Optical patterning mask and method for fabricating display device using the same

Patent metadata

Field	Value
Publication number	US-9620744-B2
Application number	US-201514680054-A
Country	US
Kind code	B2
Filing date	Apr 6, 2015
Priority date	Oct 27, 2014
Publication date	Apr 11, 2017
Grant date	Apr 11, 2017

Abstract

The optical patterning mask had a protection layer on a light absorption layer. It prevents the light absorption layer from damaged by the cleaning gas when processing the used optical patterning mask for reuse. The protection layer may be made of the same material as bank layer or of material different from the bank layer. The bank layer defines the boundary of the area to be transferred in the transfer layer. The protection layer of the present invention can maintain longer the transfer efficiency of the optical patterning mask, even when the same mask is used repeatedly after cleaning, since the light absorption layer protected from cleaning process can maintain longer its heat conversion property.

First claim

What is claimed is:

1. An optical patterning mask, comprising:
a base substrate;
a reflective layer disposed on the base substrate and including an opening;
a thermal insulation layer disposed on the reflective layer to cover the opening;
a light absorption layer disposed on the thermal insulation layer;
a tapered layer arranged between the thermal insulation layer and the light absorption layer;
a protection layer disposed on the light absorption layer to overlap the opening;
a bank layer disposed on the light absorption layer to expose the protection layer; and
a transfer layer disposed on the protection layer and the bank layer,
wherein the protection layer is thinner than the bank layer,
wherein the transfer layer comprises a transfer inclination portion having an inclination in a portion that overlaps an edge of the opening, and
wherein the tapered layer includes a tapered inclination portion formed to expose a portion of the thermal insulation layer overlapping the opening.

2. The optical patterning mask of claim 1 , wherein the protection layer and the bank layer are integrally formed.

3. The optical patterning mask of claim 1 , wherein the protection layer and the bank layer are formed of same material.

4. The optical patterning mask of claim 1 , wherein the bank layer and the protection layer are formed of an inorganic material.

5. The optical patterning mask of claim 1 , wherein a portion of the transfer layer that overlaps the opening is flat.

6. The optical patterning mask of claim 1 , wherein the thermal insulation layer comprises a groove formed in a region overlapping the opening.

7. An optical patterning mask comprising:
a base substrate;
a reflective layer disposed on the base substrate and including an opening;
a thermal insulation layer disposed on the reflective layer to cover the opening;
a light absorption layer disposed on the thermal insulation layer;
a protection layer disposed on the light absorption layer;
a bank layer disposed on the protection layer so that a portion of the protection layer that overlaps the opening is exposed; and
a transfer layer disposed on a region of the protection layer that overlaps the opening and the bank layer,
wherein the protection layer is thinner than the bank layer, and
wherein the protection layer and the bank layer are formed of different materials.

8. The optical patterning mask of claim 7 , wherein the protection layer and the bank layer have different etching rates.

9. The optical patterning mask of claim 7 , wherein the bank layer and the protection layer are formed of an inorganic material.

10. The optical patterning mask of claim 7 , wherein a region of the transfer layer that overlaps the opening is flat.

11. The optical patterning mask of claim 7 , wherein the transfer layer comprises a transfer inclination portion having an inclination in a portion that overlaps an edge of the opening.

12. The optical patterning mask of claim 11 , wherein the thermal insulation layer comprises a groove formed in a region overlapping the opening.

13. The optical patterning mask of claim 11 , further comprising:
a tapered layer arranged between the thermal insulation layer and the light absorption layer,
wherein the tapered layer includes a tapered inclination portion formed to expose a portion of the thermal insulation layer overlapping the opening.

14. A method for fabricating a display device, comprising:
preparing an optical patterning mask comprising a base substrate, a reflective layer formed on the base substrate and including an opening, a thermal insulation layer formed on the reflective layer to cover the opening, a light absorption layer formed on the thermal insulation layer, a protection layer formed to overlap the opening, a bank layer formed on the light absorption layer to expose the protection layer, and a transfer layer formed on the protection layer and the bank layer; arranging a substrate over an upper portion of the optical patterning mask so that the transfer layer faces a first electrode of a substrate of the display device; forming a material layer on the substrate by transferring a transfer material of the transfer layer disposed on the protection layer and the light absorption layer overlapping the opening by irradiating a lower portion of the optical patterning mask with light; and removing the transfer material of the transfer layer that remains,
wherein the bank layer and the protection layer have different etching rates.

15. The method of claim 14 , wherein the transfer layer is at least one of a light emitting layer, a hole injection layer, a hole transport layer, an electron injection layer, and an electron transport layer.

16. The method of claim 14 , wherein removing the transfer material is performed by injecting O 2 gas energy.

Assignees

• Samsung Display Co Ltd

Inventors

• Choi Jin Baek
• Lee Yeon Hwa
• Lee Joon Gu

Classifications

• H10K71/00

  Manufacture or treatment specially adapted for the organic devices covered by this subclass · CPC title

• H10K71/18 Primary

  using non-liquid printing techniques, e.g. thermal transfer printing from a donor sheet · CPC title

• B41M5/426

  characterised by inorganic compounds, e.g. metals, metal salts, metal complexes · CPC title

• B41M5/46

  characterised by the light-to-heat converting means; characterised by the heat or radiation filtering or absorbing means or layers · CPC title

• H01L51/0013

  Electricity · mapped topic