WO2015136859A1 - 蒸着装置及び蒸着装置を用いた蒸着方法、及びデバイスの製造方法 - Google Patents
蒸着装置及び蒸着装置を用いた蒸着方法、及びデバイスの製造方法 Download PDFInfo
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- WO2015136859A1 WO2015136859A1 PCT/JP2015/000902 JP2015000902W WO2015136859A1 WO 2015136859 A1 WO2015136859 A1 WO 2015136859A1 JP 2015000902 W JP2015000902 W JP 2015000902W WO 2015136859 A1 WO2015136859 A1 WO 2015136859A1
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- vapor deposition
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Images
Classifications
-
- 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
- C23C14/243—Crucibles for source material
-
- 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
- C23C14/54—Controlling or regulating the coating process
- C23C14/542—Controlling the film thickness or evaporation rate
-
- 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
- C23C14/56—Apparatus specially adapted for continuous coating; Arrangements for maintaining the vacuum, e.g. vacuum locks
- C23C14/564—Means for minimising impurities in the coating chamber such as dust, moisture, residual gases
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/10—Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K10/00—Organic devices specially adapted for rectifying, amplifying, oscillating or switching; Organic capacitors or resistors having potential barriers
- H10K10/40—Organic transistors
- H10K10/46—Field-effect transistors, e.g. organic thin-film transistors [OTFT]
-
- 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
-
- 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
- H10K71/10—Deposition of organic active material
- H10K71/16—Deposition of organic active material using physical vapour deposition [PVD], e.g. vacuum deposition or sputtering
- H10K71/164—Deposition of organic active material using physical vapour deposition [PVD], e.g. vacuum deposition or sputtering using vacuum deposition
Definitions
- the present invention relates to a vapor deposition apparatus used for manufacturing a device using an organic substance and a device manufacturing method using the vapor deposition apparatus.
- the present invention relates to a vapor deposition apparatus including a vapor deposition source that discharges a vapor deposition material into a chamber from a plurality of discharge ports.
- an organic function for exhibiting a specific function such as an organic light emitting layer in an organic light emitting element or an organic semiconductor layer in a TFT.
- Layers are used.
- an organic light emitting device has a configuration in which a metal electrode, a plurality of organic functional layers, and a transparent electrode layer are sequentially laminated on a substrate, and each layer is formed in a chamber mainly by a vacuum deposition method.
- a high-vacuum chamber in which a substrate is provided in an upper portion and a deposition source is provided in a lower portion is typically used (for example, Patent Document 1).
- the evaporation source has a crucible inside and contains a powdery organic substance.
- a heating device is provided around the crucible and heats the crucible using infrared radiant heat.
- the organic material accommodated in the vapor deposition source is evaporated by heating and diffused into the chamber as an organic gas. Then, the organic gas in contact with the substrate is solidified to form a thin organic functional layer on the substrate.
- a method of closing a crucible containing a vapor deposition material with a lid provided with a plurality of discharge ports has been proposed (for example, Patent Document 2).
- impurities such as a small amount of moisture in the atmosphere may be mixed into the vapor deposition material when the vapor deposition material is carried into the chamber. is there. In that case, the mixed impurities cause deterioration of the vapor deposition material due to a reaction with the vapor deposition material, and consequently, deterioration of material characteristics.
- An object of the present invention is to provide a vapor deposition apparatus that reduces deterioration of a vapor deposition material and deterioration of material characteristics, a vapor deposition method using the vapor deposition apparatus, and a device manufacturing method.
- a vapor deposition apparatus includes a chamber in which a vapor deposition target is provided, a vapor deposition source having a housing for accommodating a vapor deposition material in the chamber, A heating unit that heats the vapor deposition material, and the housing communicates the inside and outside of the housing with a plurality of discharge ports that discharge the vapor of the vapor deposition material toward the vapor deposition target; An exhaust port that can be opened and closed is provided.
- impurities mixed into the housing of the vapor deposition source can be discharged out of the housing in the device manufacturing process, so that the impurities and the vapor deposition material can be prevented from reacting. it can. For this reason, in the vapor deposition step, it is possible to reduce alteration of the vapor deposition material and deterioration of material characteristics.
- FIG. 1 is a schematic cross-sectional view showing a structure of a vapor deposition apparatus 1 according to Embodiment 1.
- FIG. 2 is a schematic diagram showing a state in which a vapor deposition material is vapor deposited on a substrate in the vapor deposition apparatus 1.
- FIG. 2 is a perspective view showing a configuration of a vapor deposition source 6 according to Embodiment 1.
- FIG. 2 is a schematic cross-sectional view of a vapor deposition source 6 according to Embodiment 1.
- FIG. (A) is an example of the temperature profile of the vapor deposition source 6 in the vapor deposition method using the vapor deposition apparatus 1 which concerns on Embodiment 1
- (b) is an example of the pressure profile in the chamber 2.
- FIG. 9 is a schematic cross-sectional view showing the structure of a vapor deposition apparatus 1B according to a modification of the third embodiment. It is a schematic cross section which shows the structure of the vapor deposition apparatus 1C which concerns on Embodiment 4.
- FIG. 6 is a schematic cross-sectional view of a vapor deposition source 6C according to Embodiment 4.
- (A) is an example of the temperature profile of the vapor deposition source 6C in the vapor deposition method using the vapor deposition apparatus 1C according to Embodiment 4, and (b) is an example of the pressure profile in the chamber 2.
- (A)-(d) is process drawing explaining the manufacturing method of the organic electroluminescent apparatus which is an aspect of the manufacturing method of the device which concerns on Embodiment 5.
- FIG. 1 is an example of the temperature profile of the vapor deposition source 6C in the vapor deposition method using the vapor deposition apparatus 1C according to Embodiment 4
- (b) is an example of the pressure profile in the chamber 2.
- (A)-(d) is process drawing explaining the manufacturing method of the organic electroluminescent apparatus which is an aspect of the manufacturing method of the device which concerns on Embodiment 5.
- a line-shaped evaporation source longer than the width of the substrate called a line source is used, and the substrate is transported perpendicularly to the longitudinal direction of the line source above the line source, so that a planar evaporation film is formed on the substrate.
- a line source longer than the width of the substrate
- Patent Document 1 a planar evaporation film is formed on the substrate.
- the uniformity of the film thickness in the longitudinal direction of the line source is improved as compared with the case where a plurality of point sources are used.
- the distance between the large substrate and the line source is increased, and even if there is some variation in the evaporation rate in the longitudinal direction, the scattering range of the vapor deposition material from each vapor deposition source is overlapped to improve the uniformity of the film thickness.
- a method is conceivable. However, this is not preferable because the volume of the chamber becomes large and time is required for evacuation.
- Patent Document 2 proposes a method of closing a crucible containing a vapor deposition material with a lid provided with a plurality of discharge ports in order to prevent non-uniformity in film formation.
- the crucible is filled with the vapor of the evaporated material by covering the opening at the top of the crucible, and the filled vapor is ejected from each discharge port at the same pressure by the crucible internal pressure. It is done. That is, once the vapor of the vapor deposition material is once filled in the crucible, the vapor can be ejected into the chamber at the same evaporation rate even if the vapor deposition material has a temperature variation in the longitudinal direction. It is thought that the influence on the evaporation rate fluctuation can be reduced.
- Replenishment of the vapor deposition material to the crucible in the chamber is performed by the following process. 1) After film formation is completed, the crucible in the chamber is returned to room temperature, and then the pressure in the chamber is set to atmospheric pressure. 2) Take out the crucible out of the chamber. 3) Fill the crucible with the vapor deposition material. The vapor deposition material is a liquid or a solid at room temperature. 4) Return the crucible filled with the vapor deposition material into the chamber. 5) Vacuum the inside of the chamber, and then heat the crucible. 6) Thereafter, a film forming process by vapor deposition is performed.
- impurities are mixed into the crucible together with the vapor deposition material when the vapor deposition material is replenished into the crucible by 3), and impurities are mixed together with the vapor deposition material when the crucible is returned into the chamber by 4). And the impurity evaporates from a vapor deposition material and a crucible in a crucible by the heating in 5).
- the impurities are, for example, moisture or oxygen in the atmosphere, and are originally contained in the vapor deposition material or adsorbed on the inner peripheral surface of the crucible when released to the atmosphere.
- the evaporated impurities are dispersed in the chamber and exhausted out of the chamber by a vacuum device, so that no problem occurs.
- evaporated impurities are filled in the crucible and are difficult to escape into the chamber (or it takes time to escape).
- the vapor deposition material since the vapor deposition material is in a relatively high active state by heating, it is in a condition where it easily reacts with impurities.
- the vapor deposition material deteriorates, for example, H of the organic material molecule is replaced with an OH group.
- the crucible has a large amount of moisture adsorbed as impurities, and the internal pressure may increase rapidly. In this case, the deterioration of the vapor deposition material is accelerated.
- the inventor has intensively studied a method for preventing the reaction between the impurities mixed in the crucible and the vapor deposition material while making the in-plane film thickness uniform in the organic functional layer in the device manufacturing process.
- the inventors have conceived the vapor deposition apparatus capable of reducing the deterioration of the vapor deposition material and the deterioration of the material characteristics described in the following embodiments, the vapor deposition method using the vapor deposition apparatus, and the device manufacturing method.
- the vapor deposition apparatus includes a chamber in which a vapor deposition object is provided, a vapor deposition source having a housing for accommodating the vapor deposition material in the chamber, and a heating unit for heating the vapor deposition material. And a plurality of outlets for discharging the vapor of the vapor deposition material toward the deposition target, and an openable and closable exhaust opening. It is characterized by being.
- the exhaust pipe is connected to the exhaust port and communicates between the inside of the casing and the outside of the chamber, and the exhaust for exhausting the gas inside the casing to the outside of the chamber through the exhaust pipe.
- a means provided with a means.
- the housing further has an air inlet, An intake pipe connected to the intake port and communicating between the inside of the housing and the outside of the chamber; It may be configured to include an intake means for sucking gas into the casing through the intake pipe.
- the exhaust port may be configured to communicate between the inside of the housing and the outside of the housing and the space in the chamber.
- the exhaust port may be configured to be opened and closed by a valve.
- the casing forms a casing main body having a bottom plate and a peripheral wall surrounding the bottom plate, and an internal space that faces the bottom plate and accommodates the vapor deposition material together with the bottom plate and the peripheral wall.
- a housing lid portion wherein the housing body portion is provided with the exhaust port, and the housing lid portion is provided with the plurality of discharge ports.
- the casing may be provided with a crucible for accommodating the vapor deposition material.
- the vapor deposition source is used in a vapor deposition apparatus for forming an organic layer on a vapor deposition target, and includes a casing that accommodates a vapor deposition material therein, and the casing includes the casing
- the inside and the outside may be communicated, and a plurality of discharge ports for discharging the vapor of the vapor deposition material toward the vapor deposition target and an openable and closable exhaust port may be provided.
- the apparatus includes a crucible for containing the vapor deposition material
- the casing includes a bottom plate and a casing main body having a peripheral wall surrounding the bottom plate, and the bottom plate and the peripheral wall together with the bottom plate and the peripheral wall.
- a housing lid portion that forms an internal space for housing the crucible, the exhaust body is provided in the housing body, and the plurality of discharge ports are provided in the housing lid portion. It may be.
- the vapor deposition method according to the present embodiment is a vapor deposition method in which the vapor deposition material is vapor-deposited on the vapor deposition object using the vapor deposition apparatus, and the vapor deposition material is removed for a predetermined time with the exhaust port opened. Maintaining the temperature near the gas temperature, and maintaining the temperature near the degassing temperature, and then maintaining the vapor deposition material at a heating temperature during vapor deposition higher than the degassing temperature with the exhaust port closed. And evaporating the vapor of the vapor deposition material from a plurality of discharge ports provided in the housing, and vapor depositing the vapor deposition material on the vapor deposition object.
- the gas inside the casing is removed from the chamber via an exhaust pipe that communicates the exhaust port and the outside of the chamber.
- the vapor deposition material may be heated while being exhausted.
- the inside of the casing is provided via an intake pipe that communicates the intake port established in the casing with the outside of the chamber.
- the vapor deposition material may be vapor-deposited on the vapor deposition object in a state where the air inlet is closed.
- the inside of the casing is provided via an intake pipe that communicates the intake port established in the casing with the outside of the chamber.
- the vapor deposition material is vapor-deposited on the vapor deposition target object while supplying the gas into the casing through an intake pipe. May be.
- the gas in the casing is exhausted to the space in the chamber outside the casing through the exhaust port.
- the vapor deposition material may be vapor-deposited on the vapor deposition object with the exhaust port closed.
- the device manufacturing method according to the present embodiment is characterized in that a layer made of the vapor deposition material is formed on the vapor deposition object using the vapor deposition method.
- Embodiment 1 a vapor deposition apparatus according to an embodiment and a device manufacturing method using the vapor deposition apparatus will be described with reference to the drawings.
- FIG. 1 is a schematic cross-sectional view showing the structure of the vapor deposition apparatus 1 according to the first embodiment.
- the vapor deposition apparatus 1 is an apparatus that deposits a vapor deposition material on the surface of the substrate 100.
- the vapor deposition apparatus 1 includes a chamber 2.
- a vacuum pump (not shown) is connected to the chamber exhaust port 3 in the chamber 2 so that the inside of the chamber 2 can be maintained in a vacuum.
- the internal space of the chamber 2 is partitioned up and down by the partition plate 4, and the substrate 100 is transported on the partition plate 4.
- a carry-in port 5 a for carrying the substrate 100 into the chamber 2 and a carry-out port 5 b for carrying the substrate 100 out of the chamber 2 are provided on the side wall of the chamber 2.
- the substrate 100 is intermittently carried into the chamber 2 from the carry-in port 5a by the carrying means, passes over the partition plate 4, and is carried out from the carry-out port 5b.
- the vapor deposition material ejected from the vapor deposition source 6 is, for example, a material that forms an electrode or a functional layer of an organic EL element, and is an inorganic material or an organic material.
- the inorganic substance include Al forming a cathode, metal materials such as Ba, Ni, Li, Mg, Au, and Ag, and metal oxide materials such as MgF 2 , SiO 2 , and Cr 2 O 3.
- the organic material include diamine, TPD, coumarin, and quinacridone, which are materials that form a functional layer of an organic EL element.
- the partition plate 4 is provided with a window 4 a through which a vapor deposition material discharged from the vapor deposition source 6 passes.
- the window 4 a can be opened and closed by a shutter 7.
- the vapor deposition material ejected from the vapor deposition source 6 passes through the window 4 a by transporting the substrate 100 while ejecting the vapor deposition material from the vapor deposition source 6 with the shutter 7 opened. Is deposited on the lower surface of the substrate 100.
- a sensor 8 is provided for measuring the amount (evaporation rate) of vapor deposition material supplied per unit time from the vapor deposition source 6 toward the substrate 100.
- the speed at which the substrate 100 is conveyed is set. Note that in the case where the vapor deposition material is pattern-deposited on the substrate 100, the mask on which the pattern is formed is provided on the lower surface side of the substrate 100 to perform the vapor deposition.
- FIG. 2 is a schematic cross-sectional view showing a state in which a vapor deposition material is deposited on the substrate 100 in the vapor deposition apparatus 1.
- the window 4a is open.
- the vapor deposition source 6 is a linear vapor deposition source (line source) extending in the width direction D orthogonal to the transport direction C. While the substrate 100 is transported in the transport direction C, the deposition material from the deposition source 6 is deposited on the lower surface of the substrate 100 through the window 4a.
- FIG. 3 is a perspective view showing the configuration of the vapor deposition source 6.
- FIG. 4 is a schematic cross-sectional view of the vapor deposition source 6.
- the vapor deposition source 6 includes a crucible 10 that stores a vapor deposition material 101 on which a vapor deposition substance is based, a casing 20 that stores the crucible 10, and a heating unit 30 that is attached around and below the casing 20.
- the casing 20 and the heating unit 30 are attached to the lower space of the chamber 2.
- the crucible 10 is an elongate container in which the vapor deposition material 101 is accommodated, and has a rectangular bottom plate 11 and a side plate 12, and an upper surface side thereof is open.
- the crucible 10 can be produced, for example, by molding a stainless steel plate into a rectangular parallelepiped shape.
- plate materials such as carbon, titanium, tantalum, and molybdenum can be used in addition to the stainless steel plate.
- the casing 20 has a long rectangular parallelepiped shape, and can accommodate the crucible 10 in its internal space.
- the housing 20 includes a long rectangular parallelepiped housing body 21 having a recessed space 21c for housing the crucible 10, a housing lid 22 covering the upper surface opening of the recessed space 21c, and one end opening of the housing body 21.
- the housing lid portion 22 has a plurality of discharge ports 23 arranged in a row.
- the housing body 21, the housing lid 22, and the open / close door 24 are each formed by molding a metal plate (for example, a stainless steel plate).
- the casing main body 21 has a rectangular bottom plate 21 a and a peripheral wall 21 b, the casing lid 22 is fixed on the peripheral wall 21 b with screws or the like, and the open / close door 24 is attached to one end of the casing main body 21. It can be opened and closed by hinges.
- the peripheral wall 21b of the housing body 21 is provided with one or a plurality of exhaust ports 21d1 for discharging the gas in the housing 20 to the outside of the housing 20.
- the opening area of each exhaust port 21d1 may be configured to be larger than the opening area of each discharge port 23. The time required for gas discharge can be shortened.
- an exhaust pipe 51 connected to the exhaust port 21d1 and communicating the inside of the housing 20 and the outside of the chamber 2, for example, a vacuum pump, a forced exhaust means of a suction pump, or a check valve connected to the exhaust pipe 51, Exhaust means 71 composed of passive exhaust means such as a discharge pipe is disposed.
- the exhaust pipe 51 is provided with a valve 61 as an opening / closing mechanism for the exhaust port 21d1 in the path to the exhaust means 71, and the exhaust port 21d1 is configured to be openable and closable.
- the gas in the housing 20 can be discharged out of the chamber 2 via the exhaust pipe 51 (arrow B in FIG. 1).
- one or a plurality of air inlets 21d2 for introducing gas into the housing 20 are provided in the peripheral wall 21b of the housing body 21.
- an intake pipe 52 connected to the intake port 21d2 and communicating the inside of the housing 20 and the outside of the chamber 2 and an intake means 72 connected to the intake pipe 52 are provided.
- the intake means 72 is a tank filled with an inert gas such as argon and a gas supply pump connected to the tank.
- the intake pipe 52 is provided with a valve 62 serving as an opening / closing mechanism for the intake port 21d2 along the path to the intake means 72, and the intake port 21d2 is configured to be openable and closable.
- a gas such as an inert gas can be introduced into the housing 20 via the intake pipe 52 (arrow A in FIG. 1). Furthermore, by simultaneously operating the exhaust means 71 and opening the valve 61, the gas in the housing 20 can be exhausted out of the chamber 2 through the exhaust pipe 51. At this time, when the forced exhaust means is used as the exhaust means 71, the gas in the housing 20 can be forcibly exhausted outside the chamber 2 through the exhaust pipe 51.
- passive exhaust means such as a check valve or a discharge pipe is used as the exhaust means 71, the gas inside the case 20 is removed from the case 20 by the pushing effect of the inert gas introduced into the case 20. Can be exhausted.
- the heating unit 30 is installed so as to cover the bottom plate 21a of the housing body 21 and the lower outer surface of the peripheral wall 21b.
- the heating unit 30 is configured by housing a sheath type heater 31 in a heating unit case 32, for example.
- a heating unit controller 40 is connected to the heating unit 30.
- a temperature sensor 41 that measures the temperature of the vapor deposition source 6 is attached to the housing 20. Then, the heating unit controller 40 monitors the temperature measured by the temperature sensor 41, and outputs the output of the heating unit 30 so that the temperature matches a predetermined set temperature (see the temperature profile in FIG. 5A). To control.
- the vapor (vapor deposition material) generated when the vapor deposition material 101 in the crucible 10 is heated by the heating unit 30 fills the housing 20, and enters the housing lid 22. It is ejected from a plurality of discharge ports 23 arranged in a row.
- the housing lid portion 22 is provided in the upper opening of the housing main body portion 21 above the crucible 10, the inside of the housing 20 can be filled with the evaporated evaporation material, The vapor
- the internal space of the housing 20 functions as a buffer for temporarily storing the vapor of the vapor deposition material 101, and the vapor deposition substance is in the Y direction in a state where the internal pressure of the housing 20 is slightly higher than the outside of the housing 20. Rectified and ejected from a plurality of discharge ports 23 arranged in a row.
- FIG. 5A is an example of a temperature profile showing a change in the set temperature for each time when the temperature of the vapor deposition source 6 is controlled in the vapor deposition apparatus 1.
- B is an example of a pressure profile in the chamber 2. In the vapor deposition apparatus 1, the temperature and pressure of the vapor deposition source 6 are controlled based on the temperature profile shown in FIG.
- the crucible 10 is filled with the vapor deposition material 101, the crucible 10 is put into the housing 20 in the chamber 2, and the open / close door 24 is closed.
- the substrate 100 is carried into the chamber 2 from the carry-in port 5a, and the vacuum pump is driven to depressurize the chamber 2 from the atmospheric pressure P0 to the vacuum P1.
- the crucible 10 When the inside of the chamber 2 is depressurized to the vacuum P1, the crucible 10 is heated by driving the heating unit 30 in the vapor deposition source 6 while keeping the inside of the chamber 2 in a vacuum state at time t0. In the period t0 to t1, the temperature of the vapor deposition source 6 is raised with a steep temperature gradient to the degassing temperature T1 at which the impurity gas is released from the vapor deposition material.
- the degassing temperature T1 is a temperature at which impurities such as moisture adsorbed on the vapor deposition material 101 are released, and is in the range of 100 ° C. to 200 ° C., for example.
- a gas such as an inert gas is introduced into the housing 20 through the intake pipe 52 by operating the intake means 72 and opening the valve 62.
- the exhaust means 71 is operated to open the valve 61, thereby exhausting the gas in the housing 20 out of the chamber 2 through the exhaust pipe 51.
- the temperature of the vapor deposition source 6 during the exhaust period is maintained at a temperature equal to or higher than the degas temperature T1 and lower than the heating temperature T2 during vapor deposition (hereinafter referred to as “deposition temperature T2”), the temperature evaporates during the exhaust period.
- the vapor deposition material 101 can be configured not to evaporate. Thereby, wasteful consumption of the vapor deposition material can be prevented and the cost can be reduced.
- the introduction of gas into the housing 20 is stopped during the period t2 to t3 by stopping the intake means 72 and closing the valve 62.
- the operation of the exhaust means 71 is stopped and the valve 61 is closed, whereby the exhaust of the gas in the housing 20 to the outside of the chamber 2 is stopped.
- the vapor deposition temperature T2 is higher than the temperature T3 at which the vapor deposition material 101 in the crucible 10 starts to evaporate, and is in the range of 250 to 350 ° C., for example.
- the deposition temperature T2 is maintained and the substrate 100 is deposited. That is, when the evaporation rate of the evaporation material measured by the sensor 8 is stabilized, the evaporation material is evaporated on the lower surface of the substrate 100 while the shutter 7 is opened and the substrate 100 is conveyed. Accordingly, the deposition material is uniformly deposited on the lower surface of the substrate 100.
- the shutter 7 is closed and the substrate 100 is taken out from the carry-out port 5b.
- vapor deposition is performed on the plurality of substrates 100.
- the temperature of the vapor deposition source 6 is lowered, the vacuum pump is stopped, the open / close door 24 is opened, and the crucible 10 is taken out from the housing 20. Then, the vapor deposition material 101 is supplied to the crucible 10.
- the gas introduction and the exhaust are stopped during the temperature increase during the period t0 to t1, during the temperature increase during the period t2 to t3 and during the temperature decrease during t4 to t5.
- a configuration may be adopted in which the introduction and exhaust of gas are continued during the temperature drop.
- the discharge port is used to suppress the flow between the case 20 and the chamber 2 and increase the internal pressure of the case 20.
- the evaporated impurities are filled with the casing 20 and are difficult to escape into the chamber 2 (or it takes time to escape).
- the vapor deposition material 101 is in a relatively high activity state by heating, the vapor deposition material 101 is in a condition where it easily reacts with impurities.
- the organic material molecule H Deposition of the vapor deposition material occurred, for example, replaced with OH group.
- the housing 20 has a large amount of moisture adsorbed as impurities, and the internal pressure may increase rapidly, which may have accelerated the deterioration of the vapor deposition material 101.
- the impurities mixed into the housing 20 of the vapor deposition source 6 together with the vapor deposition material 101 can be discharged out of the housing 20, so that the impurities and the vapor deposition material are removed. Reaction can be prevented. As a result, it is possible to reduce deterioration of the vapor deposition material and deterioration of material characteristics in the vapor deposition process. Further, by maintaining the temperature in the vicinity of the degassing temperature T1, it is possible to suppress the impurity gas from evaporating all at once.
- FIG. 6 is a schematic cross-sectional view showing the structure of the vapor deposition apparatus 1X according to the second embodiment.
- the vapor deposition apparatus 1X employs a configuration in which the exhaust port 21d1, the exhaust pipe 51, the exhaust means 71, and the valve 61 are removed from the vapor deposition apparatus 1 according to Embodiment 1. About a structure other than that, the vapor deposition apparatus 1X takes the same structure as the vapor deposition apparatus 1.
- the intake pipe 52 connected to the intake port 21d2 of the vapor deposition source 6X is connected to the intake means 72.
- the vapor deposition apparatus 1X is operated with the temperature and pressure profiles shown in FIGS. 5 (a) and 5 (b). At this time, in the period T A in FIG.
- the intake means 72 in the state where the temperature of the vapor deposition source 6X is maintained in the vicinity of the degassing temperature T1, the intake means 72 is operated and the valve 62 which is an opening / closing mechanism of the intake port 21d2 is opened.
- a gas such as an inert gas is introduced into the casing 20 through the intake pipe 52 for a predetermined period T A (arrow A in FIG. 6).
- the impurity mixed together with the vapor deposition source 6X when the vapor deposition material 101 is replenished can be discharged out of the chamber 2 similarly to the vapor deposition apparatus 1. For this reason, in the vapor deposition step, it is possible to reduce alteration of the vapor deposition material and deterioration of material characteristics.
- the gas 62 may be continuously introduced by opening the valve 62 during the vapor deposition process. This is because impurities can be discharged out of the chamber 2 even during the vapor deposition process. In this case, since the exhaust using the exhaust means 71 is not performed unlike the vapor deposition apparatus 1, the vapor deposition material is not discharged out of the chamber 2 during the vapor deposition process.
- the vapor deposition apparatus 1X is configured to stop the introduction and exhaust of gas during the temperature increase during the period t0 to t1, during the temperature increase during the period t2 to t3 and during the temperature decrease during t4 to t5. It is good also as a structure which continues exhausting gas inside.
- Embodiment 3 The vapor deposition apparatus 1 and the vapor deposition method using the vapor deposition apparatus 1 according to the first embodiment have been described above, but the present invention is not limited to the example shown in the first embodiment.
- the illustrated configuration may be the following configuration.
- the temperature of the deposition source 6, while maintaining near degassing temperature T1 the housing 20 of the gas for a predetermined duration T A
- the gas in the housing 20 was exhausted out of the chamber 2 while being introduced into the chamber 2.
- any structure that can discharge the impurities mixed together with the vapor deposition source 6 to the outside of the housing 20 may be used, and the following structure is also possible.
- FIG. 7 is a schematic cross-sectional view showing the structure of the vapor deposition apparatus 1A according to the third embodiment.
- the vapor deposition apparatus 1 ⁇ / b> A employs a configuration in which the intake port 21 d 2, the intake pipe 52, the intake unit 72, and the valve 62 are removed from the vapor deposition apparatus 1 according to Embodiment 1.
- the vapor deposition apparatus 1 ⁇ / b> A adopts the same configuration as the vapor deposition apparatus 1.
- the exhaust pipe 51 connected to the exhaust port 21d1 of the vapor deposition source 6A is connected to the exhaust means 71.
- the vapor deposition apparatus 1A operated at temperature and pressure profile shown in FIG. 5 (a) and (b), in the period T A in FIG. 5 (a), the temperature of the deposition source 6A, was maintained near degassing temperature T1 state, by opening the valve 61 is opening and closing mechanism of the exhaust port 21d1 operates the exhaust means 71 exhausts the chamber 2 out through the exhaust pipe 51 a gas only housing 20 a predetermined period of time T a It is configured.
- the exhaust means 71 includes, for example, a vacuum pump, a forced exhaust means of a suction pump, or a passive exhaust means such as a check valve or an exhaust pipe.
- FIG. 8 is a schematic cross-sectional view showing the structure of a vapor deposition apparatus 1B according to a modification of the third embodiment.
- the vapor deposition apparatus 1B employs a configuration in which the exhaust means 71 is removed from the vapor deposition apparatus 1A.
- the exhaust pipe 51 connected to the exhaust port 21d1 of the vapor deposition source 6B is connected to a vacuum pump for evacuating the chamber 2.
- the vapor deposition apparatus 1B takes the same structure as the vapor deposition apparatus 1A.
- the temperature of the vapor deposition source 6B is maintained near the degassing temperature T1 in the period T A in FIG. in a state, by opening the valve 61 is opening and closing mechanism of the exhaust port 21 d 1, is configured to exhaust the chamber 2 out through the exhaust pipe 51 a gas only housing 20 a predetermined period of time T a.
- the impurities mixed in the vapor deposition material 101 can be discharged into the chamber 2 in a simple configuration in which the exhaust means 71 is omitted, as in the vapor deposition apparatus 1A. For this reason, in the vapor deposition step, it is possible to reduce alteration of the vapor deposition material and deterioration of material characteristics.
- valve 61 it is preferable to close the valve 61 and stop the gas exhaust during the vapor deposition process. This is because the vapor deposition material can be prevented from being discharged out of the chamber 2 during the vapor deposition process, and wasteful consumption of the vapor deposition material can be prevented.
- Embodiment 4 The vapor deposition apparatus 1 and the vapor deposition method using the vapor deposition apparatus 1 according to the first embodiment have been described above, but the present invention is not limited to the example shown in the first embodiment.
- the illustrated configuration may be the following configuration.
- the temperature of the deposition source 6, while maintaining near degassing temperature T1 the housing 20 of the gas for a predetermined duration T A
- the gas in the housing 20 was exhausted out of the chamber 2 while being introduced into the chamber 2.
- any structure that can discharge the impurities mixed in the vapor deposition source to the outside of the housing 20 may be used, and the following structure is also possible.
- FIG. 9 is a schematic cross-sectional view showing the structure of the vapor deposition apparatus 1C according to the fourth embodiment.
- FIG. 10 is a schematic cross-sectional view of the vapor deposition source 6C.
- FIG. 11A is an example of a temperature profile of a vapor deposition source 6C in the vapor deposition method using the vapor deposition apparatus 1C according to Embodiment 4, and
- FIG. 11B is an example of a pressure profile in the chamber 2.
- FIG. 11A is an example of a temperature profile of a vapor deposition source 6C in the vapor deposition method using the vapor deposition apparatus 1C according to Embodiment 4
- FIG. 11B is an example of a pressure profile in the chamber 2.
- the vapor deposition apparatus 1 ⁇ / b> C further removes the exhaust pipe 51 from the vapor deposition apparatus 1 ⁇ / b> B according to the modification of the third embodiment, and is connected to one or more exhaust ports 21 d ⁇ b> 1.
- a valve 63 serving as an opening / closing mechanism for the exhaust port 21d1 in the path of the exhaust pipe 53 and the exhaust pipe 53.
- the opening area of the exhaust port 21 d 1 is preferably larger than the opening area of each discharge port 23.
- the vapor deposition apparatus 1 ⁇ / b> A adopts the same configuration as the vapor deposition apparatus 1. With this configuration, the gas in the housing 20 can be exhausted into the chamber 2 via the exhaust pipe 53 by opening the valve 63.
- the deposition apparatus 1C according to the fourth embodiment, FIGS. 11 (a) and operated at a temperature and pressure profile (b), the temperature degassed deposition source 6C represented by the period T A in FIG. 11 (a) by the valve 63 in the open state in a state of being maintained near the temperature T1, it can be exhausted into the chamber 2 through the exhaust pipe 53 a gas only housing 20 a predetermined period of time T a.
- impurities mixed into the housing 20 together with the vapor deposition source 6 when the vapor deposition material 101 is replenished can be discharged to the space inside the chamber 2 outside the housing 20.
- the impurities discharged into the chamber 2 are dispersed in the chamber 2 and exhausted out of the chamber by a vacuum device.
- valve 63 it is preferable to close the valve 63 and stop the gas exhaust during the vapor deposition process in the period t3 to t4. This is because, during the vapor deposition process, the vapor of the vapor deposition material 101 is ejected from the discharge port 23 toward the vapor deposition target 100 because the vapor deposition material 101 can be used for film formation on the vapor deposition target 100 more efficiently.
- the internal pressure of the housing 20 is increased by suppressing the flow between the housing 20 and the chamber 2. Yes.
- the vapor deposition material 101 is in a relatively high state by heating, it easily reacts with impurities, and when an organic material is used for the vapor deposition material 101, the vapor deposition material is likely to deteriorate.
- the vapor deposition apparatus 1 ⁇ / b> C since impurities mixed into the housing 20 can be discharged at least outside the housing 20, it is possible to prevent the impurities and the vapor deposition material from reacting in the housing 20. As a result, in the vapor deposition process, it is possible to reduce alteration of the vapor deposition material and deterioration of material characteristics.
- FIG. 12 is a process diagram illustrating a method for manufacturing an organic EL device, which is an aspect of a device manufacturing method according to Embodiment 5.
- a substrate 1 shown in FIG. 12 is obtained by applying a photosensitive resin on a TFT substrate and forming a planarizing film by exposure and development through a photomask.
- an anode 200, an ITO layer 300, and a hole injection layer 400 are formed in this order on a substrate 100, and a bank 500 is formed on the hole injection layer 400.
- a recessed space 500 a serving as an element formation region is formed between the banks 500.
- the anode 200 is formed by forming an Ag thin film by sputtering, for example, and patterning the Ag thin film in a matrix by, for example, a photolithography method. In addition, you may form an Ag thin film by vacuum evaporation etc. using the above-mentioned vapor deposition method.
- the ITO layer 300 is formed by forming an ITO thin film by sputtering, for example, and patterning the ITO thin film by, for example, a photolithography method.
- the hole injection layer 400 is formed using a composition containing WOx or MoxWyOz by a technique such as vacuum deposition using the above-described deposition method or sputtering.
- the bank 500 is formed by forming a bank material layer by applying a bank material on the hole injection layer 400 and removing a part of the formed bank material layer.
- the removal of the bank material layer can be performed by forming a resist pattern on the bank material layer and then etching.
- the surface of the bank material layer may be subjected to a liquid repellent treatment by a plasma treatment using a fluorine-based material, if necessary.
- the bank 500 is a line bank, and a plurality of line banks are formed in parallel with each other on the substrate 1.
- a light emitting layer 600 as a functional layer is formed.
- the recessed space 500a which is a sub-pixel formation region between the banks 500, is filled with ink containing an organic light emitting layer material by an ink jet method, and the printed film is dried.
- the light emitting layer 600 is formed by baking.
- the light emitting layer 600 is formed as shown in FIG. 12C by filling the ink 600a containing any one of the R, G, and B light emitting materials and drying the filled ink 600a under reduced pressure. To do.
- a hole transport layer as a functional layer may be formed under the light emitting layer 600 by a wet method. Further, an electron transport layer as a functional layer may be formed on the light emitting layer 600 by a wet method.
- an electron injection layer 700, a cathode 800, and a sealing layer 900 are sequentially formed.
- the electron injection layer 700 is formed into a thin film of an organic material doped with, for example, an alkali metal or an alkaline earth metal, for example, by vacuum deposition using the above-described deposition method.
- the cathode 800 is formed by forming a thin ITO film by, for example, a sputtering method.
- the sealing layer 900 is formed by applying a resin sealing material and then irradiating UV to cure the resin sealing material. Furthermore, you may seal by mounting plate glass on it.
- the organic EL device is completed and the device is manufactured.
- Organic functional layers such as the hole injection layer 400 and the electron injection layer 700 were formed by the vapor deposition method described in Embodiments 1 to 3, and mixed into the casing 20 of the vapor deposition source 6 together with the vapor deposition material 101. Since impurities can be discharged out of the housing 20, it is possible to prevent the impurities from reacting with the vapor deposition material. As a result, in the vapor deposition process, it is possible to reduce alteration of the vapor deposition material and deterioration of material characteristics. Further, the amount of impurities contained in the organic functional layer formed by vapor deposition can be reduced, and an organic functional layer with few impurities can be formed.
- the vapor deposition method shown in Embodiments 1 to 4 can be applied to a metal layer such as an Ag thin film.
- a source 6 and a heating unit 30 that heats the vapor deposition material 101 are provided, and the inside and outside of the case 20 are communicated with the case 20 and the vapor of the vapor deposition material 101 is discharged toward the vapor deposition target 100.
- a configuration is adopted in which a plurality of discharge ports 23 and an exhaust port 21d1 having an opening / closing mechanism are opened.
- the impurities mixed into the housing 20 of the vapor deposition source 6 together with the vapor deposition material 101 can be discharged out of the housing 20, so that it is possible to prevent the impurities and the vapor deposition material from reacting.
- the vapor deposition process it is possible to reduce alteration of the vapor deposition material and deterioration of material characteristics.
- ⁇ Modification ⁇ 1 In the above embodiment, only one vapor deposition source 6 is provided in the chamber 2, but two or more vapor deposition sources can be provided in the chamber.
- the casing 20 of the vapor deposition source 6 is installed on the bottom plate of the chamber 2, but the casing 20 may be formed integrally with the chamber 2.
- the vapor deposition source is a long line source.
- the vapor deposition source is not necessarily a line source, and for example, a cylindrical vapor deposition source can be similarly implemented. That is, if the crucible is housed in the concave space of the housing and the opening of the concave space is covered with a lid having a plurality of discharge openings, the bottom surface of the crucible regardless of the shape of the vapor deposition source.
- a plurality of support protrusions on the heel of the crucible or by providing a plurality of support protrusions on the casing it is possible to obtain the effect of suppressing the adhesion between the crucible and the casing.
- a light-emitting layer 600 is formed by applying ink to a substrate using a droplet discharge device having one inkjet head.
- the light emitting layer 600 can be formed by vapor deposition.
- the deposition method described in Embodiments 1 to 4 can be applied to form a film, and impurities can be prevented from being mixed into the formed organic functional layer.
- the present invention can be widely used in the manufacturing field of devices such as an organic light emitting element and a TFT substrate manufactured using a vapor deposition apparatus and a vapor deposition method.
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Abstract
Description
真空蒸着法を用いて、蒸着対象物である基板等に蒸着を行う際、蒸着面内で蒸発レートが不均一となる場合に膜厚が面内で不均一となり、例えば、有機発光素子では輝度ばらつきの要因となる。特に、従来のポイントソースと呼ばれる点形状の蒸着源では基板全面に均一に蒸着することが難しい。基板に対して均一に材料を蒸着する方法として、各種検討が行われている。
1)成膜終了後、チャンバ内の坩堝を室温まで戻し、その後、チャンバ内の圧力を大気圧にする。
2)坩堝をチャンバ外に取り出す。
3)坩堝に蒸着材料を充填する。蒸着材料は室温では液体又は固体からなる。
4)蒸着材料が充填された坩堝をチャンバ内に戻す。
5)チャンバ内を真空に引き、その後、坩堝を加熱する。
6)その後、蒸着による成膜プロセスを行う。
本実施の形態に係る蒸着装置は、蒸着対象物が内設されるチャンバと、前記チャンバ内に存し蒸着材料を収容するための筐体を有する蒸着源と、前記蒸着材料を加熱する加熱部とを備え、前記筐体には、当該筐体の内と外とを連通し前記蒸着対象物に向けて前記蒸着材料の蒸気を吐出する複数の吐出口と、開閉可能な排気口とが開設されていることを特徴とする。
前記吸気口に接続され、前記筐体内と前記チャンバ外とを連通している吸気管と、
前記吸気管を介して前記筐体内に気体を吸気する吸気手段とを備えた構成であってもよい。
以下、実施の形態実施の形態に係る蒸着装置及び蒸着装置を用いたデバイスの製造方法について、図面を参照しながら説明する。
(全体構成)
図1は実施の形態1に係る蒸着装置1の構造を示す模式断面図である。蒸着装置1は、基板100の表面に蒸着物質を蒸着する装置である。図1に示すように、蒸着装置1は、チャンバ2を備えている。チャンバ2におけるチャンバ排気口3には真空ポンプ(不図示)が接続され、チャンバ2の中を真空に維持できるようになってなっている。チャンバ2の内部空間は、仕切板4によって上下に仕切られ、仕切板4の上を基板100が搬送されるようになっている。チャンバ2の側壁には、基板100をチャンバ2内に搬入する搬入口5aと、基板100をチャンバ2から搬出する搬出口5bが設けられている。基板100は搬送手段によって、搬入口5aから間欠的にチャンバ2内に搬入され、仕切板4上を通過して搬出口5bから搬出される。
図3は、蒸着源6の構成を示す斜視図である。図4は、蒸着源6の模式断面図である。蒸着源6は、蒸着物質の基になる蒸着材料101を収納する坩堝10と、その坩堝10を収納する筐体20と、筐体20の周囲と下側に取り付けられた加熱部30とを備え、筐体20及び加熱部30はチャンバ2の下空間に取り付けられている。坩堝10は、蒸着材料101が収納される長尺状の容器であって、長方形状の底板11と側板12とを有し、その上面側は開放されている。坩堝10は、例えば、ステンレス板材を直方体状に成型することによって作製することができる。坩堝10を作製する素材としては、ステンレス板の他に、カーボン、チタン、タンタル、モリブデンなどの板材を用いることもできる。筐体20は、長尺の直方体形状であって、その内部空間に坩堝10を収納することができるようになっている。
蒸着装置1を用いて基板100の表面に蒸着を行う工程を説明する。図5(a)は蒸着装置1において蒸着源6の温度をコントロールするときの時間ごとの設定温度の変化を示す温度プロファイルの一例である。(b)はチャンバ2内の圧力プロファイルの一例である。蒸着装置1では、この図5(a)に示す温度プロファイルに基づいて蒸着源6の温度と圧力をコントロールする。
する。
管52を介して、例えば不活性ガス等の気体を導入する。並行して、排気手段71を動作させて弁61を開くことにより、筐体20内の気体を排気管51を介してチャンバ2外へ排出する。不活性ガスを筐体20内に導入してその押出し効果により筐体20内の気体を筐体20外に排気することにより、後述する排気のみを行う場合と較べて排気に要する期間TAを短縮することができる。期間TAは、例えば、予め蒸着材料を加熱する実験を行い放出される不純物量をガス分析で測定することにより、十分に不純物が除去される時間を求めて定めることができる。
以上説明したとおり、上記蒸着装置1を用いた蒸着プロセスでは、蒸着源6の温度を、脱ガス温度T1付近に維持した状態で、所定の期間TAだけ気体を筐体20内に導入しつ
つ同時に筐体20内の気体をチャンバ2外に排気する。これにより、蒸着材料101を補充する際に蒸着源6とともに蒸着源6の筐体20内へ混入した不純物を筐体20外に排出することができる。
図6は、実施の形態2に係る蒸着装置1Xの構造を示す模式断面図である。蒸着装置1Xは、実施の形態1に係る蒸着装置1から、排気口21d1、排気管51、排気手段71、弁61を取り除いた構成を採る。それ以外に構成については、蒸着装置1Xは、蒸着装置1と同じ構成を採る。
に筐体20内の気体をチャンバ2外に排気する点に特徴がある。図6に示すように、蒸着装置1Xでは蒸着源6Xの吸気口21d2に接続された吸気管52は吸気手段72と接続されている。蒸着装置1Xを、図5(a)及び(b)に示す温度及び圧力プロファイルで運転する。このとき、図5(a)における期間TAにおいて、蒸着源6Xの温度を、脱ガ
ス温度T1付近に維持した状態で、吸気手段72を動作させて吸気口21d2の開閉機構である弁62を開くことにより、所定の期間TAだけ筐体20内へ吸気管52を介して、例えば不活性ガス等の気体を導入する(図6における矢印A)。これにより、蒸着装置1Xにおいても蒸着装置1と同様に、蒸着材料101を補充する際に蒸着源6Xとともに混入した不純物をチャンバ2外に排出することができる。そのため、蒸着工程において、蒸着材料の変質や材料特性の劣化を軽減することができる。
以上、実施の形態1に係る蒸着装置1及び蒸着装置1を用いた蒸着方法について説明したが、本発明が上述の実施の形態1で示した例に限られないことは勿論である。例示した構成を以下の構成とすることも可能である。上記した実施の形態に係る蒸着装置1及び蒸着装置1を用いた蒸着方法では、蒸着源6の温度を、脱ガス温度T1付近に維持した状態で、所定の期間TAだけ気体を筐体20内に導入しつつ同時に筐体20内の気体をチャン
バ2外に排気する構成とした。しかしながら、蒸着源6とともに混入した不純物を筐体20外に排出することができる構成であれば良く、下記の構成とすることも可能である。
温度を、脱ガス温度T1付近に維持した状態で、排気手段71を動作させて排気口21d1の開閉機構である弁61を開くことにより、所定の期間TAだけ筐体20内の気体を排
気管51を介してチャンバ2外へ排気する構成としている。排気手段71は、例えば真空ポンプ、吸引ポンプの強制排気手段、又は逆止弁、排気用配管等の受動的排気手段からなる。これにより、蒸着装置1Aにおいても蒸着装置1と同様に、蒸着材料101を補充する際に蒸着源6とともに混入した不純物をチャンバ2外に排出することができる。そのため、蒸着工程において、蒸着材料の変質や材料特性の劣化を軽減することができる。また、蒸着プロセス中に蒸着材料がチャンバ2外に排出されることを防止するため、蒸着プロセス中には弁61を閉じて気体の排気を停止することが好ましい。
図8は、実施の形態3の変形例に係る蒸着装置1Bの構造を示す模式断面図である。蒸着装置1Bは、蒸着装置1Aから、排気手段71を取り除いた構成を採る。蒸着装置1Bでは、蒸着源6Bの排気口21d1に接続された排気管51はチャンバ2を真空引きするための真空ポンプと接続されている。それ以外に構成については、蒸着装置1Bは、蒸着装置1Aと同じ構成を採る。
に維持した状態で、排気口21d1の開閉機構である弁61を開くことにより、所定の期間TAだけ筐体20内の気体を排気管51を介してチャンバ2外へ排気する構成としてい
る。
以上、実施の形態1に係る蒸着装置1及び蒸着装置1を用いた蒸着方法について説明したが、本発明が上述の実施の形態1で示した例に限られないことは勿論である。例示した構成を以下の構成とすることも可能である。上記した実施の形態に係る蒸着装置1及び蒸着装置1を用いた蒸着方法では、蒸着源6の温度を、脱ガス温度T1付近に維持した状態で、所定の期間TAだけ気体を筐体20内に導入しつつ同時に筐体20内の気体をチャン
バ2外に排気する構成とした。しかしながら、蒸着源に混入した不純物を筐体20外に排出することができる構成であれば良く、下記の構成とすることも可能である。
温度T1付近に維持された状態において弁63を開状態とすることにより、所定の期間TAだけ筐体20内の気体を排気管53を介してチャンバ2内へ排気することができる。
以上説明したとおり、上記蒸着装置1Cを用いた蒸着プロセスでは、蒸着源6Cの温度を、脱ガス温度T1付近に維持した状態で、所定の期間TAだけ気体を筐体20内に導入
しつつ同時に筐体20内の気体を筐体20外であってチャンバ2内の空間に排気する。これにより、蒸着材料101を補充する際に蒸着源6とともに蒸着源6の筐体20内へ混入した不純物を筐体20外へ排出することができる。
(有機EL素子の製造工程)
図12は、実施の形態5に係るデバイスの製造方法の一態様である有機EL装置の製造方法を説明する工程図である。図12に示す基板1は、TFT基板上に、感光性樹脂を塗布しフォトマスクを介した露光・現像によって平坦化膜が形成されたものである。
以上、説明したとおり上記各実施の形態に係る蒸着装置では、蒸着対象物100が内設されるチャンバ2と、チャンバ2内に存し、蒸着材料101を収容するための筐体20を有する蒸着源6と、蒸着材料101を加熱する加熱部30とを備え、筐体20には、当該筐体20の内と外とを連通し蒸着対象物100に向けて蒸着材料101の蒸気を吐出する複数の吐出口23と、開閉機構を備えた排気口21d1とが開設されている構成を採る。
1.上記実施の形態では、チャンバ2に蒸着源6が1つだけ設けられていたが、チャンバ内に2つ以上の蒸着源を設けることもでき、その場合も、各蒸着源において、上記実施の形態で説明した構成を適用することによって、蒸着材料の変質や材料特性の劣化を軽減することができる。
以上で説明した実施の形態は、いずれも本発明の好ましい一具体例を示すものである。実施の形態で示される数値、形状、材料、構成要素、構成要素の配置位置及び接続形態、工程、工程の順序などは一例であり、本発明を限定する主旨ではない。また、実施の形態における構成要素のうち、本発明の最上位概念を示す独立請求項に記載されていない工程については、より好ましい形態を構成する任意の構成要素として説明される。
2 チャンバ
3 チャンバ排気口
4 仕切板
4a 窓
5a 搬入口
5b 搬出口
6、6X,6A、6B、6C 蒸着源
7 シャッタ
10 坩堝
20 筐体
21 筐体本体部
21a 底板
21b 周壁
22 筐体蓋部
23 吐出口
30 加熱部
51、53 排気管
52 吸気管
61、62、63 弁(開閉機構)
71 排気手段
72 吸気手段
100 基板(蒸着対象物)
101 蒸着材料
Claims (15)
- 蒸着対象物が内設されるチャンバと、
前記チャンバ内に存し蒸着材料を収容するための筐体を有する蒸着源と、
前記蒸着材料を加熱する加熱部とを備え、
前記筐体には、当該筐体の内と外とを連通し前記蒸着対象物に向けて前記蒸着材料の蒸気を吐出する複数の吐出口と、開閉可能な排気口とが開設されている
蒸着装置。 - 前記排気口に接続され、前記筐体内と前記チャンバ外とを連通している排気管と、
前記筐体内の気体を前記排気管を介して前記チャンバ外へ排気する排気手段とを備えた
請求項1に記載の蒸着装置。 - 前記筐体には、さらに吸気口が開設され、
前記吸気口に接続され、前記筐体内と前記チャンバ外とを連通している吸気管と、
前記吸気管を介して前記筐体内に気体を吸気する吸気手段とを備えた
請求項1又は2に記載の蒸着装置。 - 前記排気口は、前記筐体内と前記筐体外であって前記チャンバ内の空間とを連通している
請求項1に記載の蒸着装置。 - 前記排気口は弁により開閉可能に構成されている
請求項1から4の何れか1項に記載の蒸着装置。 - 前記筐体は、底板と前記底板を囲繞する周壁を有する筐体本体部と、
前記底板に対向し前記底板及び前記周壁とともに前記蒸着材料を収容する内部空間を形成する筐体蓋部とを有し、
前記筐体本体部には前記排気口が開設され、前記筐体蓋部には前記複数の吐出口が開設されている
請求項1に記載の蒸着装置。 - 前記筐体には、前記蒸着材料を収容する坩堝が内設されている
請求項1に記載の蒸着装置。 - 有機層を蒸着対象物に形成するための蒸着装置に用いる蒸着源であって、
蒸着材料を内部に収容する筐体を有し、
前記筐体には、当該筐体の内と外とを連通し前記蒸着対象物に向け前記蒸着材料の蒸気を吐出する複数の吐出口と、開閉可能な排気口とが開設されている
蒸着源。 - 前記蒸着材料を収容する坩堝を備え、
前記筐体は、底板と前記底板を囲繞する周壁を有する筐体本体部と、
前記底板に対向し前記底板及び前記周壁とともに前記坩堝を収容する内部空間を形成する筐体蓋部とを有し、
前記筐体本体部には前記排気口が開設され、前記筐体蓋部には前記複数の吐出口が開設されている
請求項8に記載の蒸着源。 - 請求項1に記載の蒸着装置を用いて前記蒸着対象物に前記蒸着材料を蒸着する蒸着方法であって、
前記排気口が開いた状態で前記蒸着材料を所定時間脱ガス温度付近の温度に維持する工程と、
前記脱ガス温度付近の温度に維持した後に、前記排気口が閉じた状態で、前記蒸着材料を前記脱ガス温度よりも高い蒸着時加熱温度に維持して前記筐体に開設されている複数の吐出口から前記蒸着材料の蒸気を吐出させ、前記蒸着材料を前記蒸着対象物上に蒸着する工程と
を有する蒸着方法。 - 前記蒸着材料を脱ガス温度付近の温度に維持する工程では、前記排気口と前記チャンバ外とを連通している排気管を介して前記筐体内の気体を前記チャンバ外へ排気しながら前記蒸着材料を加熱する
請求項10に記載の蒸着方法。 - 前記蒸着材料を脱ガス温度付近の温度に維持する工程では、前記筐体に開設されている吸気口と前記チャンバ外とを連通する吸気管を介して前記筐体内に気体を吸気しながら前記蒸着材料を加熱し、
前記蒸着材料を蒸着する工程では、前記吸気口を閉じた状態で前記蒸着材料を前記蒸着対象物上に蒸着する
請求項11に記載の蒸着方法。 - 前記蒸着材料を脱ガス温度付近の温度に維持する工程では、前記筐体に開設されている吸気口と前記チャンバ外とを連通する吸気管を介して前記筐体内に気体を吸気しながら前記蒸着材料を加熱し、
前記蒸着材料を蒸着する工程では、前記吸気管を介して前記筐体内に気体を供給しながら前記蒸着材料を前記蒸着対象物上に蒸着する
請求項11に記載の蒸着方法。 - 前記蒸着材料を脱ガス温度付近の温度に維持する工程では、前記排気口を介して前記筐体内の気体を前記筐体外であって前記チャンバ内の空間に排気しながら前記蒸着材料を加熱し、
前記蒸着材料を蒸着する工程では、前記排気口を閉じた状態で前記蒸着材料を前記蒸着対象物上に蒸着する
請求項10に記載の蒸着方法。 - 請求項10から14の何れか1項に記載の蒸着方法を用いて、前記蒸着材料からなる層を前記蒸着対象物上に形成するデバイスの製造方法。
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- 2015-02-24 CN CN201580012609.3A patent/CN106062240B/zh not_active Expired - Fee Related
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KR20170123244A (ko) * | 2016-04-28 | 2017-11-07 | 캐논 톡키 가부시키가이샤 | 진공 증착 장치 및 증발원의 냉각 방법 |
KR102190775B1 (ko) | 2016-04-28 | 2020-12-14 | 캐논 톡키 가부시키가이샤 | 진공 증착 장치 및 증발원의 냉각 방법 |
Also Published As
Publication number | Publication date |
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US9909205B2 (en) | 2018-03-06 |
JP6241903B2 (ja) | 2017-12-06 |
JPWO2015136859A1 (ja) | 2017-04-06 |
US20170051394A1 (en) | 2017-02-23 |
CN106062240A (zh) | 2016-10-26 |
CN106062240B (zh) | 2018-09-28 |
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