process and separating to form a preliminary mold; forming a second metal layer on the preliminary mold by an electroforming plating process and separating to form a mold for fine metal mask manufacturing; forming a non-conductive layer on the convex portion of the mold for fine metal mask manufacturing; a third metal layer is formed on the fine metal mask manufacturing mold by an electroforming plating process and separated to form a fine metal mask.
The third metal layer may include iron (Fe) and nickel (Ni).
According to still another aspect, there is provided a fine metal mask manufacturing method including the steps of: forming a first insulating portion corresponding to a slit shape of the fine metal mask on the first production substrate; forming a first conductive layer on a surface of the first insulating portion; forming a first metal layer on a first manufacturing substrate by an electroforming plating process and separating to form a preliminary mold; forming a second metal layer on the preliminary mold by an electroforming plating process and separating to form a first mold; forming a second insulating part corresponding to a slit shape of the fine metal mask on the second manufacturing substrate; forming a second conductive layer on a surface of the second insulating portion; forming a third metal layer on the second production substrate by an electroforming plating process and separating to form a second mold; forming a non-conductive layer on the convex portion of the first mold; forming a fourth metal layer on the first mold through an electroforming plating process; contacting the first mold and the second mold and heat treating the fourth metal layer; and removing the second mold and separating the fourth metal layer from the first mold to form a fine metal mask.
The second insulating portion may have a height lower than the first insulating portion by a height corresponding to a thickness of the fine metal mask.
The step of forming the second insulating part may include the steps of: forming an insulating substance portion on the second production substrate; and mechanically polishing the insulating substance portion to form a second insulating portion having a height lower than the first insulating portion by a height corresponding to the thickness of the fine metal mask.
The second insulating portion surface may have roughness.
The first insulating portion may be formed obliquely from the upper surface toward the first production substrate, and the second insulating portion may be formed obliquely from the upper surface toward the second production substrate.
The third metal layer may include iron (Fe) and nickel (Ni), and the fourth metal layer includes iron (Fe) and nickel (Ni).
According to still another aspect, there is provided a fine metal mask manufacturing method including the steps of: forming a first insulating portion corresponding to a slit shape of the fine metal mask on the first production substrate; forming a first conductive layer on a surface of the first insulating portion; forming a first metal layer on a first production substrate by an electroforming plating process and separating to form a preliminary mold; forming a second metal layer on the preliminary mold by an electroforming plating process and separating to form a first mold; forming a non-conductive layer on the convex portion of the first mold; forming a third metal layer on the first mold by an electroforming plating process; contacting the preliminary mold on the first mold and heat-treating the third metal layer; and removing the preliminary mold and separating the third metal layer from the first mold to form a fine metal mask.
The convex portion of the preliminary mold corresponding to the thickness of the fine metal mask may be removed before contacting the preliminary mold on the first mold.
Advantageous effects
According to the method for manufacturing a mold for manufacturing a fine metal mask according to the embodiment of the present invention, the preliminary mold is formed by electroforming plating, and the plating layer is formed again in the preliminary mold to manufacture the mold for manufacturing the fine metal mask, thereby having an effect of enabling permanent use of the mold to reduce the cost of the manufacturing process of the fine metal mask and manufacture the fine metal mask with high reliability.
Further, according to the method for manufacturing a fine metal mask according to the embodiment of the present invention, when manufacturing a fine metal mask by using a mold for manufacturing a fine metal mask after manufacturing the fine metal mask by electroforming plating, it is possible to increase the mold for heat treatment to prevent deformation or bending of the fine metal mask at the time of heat treatment, thereby manufacturing a fine metal mask having excellent performance with improved reliability.
Drawings
Fig. 1 to 5 are diagrams provided for explanation of a mold manufacturing method for fine metal mask manufacturing according to an embodiment of the present invention.
Fig. 6 to 8 are views provided for explanation of a fine metal mask manufacturing method according to another embodiment of the present invention.
Fig. 9 to 21 are views provided for explanation of a fine metal mask manufacturing method according to an embodiment of the present invention.
Best mode for carrying out the invention
Hereinafter, embodiments of the present invention will be described with reference to the drawings. However, the embodiment of the present invention may be modified into various other embodiments, and the scope of the present invention is not limited to the embodiments described below. The embodiments of the present invention are provided to more fully explain the present invention to those having ordinary skill in the art. Although the components having a specific pattern or a predetermined thickness are illustrated in the drawings, this is for convenience of explanation and distinction, and thus even if reference is made to the components having a specific pattern or a specific thickness, the features of the components illustrated in the present invention are not limited thereto.
Fig. 1 to 5 are diagrams provided for explanation of a mold manufacturing method for fine metal mask manufacturing according to an embodiment of the present invention. The mold manufacturing method for manufacturing a fine metal mask according to the present embodiment includes the steps of: forming an insulating part 120 corresponding to a slit shape of the fine metal mask on the manufacturing substrate 110; forming a conductive layer 130 on a surface of the insulating portion 120; forming a preliminary mold 140 by forming a first metal layer 140 on the production substrate 110 through an electroforming plating process and separating; and forming a second metal layer 150 on the preliminary mold 140 by an electroforming plating process and separating to form a fine metal mask manufacturing mold 150.
The mold for manufacturing a fine metal mask manufactured by the mold manufacturing method for manufacturing a fine metal mask according to the present invention is a mold for manufacturing a fine metal mask for manufacturing an OLED element. In the process for producing an OLED element, the organic light-emitting layer produced by depositing an organic multilayer film on a transparent insulating substrate has the following configuration. That is, an organic light emitting layer is formed by selectively supplying from a supply portion including an organic light emitting substance emitting a predetermined color to a predetermined sub-pixel region through an opening portion of a fine metal mask. At this time, the principle of forming the organic light emitting layer is evaporation (evaporation), and the organic light emitting substance is supplied in a vaporized state and deposited on the exposed substrate. In this case, if an organic electroluminescent element to be formed is provided with organic light-emitting layers for emitting R, G, and B colors, the organic electroluminescent element is provided with separate supply units for the respective colors, and the process for forming the organic light-emitting layers is further performed for the respective colors.
The fine metal mask has a structure in which slits (slots) for forming a predetermined pattern of a plurality of organic films or electrodes are formed in a thin plate in order to manufacture an OLED element. Methods for manufacturing such masks include using a method using an etching method and a method using an electroforming method. The mask manufacturing method using etching is performed in the following manner: a resist layer having a pattern of slits is formed on a thin plate by a photoresist method, or a film having a pattern of slits is attached to a thin plate and then the thin plate is etched (etching). However, the mask manufacturing method using etching has a problem that the width tolerance and the tolerance of the slit edge portion cannot be accurately matched with each other as the mask is enlarged and the slit pattern is made finer. In particular, when a mask is manufactured by etching a thin plate, if the thin plate is over-etched or under-etched, the specification of the slits cannot be made uniform.
In addition, as a method for solving the problem of the etching method, the electroforming method (electro forming) manufactures a mask using the following principle: if a metal is separated from a die (matrix) after a desired thickness is deposited by electrolysis on the matrix by means of electrolysis of a metal salt solution by an operation such as plating, the metal becomes an electroformed product opposite to the irregularities of the matrix. In the present embodiment, in order to manufacture a fine metal mask, a metal layer is formed by an electroforming method (i.e., an electroforming plating method).
Referring to fig. 1, an insulating part 120 corresponding to a slit shape of a fine metal mask is formed on a production substrate 110. As the substrate capable of electroforming plating, for example, a stainless steel substrate which facilitates mold release of a plating layer can be used to manufacture the substrate 110.
The insulating part 120 is a structure formed on the surface of the production substrate 110, and is used to form a slit of a fine metal mask. Accordingly, the insulating part 120 is formed to correspond to the slit shape of the fine metal mask. The insulating part 120 may include any one of a photosensitive Film Resist (DFR: dry Film Resist) and a photoresist (PR: photo Resist). The insulating part 120 may be formed on the fabrication substrate 110 in a desired shape by etching DFR or PR.
The insulating part 120 may be formed obliquely from the upper surface toward the manufacturing substrate 110. Referring to fig. 1, the insulating part 120 is implemented in a trapezoidal shape, but may be differently formed in consideration of a slit shape of a fine metal mask to be formed later, an inclination of the inside of the slit, or the like.
Thereafter, as shown in fig. 2, a conductive layer 130 is formed on the surface of the insulating portion 120. Since the insulating portion 120 is made of an insulating substance, the conductive layer 130 is formed so as to be capable of performing electroforming plating.
When the conductive layer 130 is formed on the surface of the insulating portion 120, a first metal layer 140 is formed on the surface of the manufacturing substrate 110 by an electroforming plating process (fig. 3). The first metal layer 140 is used to form a preliminary mold for duplicating the surface shape of the manufacturing substrate 110. If the first metal layer 140 is plated on the surface of the production substrate 110 and separated, a preliminary mold 140 (fig. 4) for forming a mold for manufacturing a fine metal mask can be obtained.
When the second metal layer 150 is formed on the preliminary mold 140 by the electroforming process and separated, the metal mask manufacturing mold 150 (fig. 5) that replicates the surface shape of the manufacturing substrate 110 having the insulating portion 120 formed thereon in fig. 1 is obtained.
The thickness of the first and second metal layers 140 and 150 may be 50 to 500 μm. In addition, the first and second metal layers 140 and 150 may include at least one of nickel (Ni), iron (Fe), and copper (Cu).
Fig. 6 to 8 are views for explaining a fine metal mask manufacturing method according to another embodiment of the present invention. Hereinafter, the description will be given with reference to fig. 1 to 8, but the description will be omitted.
The fine metal mask manufacturing method according to the present embodiment may include the steps of: forming an insulating part 120 corresponding to the shape of the fine metal mask slit 181 on the production substrate 110; forming a conductive layer 130 on a surface of the insulating portion 120; forming a first metal layer 140 on the manufacturing substrate 110 by an electroforming plating process and separating to form a preliminary mold 140; forming a second metal layer 150 on the preliminary mold 140 by an electroforming plating process and separating to form a fine metal mask manufacturing mold 150; forming a non-conductive layer 170 on the convex portion 160 of the fine metal mask manufacturing mold 150; and forming a third metal layer 180 on the fine metal mask manufacturing mold 150 by an electroforming plating process and separating to form the fine metal mask 180.
In the present fine metal mask manufacturing method, first, the fine metal mask manufacturing mold 150 described with reference to fig. 1 to 5 is manufactured, and the fine metal mask 180 is manufactured using the same.
As shown in fig. 5, when the fine metal mask manufacturing mold 150 is manufactured, a fine metal mask 180 is formed using the same. Referring to fig. 6, a non-conductive layer 170 is formed on the convex portion 160 of the fine metal mask manufacturing mold 150 (i.e., on the convex portion 160 that reproduces the shape of the insulating portion 120 formed on the manufacturing substrate 110 so as to correspond to the shape of the fine metal mask slit 181) (fig. 6).
The non-conductive layer 170 is formed only in the convex portion 160 portion in the fine metal mask manufacturing mold 150. Accordingly, in the subsequent process, the fine metal mask slits 181 are not plated due to the non-conductive layer 170 of the protrusion 160, so that the fine metal mask slits 181 are easily formed.
If the third metal layer 180 is formed on the fine metal mask manufacturing mold 150 in which the non-conductive layer 170 is formed on the convex portions 160 through the electroforming plating process, the plating layer is not formed on the convex portions 160 due to the non-conductive layer 170, and the third metal layer 180 is formed only between the convex portions 160. Accordingly, the fine metal mask slits 181 in the shape of the projections 160 can be formed (fig. 7).
After that, when the third metal layer 180 is separated from the fine metal mask manufacturing mold 150, the fine metal mask 180 having a desired shape of the fine metal mask slit 181 is obtained as shown in fig. 8.
The third metal layer 180 for manufacturing the fine metal mask 180 may include iron (Fe) and nickel (Ni). The metal used for the fine metal mask 180 is preferably very small in thermal expansion rate in order to have durability against high-temperature deformation in an organic deposition process as a subsequent process. Third metal layer 180 may include iron (Fe) and nickel (Ni), and a so-called Invar (Invar) alloy including iron (Fe) and nickel (Ni) exhibits a very low thermal expansion rate according to a ratio of iron and nickel. The thickness of the third metal layer 180 may be 5 μm to 30 μm.
In the mold manufacturing method for manufacturing a fine metal mask according to the present embodiment, the insulating part may be formed and then the plating process may be performed, thereby omitting a process of separating the fine metal mask together with the insulating part from the manufacturing substrate and removing the insulating part from the fine metal mask again, and forming the protrusion part corresponding to the insulating part using a metal based on the plating process, and thus the mold for manufacturing a fine metal mask can be semi-permanently used, thereby enabling an economical process to be performed.
Fig. 9 to 21 are views for explaining a fine metal mask manufacturing method according to an embodiment of the present invention. In the fine metal mask manufacturing method according to the present embodiment, first, a mold for fine metal mask manufacturing is manufactured, and a mold for heat treatment is manufactured using the same method, and after forming a fine metal mask with the mold for fine metal mask manufacturing, the mold for heat treatment is covered and a heat treatment process is performed, thereby manufacturing a fine metal mask.
The fine metal mask manufactured by the fine metal mask manufacturing method according to the present invention is a mask for OLED element manufacturing. In the process of manufacturing the OLED element, formation of an organic light-emitting layer manufactured by depositing an organic multilayer film on a transparent insulating substrate is realized as follows. That is, an organic light emitting layer is formed by selectively supplying a predetermined sub-pixel region from a supply portion including an organic light emitting substance emitting a predetermined color through an opening portion of a fine metal mask. At this time, the principle of forming the organic light emitting layer is evaporation (evaporation), and the organic light emitting substance is supplied in a vaporized state and deposition is performed on the exposed substrate. In this case, if an organic electroluminescent element to be formed is provided with organic light-emitting layers for emitting R, G, and B colors, a separate supply unit for each color is provided, and a process for forming the organic light-emitting layer is further performed for each color.
The fine metal mask has a structure in which slits (slots) for forming a predetermined pattern of a plurality of organic films or electrodes are formed in a thin plate to manufacture an OLED element. In order to manufacture such a mask, a method using an etching method and a method using an electroforming method are used. The mask manufacturing method using etching is performed as follows: a resist layer having a pattern of slits is formed on a thin plate by a photoresist method, or a film having a pattern of slits is attached to a thin plate and then the thin plate is etched (etching). However, the mask manufacturing method using etching has a problem that the width tolerance and the tolerance of the slit edge portion cannot be accurately matched with each other with the increase in size of the mask and the miniaturization of the slit pattern. In particular, when a mask is manufactured by etching a thin plate, if the thin plate is over-etched or under-etched, the specification of the slits cannot be made uniform.
In addition, as a method for solving the problem of the etching method, the electroforming method (electro forming) manufactures a mask using the following principle: if a metal is deposited on the matrix by electrolysis in a desired thickness by electrolysis of a metal salt solution by an operation such as electroplating and then peeled off from the matrix, it becomes an electroformed article as opposed to the matrix unevenness. In the present embodiment, in order to manufacture a fine metal mask, a metal layer is formed by an electroforming method (i.e., an electroforming plating method).
To manufacture the fine metal mask, a mold for manufacturing the fine metal mask is first manufactured. Referring to fig. 9, a first insulating portion 121 corresponding to a slit shape of a fine metal mask is formed on a first production substrate 111. As the substrate capable of electroforming plating, for example, a stainless steel substrate which is favorable for mold release can be used as the first production substrate 111.
The first insulating portion 121 serves as a structure formed on the surface of the first production substrate 111 for forming slits of a fine metal mask. Therefore, the first insulating portion 121 is formed to correspond to the slit shape of the fine metal mask. The first insulating portion 121 may include any one of a photosensitive Film Resist (DFR: dry Film Resist) and a photoresist (PR: photo Resist). The first insulating portion 121 may be formed in a desired shape on the fabrication substrate 110 by etching DFR or PR.
The first insulating portion 121 may be formed obliquely from the upper surface toward the first production substrate 111. Referring to fig. 9, the first insulating portion 121 is implemented in a trapezoidal shape, but may be formed differently from this in consideration of a slit shape of a fine metal mask to be formed later, an inclination of the inside of the slit, or the like.
After that, as shown in fig. 10, a first conductive layer 131 is formed on the surface of the first insulating portion 121. Since the first insulating portion 121 is formed using an insulating substance, the first conductive layer 131 is formed so as to be capable of electroforming plating.
If the first conductive layer 131 is formed on the surface of the first insulating portion 121, a first metal layer 141 is formed on the surface of the first production substrate 111 by an electroforming plating process (fig. 11). The first metal layer 141 is used to form a preliminary mold and to replicate the surface shape of the first production substrate 111. If the first metal layer 141 is plated on the surface of the first production substrate 111 and separated, a preliminary mold 141 for forming a mold for manufacturing a fine metal mask can be obtained (fig. 12).
When the second metal layer is formed on the preliminary mold 141 by the electroforming plating process and separated, a first mold 151, which is a mold for manufacturing a metal mask and reproduces the surface shape of the first production substrate 111 in which the first insulating portion 121 is formed in fig. 9, is obtained (fig. 13).
The thickness of the first and second metal layers 141 and 151 may be 50 to 500 μm. In addition, the first and second metal layers 141 and 151 may include at least one of nickel (Ni), iron (Fe), and copper (Cu).
Next, a process of manufacturing a heat treatment mold for heat treatment of the fine metal mask is performed. As shown in fig. 14, the second insulating portion 122 corresponding to the slit shape of the fine metal mask is formed on the second production substrate 112, and at this time, it is preferable that the height of the second insulating portion 122 is lower than the first insulating portion 121 by a height corresponding to the thickness of the fine metal mask 180. That is, since a mold for heat treatment of the fine metal mask is prepared, the second insulating portion 122 is formed to have a thickness lower than the first insulating portion 121 by the thickness of the fine metal mask so that the upper surface of the fine metal mask can be covered and heat treated to prevent deformation or bending during the heat treatment.
The step of forming the second insulating part 122 may include the steps of: forming an insulating substance portion on the second production substrate 112; and mechanically polishing the insulating substance portion to form a second insulating portion 122 having a height lower than the first insulating portion 121 by a height corresponding to the thickness of the fine metal mask. In this case, the surface of the second insulating part 122 may exhibit roughness (roughness) due to the mechanical polishing process performed.
In order to form the heat treatment mold, a second conductive layer 132 for electroforming plating is formed on the surface of the second insulating portion 122 (fig. 15). As described above, if roughness is formed on the surface of the second insulating portion 122, it is possible to prevent peeling or separation after the second conductive layer 132 is formed.
After that, a third metal layer 142 is formed on the second production substrate 112 by an electroforming plating process (fig. 16), and is separated to obtain a second mold 142 as a mold for heat treatment (fig. 17). The third metal layer 142 may include at least one of nickel (Ni), iron (Fe), and copper (Cu).
Finally, in order to form the fine metal mask, the non-conductive layer 170 is formed on the convex portion 160 of the first mold 151 as a mold for manufacturing the fine metal mask (i.e., the convex portion 160 that replicates the shape of the first insulating portion 121 formed on the first production substrate 111 so as to correspond to the shape of the fine metal mask slit 181) (fig. 18).
The non-conductive layer 170 is formed only on the portions of the projections 160 in the first mold 151. Accordingly, in the subsequent process, the fine metal mask slits 181 do not form a plating layer due to the non-conductive layer 170 of the projections 160, so that the fine metal mask slits 181 are easily formed.
If the fourth metal layer 180 is formed on the first mold 151 in which the non-conductive layers 170 are formed on the embossed portions 160 through the electroforming plating process, no plating layer is formed on the embossed portions 160 due to the non-conductive layers 170, and the fourth metal layer 180 is formed only between the embossed portions 160. Therefore, the fine metal mask slits 181 in the shape of the projections 160 can be formed (fig. 19).
When the fine metal mask 180 is formed on the first mold 151, the second mold 142, which is a mold for heat treatment, is positioned on the first mold 151 to bring the first mold 151 and the second mold 142 into contact with each other, and the fourth metal layer 180 is heat-treated (fig. 20).
Thereafter, if the second mold 142 is removed and the fourth metal layer 180 is separated from the first mold 151, a fine metal mask 180 having a desired shape of the fine metal mask slits 181 is obtained as shown in fig. 21.
The fourth metal layer 180 for manufacturing the fine metal mask 180 may include iron (Fe) and nickel (Ni). The metal used for the fine metal mask 180 is preferably very small in thermal expansion rate in order to have durability against high-temperature deformation in an organic deposition process as a subsequent process. Fourth metal layer 180 may include iron (Fe) and nickel (Ni), and a so-called Invar (Invar) alloy including iron (Fe) and nickel (Ni) exhibits a very low thermal expansion rate according to a ratio of iron and nickel. The thickness of the fourth metal layer 180 may be 5 μm to 30 μm.
In the case of the second mold 142 used for such heat treatment of the fourth metal layer 180, it is preferable to select the third metal layer 142 in consideration of the thermal expansion coefficients of the fourth metal layer 180 and the second mold 142. That is, when the heat treatment is performed, if there is a difference in thermal expansion coefficient between the fourth metal layer 180 and the second mold 142, the fourth metal layer 180 is distorted or bent, and the second mold 142 may not be separated by the heat treatment process.
In the fine metal mask, it is important to maintain the precision in the heat treatment process because it is very important to realize the positional precision such as the hole size and the space of the mask in terms of the function of the part. Accordingly, it is preferable to use metals having the same thermal expansion coefficient for the first mold 151 and the second mold 142 located above and below the fourth metal layer 180. In the case of using metals having different thermal expansion coefficients, secondary deformation occurs due to interference between the fine metal mask (fourth metal layer) and the first mold 151 and the second mold 142 (second metal layer and third metal layer) in the heat treatment process, and as a result, the possibility of losing the function of the fine metal mask may be increased.
Therefore, in order to achieve effective heat treatment, the fourth metal layer 180, the first mold 151, and the second mold 142 may include metals having the same thermal expansion coefficient, or most preferably, may include the same metal. For example, the second metal layer and the third metal layer may include iron (Fe) and nickel (Ni), and the fourth metal layer may also include iron (Fe) and nickel (Ni).
According to still another aspect of the present invention, there is provided a fine metal mask manufacturing method, comprising the steps of: forming a first insulating portion corresponding to a slit shape of the fine metal mask on the first production substrate; forming a first conductive layer on a surface of the first insulating portion; forming a first metal layer on a first manufacturing substrate by an electroforming plating process and separating to form a preliminary mold; forming a second metal layer on the preliminary mold by an electroforming plating process and separating to form a first mold; forming a non-conductive layer on the convex portion of the first mold; forming a third metal layer on the first mold by an electroforming plating process; contacting the preliminary mold with the first mold, and heat-treating the third metal layer; and removing the preliminary mold and separating the third metal layer from the first mold to form a fine metal mask. The description of the above description is omitted.
According to the present embodiment, as the mold for heat treatment, a preliminary mold for manufacturing the first mold is used. That is, the heat treatment is performed using the preliminary mold manufactured in the manufacture of the first mold, instead of separately manufacturing the second mold as a mold for the heat treatment as in the foregoing embodiment.
However, the height of the projection of the preliminary mold is removed only by a height corresponding to the thickness of the fine metal mask, so that the heat treatment can be efficiently performed by accurately covering the upper portion after the fine metal mask is formed on the first mold.
Although the embodiments of the present invention have been described above, those having ordinary knowledge in the art can variously modify and change the present invention by adding, modifying, deleting, or adding components without departing from the scope of the idea of the present invention described in the claims, and such modifications and changes are also included in the scope of the claims of the present invention.
Claims (8)
1. A fine metal mask manufacturing method comprising the steps of:
forming a first insulating portion corresponding to a slit shape of a fine metal mask on a first production substrate;
forming a first conductive layer on a surface of the first insulating portion;
forming a first metal layer on a first manufacturing substrate by an electroforming plating process and separating to form a preliminary mold;
forming a second metal layer on the preliminary mold by an electroforming plating process and separating to form a first mold;
forming a second insulating part corresponding to a slit shape of the fine metal mask on the second manufacturing substrate;
forming a second conductive layer on a surface of the second insulating portion;
forming a third metal layer on the second manufacturing substrate by an electroforming plating process and separating to form a second mold;
forming a non-conductive layer on the convex portion of the first mold;
forming a fourth metal layer on the first mold by an electroforming plating process;
contacting the first mold and the second mold, and performing heat treatment on the fourth metal layer; and
the second mold is removed and the fourth metal layer is separated from the first mold to form a fine metal mask.
2. The fine metal mask manufacturing method according to claim 1,
the second insulating portion has a height lower than the first insulating portion by a height corresponding to the thickness of the fine metal mask.
3. The fine metal mask manufacturing method according to claim 1,
the step of forming the second insulating portion includes the steps of:
forming an insulating substance portion on the second production substrate; and
the insulating substance portion is mechanically polished to form a second insulating portion having a height lower than the first insulating portion by a thickness corresponding to the fine metal mask.
4. The fine metal mask manufacturing method according to claim 3,
the second insulating portion surface has roughness.
5. The fine metal mask manufacturing method according to claim 1,
the first insulating portion is formed obliquely from the upper surface toward the first production substrate,
the second insulating portion is formed obliquely from the upper surface toward the second production substrate.
6. The fine metal mask manufacturing method according to claim 1,
the third metal layer includes iron and nickel,
the fourth metal layer includes iron and nickel.
7. A fine metal mask manufacturing method comprising the steps of:
forming a first insulating portion corresponding to a slit shape of the fine metal mask on the first production substrate;
forming a first conductive layer on a surface of the first insulating portion;
forming a first metal layer on a first manufacturing substrate by an electroforming plating process and separating to form a preliminary mold;
forming a second metal layer on the preliminary mold by an electroforming plating process and separating to form a first mold;
forming a non-conductive layer on the convex portion of the first mold;
forming a third metal layer on the first mold by an electroforming plating process;
contacting the preliminary mold on the first mold and heat-treating the third metal layer; and
the preliminary mold is removed, and the third metal layer is separated from the first mold to form a fine metal mask.
8. The fine metal mask manufacturing method according to claim 7,
the projection of the preliminary mold corresponding to the thickness of the fine metal mask is removed before contacting the preliminary mold on the first mold.
Applications Claiming Priority (6)
| Application Number | Priority Date | Filing Date | Title |
|---|---|---|---|
| KR10-2019-0055881 | 2019-05-13 | ||
| KR1020190055881A KR102186989B1 (en) | 2019-05-13 | 2019-05-13 | Manufacturing method of mold for fine metal mask |
| KR1020190055887A KR102129777B1 (en) | 2019-05-13 | 2019-05-13 | Manufacturing method of fine metal mask |
| KR10-2019-0055887 | 2019-05-13 | ||
| PCT/KR2020/006277 WO2020231172A1 (en) | 2019-05-13 | 2020-05-13 | Method for manufacturing mold for manufacturing fine metal mask, and method for manufacturing fine metal mask |
| CN202080051095.3A CN114127338B (en) | 2019-05-13 | 2020-05-13 | Method for manufacturing mold for manufacturing fine metal mask and method for manufacturing fine metal mask |
Related Parent Applications (1)
| Application Number | Title | Priority Date | Filing Date |
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| CN202080051095.3A Division CN114127338B (en) | 2019-05-13 | 2020-05-13 | Method for manufacturing mold for manufacturing fine metal mask and method for manufacturing fine metal mask |
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| Publication Number | Publication Date |
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| CN114574908A CN114574908A (en) | 2022-06-03 |
| CN114574908B true CN114574908B (en) | 2022-11-25 |
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| CN202210194698.XA Active CN114574908B (en) | 2019-05-13 | 2020-05-13 | Method for manufacturing fine metal mask |
| CN202080051095.3A Active CN114127338B (en) | 2019-05-13 | 2020-05-13 | Method for manufacturing mold for manufacturing fine metal mask and method for manufacturing fine metal mask |
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| CN202080051095.3A Active CN114127338B (en) | 2019-05-13 | 2020-05-13 | Method for manufacturing mold for manufacturing fine metal mask and method for manufacturing fine metal mask |
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| WO (1) | WO2020231172A1 (en) |
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| KR102353349B1 (en) * | 2015-03-31 | 2022-01-19 | 삼성디스플레이 주식회사 | Manufacturing method of metal mask and mask for deposition using thereof |
| KR102378358B1 (en) * | 2015-10-05 | 2022-03-25 | 삼성디스플레이 주식회사 | Method of manufacturing mask for deposition |
| US20190036026A1 (en) * | 2016-02-03 | 2019-01-31 | Applied Materials, Inc. | A shadow mask with tapered openings formed by double electroforming using positive/negative photoresists |
| KR102314854B1 (en) * | 2017-05-02 | 2021-10-18 | 주식회사 오럼머티리얼 | Producing method of mask integrated frame |
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- 2020-05-13 CN CN202210194698.XA patent/CN114574908B/en active Active
- 2020-05-13 WO PCT/KR2020/006277 patent/WO2020231172A1/en active Application Filing
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| CN1392905A (en) * | 2000-09-26 | 2003-01-22 | 伊斯曼柯达公司 | Method for producing metal mask and metal mask |
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Also Published As
| Publication number | Publication date |
|---|---|
| CN114127338A (en) | 2022-03-01 |
| CN114574908A (en) | 2022-06-03 |
| WO2020231172A1 (en) | 2020-11-19 |
| CN114127338B (en) | 2022-12-09 |
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