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TWI791549B - Evaporation hood - Google Patents

Evaporation hood Download PDF

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Publication number
TWI791549B
TWI791549B TW107123244A TW107123244A TWI791549B TW I791549 B TWI791549 B TW I791549B TW 107123244 A TW107123244 A TW 107123244A TW 107123244 A TW107123244 A TW 107123244A TW I791549 B TWI791549 B TW I791549B
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frame
vapor deposition
layer
cover
frame body
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TW107123244A
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Chinese (zh)
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TW201911622A (en
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石川樹一郎
田丸裕仁
小林良弘
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日商麥克賽爾股份有限公司
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Abstract

本發明提供一種蒸鍍罩,其將框體的基於截面形狀的強度的設定最佳化,利用框體適當抑制罩主體的變形,防止罩主體從正確的位置的偏移,且提高蒸鍍的精度。將框體3的內框部的最小寬度部的截面形狀形成為其寬度與厚度的關係適當者,可靠地賦予最小寬度部的彎曲剛性,因此,賦予相對於來自罩主體2側的力的所需充分的強度,與相比該最小寬度部寬度寬且強度高的框體3的其他部分,一同作為框體3整體而抑制罩主體2各部之從本應存在的位置的偏移,可確保蒸鍍步驟中罩與被蒸鍍基板的整合狀態,可在被蒸鍍基板的適當的位置精度良好地進行蒸鍍。The present invention provides a vapor deposition cover which optimizes the setting of the strength based on the cross-sectional shape of the frame, appropriately suppresses the deformation of the cover main body by the frame, prevents the cover main body from shifting from a correct position, and improves the efficiency of vapor deposition. precision. Forming the cross-sectional shape of the minimum width portion of the inner frame portion of the frame body 3 into a suitable relationship between the width and thickness can reliably impart bending rigidity to the minimum width portion. Sufficient strength is required, and other parts of the frame body 3 that are wider than the minimum width portion and have higher strength, together with the frame body 3 as a whole, can suppress the deviation of each part of the cover main body 2 from the position where it should exist, and can ensure The integrated state of the mask and the substrate to be vapor deposited in the vapor deposition step enables vapor deposition to be performed with high precision at an appropriate position of the substrate to be vapor deposited.

Description

蒸鍍罩Evaporation hood

本發明係關於例如藉由蒸鍍罩法形成有機EL元件之發光層時使用之蒸鍍罩。The present invention relates to a vapor deposition mask used, for example, when forming a light-emitting layer of an organic EL element by a vapor deposition mask method.

作為形成有機EL(Electroluminescence)元件之發光層的方法,多使用蒸鍍罩法。該蒸鍍罩法中,為了在由玻璃等透明材質構成之基板上的期望之位置蒸鍍形成有機發光物質,使用已穿孔去除對應於基板之蒸鍍部位的部分之蒸鍍罩。As a method of forming a light-emitting layer of an organic EL (Electroluminescence) device, a vapor deposition mask method is often used. In this vapor deposition mask method, in order to vapor-deposit and form an organic luminescent substance at a desired position on a substrate made of a transparent material such as glass, a vapor deposition mask in which a portion corresponding to the vapor deposition portion of the substrate is perforated is used.

在進行蒸鍍的蒸鍍裝置中,相對於蒸鍍對象之基板將蒸鍍罩以正確對位的狀態設置,並執行蒸鍍。然而,在進行蒸鍍時,為了使蒸鍍裝置內成為可蒸鍍的環境,一般進行加熱,因此於蒸鍍罩及玻璃基板的熱變形狀態不同的情況,存在以下問題:蒸鍍罩與基板的相對位置關係變化,變得無法滿足形成之發光層所要求的精度。In the vapor deposition apparatus for performing vapor deposition, the vapor deposition mask is set in a state correctly aligned with respect to the substrate to be vapor deposited, and vapor deposition is performed. However, when vapor deposition is performed, heating is generally performed to make the vapor deposition environment possible in the vapor deposition apparatus. Therefore, when the thermal deformation states of the vapor deposition cover and the glass substrate are different, there is a problem that the vapor deposition cover and the substrate are different. The relative positional relationship changes, and it becomes impossible to meet the precision required for the formed light-emitting layer.

近年來,提出有以下蒸鍍罩,其藉由採用在較薄之罩主體的外周緣裝配有由具有與玻璃等被蒸鍍基板同等之熱膨脹係數的原料或低熱膨脹係數的原料構成之加強用的框體之罩構造,而即使使用熱膨脹係數與被蒸鍍基板不同原料製之罩主體,罩主體亦追隨具有與被蒸鍍基板同等的熱膨脹係數之框體之膨脹而進行形狀變化,或成為被具有低熱膨脹係數之框體抑制而不進行形狀變化的狀態,可確保蒸鍍裝置內升溫時之罩主體相對於被蒸鍍基板的整合精度,可在被蒸鍍基板上高精度地形成發光層。 作為此種習知蒸鍍罩的一例,舉例有日本特開2005-15908號公報揭示者。 [先前技術文獻] [專利文獻]In recent years, the following vapor deposition cover has been proposed, which is equipped with a reinforcement made of a material having a thermal expansion coefficient equal to that of a substrate to be deposited such as glass or a material with a low thermal expansion coefficient on the outer peripheral edge of a relatively thin cover body. Even if a cover body made of a material with a thermal expansion coefficient different from that of the vapor-deposited substrate is used, the shape of the cover body changes according to the expansion of the frame having the same thermal expansion coefficient as the vapor-deposited substrate, or becomes The state of being suppressed by the frame with a low thermal expansion coefficient without shape change can ensure the integration accuracy of the cover body with respect to the evaporated substrate when the temperature rises in the evaporation device, and can form light emission on the evaporated substrate with high precision layer. As an example of such a conventional vapor deposition mask, the one disclosed in Japanese Patent Application Laid-Open No. 2005-15908 is exemplified. [Prior Art Document] [Patent Document]

專利文獻1:日本特開2005-15908號公報Patent Document 1: Japanese Patent Laid-Open No. 2005-15908

[發明所欲解決之課題][Problem to be Solved by the Invention]

習知蒸鍍罩成為上述專利文獻1所示的結構,可抑制因熱膨脹係數的差異而引起之罩與基板之相對變形,且防止蒸鍍形成物之位置精度的顯著惡化。 然而,市場上存在蒸鍍形成物之進一步高精度化的要求,並要求進一步抑制因罩的位移而引起之偏移的產生。The conventional vapor deposition cover has the structure shown in the aforementioned Patent Document 1, which can suppress the relative deformation between the cover and the substrate due to the difference in thermal expansion coefficient, and prevent significant deterioration of the positional accuracy of the vapor deposition formation. However, there is a demand in the market for higher precision of vapor-deposited products, and further suppression of offset due to displacement of the mask.

關於習知罩主體與框體之組合結構,為了確保可對抗欲位移的罩主體之框體強度,容易考慮加厚框體,然若罩主體附近的框體變得過厚,則產生在蒸鍍時有機發光物質等蒸鍍材料向罩主體的通孔行進受到框體局部妨礙等不良影響,因此無法單純增加厚度。另外,當框體加厚某程度時,框體之重量亦增加,產生因框體本身的重量而引起之撓曲等變形的問題,於該情況,反而導致對罩主體產生影響而使位置精度惡化。因此,就藉由增大框體的厚度來謀求強度提高,且提高罩的精度之方法而言,存在可應用的厚度之極限值,以超過該極限值之方式謀求強度提高可謂並不現實。Regarding the combined structure of the conventional cover body and frame, in order to ensure the strength of the frame against the cover body to be displaced, it is easy to consider thickening the frame. During plating, vapor deposition materials such as organic light-emitting substances travel to the through holes of the cover main body due to adverse effects such as local obstruction by the frame, so the thickness cannot be simply increased. In addition, when the frame is thickened to a certain extent, the weight of the frame also increases, and the problem of deformation such as deflection caused by the weight of the frame itself occurs. deterioration. Therefore, in the method of improving the strength by increasing the thickness of the frame and improving the accuracy of the cover, there is a limit value of the applicable thickness, and it is not realistic to improve the strength beyond this limit value.

另外,於由普遍流通且容易獲得之金屬板原料而形成框體的情況,如此之板原料經由軋延等加工而製造,故板原料成為因加工而產生的應變大量殘留於內部的狀態。此種製造過程中產生之板原料之內部應變的影響隨該板厚的增大而越來越顯著地顯現。因此當增加框體的板厚,即增大用於框體之板原料的厚度時,在從板原料藉由切割等進一步加工而最終得到框體之階段,應變以框體之稍微翹曲等方式顯現,無法嚴格地謀求框體本應具有之形狀,對罩的精度造成不良影響。從這方面考慮,亦可謂難以藉由單純地加厚框體來謀求強度提高。In addition, when the frame is formed from a commonly distributed and easily obtained metal plate material, such a plate material is manufactured through processing such as rolling, so a large amount of strain caused by the processing remains inside the plate material. The influence of the internal strain of the plate material produced in such a manufacturing process becomes more and more prominent as the thickness of the plate increases. Therefore, when the plate thickness of the frame is increased, that is, the thickness of the plate material used for the frame is increased, at the stage where the frame is finally obtained from the plate material through further processing such as cutting, the strain is based on a slight warpage of the frame, etc. The method shows that it is impossible to strictly pursue the shape that the frame should have, which has a negative impact on the accuracy of the cover. Considering this aspect, it can also be said that it is difficult to improve the strength simply by thickening the frame.

再者,作為用於框體之金屬板原料,亦可採用藉由特殊加工製造之無應變之板原料或預先實施了內部應力去除處理之板原料,以使框體不受應變的影響,然無應變的板原料或應力去除處理的成本較高,故無法經濟地得到框體。Furthermore, as the metal plate material used for the frame body, it is also possible to use a plate material without strain produced by special processing or a plate material that has been subjected to internal stress relief treatment in advance so that the frame body will not be affected by the strain. The cost of unstrained plate material or stress relief treatment is high, so the frame cannot be obtained economically.

如上所述,習知罩結構具有如下課題:在框體強度的方面,難以使罩主體的位移收斂於伴隨高精度化而變得嚴格之容許範圍,無法避免因蒸鍍形成物的錯位而引起之產率的惡化。As described above, the conventional cover structure has the following problems: In terms of frame strength, it is difficult to keep the displacement of the cover main body within the allowable range that becomes stricter with higher precision, and it is unavoidable to avoid the displacement caused by the vapor deposition formation. deterioration in productivity.

本發明係為了解決上述課題而完成者,其目的在於,提供一種蒸鍍罩,將框體基於截面形狀之強度之設定最佳化,利用框體適當抑制罩主體的變形,防止罩主體從正確的位置的偏移,而提高蒸鍍的精度。 [解決課題之技術手段]The present invention was made to solve the above-mentioned problems, and its object is to provide a vapor deposition cover that optimizes the setting of the strength of the frame based on the cross-sectional shape, appropriately suppresses the deformation of the cover main body by the frame, and prevents the cover main body from being corrected. The offset of the position improves the precision of evaporation. [Technical means to solve the problem]

本發明揭示之蒸鍍罩具備:多個罩主體,其將獨立的多個蒸鍍通孔以特定之圖案設置;及框體,其配置於罩主體之周圍;上述蒸鍍罩中,上述框體具有:位於最外周的矩形或方形之外框部、及將該外框部的內側劃分成多個開口區域之內框部,且作為整體形成為格子狀,上述罩主體各自位於框體之多個開口區域,且與框體一體化而成,框體的上述內框部中成為最窄寬度的部分之截面形狀為將厚度尺寸相對於寬度尺寸的比例設為0.8/5以上且2/5以下之矩形截面。The evaporation cover disclosed by the present invention has: a plurality of cover main bodies, which arrange a plurality of independent evaporation through holes in a specific pattern; and a frame, which is arranged around the cover main body; in the above-mentioned evaporation cover, the above-mentioned frame The body has: a rectangular or square outer frame portion located on the outermost periphery, and an inner frame portion that divides the inner side of the outer frame portion into a plurality of opening areas, and is formed in a lattice shape as a whole, and the above-mentioned cover main bodies are respectively located on the frame body. A plurality of open areas, and integrally formed with the frame body, the cross-sectional shape of the part with the narrowest width among the above-mentioned inner frame parts of the frame body is such that the ratio of the thickness dimension to the width dimension is 0.8/5 or more and 2/ Rectangular section below 5.

因此,根據本發明之揭示,藉由將框體之內框部的最小寬度部之截面形狀形成為其寬度與厚度的關係適當者,可靠地賦予最小寬度部之彎曲剛性(彎曲變形的難度),而賦予相對於來自罩主體側的力的所需充分之強度,與相比該最小寬度部寬度寬且強度高的框體之其他部分,一同作為框體整體而抑制罩主體各部之從本應存在的位置之偏移,可確保蒸鍍步驟中罩與被蒸鍍基板之整合狀態,可在被蒸鍍基板的適當的位置精度良好地進行蒸鍍。 另外,藉由最小寬度部之彎曲變形的難度,亦可抑制最小寬度部之因自身重量而引起的撓曲,抑制框體之變形及因其而引起的對罩主體之影響。Therefore, according to the disclosure of the present invention, the bending rigidity (difficulty in bending deformation) of the minimum width portion can be reliably imparted to the minimum width portion by forming the cross-sectional shape of the minimum width portion of the inner frame portion of the frame so that the relationship between width and thickness is appropriate. , and give the required sufficient strength with respect to the force from the side of the cover main body, and other parts of the frame body that are wider than the minimum width portion and have high strength, together with the frame as a whole, restrain the various parts of the cover main body from the original. The offset of the position that should exist can ensure the integrated state of the cover and the substrate to be vapor deposited in the vapor deposition step, and vapor deposition can be performed with high precision at an appropriate position of the substrate to be vapor deposited. In addition, due to the difficulty of bending deformation of the minimum width part, the deflection of the minimum width part due to its own weight can also be suppressed, and the deformation of the frame and its influence on the cover main body can be suppressed.

另外,就本發明揭示之蒸鍍罩而言,根據需要,上述框體之外框部及內框部中成為最窄寬度的部分以外之部位之各截面形狀為將厚度尺寸相對於寬度尺寸的比例設為0.8/90以上,且較上述內框部中成為最窄寬度的部分之厚度尺寸相對於寬度尺寸的比例小之矩形截面。In addition, in the vapor deposition cover disclosed in the present invention, if necessary, the cross-sectional shapes of the parts other than the parts with the narrowest width among the outer frame portion and the inner frame portion of the above-mentioned frame body are the ratio of the thickness dimension to the width dimension. The ratio is set to 0.8/90 or more, and the rectangular cross section is smaller than the ratio of the thickness dimension to the width dimension of the portion that becomes the narrowest width in the inner frame portion.

因此,根據本發明之揭示,框體之最小寬度部以外的各部亦做成適當之截面形狀,在框體各部,相對於寬度尺寸設定一定程度以上之厚度尺寸,賦予難以撓曲的所需最小限度之彎曲剛性,藉此可充分確保相對於來自罩主體側的力之框體的強度,抑制框體之變形及其引起的對罩主體之影響,提高罩主體之通孔位置的精度,可進行相對於蒸鍍對象之高精度的蒸鍍。Therefore, according to the disclosure of the present invention, the parts other than the minimum width part of the frame body are also made into appropriate cross-sectional shapes, and the thickness dimension is set to a certain degree or more relative to the width dimension in each part of the frame body, so as to give the required minimum width that is difficult to bend. The maximum bending rigidity can fully ensure the strength of the frame relative to the force from the side of the cover body, suppress the deformation of the frame and its influence on the cover body, and improve the accuracy of the through hole position of the cover body. Performs high-precision vapor deposition relative to the vapor deposition target.

另外,本發明揭示之蒸鍍罩,根據需要,上述框體以將各部的厚度尺寸設為0.8 mm以上且2 mm以下之方式形成。In addition, in the vapor deposition mask disclosed in the present invention, if necessary, the frame is formed such that the thickness of each part is 0.8 mm or more and 2 mm or less.

如此,根據本發明之揭示,藉由在可得到框體各部中難以撓曲之截面形狀之現實的寬度尺寸的範圍內,以不會使截面形狀中的厚度尺寸變得過大的方式來設定,而可在框體各部抑制作為因自身重量而引起的撓曲或內部應變的變形之體現,形成精度高的框體,亦能以較高的精度進行蒸鍍。另外,藉由不將厚度增大至所需以上,而可抑制框體的重量增加,防止蒸鍍罩的操作性惡化。Thus, according to the disclosure of the present invention, by setting the thickness dimension in the cross-sectional shape so as not to become too large within the range of the actual width dimension of the cross-sectional shape that is difficult to bend in each part of the frame, In addition, it is possible to suppress the deflection due to its own weight or the deformation of the internal strain in each part of the frame to form a high-precision frame, and it is also possible to perform vapor deposition with high precision. In addition, by not increasing the thickness more than necessary, the increase in the weight of the frame can be suppressed, and the operability of the vapor deposition cover can be prevented from deteriorating.

另外,就本發明之揭示的蒸鍍罩而言,根據需要,上述框體為將第一框構件及第二框構件重疊地一體化而成的積層構造,上述第一框構件及第二框構件為由金屬薄板原料而形成之具有翹曲的框構件,且將各自之翹曲方向朝向相反方向。In addition, in the vapor deposition cover disclosed in the present invention, if necessary, the frame body has a laminated structure in which a first frame member and a second frame member are overlapped and integrated, and the first frame member and the second frame The member is a warped frame member formed from a sheet metal material, and the respective warping directions are oriented in opposite directions.

因此,根據本發明之揭示,將框體做成將以金屬薄板材料為原料的第一框構件及第二框構件重疊地一體化接合而成之積層構造,並將具有翹曲之第一框構件及第二框構件以分別的翹曲方向成為相反方向之方式積層配置而構成框體,藉此在框體中,翹曲抵消,得到平坦的狀態,以更低成本得到提高平坦度之框體,可提高罩的形狀精度,並且高效地執行蒸鍍。另外,將框體設為組合了第一框構件及第二框構件之構成,藉此即使於框體的厚度達到了在使用單純一片薄板材料時有可能產生翹曲的厚度的情況,亦形成為不會出現翹曲等不必要之變形的狀態,不會對罩主體之位置精度造成不良影響,可得到提高了強度的罩結構,可使用該罩以較高精度執行蒸鍍。Therefore, according to the disclosure of the present invention, the frame body is made into a laminated structure in which the first frame member and the second frame member made of metal sheet materials are overlapped and integrally bonded, and the warped first frame The member and the second frame member are laminated so that the respective warping directions are opposite to each other to form a frame. In this way, the warping is canceled out in the frame, and a flat state is obtained. A frame with improved flatness can be obtained at a lower cost. body, the shape accuracy of the cover can be improved, and evaporation can be performed efficiently. In addition, by making the frame body a combination of the first frame member and the second frame member, even when the thickness of the frame body reaches a thickness that may warp when a single sheet of thin plate material is used, the In a state where unnecessary deformation such as warping does not occur, and does not adversely affect the positional accuracy of the mask body, a mask structure with increased strength can be obtained, and vapor deposition can be performed with high precision using this mask.

另外,就本發明之揭示的蒸鍍罩而言,根據需要,使內框部的材質及外框部的材質不同而形成上述框體。In addition, in the vapor deposition mask disclosed in the present invention, the frame body is formed by changing the material of the inner frame portion and the material of the outer frame portion as needed.

因此,根據本發明之揭示,藉由使框體中內框部及外框部的材質各自不同,對內框部及外框部賦予不同的性質,而於例如對外框部使用強度較內框部高的材質之情況,主要利用外框部抑制基於來自罩主體側之力之變形而可高效地加強罩主體,可提高罩主體的位置之精度。此外,於例如對框體之內框部使用線膨脹係數較外框部小的材質之情況,可在蒸鍍步驟等中的升溫狀態利用與罩主體相鄰之內框部高效地抑制因罩主體之熱變形而引起的罩各位置之位移,即使於升溫狀態亦能可靠地維持常溫狀態之罩與被蒸鍍基板的位置關係,可以較高的精度進行蒸鍍。Therefore, according to the disclosure of the present invention, by making the materials of the inner frame part and the outer frame part of the frame body different, different properties are given to the inner frame part and the outer frame part, and for example, the outer frame part is used with a stronger frame than the inner frame. In the case of a material with a high portion, the cover body can be efficiently reinforced by mainly utilizing the outer frame portion to suppress deformation due to force from the cover body side, and the positional accuracy of the cover body can be improved. In addition, for example, when using a material with a smaller coefficient of linear expansion than the outer frame for the inner frame of the frame, the inner frame adjacent to the cover main body can effectively suppress the heat loss caused by the cover in the state of temperature rise in the vapor deposition step or the like. The displacement of each position of the cover caused by the thermal deformation of the main body can reliably maintain the positional relationship between the cover and the substrate to be evaporated at room temperature even in a state of elevated temperature, and can perform evaporation with high precision.

以下,基於圖1至圖11,說明本發明的一實施方式的蒸鍍罩。本實施方式中,對應用於有機EL元件用蒸鍍罩的例子進行說明。 上述各圖中,本實施方式的蒸鍍罩1為具備將多個蒸鍍通孔8以特定圖案設置之多個罩主體2及配置於罩主體2的周圍之框體3的結構。Hereinafter, a vapor deposition cover according to an embodiment of the present invention will be described based on FIGS. 1 to 11 . In this embodiment, an example applied to a vapor deposition mask for an organic EL element will be described. In each of the above-mentioned figures, the vapor deposition cover 1 of this embodiment has a structure including a plurality of cover main bodies 2 in which a plurality of vapor deposition through-holes 8 are provided in a specific pattern, and a frame body 3 arranged around the cover main body 2 .

上述罩主體2為以下構成:以鎳或鎳鈷等鎳合金、其他電沉積金屬為原料,藉由電鑄形成為片狀,且將供蒸鍍物質穿過的獨立的多個蒸鍍通孔8以特定圖案設置。The above-mentioned cover main body 2 has the following configuration: using nickel alloys such as nickel or nickel-cobalt, and other electrodeposited metals as raw materials, it is formed into a sheet shape by electroforming, and a plurality of independent evaporation through holes for the evaporation material to pass through are formed. 8 set in a specific pattern.

罩主體2包含:設置多個蒸鍍通孔8的內部之圖案形成區域2a、及經由利用鍍覆形成之金屬層7與框體3一體地接合之外周緣2b。圖案形成區域2a中,多個蒸鍍通孔8作為發光層形成用,形成以沿前後方向直線排列之多個通孔群為行且沿左右方向呈並列狀配設有多行的矩陣狀之蒸鍍圖案9。 罩主體2之厚度較佳為設為5~20 μm的範圍,本實施方式中設定為8 μm。The cover main body 2 includes a pattern forming region 2 a inside where a plurality of vapor deposition through holes 8 are provided, and an outer peripheral edge 2 b integrally joined to the frame body 3 via the metal layer 7 formed by plating. In the pattern forming region 2a, a plurality of vapor deposition through holes 8 are used for forming a light emitting layer, and a matrix is formed in which a plurality of through hole groups arranged in a straight line in the front-rear direction are used as a row and a plurality of rows are arranged side by side in the left-right direction. Evaporation pattern9. The thickness of the cover main body 2 is preferably set in the range of 5 to 20 μm, and is set to 8 μm in the present embodiment.

上述框體3係將較罩主體2壁厚之板狀體作為矩形的框形狀者,作為罩主體2之加強用而構成為包圍罩主體2的外側來配置,且與罩主體2連結而一體化。詳細而言,框體3具有:位於最外周的矩形狀之外框部4、及將該外框部4的內側劃分成多個開口區域6之內框部5,且作為整體形成為格子狀。並且構成為,罩主體2各自位於由框體3的內框部5劃分的各開口區域6,經由金屬層7與框體3一體化。The above-mentioned frame body 3 is a plate-like body having a thicker wall than the cover main body 2 as a rectangular frame shape, and is configured to surround the outside of the cover main body 2 as a reinforcement of the cover main body 2, and is connected with the cover main body 2 to form a single body. change. Specifically, the frame body 3 has a rectangular outer frame portion 4 located on the outermost periphery, and an inner frame portion 5 that divides the inner side of the outer frame portion 4 into a plurality of opening regions 6, and is formed in a lattice shape as a whole. . In addition, the cover main bodies 2 are located in the respective opening regions 6 defined by the inner frame portion 5 of the frame body 3 , and are integrated with the frame body 3 via the metal layer 7 .

該框體3為以下構成,將其內框部5中成為最窄寬度的部分之截面形狀設為厚度尺寸T相對於寬度尺寸W的比例(長寬比)為0.8/4以上且2/4以下之矩形截面。 另一方面,框體3的外框部4或內框部5中成為最窄寬度的部分以外之各截面形狀設為厚度尺寸T相對於寬度尺寸W的比例(長寬比)為0.8/90以上之矩形截面。The frame body 3 is configured such that the cross-sectional shape of the narrowest part of the inner frame portion 5 is such that the ratio of the thickness dimension T to the width dimension W (aspect ratio) is 0.8/4 or more and 2/4 The following rectangular section. On the other hand, the ratio of the thickness dimension T to the width dimension W (aspect ratio) of each cross-sectional shape of the outer frame portion 4 or the inner frame portion 5 of the frame body 3 other than the narrowest portion is 0.8/90. The above rectangular section.

並且,框體3之外框部4及內框部5設為相同之厚度,形成為將其厚度尺寸設為0.2 mm以上且6 mm以下,較佳為設為0.8 mm以上且3 mm以下,更佳為設為2 mm。在此,厚度尺寸較佳為設為0.8 mm以上是由於在框體各部的厚度尺寸低於0.8 mm之情況時,存在框體之強度無法對抗罩主體內部存在之張力(拉伸應力)而變形的問題。In addition, the outer frame part 4 and the inner frame part 5 of the frame body 3 are set to have the same thickness, and are formed so that the thickness dimension thereof is not less than 0.2 mm and not more than 6 mm, preferably not less than 0.8 mm and not more than 3 mm, More preferably, it is set to 2 mm. Here, the thickness dimension is preferably set at 0.8 mm or more because when the thickness dimension of each part of the frame body is less than 0.8 mm, the strength of the frame body cannot resist the tension (tensile stress) existing inside the cover body and deform The problem.

另一方面,若以此方式製成之框體各部之厚度尺寸超過2 mm時,在蒸鍍時可能引起所謂陰影之問題(框體成為妨礙蒸鍍材料的行進之障礙物),或因相對於框體,基材之厚度通常設為1 mm,故難以進行框體的壓接後的操作等,因此,較佳為將厚度尺寸設為2 mm以下。On the other hand, if the thickness of each part of the frame made in this way exceeds 2mm, the problem of so-called shadows may be caused during evaporation (the frame becomes an obstacle that hinders the progress of the evaporation material), or due to relative In the frame, since the thickness of the base material is usually set to 1 mm, it is difficult to perform operations after crimping of the frame, etc. Therefore, it is preferable to set the thickness dimension to 2 mm or less.

本實施方式中,內框部5之成為最窄寬度的部分(最小寬度部)之寬度尺寸W1 設為4 mm,成為最寬寬度的部分(最大寬度部)之寬度尺寸W2 設為約90 mm。當該最小寬度部的寬度尺寸低於4 mm時,框體的強度有無法對抗罩主體內部存在之張力(拉伸應力)而變形之虞,因此,寬度尺寸較佳為設為4 mm以上。In this embodiment, the width dimension W 1 of the narrowest part (minimum width part) of the inner frame part 5 is set to 4 mm, and the width dimension W 2 of the widest part (maximum width part) is set to approximately 90 mm. When the width dimension of the minimum width portion is less than 4 mm, the strength of the frame may not be able to deform against the tension (tensile stress) existing inside the cover body. Therefore, the width dimension is preferably 4 mm or more.

此外,於最大寬度部的寬度尺寸超過90 mm之情況,可形成於一片基材上之罩主體的數量(取得數)過度減少,罩製造效率降低,故寬度尺寸較佳為設為90 mm以下。In addition, when the width dimension of the maximum width portion exceeds 90 mm, the number (obtained number) of cover bodies that can be formed on one base material is excessively reduced, and the efficiency of cover production decreases, so the width dimension is preferably set to 90 mm or less. .

如此,框體3將內框部之最小寬度部的矩形截面形狀以滿足最小寬度部之厚度尺寸T相對於寬度尺寸W的比例成為上述範圍內之值的條件的形狀的方式來形成。如此,將最小寬度部的截面形狀的長寬比設於特定範圍內,確保相對於寬度不會過大之適當厚度,基於截面形狀,可靠地賦予最小寬度部針對彎曲之變形難度(剛性),而難以產生最小寬度部因自身重量而引起的撓曲,並確保相對於欲使框體3從罩主體側變形之力的強度,抑制框體3之變形及因其而引起之對罩主體2的影響,提高罩主體2之通孔位置的精度,可進行對蒸鍍對象的高精度蒸鍍。In this way, the frame body 3 is formed so that the rectangular cross-sectional shape of the minimum width portion of the inner frame portion satisfies the condition that the ratio of the thickness dimension T to the width dimension W of the minimum width portion is a value within the above range. In this way, the aspect ratio of the cross-sectional shape of the minimum width part is set within a specific range to ensure an appropriate thickness that is not too large relative to the width. It is difficult to generate the deflection of the minimum width part due to its own weight, and ensure the strength against the force to deform the frame body 3 from the cover body side, and suppress the deformation of the frame body 3 and the resulting force on the cover body 2 As a result, the accuracy of the position of the through hole of the cover main body 2 is improved, and high-precision vapor deposition on the vapor deposition target can be performed.

另外,在框體3之最小寬度部以外的各部,亦作為可賦予所需的彎曲剛性之截面形狀,充分確保相對於來自罩主體側之力的強度,並且適當設定相對於該寬度尺寸的厚度,藉此抑制因厚度(截面面積)變大為所需以上而引起的框體3的重量增加,防止因蒸鍍罩整體的重量或自身重量而引起之撓曲變大。In addition, each part of the frame body 3 other than the minimum width part has a cross-sectional shape capable of imparting required bending rigidity, sufficiently secures strength against a force from the side of the cover main body, and appropriately sets a thickness relative to the width dimension. In this way, the increase in the weight of the frame body 3 caused by the thickness (cross-sectional area) being increased more than necessary is suppressed, and the warpage caused by the overall weight of the vapor deposition cover or its own weight is prevented from becoming large.

另一方面,框體3設為以下構成,即將同一形狀的第一框構件3a及第二框構件3b使接著劑介於之間並且重合地一體化接合之積層結構。第一框構件3a及第二框構件3b為自經由相同薄板製造步驟製造的金屬薄板原料形成之框構件,且具有基於源自薄板製造步驟之金屬薄板原料之內部應變的翹曲,使各自的翹曲方向朝向相反方向,成為作為框體3的積層構造。On the other hand, the frame body 3 has a laminated structure in which the first frame member 3 a and the second frame member 3 b of the same shape are overlapped and integrally bonded with an adhesive therebetween. The first frame member 3a and the second frame member 3b are frame members formed from metal sheet stock produced through the same sheet manufacturing step, and have warpage based on internal strain of the metal sheet stock derived from the sheet manufacturing step so that the respective The direction of warping faces the opposite direction, and it becomes a laminated structure as the frame body 3 .

將如此由經相同之薄板製造步驟,具體而言為軋延步驟,製造之金屬薄板原料藉由切割等加工而形成的同一形狀之第一框構件3a及第二框構件3b,以使各自的翹曲方向朝向相反方向的方式利用接著劑來一體化接合,而在得到的框體3中,翹曲抵消而成為平坦的狀態(參照圖5)。再者,於圖5中,第一框構件3a及第二框構件3b的翹曲的大小為使理解容易而誇張地圖示,實際之翹曲極小。然而,該等翹曲的大小假設直接出現於框體3,則對罩主體2造成影響,使與其位置相關的精度惡化,成為蒸鍍罩的高精度化的障礙,故藉由上述的積層構造謀求了翹曲的消除。In this way, the first frame member 3a and the second frame member 3b of the same shape are formed by processing the metal sheet raw material manufactured through the same sheet manufacturing step, specifically the rolling step, by cutting or the like, so that the respective The direction of the warping is in the opposite direction and is integrally joined with an adhesive, and the obtained frame body 3 is in a flat state in which the warping is canceled out (see FIG. 5 ). In addition, in FIG. 5, the magnitude|size of the warpage of the 1st frame member 3a and the 2nd frame member 3b is illustrated exaggeratedly for easy understanding, and actual warpage is extremely small. However, assuming that the size of the warpage appears directly on the frame body 3, it will affect the cover main body 2, degrade the accuracy related to its position, and become an obstacle to the high precision of the vapor deposition cover. Therefore, by the above-mentioned laminated structure Elimination of warpage is sought.

本實施方式中,作為接著劑,以使介於第一框構件3a與第二框構件3b之間的方式使用片狀之未硬化感光性乾膜抗蝕劑。在接合第一框構件3a及第二框構件3b後,去除在第一框構件3a與第二框構件3b間成為接著層3c的部分以外之抗蝕劑不要部分。此外,接著劑亦可使用一般可獲得的各種接著劑。再者,如果可成為藉由接合使翹曲抵消的平坦狀態,即成為框體3的階段中之框體正反面之平面度或平行度收斂於容許範圍內的狀態,則第一框構件3a及第二框構件3b的平面形狀或截面形狀、翹曲的大小亦可不同。In the present embodiment, a sheet-shaped uncured photosensitive dry film resist is used as an adhesive agent so as to be interposed between the first frame member 3 a and the second frame member 3 b. After the first frame member 3a and the second frame member 3b are bonded, the unnecessary portion of the resist other than the portion to be the adhesive layer 3c between the first frame member 3a and the second frame member 3b is removed. In addition, as the adhesive agent, generally available various adhesive agents can also be used. Furthermore, if it can be in a flat state in which warping is canceled out by bonding, that is, a state in which the flatness or parallelism of the front and back surfaces of the frame in the stage of becoming the frame 3 converges within the allowable range, then the first frame member 3a The plane shape, the cross-sectional shape, and the magnitude of the warpage of the second frame member 3b may also be different.

將第一框構件3a及第二框構件3b以使各自的翹曲方向朝向相反方向的方式一體化接合,形成平坦之框體3,藉此即使在框體3的厚度達到了使用單純一片薄板材料時很有可能產生翹曲的厚度的情況,亦形成為不會出現翹曲等不必要的變形的狀態,不會對罩主體的位置精度造成不良影響,可使用該罩以較高精度執行蒸鍍。The first frame member 3a and the second frame member 3b are integrally bonded so that the respective warping directions face opposite directions to form a flat frame body 3, so that even if the thickness of the frame body 3 is as high as that of a single thin plate Even when the thickness of the material is likely to cause warping, it is also formed in a state where unnecessary deformation such as warping does not occur, and does not adversely affect the positional accuracy of the cover body, and can be executed with high precision using this cover. Evaporation.

該框體3藉由低熱膨脹係數之材質,例如作為鎳-鐵合金的恆範鋼材料或作為鎳-鐵-鈷合金的超恆範鋼材料等般之材質形成。並且,框體3利用藉由電鑄形成的金屬層7,與罩主體2的圖案形成區域2a的外周緣2b以相互不分離的方式連結而一體化。The frame body 3 is formed of a material with a low thermal expansion coefficient, such as a nickel-iron alloy constant steel material or a nickel-iron-cobalt alloy super constant steel material. Furthermore, the frame body 3 is integrally connected with the outer peripheral edge 2b of the pattern formation area 2a of the cover main body 2 by the metal layer 7 formed by electroforming so that they may not separate from each other.

於作為框體3的材質採用了恆範鋼材料或超恆範鋼材料之情況,其熱膨脹係數極小,藉此可良好地抑制蒸鍍步驟中的熱影響引起之罩主體2的尺寸變化。即,即使罩主體2為例如鎳等之熱膨脹係數較作為被蒸鍍基板(省略圖示)的一般玻璃之熱膨脹係數大的材料,亦不會由於蒸鍍時的高溫引起之熱膨脹率的不同,而在常溫時使蒸鍍罩1與被蒸鍍基板整合時的相對於基板的通孔位置與實際蒸鍍時的蒸鍍物質的蒸鍍位置之間產生偏移,藉由保持罩主體2之框體3的熱膨脹係數較小的特徵,可良好地抑制升溫時之罩主體2的膨脹所引起的尺寸變化、形狀變化,在蒸鍍時的升溫時亦可良好地保持常溫時的整合精度。When the frame body 3 is made of constant steel or super constant steel, its coefficient of thermal expansion is extremely small, so that the dimensional change of the cover body 2 caused by the thermal influence in the vapor deposition step can be well suppressed. That is, even if the cover main body 2 is made of a material having a thermal expansion coefficient greater than that of general glass as a substrate to be vapor-deposited (not shown), for example, nickel, etc., there will be no difference in thermal expansion coefficient due to the high temperature during vapor deposition. At room temperature, when the vapor deposition cover 1 is integrated with the substrate to be vapor deposited, there is a deviation between the through hole position relative to the substrate and the vapor deposition position of the vapor deposition material during actual vapor deposition. By holding the cover main body 2 The small thermal expansion coefficient of the frame body 3 can well suppress the size change and shape change caused by the expansion of the cover body 2 when the temperature rises, and can maintain the integration accuracy at room temperature well when the temperature rises during vapor deposition.

再者,框體3的材質亦可使用低熱膨脹係數接近作為被蒸鍍基板的玻璃等的材料,例如類似於玻璃、陶瓷的材料。於該情況,對該等材料的至少表面賦予導電性。Furthermore, the material of the frame body 3 may also use a material with a low thermal expansion coefficient close to that of glass as the substrate to be vapor-deposited, for example, a material similar to glass or ceramics. In this case, conductivity is imparted to at least the surface of these materials.

上述蒸鍍罩1係以如下方法製造:在基材10的表面,與一次電沉積層15的非配置部分對應地設置一次圖案抗蝕劑14後,在基材10上藉由電沉積金屬的電鑄形成一次電沉積層15,且形成覆蓋該一次電沉積層15的圖案形成區域2a對應部分之二次圖案抗蝕劑18,進而,以包圍一次電沉積層15的方式配置框體3後,以覆蓋框體3的表面及一次電沉積層15之外周緣2b表面的方式藉由電鑄形成金屬層7,經由該金屬層7將一次電沉積層15及框體3以不分離的方式連結成一體,於該狀態,將該等一體的一次電沉積層15、框體3及金屬層7、與基材10進行分離。The above-mentioned vapor deposition mask 1 is manufactured by the following method: After the primary pattern resist 14 is provided on the surface of the substrate 10 corresponding to the non-arranged portion of the primary electrodeposition layer 15, the substrate 10 is deposited by electrodepositing metal. The primary electrodeposition layer 15 is formed by electroforming, and the secondary pattern resist 18 covering the corresponding part of the pattern formation area 2a of the primary electrodeposition layer 15 is formed, and then the frame body 3 is arranged so as to surround the primary electrodeposition layer 15 The metal layer 7 is formed by electroforming in a manner covering the surface of the frame body 3 and the surface of the outer periphery 2b of the primary electrodeposited layer 15, and the primary electrodeposited layer 15 and the frame body 3 are not separated through the metal layer 7. In this state, the integrated primary electrodeposited layer 15 , frame body 3 and metal layer 7 are separated from the substrate 10 .

本實施方式的蒸鍍罩1的製造步驟中使用的上述基材10由不銹鋼材料、黃銅、鋼等具有導電性的材質形成,且至蒸鍍罩的製造步驟中分離前,支撐形成罩主體2之一次電沉積層15,且在蒸鍍罩製造步驟的各階段,在表面側形成一次圖案抗蝕劑14、一次電沉積層15、二次圖案抗蝕劑18以及金屬層7。在形成一次電沉積層15、金屬層7時,進行經由該基材10的通電,藉此,在基材10表面的未被抗蝕劑覆蓋的可通電的部分,藉由電鑄(鍍覆)形成一次電沉積層15或金屬層7。The above-mentioned base material 10 used in the manufacturing process of the vapor deposition cover 1 of this embodiment is formed of a conductive material such as stainless steel, brass, steel, etc., and is supported to form the cover body until it is separated in the manufacturing step of the vapor deposition cover. 2, the primary electrodeposition layer 15, and at each stage of the vapor deposition mask manufacturing steps, the primary pattern resist 14, the primary electrodeposition layer 15, the secondary pattern resist 18, and the metal layer 7 are formed on the surface side. When forming the primary electrodeposited layer 15 and the metal layer 7, conduct electricity through the base material 10, thereby, on the part of the surface of the base material 10 that is not covered by the resist, through electroforming (plating) ) to form the primary electrodeposited layer 15 or the metal layer 7 .

基材10亦可採用例如42合金(42%鎳-鐵合金)或恆範鋼(36%鎳-鐵合金)、SUS430等低熱膨脹係數的原料。此外,基材亦可為在玻璃板、樹脂板等絕緣性基板的表面形成由鉻、鈦等具有導電性的金屬構成之金屬膜者。The base material 10 can also be made of materials with low thermal expansion coefficient such as 42 alloy (42% nickel-iron alloy) or constant steel (36% nickel-iron alloy), SUS430 and the like. In addition, the base material may be one in which a metal film made of conductive metal such as chromium or titanium is formed on the surface of an insulating substrate such as a glass plate or a resin plate.

於蒸鍍罩1的製造步驟中,在基材10上藉由鍍覆形成金屬層7(參照圖11(B))後,將基材10自其等分離去除(參照圖11(C))。於基材10為不銹鋼材料之情況,較佳為採用施加力而從蒸鍍罩側物理性地剝離去除的方法,另外,於基材10為其他金屬材料之情況,較佳為採用使用化學液而溶解去除的蝕刻的方法。於蝕刻之情況,使用基材10會溶解但不會侵害形成一次電沉積層15或框體3、金屬層7的材質般之具選擇蝕刻性的蝕刻液。In the manufacturing process of the vapor deposition cover 1, after the metal layer 7 is formed by plating on the base material 10 (see FIG. 11(B)), the base material 10 is separated and removed from them (see FIG. 11(C)) . When the base material 10 is made of stainless steel, it is preferable to use a method of physically peeling and removing it from the side of the evaporation cover by applying force. In addition, when the base material 10 is made of other metal materials, it is preferable to use a chemical solution. And the etching method of dissolution removal. In the case of etching, an etchant with selective etching properties that dissolves the base material 10 but does not damage the materials forming the primary electrodeposited layer 15 or the frame body 3 and the metal layer 7 is used.

上述一次電沉積層15為以下構成,即由適於電鑄的鎳、鎳-鈷等鎳合金構成,且藉由電鑄形成於基材10上的不存在一次圖案抗蝕劑14的部分。蒸鍍罩1中,一次電沉積層15成為與被蒸鍍基板中之發光層等的蒸鍍對象部分對應之蒸鍍通孔8以外之,作為覆蓋被蒸鍍基板的表面之罩主體2的層而形成。The above-mentioned primary electrodeposited layer 15 is composed of a nickel alloy suitable for electroforming such as nickel and nickel-cobalt, and is formed by electroforming on a portion of the substrate 10 where the primary pattern resist 14 does not exist. In the vapor deposition cover 1, the primary electrodeposition layer 15 is used as the cover main body 2 covering the surface of the vapor deposition substrate except for the vapor deposition through hole 8 corresponding to the vapor deposition target portion such as the light emitting layer in the vapor deposition substrate. layer formed.

上述一次圖案抗蝕劑14由對一次電沉積層15的電鑄使用的電解液具備耐溶解性的絕緣性材料形成,配設為與預先設定於基材10上的一次電沉積層15的非配置部分對應,且在形成一次電沉積層15後被去除(參照圖6、圖7)。The above-mentioned primary pattern resist 14 is formed of an insulating material having dissolution resistance to the electrolytic solution used for electroforming of the primary electrodeposition layer 15, and is arranged so as to be incompatible with the primary electrodeposition layer 15 previously set on the base material 10. The configuration part corresponds and is removed after forming the primary electrodeposited layer 15 (refer to FIG. 6 and FIG. 7 ).

此一次圖案抗蝕劑14,在形成一次電沉積層15之前配設於基材10上,將感光性抗蝕劑、例如負型的感光性乾膜抗蝕劑以成為特定的厚度、例如約20 μm的厚度的方式配設於基材10,在載置有與蒸鍍罩1的罩主體2位置,即一次電沉積層15的配置位置對應之特定圖案之罩膜12之狀態,經由利用紫外線照射進行曝光的硬化、去除非照射部分的抗蝕劑之顯影等處理,形成為與一次電沉積層15的非配置部分對應的形狀。This primary pattern resist 14 is arranged on the base material 10 before forming the primary electrodeposited layer 15, and the photosensitive resist, such as a negative photosensitive dry film resist, is made into a specific thickness, such as about The thickness of 20 μm is arranged on the substrate 10, and the mask film 12 of a specific pattern corresponding to the position of the cover body 2 of the evaporation cover 1, that is, the position of the primary electrodeposited layer 15 is placed, by using Ultraviolet radiation is used to perform treatments such as hardening by exposure and development to remove the resist in the non-irradiated portion, and forms a shape corresponding to the non-arrangement portion of the primary electrodeposited layer 15 .

上述二次圖案抗蝕劑18由對金屬層7的鍍覆使用之電解液具備耐溶解性,較佳為成為100~120 μm之範圍的厚度之絕緣性材料形成,以與預先設定於一次電沉積層15的對應金屬層7之非配置部分的方式在形成金屬層7之前配設,且在形成金屬層7後被去除(參照圖8、圖9)。The above-mentioned secondary pattern resist 18 is formed of an insulating material having solubility resistance to the electrolytic solution used for plating the metal layer 7, preferably having a thickness in the range of 100 to 120 μm, so as to be compatible with the primary electrode set in advance. The non-arranged portion of the deposited layer 15 corresponding to the metal layer 7 is arranged before the formation of the metal layer 7 and removed after the formation of the metal layer 7 (see FIGS. 8 and 9 ).

就該二次圖案抗蝕劑18而言,將感光性抗蝕劑、例如負型感光性乾膜抗蝕劑黏貼配設於基材10及已配置之一次電沉積層15上,並進行一次或反覆進行多次之在載置有與蒸鍍罩1的金屬層7及框體3位置對應的特定圖案的罩膜17的狀態利用紫外線照射進行曝光的一連串的步驟,形成所需抗蝕劑厚度後,經由去除曝光中的非照射部分的感光性材料的顯影等處理,而形成與金屬層7的非配置部分(罩主體2的圖案形成區域2a)對應的形狀。For the secondary pattern resist 18, a photosensitive resist, such as a negative photosensitive dry film resist, is pasted and arranged on the substrate 10 and the configured primary electrodeposited layer 15, and a primary electrodeposition layer 15 is carried out. Or repeat a series of steps of exposing by ultraviolet irradiation in the state where the mask film 17 of a specific pattern corresponding to the position of the metal layer 7 of the vapor deposition mask 1 and the frame body 3 is placed, to form the desired resist. After the thickness is removed, the shape corresponding to the non-disposition portion of the metal layer 7 (pattern formation region 2 a of the cover main body 2 ) is formed through processing such as development of a photosensitive material that removes the non-irradiated portion during exposure.

上述金屬層7係藉由鍍覆而形成者,由鎳或鎳-鈷合金等構成,且為以下構成,即藉由鍍覆而形成於基材10及已配置之一次電沉積層15及框體3上的未配設二次圖案抗蝕劑18而露出的部分。The above-mentioned metal layer 7 is formed by plating, is made of nickel or nickel-cobalt alloy, etc., and has the following structure, that is, it is formed on the base material 10 and the primary electrodeposited layer 15 and the frame by plating. The exposed portion on the body 3 without the secondary patterning resist 18 disposed thereon.

該金屬層7係將罩主體2的圖案形成區域2a的外周緣2b及框體3接合者。金屬層7藉由鍍覆而積層於圖案形成區域之外周緣2b的罩主體2的上表面。詳細而言,金屬層7形成於圖案形成區域2a之外周緣2b的上表面、框體3的上表面及圖案形成區域2a側的側面、以及罩主體2與框體3之間隙部分,藉此將圖案形成區域2a的外周緣2b及框體3的開口周緣以不分離的方式連結成一體。This metal layer 7 is what joins the outer peripheral edge 2b of the pattern formation area 2a of the cover main body 2, and the frame body 3. As shown in FIG. The metal layer 7 is laminated|stacked on the upper surface of the cover main body 2 of the periphery 2b outside a pattern formation area by plating. Specifically, the metal layer 7 is formed on the upper surface of the outer peripheral edge 2b of the pattern forming region 2a, the upper surface of the frame body 3, the side surface of the pattern forming region 2a side, and the gap between the cover main body 2 and the frame body 3, thereby The outer peripheral edge 2b of the pattern forming region 2a and the opening peripheral edge of the frame body 3 are integrally connected so as not to be separated.

接著,說明本實施方式之蒸鍍罩的框體的形成步驟及包含該框體之蒸鍍罩整體的製造步驟。 首先,說明罩主體2的加強使用之框體3的形成步驟。Next, the steps of forming the frame of the vapor deposition mask according to the present embodiment and the steps of manufacturing the entire vapor deposition mask including the frame will be described. First, the steps of forming the frame body 3 for reinforcing the use of the cover main body 2 will be described.

首先,自經由軋延加工等的一般之金屬薄板原料,藉由放電加工、雷射加工等進行切割步驟而形成同一形狀之第一框構件3a及第二框構件3b。在自金屬薄板原料切割第二框構件3b時,在金屬薄板原料上作為第二框構件3b而設定的部位,以相對於第一框構件3a的部位使其以方向反轉之方式設置,在第一框構件3a及第二框構件3b中,使應變引起之翹曲產生於相反方向。First, the first frame member 3a and the second frame member 3b of the same shape are formed by performing a cutting step by electrical discharge machining, laser machining, etc. from a general sheet metal material that has been processed by rolling or the like. When cutting the second frame member 3b from the sheet metal stock, the portion set as the second frame member 3b on the sheet metal stock is set in such a way that its direction is reversed relative to the portion of the first frame member 3a. In the first frame member 3a and the second frame member 3b, warpage due to strain is generated in opposite directions.

切割後,對切出的各構件藉由蝕刻、雷射加工等設置開口區域6,從而作為第一框構件3a及第二框構件3b而完成。在得到之第一框構件3a與第二框構件3b之間介隔成為接著層3c的接著劑,以翹曲的方向相反的狀態進行一體化接合,藉此得到各部形成特定的截面形狀之框體3。After dicing, opening regions 6 are provided on each of the cut members by etching, laser processing, etc., and the first frame member 3 a and the second frame member 3 b are completed. The obtained first frame member 3a and the second frame member 3b are interposed with an adhesive to be the adhesive layer 3c, and are integrally bonded in a state in which the direction of warpage is reversed, thereby obtaining a frame in which each part has a specific cross-sectional shape Body 3.

作為用於將第一框構件3a及第二框構件3b一體化的接著劑,例如,使用在未硬化狀態具有黏著性的片狀的感光性乾膜抗蝕劑,藉由使與在後續步驟中亦使用的材料相同,而可以從統一預備、補充後之相應量之中挪用一部分的方式準備,不需僅為了設置接著層而額外準備市售之接著劑等,如此不會產生使用專用之接著劑之成本,可相應地降低蒸鍍罩的製造成本,故較佳。As an adhesive for integrating the first frame member 3a and the second frame member 3b, for example, a sheet-shaped photosensitive dry film resist having adhesiveness in an uncured state is used, and by using The same materials are used in the same, but can be prepared by diverting a part of the corresponding amount after uniform preparation and supplementation. It is not necessary to prepare additional commercially available adhesives for the purpose of setting the adhesive layer, so that there will be no special use. The cost of the adhesive can reduce the manufacturing cost of the evaporation mask accordingly, so it is preferable.

視需要,亦可利用一對之加壓用輥等、對積層的構件可賦予夾壓力的裝置,對經接合成一體化的第一框構件3a及第二框構件3b施行目的為接合狀態的固定之步驟。If necessary, a pair of pressurizing rollers, etc., can also be used to apply a clamping force to the laminated members, so that the first frame member 3a and the second frame member 3b that have been bonded into one body can be bonded. fixed steps.

接合後,去除接著層3c的不要部分,即位於開口區域6、外框部4的外側的部分,藉此框體3完成。再者,於接著劑為薄膜抗蝕劑之情況,藉由顯影步驟去除。After bonding, the unnecessary portion of the adhesive layer 3c, that is, the portion located outside the opening area 6 and the outer frame portion 4 is removed, thereby completing the frame body 3 . Furthermore, in the case where the adhesive is a thin film resist, it is removed by a developing step.

對完成的框體3配設用於將其與基材10接著的另一接著層19。作為該接著層19,例如可貼附而使用在未硬化狀態具有黏著性之感光性乾膜抗蝕劑,在向框體3貼附薄膜抗蝕劑後,去除位於框體3的開口區域6的部分或從外框部4溢出的部分之薄膜抗蝕劑,藉此得到接著層19。Another adhesive layer 19 for bonding it to the base material 10 is arranged on the completed frame body 3 . As the adhesive layer 19, for example, a photosensitive dry film resist that has adhesiveness in an uncured state can be attached and used, and after the thin film resist is attached to the frame body 3, the opening area 6 located in the frame body 3 is removed. The part or the part overflowing from the outer frame part 4 is thin-film resist, whereby the bonding layer 19 is obtained.

另一方面,對於蒸鍍罩的製造步驟,首先,與預先設定於基材10上之罩主體2之蒸鍍通孔8,即一次電沉積層15之非配置部分對應地在基材10配設抗蝕劑層11(參照圖6)。具體而言,在基材10的表面側,將例如負型感光性乾膜抗蝕劑,根據一次電沉積層15的形成所需的特定厚度(例如約20 μm)積層一至多片,藉由熱壓接形成抗蝕劑層11(參照圖6(A))。On the other hand, for the manufacturing steps of the vapor deposition cover, first, the vapor deposition through hole 8 of the cover main body 2 set on the substrate 10 in advance, that is, the non-arrangement part of the primary electrodeposition layer 15 is arranged on the substrate 10. A resist layer 11 is provided (see FIG. 6 ). Specifically, on the surface side of the substrate 10, for example, a negative-type photosensitive dry film resist is laminated in one or more sheets according to a specific thickness (for example, about 20 μm) required for the formation of the primary electrodeposition layer 15, by The resist layer 11 is formed by thermocompression bonding (see FIG. 6(A) ).

接著,使具有與上述蒸鍍通孔8對應之透光孔12a等,與一次電沉積層15的配置位置對應的特定圖案之罩膜(玻璃罩)12密接於抗蝕劑層11的表面後,進行藉由紫外線照射而曝光的硬化(參照圖6(B)、(C))、去除曾被遮蓋之非照射部分的抗蝕劑的顯影、乾燥等之各處理。如此,在基材10上形成與一次電沉積層15的非配置部分對應之一次圖案抗蝕劑14(參照圖7(A))。 再者,此種一次圖案抗蝕劑14可藉由使用光阻等的微影法其他的任意的方法形成,其形成方法不限定於上述。Next, the cover film (glass cover) 12 having a specific pattern corresponding to the light transmission hole 12a corresponding to the above-mentioned vapor deposition through hole 8 and the position corresponding to the arrangement position of the primary electrodeposition layer 15 is closely attached to the surface of the resist layer 11. Each treatment such as hardening by exposure by ultraviolet irradiation (see FIG. 6(B) and (C)), development and drying of the resist to remove the masked non-irradiated portion is performed. In this manner, the primary pattern resist 14 corresponding to the non-arranged portion of the primary electrodeposited layer 15 is formed on the substrate 10 (see FIG. 7(A) ). In addition, such a primary pattern resist 14 can be formed by lithography using a photoresist etc., and other arbitrary methods, and the formation method is not limited to the above.

將具有該一次圖案抗蝕劑14之基材10放入初始為特定的條件的電鑄槽,在一次圖案抗蝕劑14的厚度的範圍內,在基材10的未被一次圖案抗蝕劑14覆蓋的表面(露出區域),藉由鎳合金等的電沉積金屬的電鑄形成例如8 μm厚的成為罩主體2之一次電沉積層15(參照圖7(B))。Put the base material 10 with the primary pattern resist 14 into the electroforming bath under specific conditions initially, within the range of the thickness of the primary pattern resist 14, the substrate 10 that is not coated with the primary pattern resist The surface covered with 14 (exposed area) is formed by electroforming of an electrodeposited metal such as nickel alloy, for example, with a thickness of 8 μm, a primary electrodeposited layer 15 serving as the cover main body 2 (see FIG. 7(B)).

其後,藉由溶解去除一次圖案抗蝕劑14,得到成為罩主體2之一次電沉積層15,該罩主體2設有形成特定之蒸鍍圖案9之獨立的多個蒸鍍通孔8(參照圖7(C))。Thereafter, the primary pattern resist 14 is removed by dissolving to obtain the primary electrodeposition layer 15 which becomes the cover main body 2, and the cover main body 2 is provided with a plurality of independent vapor deposition through holes 8 ( Refer to FIG. 7(C)).

得到該一次電沉積層15後,在包含該一次電沉積層15的形成部分之基材10的整個表面,配設較佳為成為50~60 μm的範圍的厚度之抗蝕劑層16。具體而言,在基材10的表面側貼附例如厚度56 μm的負型感光性乾膜抗蝕劑,藉由曝光使主要部分硬化。以從抗蝕劑層16最終得到之二次圖案抗蝕劑18成為預先設定的特定厚度的方式視需要反覆進行多次此步驟,而形成由一片或多片薄膜抗蝕劑構成的單層或積層構造的抗蝕劑層16。After the primary electrodeposition layer 15 is obtained, the resist layer 16 preferably having a thickness in the range of 50 to 60 μm is disposed on the entire surface of the substrate 10 including the portion where the primary electrodeposition layer 15 is formed. Specifically, a negative photosensitive dry film resist having a thickness of, for example, 56 μm is attached to the surface side of the substrate 10 , and the main part is cured by exposure. This step is repeated as many times as necessary so that the secondary pattern resist 18 finally obtained from the resist layer 16 becomes a preset specific thickness, and a single layer or a single layer composed of one or more thin film resists is formed. The resist layer 16 of the laminated structure.

每貼附一片便進行薄膜抗蝕劑的曝光。詳細而言,作為以下步驟進行:使具有與罩主體2之圖案形成區域2a對應的透光孔17a之罩膜17密接於新貼附之薄膜抗蝕劑的表面後,藉由紫外線照射曝光而硬化(參照圖8(B)、圖9(A))。 視需要反覆進行該步驟,在與圖案形成區域2a對應的部分得到預先設定之特定厚度之藉由曝光而硬化之抗蝕劑層16a,在除此以外的部分,得到預先設定的特定厚度的未曝光之抗蝕劑層16b。Exposure of the thin film resist is performed every time one sheet is attached. Specifically, it is carried out as the following steps: after making the cover film 17 having the light transmission hole 17a corresponding to the pattern forming area 2a of the cover main body 2 adhere to the surface of the newly attached thin film resist, and then exposing it by ultraviolet radiation hardening (see FIG. 8(B), FIG. 9(A)). This step is repeated as necessary to obtain a resist layer 16a of a predetermined thickness hardened by exposure in the portion corresponding to the pattern formation region 2a, and to obtain a resist layer 16a of a predetermined thickness in other portions. The exposed resist layer 16b.

於本實施方式中,反覆進行兩次貼附薄膜抗蝕劑而進行曝光之步驟,形成雙層厚度56 μm之抗蝕劑層16。 其後,進行溶解去除在表面露出之未曝光之抗蝕劑層16b的處理,而形成覆蓋圖案形成區域2a之厚度112 μm之二次圖案抗蝕劑18(參照圖9(C))。In this embodiment, the step of attaching a thin film resist and exposing is repeated twice to form a resist layer 16 with a double layer thickness of 56 μm. Thereafter, a process of dissolving and removing the unexposed resist layer 16 b exposed on the surface was performed to form a secondary pattern resist 18 covering the pattern forming region 2 a with a thickness of 112 μm (see FIG. 9(C) ).

如此形成二次圖案抗蝕劑18後,將在經由上述框體形成步驟已形成之框體3的下表面側預先配置有接著層19者對位配置於一次電沉積層15上之預先設定的部位(參照圖9(C))。 該狀態的框體3藉由接著層19的黏著性,可不容易移動地暫時固定於一次電沉積層15上。After the secondary pattern resist 18 is formed in this way, on the lower surface side of the frame body 3 that has been formed through the above-mentioned frame body forming step, the adhesive layer 19 is preliminarily arranged on the primary electrodeposited layer 15 in a predetermined position. site (see Figure 9(C)). The frame body 3 in this state can be temporarily fixed on the primary electrodeposited layer 15 so as not to move easily by the adhesiveness of the adhesive layer 19 .

對暫時固定的框體3執行從框體3的上方施加負載進行壓接的步驟,使框體3不容易從一次電沉積層15分離(參照圖10)。具體而言,首先,作為暫時壓接,對框體3施加特定時間的將其向基材側壓接的靜負載。即,在框體3上載置50 kg以上,例如105 kg的玻璃板等,放置1小時以上,例如放置4小時。再者,該暫時壓接中,作為靜負載,只要是可載置於框體3上的物體,亦可使用玻璃板以外的物體。The temporarily fixed frame 3 is crimped by applying a load from above the frame 3 so that the frame 3 is not easily separated from the primary electrodeposited layer 15 (see FIG. 10 ). Specifically, first, as temporary pressure bonding, a static load is applied to the frame body 3 for a predetermined period of time to pressure bond it to the base material side. That is, a glass plate weighing 50 kg or more, eg, 105 kg, is placed on the frame body 3 and left to stand for 1 hour or more, for example, 4 hours. In this temporary pressure bonding, as the static load, as long as it can be placed on the frame body 3, an object other than a glass plate may be used.

接續,作為正式壓接,均勻地壓製框體3各部而牢固地固定於一次電沉積層15。作為具體例,在去除玻璃板等後,相對於框體3相對移動,同時以0.1 MPa以上、例如0.6 MPa的壓力按壓之加壓輥(積層機)在框體3上往返一次以上,例如往返三次,而執行壓製。Next, as final crimping, each part of the frame body 3 is uniformly pressed to be firmly fixed to the primary electrodeposited layer 15 . As a specific example, after removing the glass plate, etc., relatively move relative to the frame body 3, and at the same time press the pressure roller (laminator) with a pressure of 0.1 MPa or more, such as 0.6 MPa, on the frame body 3. Three times while performing the suppression.

作為該正式壓接,利用加壓輥進行按壓時,使不容易變形之剛性高的板體、例如由SUS材料構成的板介於框體3與輥之間,若介由該板體施行利用輥之按壓,則來自輥的力被板體分散而傳遞至框體3,相較於利用輥直接進行按壓的情況,難以產生按壓力的偏差,從而較佳。As this final crimping, when pressing with a pressure roller, a rigid plate body that is not easily deformed, such as a plate made of SUS material, is interposed between the frame body 3 and the rollers. In the pressing of the rollers, the force from the rollers is dispersed by the plate and transmitted to the frame body 3, which is preferable because it is less likely to cause variations in the pressing force than the case of direct pressing with the rollers.

此外,亦可使重合了剛性高的板體及橡膠等的彈性體製之片材者,以片材側面向框體3的狀態介於框體3與輥之間,經由該等板體及片材進行利用輥的按壓。於該情況,可藉由介於板體與框體之間的片材之彈性變形吸收因板體表面的些許傾斜、應變、凹凸等而引起的板體與框體之間隔的不均勻狀態,來自輥之力經由與框體3緊貼之片材而更均勻地傳遞至框體3,可對一次電沉積層15更進一步均勻地壓接框體3,可抑制在框體3與一次電沉積層15之間產生間隙,防止金屬層7形成時因間隙而導致之鍍覆的異常成長等不良影響。In addition, it is also possible to make a sheet made of an elastic system such as a high-rigidity plate body and rubber, which is interposed between the frame body 3 and the roller in a state where the side of the sheet material faces the frame body 3, and pass through the plate body and the sheet material. The material is pressed with a roller. In this case, the unevenness of the interval between the board and the frame caused by slight inclination, strain, unevenness, etc. on the surface of the board can be absorbed by the elastic deformation of the sheet between the board and the frame. The force of the roller is more evenly transmitted to the frame body 3 through the sheet close to the frame body 3, and the primary electrodeposition layer 15 can be further uniformly pressed against the frame body 3, which can suppress the Gaps are formed between the buildup layers 15 to prevent adverse effects such as abnormal growth of plating caused by the gaps during the formation of the metal layer 7 .

再者,除使用加壓輥(積層機)進行作為正式壓接之框體3的按壓外,亦可使用可使按壓部分僅沿框體3的厚度方向作動來按壓框體3之壓式的裝置,不會如使用輥進行壓製之情況般存在自滾動之輥錯誤地對框體施加輥切線方向(橫向)的力而導致框體的橫向偏移的問題,從而較佳。Furthermore, in addition to using a pressure roller (laminator) to press the frame body 3 as the final crimping, it is also possible to use a pressing type that can press the frame body 3 by moving the pressing part only in the thickness direction of the frame body 3. It is preferable that the device does not have the problem that the self-rolling roller erroneously applies a force in the direction of the roller tangential (lateral direction) to the frame, as in the case of pressing using a roller, causing the frame to shift laterally.

如此壓接步驟之後,在未被二次圖案抗蝕劑18覆蓋而露出於圖案形成區域2a的之外周緣2b的表面之一次電沉積層15的上表面、在框體3下側之一次電沉積層15a及其側方露出於表面之基材10的各露出面、及框體3的表面上,藉由電沉積金屬的鍍覆形成金屬層7(參照圖11(B))。利用該金屬層7,可將一次電沉積層15及框體3以不分離的方式連結成一體。After such a crimping step, on the upper surface of the primary electrodeposited layer 15 that is not covered by the secondary pattern resist 18 but exposed on the surface of the outer periphery 2b of the pattern formation area 2a, the primary electrodeposited layer on the lower side of the frame body 3 The deposition layer 15a and the exposed surfaces of the base material 10 whose sides are exposed on the surface, and the surface of the frame 3 form the metal layer 7 by electro-deposited metal plating (see FIG. 11(B) ). With this metal layer 7, the primary electrodeposited layer 15 and the frame body 3 can be integrally connected without being separated.

於該情況,就金屬層7而言,相對於露出於圖案形成區域2a的外周緣2b的表面之一次電沉積層15的上表面或於一次電沉積層15與框體3之間露出於表面之基材10表面的厚度,框體3的表面之金屬層7的厚度形成得更薄。該厚度的差異是由於,金屬層7從基材10或一次電沉積層15的表面起依序積層,當超過接著層19的高度尺寸而達到框體3時,框體3始成為與基材10或一次電沉積層15導通的狀態,開始向框體3的表面形成金屬層7。In this case, the metal layer 7 is exposed to the upper surface of the primary electrodeposition layer 15 on the surface exposed on the outer peripheral edge 2b of the pattern formation region 2a or between the primary electrodeposition layer 15 and the frame body 3. The thickness of the surface of the substrate 10 and the thickness of the metal layer 7 on the surface of the frame body 3 are formed thinner. The difference in thickness is due to the fact that the metal layer 7 is stacked sequentially from the surface of the substrate 10 or the primary electrodeposition layer 15. When the height dimension of the next layer 19 is exceeded and the frame 3 is reached, the frame 3 begins to be in contact with the substrate. 10 or the state where the primary electrodeposited layer 15 is turned on, the metal layer 7 starts to be formed on the surface of the frame body 3 .

金屬層7的形成完成後,作為最終步驟,從基材10剝離一體之一次電沉積層15、框體3及金屬層7(參照圖11(C))。進而,將存在於框體3的下側之一次電沉積層15a與接著層19一同去除,接著,去除二次圖案抗蝕劑18,藉此,完成蒸鍍罩1的製造。再者,於框體3的下側殘留有接著層19的情況,在二次圖案抗蝕劑18之去除時進行去除。After the formation of the metal layer 7 is completed, as a final step, the integrated primary electrodeposition layer 15 , frame body 3 , and metal layer 7 are peeled off from the substrate 10 (see FIG. 11(C) ). Furthermore, the primary electrodeposited layer 15 a present on the lower side of the frame body 3 is removed together with the adhesive layer 19 , and then the secondary pattern resist 18 is removed, thereby completing the manufacture of the vapor deposition mask 1 . In addition, when the adhesive layer 19 remains on the lower side of the frame body 3, it removes it when the pattern resist 18 is removed twice.

如此,本實施方式之蒸鍍罩將框體3之內框部5中最小寬度部的截面形狀成為其寬度與厚度的關係適當者,可靠地賦予最小寬度部的彎曲剛性,因此,賦予相對於來自罩主體2側的力之所需充分的強度,與較該最小寬度部寬度寬且強度高之框體3的其他部分,一同作為框體3整體而抑制罩主體2各部之從本應存在的位置的偏移,可確保蒸鍍步驟中罩與被蒸鍍基板的整合狀態,可在被蒸鍍基板的適當的位置高精度地進行蒸鍍。另外,藉由最小寬度部的彎曲變形的難度,可抑制最小寬度部之自身重量引起的撓曲,抑制框體3的變形及由此引起之對罩主體2的影響。In this way, the vapor deposition cover of this embodiment makes the cross-sectional shape of the minimum width part in the inner frame part 5 of the frame body 3 an appropriate relationship between the width and thickness, and reliably imparts bending rigidity to the minimum width part. The required and sufficient strength of the force from the side of the cover main body 2, together with other parts of the frame body 3 that are wider and stronger than the minimum width portion, together with the frame body 3 as a whole, prevents the parts of the cover main body 2 from existing. The offset of the position can ensure the integrated state of the cover and the substrate to be evaporated in the evaporation step, and can perform evaporation at an appropriate position of the substrate to be evaporated with high precision. In addition, due to the difficulty of bending deformation of the minimum width portion, the deflection caused by the weight of the minimum width portion can be suppressed, and the deformation of the frame body 3 and its influence on the cover main body 2 can be suppressed.

再者,上述實施方式之蒸鍍罩之構成為,罩主體2以位於框體3之各開口區域6的方式配設,且形成為在內部僅配置一個設有多個蒸鍍通孔8之圖案形成區域2a,但不限於此,如圖12所示,亦可為罩主體2具有多個圖案形成區域2a之構成。於該情況,為了可靠地抑制罩主體2的錯位,較佳為將罩主體周圍的框體各部的寬度形成為較作為最小寬度部而容許的寬度尺寸大,而確保充分的剛性。此外,亦可以代替將位於框體3之各開口區域6之罩主體2僅設為一個的結構,而構成為在一個開口區域6排列配置多個罩主體2。於該情況,罩主體2的外周緣分成與框體3相鄰的部位及在罩主體彼此相鄰的部位,在該罩主體彼此相鄰的部位,與將罩主體2及框體3接合成一體的情況相同,將罩主體彼此利用藉由鍍覆形成之金屬層接合成一體。Furthermore, the vapor deposition cover of the above-mentioned embodiment is configured such that the cover main body 2 is arranged so as to be located in each opening area 6 of the frame body 3, and is formed so that only one with a plurality of vapor deposition through holes 8 is arranged inside. The pattern forming area 2a is not limited thereto, and as shown in FIG. 12 , the cover main body 2 may have a plurality of pattern forming areas 2a. In this case, in order to reliably suppress the displacement of the cover body 2, it is preferable to form the width of each part of the frame around the cover body larger than the allowable width dimension as the minimum width part to ensure sufficient rigidity. In addition, instead of providing only one cover main body 2 located in each opening area 6 of the frame body 3 , a plurality of cover main bodies 2 may be arranged in line in one opening area 6 . In this case, the outer peripheral edge of the cover main body 2 is divided into a portion adjacent to the frame body 3 and a portion adjacent to the cover main body. The case of integration is the same, and the cover main bodies are joined together by metal layers formed by plating.

另外,上述實施方式之蒸鍍罩構成為,框體3為同一形狀之第一框構件3a及第二框構件3b一體化接合而形成,但不限於此,亦可構成為,使第一框構件3a及第二框構件3b的形狀不同,例如,如圖13所示,相對於接近罩主體2側之第二框構件3b的開口,將遠離罩主體2的側的第一框構件3a的開口設置得更大,將第二框構件3b中各部的寬度形成為較第一框構件3a大,再將第一框構件3a及第二框構件3b一體化接合而形成框體3。於該情況,框體3的開口區域6在遠離罩主體2的部位變寬,成為包圍開口區域6的周緣部分為後退的狀態,藉此,在蒸鍍步驟中,相對於經由框體3之開口區域6及罩主體2的蒸鍍通孔8朝向蒸鍍對象基板的蒸鍍材料,框體3中的開口區域6周圍的周緣部分難以成為妨礙蒸鍍材料的行進的障礙物,可對各蒸鍍通孔8排除框體3的影響,使蒸鍍材料順利地行進,可更適當地執行蒸鍍。In addition, the vapor deposition cover of the above-mentioned embodiment is configured such that the frame body 3 is formed by integrally joining the first frame member 3a and the second frame member 3b of the same shape, but it is not limited thereto, and may be configured so that the first frame The shapes of the member 3a and the second frame member 3b are different. For example, as shown in FIG. The opening is made larger, the width of each part of the second frame member 3b is made larger than that of the first frame member 3a, and the first frame member 3a and the second frame member 3b are integrally joined to form the frame body 3 . In this case, the opening area 6 of the frame body 3 is widened at a position away from the cover main body 2, and the peripheral portion surrounding the opening area 6 is in a receded state. The vapor deposition through hole 8 of the opening area 6 and the cover main body 2 faces the vapor deposition material of the vapor deposition target substrate, and the peripheral portion around the opening area 6 in the frame body 3 is difficult to become an obstacle hindering the progress of the vapor deposition material, and can be used for each The vapor deposition through hole 8 eliminates the influence of the frame 3, so that the vapor deposition material can travel smoothly, and the vapor deposition can be performed more properly.

另外,上述實施方式之蒸鍍罩的製造構成為,以與一次電沉積層15及框體3相接的方式形成金屬層7,利用金屬層7謀求一次電沉積層15及框體3的一體化,但不限於此,亦可構成為,對下側之一次電沉積層15,將框體3,以較未硬化的薄膜抗蝕劑強力的接著劑介在並載置,而利用接著將一次電沉積層15及框體3一體化,可簡單執行一次電沉積層,即罩主體2與框體3的一體化,謀求罩的製造效率的提高。於該情況,進而,以覆蓋罩主體2的表面及框體3的表面的方式形成金屬層,藉此,可將罩主體2與框體3的接合狀態形成為更佳者。特別是藉由利用金屬層覆蓋接著劑的表面(側部),可有效防止因清洗處理或升溫而引起的接著劑的變質,可長期維持罩主體2與框體3的接合狀態。In addition, the manufacturing structure of the vapor deposition cover of the above-mentioned embodiment is such that the metal layer 7 is formed in contact with the primary electrodeposited layer 15 and the frame body 3, and the primary electrodeposited layer 15 and the frame body 3 are integrated by the metal layer 7. However, it is not limited thereto. It may also be configured such that the frame body 3 is interposed and placed on the primary electrodeposited layer 15 on the lower side with an adhesive stronger than the unhardened film resist, and then the primary electrodeposited layer 15 is used. The electrodeposition layer 15 and the frame body 3 are integrated, and the electrodeposition layer, that is, the integration of the cover body 2 and the frame body 3 can be easily performed once, and the manufacturing efficiency of the cover can be improved. In this case, furthermore, by forming the metal layer so as to cover the surface of the cover main body 2 and the surface of the frame body 3, the joint state of the cover main body 2 and the frame body 3 can be made more favorable. In particular, by covering the surface (side) of the adhesive with the metal layer, deterioration of the adhesive due to cleaning or temperature rise can be effectively prevented, and the bonded state between the cover body 2 and the frame 3 can be maintained for a long period of time.

另外,上述實施方式之蒸鍍罩的製造中,在基材10上配置框體3後,在框體3表面形成金屬層7,但不限於此,亦可構成為,在藉由鍍覆形成金屬層7前,在框體上表面的一部分或整體配設抗蝕劑,不在整個框體上表面形成金屬層7,而於所需的部位以外,將金屬層7僅於框體上表面的一部分設置、省略,並在框體3表面設置應力緩和部。In addition, in the manufacture of the vapor deposition cover of the above-mentioned embodiment, after disposing the frame body 3 on the base material 10, the metal layer 7 is formed on the surface of the frame body 3, but it is not limited to this, and it may also be configured such that it is formed by plating. In front of the metal layer 7, a resist is provided on a part or the whole of the upper surface of the frame, so that the metal layer 7 is not formed on the entire upper surface of the frame, and the metal layer 7 is only placed on the upper surface of the frame except for the required parts. A part is provided, omitted, and a stress relieving part is provided on the surface of the frame body 3 .

於該情況,在框體3的上表面,金屬層7並非一樣地連續,而是局部性、不完整的,藉此即使在金屬層產生內部應力,亦不會作用於整個框體3,而是局部性地、間斷性地作用,框體3難以受到變形等不良影響,可確保平面形狀。In this case, on the upper surface of the frame body 3, the metal layer 7 is not uniformly continuous, but localized and incomplete, so that even if internal stress occurs in the metal layer, it will not act on the entire frame body 3, and Since it acts locally and intermittently, the frame body 3 is less likely to be affected by deformation or the like, and the planar shape can be ensured.

另外,上述實施方式之蒸鍍罩的製造中,在形成一次電沉積層15之後,在一次電沉積層不特別進行表面處理,而形成金屬層7,但不限於此,亦可在形成一次電沉積層15後且形成金屬層7前之階段,對一次電沉積層15中重疊配設金屬層之預定的特定範圍實施酸浸、電解處理等活化處理。In addition, in the manufacture of the vapor deposition mask of the above-mentioned embodiment, after forming the primary electrodeposited layer 15, the metal layer 7 is formed on the primary electrodeposited layer without special surface treatment. After the layer 15 is deposited and before the metal layer 7 is formed, activation treatments such as acid leaching and electrolytic treatment are performed on the predetermined specific range where the metal layer is overlapped in the primary electrodeposition layer 15 .

於該情況,與無處理的情況相比,謀求一次電沉積層15之活化處理部分與其上之金屬層7之間的接合強度之大幅提高。另外,亦可以對一次電沉積層15的特定範圍形成衝擊鎳(strike nickel)、無光澤鎳等之薄層代替活化處理。藉此亦可謀求一次電沉積層15之薄層形成部分與其上之金屬層7之接合強度的提高。In this case, compared with the case of no treatment, the bonding strength between the activation-treated portion of the primary electrodeposited layer 15 and the metal layer 7 thereon is greatly improved. In addition, instead of activation treatment, a thin layer of strike nickel, matte nickel, or the like may be formed on a specific range of the primary electrodeposition layer 15 . Thereby, the bonding strength between the thin layer forming portion of the primary electrodeposited layer 15 and the metal layer 7 thereon can also be improved.

另外,上述實施方式之蒸鍍罩的製造構成為,一次電沉積層15或框體3與金屬層7重疊之處單純地以平面彼此接觸,此外,亦可構成為,遍及一次電沉積層15(罩主體2)中之圖案形成區域2a之外周緣2b的整周設置多個貫通孔或凹部,對於形成於一次電沉積層15的外周緣2b上之金屬層7,埋入上述貫通孔或凹部而形成為金屬層7局部沒入外周緣2b的狀態。In addition, the manufacturing configuration of the vapor deposition cover of the above-mentioned embodiment is such that the primary electrodeposition layer 15 or the overlapped portion of the frame body 3 and the metal layer 7 are simply in contact with each other on a plane. (Cover main body 2) A plurality of through-holes or recesses are provided around the outer periphery 2b of the pattern forming region 2a, and the metal layer 7 formed on the outer periphery 2b of the primary electrodeposited layer 15 is buried in the above-mentioned through-holes or recesses. The concave portion is formed in a state where the metal layer 7 partially sinks into the outer peripheral edge 2b.

於該情況,金屬層7相對於一次電沉積層15不僅存在於圖案形成區域2a之外周緣2b的上表面,亦存在於外周緣2b之各貫通孔或凹部內,使與一次電沉積層15之外周緣2b的接合強度更大。藉此,經由金屬層7可將罩主體2及框體3更牢固地一體化連結,能可靠地抑制罩主體2相對於框體3之不經意的脫落或錯位,可謀求進一步提高蒸鍍精度及蒸鍍形成物的再現精度。In this case, the metal layer 7 exists not only on the upper surface of the outer peripheral edge 2b of the pattern forming region 2a, but also in each through hole or recess of the outer peripheral edge 2b relative to the primary electrodeposited layer 15. The bonding strength of the outer peripheral edge 2b is greater. Thereby, the cover main body 2 and the frame body 3 can be integrally connected more firmly through the metal layer 7, and the inadvertent fall-off or misalignment of the cover main body 2 relative to the frame body 3 can be reliably suppressed, and further improvement in vapor deposition accuracy and Reproducibility of vapor deposition formations.

另外,上述實施方式之蒸鍍罩的製造中,對於在基材10的未被一次圖案抗蝕劑14覆蓋的表面形成之成為罩主體2之一次電沉積層15的構造雖未特別詳述,但亦可將該一次電沉積層15做成形成於基材10側之無光澤鎳層及形成於該無光澤鎳層上的光澤鎳層的雙層構造。詳細而言,在基材10的未被一次圖案抗蝕劑14覆蓋的表面,藉由電鑄形成由無光澤鎳構成之電沉積層後,於其上藉由電鑄形成由光澤鎳構成的電沉積層,而製成一次電沉積層15。就無光澤鎳層與光澤鎳層的厚度的關係而言,若使無光澤鎳層過厚,則在完成後的罩主體2產生的張力過度變大,有導致框體3的變形之虞,因此,較佳為光澤鎳層相對於無光澤鎳層的厚度的比例為約5/7。In addition, in the manufacture of the vapor deposition mask of the above-mentioned embodiment, the structure of the primary electrodeposited layer 15 to be the mask main body 2 formed on the surface of the substrate 10 not covered by the primary pattern resist 14 is not specifically described in detail. However, the primary electrodeposited layer 15 may also have a two-layer structure of a matte nickel layer formed on the substrate 10 side and a glossy nickel layer formed on the matte nickel layer. Specifically, on the surface of the substrate 10 that is not covered with the primary pattern resist 14, after forming an electrodeposited layer made of matte nickel by electroforming, a layer made of glossy nickel is formed thereon by electroforming. electrodeposited layer to make the primary electrodeposited layer 15. Regarding the relationship between the thicknesses of the matte nickel layer and the glossy nickel layer, if the matte nickel layer is too thick, the tension generated in the completed cover main body 2 becomes excessively large, which may cause deformation of the frame body 3. Therefore, it is preferable that the ratio of the thickness of the glossy nickel layer to the matte nickel layer is about 5/7.

亦可將無光澤鎳層及光澤鎳層的形成順序顛倒,製成在光澤鎳層上形成有無光澤鎳層之雙層構造。然而,於該後者的在光澤鎳層上形成有無光澤鎳層之雙層構造的情況,考慮到發生層間剝離的機率較前者之雙層構造的情況高,故較佳為採用前者之在無光澤鎳層上形成有光澤鎳層之雙層構造。It is also possible to reverse the formation order of the matte nickel layer and the glossy nickel layer to form a two-layer structure in which the matte nickel layer is formed on the glossy nickel layer. However, in the case of the latter two-layer structure in which a matte nickel layer is formed on a glossy nickel layer, it is preferable to use the former in the case of a matte nickel layer, considering that the probability of interlayer delamination is higher than that of the former two-layer structure. A double-layer structure of a shiny nickel layer is formed on the nickel layer.

如此,採用在無光澤鎳層之上側配置有光澤鎳層之雙層構造,並且使無光澤鎳層適度地較光澤鎳層厚,藉此在完成後的罩主體2中,可增大欲向內方收縮的張力(拉伸應力),可得到即使受到因熱而引起之各部的膨脹的影響,罩主體2亦不會變形之耐熱性優異之蒸鍍罩1。In this way, by adopting a two-layer structure in which the glossy nickel layer is disposed on the upper side of the matte nickel layer, and making the matte nickel layer moderately thicker than the glossy nickel layer, the desired orientation can be increased in the completed cover main body 2. The tension (tensile stress) of the inner contraction can provide the vapor deposition cover 1 with excellent heat resistance without deformation of the cover main body 2 even under the influence of expansion of each part due to heat.

再者,在僅由無光澤鎳形成一次電沉積層的情況,在完成後的罩主體2產生之張力過度變大,有導致框體3的變形之虞,且成為該一次電沉積層之無光澤鎳層的表面為粗糙面,故對表面之鍍覆等的接合力變大,在罩製造步驟中容易產生無法分離一次電沉積層15a及金屬層7等問題。上述在無光澤鎳層上形成有光澤鎳層之雙層構造之一次電沉積層亦可避免此問題。在該無光澤鎳層上形成有光澤鎳層之雙層構造的情況,在一次電沉積層的光澤鎳層部分,儘管接合力相比於無光澤鎳層變小,一次電沉積層15及金屬層7相應地容易分離,然而,藉由對一次電沉積層之通孔的形成、活化處理、或衝擊鎳、無光澤鎳等之薄層形成等,可充分地確保與金屬層的接合強度。Furthermore, in the case where only the primary electrodeposition layer is formed of matte nickel, the tension generated in the cover main body 2 after completion becomes excessively large, which may cause deformation of the frame body 3, and become a failure of the primary electrodeposition layer. The surface of the glossy nickel layer is rough, so the bonding force to the surface such as plating becomes large, and problems such as inability to separate the primary electrodeposited layer 15a and the metal layer 7 easily occur in the mask manufacturing step. This problem can also be avoided by the above-mentioned primary electrodeposited layer with a double-layer structure of a glossy nickel layer formed on a matte nickel layer. In the case where a two-layer structure of a glossy nickel layer is formed on the matte nickel layer, in the glossy nickel layer part of the primary electrodeposited layer, although the bonding force becomes smaller than that of the matte nickel layer, the primary electrodeposited layer 15 and the metal The layer 7 is correspondingly easy to separate, however, the bonding strength with the metal layer can be sufficiently ensured by forming a through hole to the primary electrodeposited layer, activation treatment, or forming a thin layer of impact nickel, matte nickel, or the like.

1‧‧‧蒸鍍罩2‧‧‧罩主體2a‧‧‧圖案形成區域2b‧‧‧外周緣3‧‧‧框體3a‧‧‧第一框構件3b‧‧‧第二框構件3c‧‧‧接著層4‧‧‧外框部5‧‧‧內框部6‧‧‧開口區域7‧‧‧金屬層8‧‧‧蒸鍍通孔9‧‧‧蒸鍍圖案10‧‧‧基材11‧‧‧抗蝕劑層12‧‧‧罩膜12a‧‧‧透光孔14‧‧‧一次圖案抗蝕劑15、15a‧‧‧一次電沉積層16‧‧‧抗蝕劑層16a、16b‧‧‧抗蝕劑層17‧‧‧罩膜17a‧‧‧透光孔18‧‧‧二次圖案抗蝕劑19‧‧‧接著層1‧‧‧evaporation cover 2‧‧‧cover main body 2a‧‧‧pattern forming area 2b‧‧‧outer peripheral edge 3‧‧‧frame body 3a‧‧‧first frame member 3b‧‧‧second frame member 3c‧ . Material 11‧‧‧resist layer 12‧‧‧cover film 12a‧‧‧opaque 14‧‧‧primary pattern resist 15, 15a‧‧‧primary electrodeposition layer 16‧‧‧resist layer 16a , 16b‧‧‧resist layer 17‧‧‧cover film 17a‧‧‧light-transmitting hole 18‧‧‧secondary pattern resist 19‧‧‧adhesion layer

圖1是本發明之一實施方式之蒸鍍罩的概略俯視圖。 圖2是本發明之一實施方式之蒸鍍罩的主要部分結構說明圖。 圖3是本發明之一實施方式之蒸鍍罩的主要部分概略截面圖。 圖4是本發明之一實施方式之蒸鍍罩之框體的俯視圖。 圖5是本發明之一實施方式之蒸鍍罩之框體的形成步驟說明圖。 圖6是本發明之一實施方式之蒸鍍罩的製造中之一次圖案抗蝕劑形成過程說明圖。 圖7是本發明之一實施方式之蒸鍍罩的製造中之一次電沉積層形成步驟說明圖。 圖8是本發明之一實施方式之蒸鍍罩的製造中之二次圖案抗蝕劑形成過程前半說明圖。 圖9是本發明之一實施方式之蒸鍍罩的製造中之二次圖案抗蝕劑形成過程後半說明圖。 圖10是本發明之一實施方式之蒸鍍罩的製造中之框體的壓接步驟說明圖。 圖11是本發明之一實施方式之蒸鍍罩的製造中之金屬層形成步驟及蒸鍍罩與基材的分離狀態說明圖。 圖12是本發明之一實施方式之蒸鍍罩的另一例的概略俯視圖。 圖13是本發明之一實施方式之蒸鍍罩的另一框體的俯視圖及概略截面圖。FIG. 1 is a schematic plan view of a vapor deposition cover according to one embodiment of the present invention. FIG. 2 is an explanatory view showing the configuration of main parts of a vapor deposition cover according to an embodiment of the present invention. Fig. 3 is a schematic sectional view of main parts of a vapor deposition cover according to an embodiment of the present invention. FIG. 4 is a plan view of a frame of a vapor deposition cover according to an embodiment of the present invention. FIG. 5 is an explanatory diagram of steps of forming a frame of a vapor deposition cover according to an embodiment of the present invention. Fig. 6 is an explanatory diagram of a primary pattern resist formation process in the manufacture of the vapor deposition mask according to the embodiment of the present invention. Fig. 7 is an explanatory diagram of a step of forming a primary electrodeposited layer in the manufacture of a vapor deposition mask according to an embodiment of the present invention. FIG. 8 is an explanatory view of the first half of the secondary pattern resist formation process in the manufacture of the vapor deposition mask according to the embodiment of the present invention. FIG. 9 is an explanatory diagram of the second half of the second pattern resist formation process in the manufacture of the vapor deposition mask according to the embodiment of the present invention. FIG. 10 is an explanatory diagram of a crimping process of a frame in the manufacture of a vapor deposition cover according to an embodiment of the present invention. FIG. 11 is an explanatory diagram of a metal layer forming step and a separation state of the vapor deposition mask and the base material in the manufacture of the vapor deposition mask according to the embodiment of the present invention. Fig. 12 is a schematic plan view of another example of the vapor deposition cover according to the embodiment of the present invention. 13 is a plan view and a schematic cross-sectional view of another frame of the vapor deposition cover according to the embodiment of the present invention.

1‧‧‧蒸鍍罩 1‧‧‧Evaporation cover

2‧‧‧罩主體 2‧‧‧Cover main body

2a‧‧‧圖案形成區域 2a‧‧‧pattern formation area

2b‧‧‧外周緣 2b‧‧‧outer periphery

3‧‧‧框體 3‧‧‧frame

Claims (6)

一種蒸鍍罩,其具備:多個罩主體,其將獨立的多個蒸鍍通孔以特定圖案設置;及框體,其配置於罩主體之周圍;上述蒸鍍罩之特徵在於:上述框體具有:位於最外周的矩形或方形之外框部、及將該外框部的內側劃分成多個開口區域之內框部,且作為整體形成為格子狀,上述罩主體各自位於框體之多個開口區域,且與上述框體一體化而成,上述框體之上述內框部中,成為於上述框體之厚度方向之最窄寬度的部分之截面形狀為:厚度尺寸相對於寬度尺寸的比例為0.8/4以上且2/4以下。 An evaporation cover, which includes: a plurality of cover main bodies, which arrange a plurality of independent evaporation through holes in a specific pattern; and a frame, which is arranged around the cover main body; the above-mentioned evaporation cover is characterized in that: the above-mentioned frame The body has: a rectangular or square outer frame portion located on the outermost periphery, and an inner frame portion that divides the inner side of the outer frame portion into a plurality of opening areas, and is formed in a lattice shape as a whole, and the above-mentioned cover main bodies are respectively located on the frame body. A plurality of opening areas are integrated with the above-mentioned frame body. Among the above-mentioned inner frame parts of the above-mentioned frame body, the cross-sectional shape of the part with the narrowest width in the thickness direction of the above-mentioned frame body is: thickness dimension relative to width dimension The ratio of 0.8/4 or more and 2/4 or less. 如請求項1之蒸鍍罩,其中,上述框體之上述外框部及上述內框部中,成為於上述框體之厚度方向之最窄寬度的部分以外的截面形狀為:厚度尺寸相對於寬度尺寸的比例為0.8/90以上,且較上述內框部中成為最窄寬度的部分之厚度尺寸相對於寬度尺寸的比例小。 The vapor deposition cover according to claim 1, wherein, among the above-mentioned outer frame portion and the above-mentioned inner frame portion of the above-mentioned frame body, the cross-sectional shape other than the portion having the narrowest width in the thickness direction of the frame body is: the thickness dimension is relative to The ratio of the width dimension is 0.8/90 or more, and is smaller than the ratio of the thickness dimension to the width dimension of the narrowest portion of the inner frame portion. 如請求項1之蒸鍍罩,其以上述框體的厚度尺寸成為0.8mm以上且2mm以下之方式形成。 The vapor deposition cover according to claim 1 is formed such that the thickness dimension of the frame is 0.8 mm or more and 2 mm or less. 如請求項2之蒸鍍罩,其以上述框體的厚度尺寸成為0.8mm以上且2mm以下之方式形成。 The vapor deposition cover according to claim 2 is formed such that the thickness dimension of the frame is 0.8 mm or more and 2 mm or less. 如請求項1至4中任一項之蒸鍍罩,其中,上述框體為將第一框構件及第二框構件重疊而一體化的積層構造,上述第一框構件及上述第二框構件為由金屬薄板原料而形成之具有翹曲的框構件,且將各自之翹曲方向朝向相反方向。 The vapor deposition cover according to any one of claims 1 to 4, wherein the frame body is a laminated structure in which the first frame member and the second frame member are overlapped and integrated, and the first frame member and the second frame member are It is a warped frame member formed from a sheet metal material, and the respective warped directions are directed in opposite directions. 如請求項1至4中任一項之蒸鍍罩,其中,使上述內框部的材質及上述外框部的材質不同而形成上述框體。The vapor deposition cover according to any one of claims 1 to 4, wherein the frame body is formed by making the material of the inner frame part and the material of the outer frame part different.
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