Shadow mask for OLED evaporation and manufacturing method therefor, and OLED panel manufacturing method

Patent metadata

Field	Value
Publication number	US-11038009-B2
Application number	US-201916599734-A
Country	US
Kind code	B2
Filing date	Oct 11, 2019
Priority date	Apr 14, 2017
Publication date	Jun 15, 2021
Grant date	Jun 15, 2021

Abstract

A shadow mask used for OLED evaporation and a manufacturing method therefor, and an OLED panel manufacturing method. The shadow mask used for OLED evaporation includes: a semiconductor substrate including a front surface and a back surface opposite thereto, a recess penetrating the front surface and the back surface being provided in the semiconductor substrate; and a grid film layer provided on the front surface of the semiconductor substrate. A number of openings arranged in an array are provided in the grid film layer. Each of the openings has an upper portion and a lower portion. A width of the upper portion is greater than a width of the lower portion. The recess exposes the number of openings in the grid film layer and the grid film layer between adjacent openings.

First claim

What is claimed is:

1. A method for manufacturing a shadow mask for OLED evaporation, comprising:
providing a first semiconductor substrate, the first semiconductor substrate comprising a front surface and a back surface opposite thereto;
forming a grid film layer on the front surface of the first semiconductor substrate;
forming a number of openings arranged in an array in the grid film layer, wherein each of the openings has an upper portion and a lower portion and a width of the upper portion is greater than a width of the lower portion;
providing a second semiconductor substrate, the second semiconductor substrate comprising a front surface and a back surface opposite thereto;
bonding the second semiconductor substrate and the first semiconductor substrate, the front surface of the second semiconductor substrate facing the grid film layer on the front surface of the first semiconductor substrate;
performing etching along the back surface of the second semiconductor substrate to remove a part of the second semiconductor substrate to form a recess in the second semiconductor substrate, the recess exposing the number of openings in the grid film layer and the grid film layer between adjacent openings; and
removing the first semiconductor substrate to expose the grid film layer and the openings in the grid film layer.

2. The method for manufacturing a shadow mask for OLED evaporation according to claim 1 , wherein a process of forming the grid film layer comprises: forming a grid thin film layer covering the front surface, the back surface, and side surfaces of the first semiconductor substrate; forming a first hard mask layer on a surface of the grid thin film layer on the front surface of the first semiconductor substrate; and performing etching to remove the grid thin film layer on the back surface and the side surfaces of the first semiconductor substrate, the grid thin film layer remaining on the front surface of the first semiconductor substrate serving as the grid film layer.

3. The method for manufacturing a shadow mask for OLED evaporation according to claim 2 , wherein the grid film layer and the grid thin film layer have tensile stress.

4. The method for manufacturing a shadow mask for OLED evaporation according to claim 2 , wherein a process of forming a number of openings in the grid film layer comprises: patterning the first hard mask layer; etching the grid film layer remaining on the front surface of the first semiconductor substrate by using the patterned first hard mask layer as a mask, to form the number of openings arranged in an array in the grid film layer; and removing the patterned first hard mask layer.

5. The method for manufacturing a shadow mask for OLED evaporation according to claim 4 , wherein an inclination angle of a sidewall of each of the openings is 40° to 80°, and a size of each of the openings is 2 to 20 micrometers.

6. The method for manufacturing a shadow mask for OLED evaporation according to claim 1 , further comprising, prior to said bonding: forming a second hard mask layer covering the back surface and side surfaces of the second semiconductor substrate; and forming a bonding layer on the front surface of the second semiconductor substrate.

7. The method for manufacturing a shadow mask for OLED evaporation according to claim 6 , wherein a material of the bonding layer is silicon oxide.

8. The method for manufacturing a shadow mask for OLED evaporation according to claim 6 , wherein a process of forming the recess comprises: forming a patterned second photoresist layer on a surface of the second hard mask layer on the back surface of the second semiconductor substrate; etching the second hard mask layer on the back surface of the second semiconductor substrate by using the patterned second photoresist layer as a mask; and then etching the second semiconductor substrate and the bonding layer along the back surface of the second semiconductor substrate, to form the recess in the semiconductor substrate and the bonding layer, the recess exposing the number of openings in the grid film layer and the grid film layer between adjacent openings.

9. The method for manufacturing a shadow mask for OLED evaporation according to claim 8 , wherein the first semiconductor substrate is removed while etching the second semiconductor substrate.

10. The method for manufacturing a shadow mask for OLED evaporation according to claim 6 , further comprising, prior to said forming the second hard mask layer forming a third hard mask layer on the front surface of the second semiconductor substrate, the third hard mask layer having a mesh-shaped opening exposing the front surface of the second semiconductor substrate; forming a mesh-shaped support layer in the second semiconductor substrate along the mesh-shaped opening, a surface of the support layer being flush with the front surface of the second semiconductor substrate; and removing the third hard mask layer.

11. The method for manufacturing a shadow mask for OLED evaporation according to claim 10 , wherein a process of forming the mesh-shaped support layer comprises: doping B into the exposed second semiconductor substrate along the mesh-shaped opening; and then performing annealing.

12. The method for manufacturing a shadow mask for OLED evaporation according to claim 10 , wherein after said bonding, the mesh-shaped support layer is located on the bonding layer on a back surface of the grid film layer between adjacent openings.

13. The method for manufacturing a shadow mask for OLED evaporation according to claim 12 , wherein a width of the mesh-shaped support layer is smaller than a width of the grid film layer between adjacent openings.

14. The method for manufacturing a shadow mask for OLED evaporation according to claim 13 , wherein after the recess is formed, at least a part of the mesh-shaped support layer is connected to a part of the second semiconductor substrate exposed by the recess, or the mesh-shaped support layer is at least partially located in the second semiconductor substrate exposed by the recess.

15. A shadow mask for OLED evaporation, comprising:
a semiconductor substrate comprising a front surface and a back surface opposite thereto, a recess penetrating the front surface and the back surface being provided in the semiconductor substrate;
a grid film layer provided on the front surface of the semiconductor substrate, a number of openings arranged in an array being provided in the grid film layer, wherein each of the openings has an upper portion and a lower portion, a width of the upper portion is greater than a width of the lower portion, and the recess exposes the number of openings in the grid film layer and the grid film layer between adjacent openings; and
a bonding layer between the front surface of the semiconductor substrate and the grid film layer.

16. The shadow mask for OLED evaporation according to claim 15 , wherein the grid film layer has tensile stress.

17. The shadow mask for OLED evaporation according to claim 16 , wherein a material of the grid film layer is silicon nitride, the grid film layer has a thickness of 1 to 1.5 micrometers, the tensile stress in a magnitude of 100 to 400 MPa, and a surface roughness smaller than 20 nanometers.

18. The shadow mask for OLED evaporation according to claim 15 , wherein an inclination angle of a sidewall of each of the openings is 130° to 170°, and a size of each of the openings is 2 to 20 micrometers.

19. The shadow mask for OLED evaporation according to claim 16 , wherein a material of the

Assignees

• Seeya Optronics Co Ltd

Inventors

• Ju Yuhan
• Gu Tieer
• Kong Jie

Classifications

• H10K59/173

  comprising banks or shadow masks · CPC title

• C23C14/24 Primary

  Vacuum evaporation · CPC title

• C23C14/12

  Organic material · CPC title

• C23C14/042 Primary

  using masks · CPC title

• H01L51/0011

  Electricity · mapped topic