The invention relates to a device for coating a substrate, having a process chamber in which a temperature-controllable gas inlet element for introducing a starting material together with a carrier gas, and a susceptor for receiving the substrate are situated, having a substrate storage chamber, for storing a substrate, which is connected to the process chamber via a loading opening, and having a conveying device for loading and unloading substrates to and from the process chamber.
The invention further relates to a method for operating this type of device.
DE 101 59 702 A1 describes a device comprising a process chamber having a gas inlet element and a susceptor, the process chamber being loadable with substrates using a gripper arm which removes the substrates from a substrate storage chamber. A coating process takes place within the process chamber. For this purpose, gaseous starting materials are introduced, with the aid of a carrier gas, by the gas inlet element into the process chamber. A thin layer is deposited on the substrate surface.
A chemical or a physical coating process may be involved. DE 10 2008 026 974 A1 describes, for example, a device having an evaporator for evaporating a solid or liquid starting material. The evaporated starting material together with a carrier gas is introduced via a carrier gas line into a pyrolysis chamber. The starting material may be polymeric paraxylylenes. The evaporated dimer is decomposed into a monomer in the pyrolysis chamber. The monomer together with the carrier gas is introduced into the gas inlet element. The gas inlet element is located in a process chamber which is sealed against the outside in a gas-tight manner, and has a gas discharge surface with a multiplicity of openings arranged in a screen-like manner, through which the carrier gas transporting the starting material flows into the process chamber. The gas inlet element is temperature-controlled by heating. A cooled susceptor is located beneath the gas inlet element. A substrate, for example a glass plate, may be placed on the cooled substrate bearing surface of the susceptor. The substrate is coated with a polymer layer, polymer which is introduced in gaseous form into the process chamber being condensed therein.
DE 10 2008 037 387 describes a mask arrangement. The shadow mask described therein is placed on the surface of a substrate to be coated in order to coat the substrate in a structured manner.
DE 102 32 731 A1 describes a coating device by means of which semiconductor layers composed of elements of groups IV, III-IV, and II-VI of the periodic table as well as organic materials may be deposited.
It is an object of the invention to design a more efficient device of the generic kind.
The object is achieved by the invention set forth in the claims, each claim representing an independent achievement of the object, and being combinable with any other claim.
The device according to the invention is particularly suited for depositing paraxylylenes or also multicomponent layers, for example OLEDs as well as semiconductor layers. The starting materials are prepared in a gas mixing system or a gas preparation device located outside the process chamber, and pass into the heated gas inlet element through a feed line which in particular is temperature-controlled. The gas inlet element has a hollow body with at least one chamber into which the carrier gas transporting the starting material is introduced. The gas inlet element has a gas discharge surface which has a circular, but preferably rectangular, in particular square, outline in plan view. The plan view outline substantially corresponds to the surface area of the substrate. The gas discharge surface contains a multiplicity of gas discharge openings, arranged in a screen-like manner, through which the process gas flows into the process chamber, the base of which is formed by a susceptor. This gas inlet element, having the shape of a shower head, is heated to temperatures of 200° C. to 400° C. The process chamber is operated in a pressure range between 0.1 mbar and 2 mbar, using a vacuum device. The susceptor is a cooled body having a substrate bearing surface. The bearing surface is selected in such a way that heat may be dissipated from the substrate toward the susceptor. The susceptor is temperature-controlled to temperatures between −30° C. and 80° C. The coating process takes place with the substrate actively cooled, so that the starting materials may be deposited on the substrate at the low temperatures. In the method according to the invention, it is provided that the loading and unloading of the process chamber take place with the gas inlet element heated. To avoid the substrate heating up before it is placed on the susceptor, a shielding plate is introduced between the gas inlet element and the susceptor before the loading or unloading takes place. Alternatively, the shielding plate may be used to protect a mask, which is placed on the substrate for structuring the layer to be deposited, from heating up. The shielding plate is located directly beneath the gas discharge surface of the gas inlet element. The shielding plate has a highly reflective surface, so that the substrate or the mask is protected against radiation from the gas inlet element. The shielding plate may have a highly reflective coating on both sides. The shielding plate is preferably composed of two glass or quartz plates extending parallel, between which a thin metal foil is situated. This may be a foil 100 μm thick which is made of Invar, gold, or aluminum. The foil is floatingly-mounted between the glass plate and the quartz glass plate. The foil has an emissivity ε<0.1. To protect the shielding plate outside the process chamber during the coating process, an additional storage chamber is provided in which the shielding plate is accommodated. This storage chamber may be a mask storage chamber in which at least one mask, which is applied to the substrate surface for the structured coating of the substrate surface, is stored. In a preferred embodiment of the invention, the shielding plate is the transport element for bringing the mask from the mask storage chamber into the process chamber. For this purpose, the shielding plate has holding means. The holding means may be situated on the underside of the shielding plate and engage in a positive-fit manner with corresponding counter-holding means of the mask. The mask may be removed from a mask magazine in the mask storage chamber with the aid of the shielding plate. By means of the shielding plate, the mask is shielded from the heated gas inlet element during the mask transfer. The mask is thus protected against a temperature increase. Thus, the shielding plate may be used to protect not only the substrate, but also the mask, against a temperature increase. The mask magazine may be vertically displaced within the storage chamber, similarly as for an elevator. Masks of various designs may be stored in the magazine in vertically superposed pockets. This magazine also has a compartment into which the shielding plate is able to enter. The shielding plate is preferably able to enter into each of the magazine compartments of the magazine in which a mask is also accommodated. A shielding plate displacement device may be situated within the magazine storage chamber. The shielding plate displacement device may be a rail system. The rail system may have two pairs of rails, one rail pair being situated in the magazine and a second rail pair being situated in the process chamber. The shielding plate may have a roller guide by means of which the shielding plate is guided on the pair of rails. The horizontal displacement drive for displacing the shielding plate between its shielding position beneath the gas inlet element and its storage position inside the magazine may be a pneumatic drive or an electric linear drive. This may also be a spindle drive. The substrate storage chamber may likewise have a magazine, in which various substrates are situated in vertically superposed pockets. The substrates may rest on in particular fork-shaped substrate holders which are also used for bringing the substrate into the process chamber. Each storage chamber is connected to the process chamber via loading/unloading openings which are closable in a gas-tight manner. The loading openings may be closed using gas-tight gates. The mask storage chamber as well as the substrate storage chamber may be evacuated using a vacuum device. The substrate storage chamber may be brought to atmospheric pressure in order to remove the substrates from the overall device. The susceptor may be water-cooled. The susceptor may be displaceable in the vertical direction. In the loading/unloading position, the susceptor has a lowered position. In this position, support pins protrude from the substrate bearing surface of the susceptor.
A substrate may be placed on these support pins by means of a conveying device, for example the fork-shaped substrate holder. This is achieved through the loading opening. The shielding plate has previously been brought beneath the heated gas inlet element by the above-described displacement of the shielding plate. The susceptor is raised to bring it into surface contact with the underside of the substrate. However, the substrate may also be set down on a stationary susceptor with the aid of retractable support pins.
In the method according to the invention, the loading and unloading of one or more substrates into and from the process chamber is carried out with the gas inlet element heated and the susceptor cooled. During the loading/unloading phase, only a carrier gas passes through the gas inlet element and into the process chamber. At the beginning, the unloaded susceptor is at a maximum distance from the gas inlet element. The loading gate for the magazine storage chamber is opened. With the aid of the shielding plate displacement device, the shielding plate is moved into the process chamber and positioned beneath the gas inlet element in such a way that the shielding plate reflects the heat radiation emanating from the gas inlet element. The shielding plate has an insulating effect, and is used to interrupt, but at least inhibit, the inflow of heat from the gas inlet element to the substrate. The magazine is then brought into a vertical position in which a mask to be used is situated directly in front of the loading opening. With the aid of the shielding plate displacement device, the shielding plate is moved back into the magazine and directly above the mask to be used, or the mask frame holding the mask. The mask frame or the mask is secured to the underside of the shielding plate, using a holding device, and is brought into the process chamber by the shielding plate. The loading opening to the substrate storage chamber is then opened, and a substrate is brought onto the above-mentioned pins by means of a conveying device. The substrate is now located between the susceptor and the shielding plate. As a result of the reflective or insulating effect of the shielding plate, there is no harmful heating of the substrate arising out of the heat emitted by the gas inlet element. The substrate is placed on the substrate set-down surface of the susceptor by lowering the pins or raising the susceptor, so that the substrate is cooled by the susceptor. The mask is then placed on the substrate, either by an upward movement of the susceptor or by a downward movement of the shielding plate. The shielding plate is subsequently moved back into the magazine in the mask storage chamber. After the gates of the loading openings have been closed gas-tight, the process gas is introduced into the process chamber so that a layer may be deposited on the substrate. Before the substrate is placed on the susceptor, the susceptor together with the substrate and the mask may also be jointly lowered. The mask is not in contact with the susceptor when the susceptor is lowered.
The above-mentioned organic or inorganic compounds may be used as starting material. Preferably paraxylylenes are deposited on a substrate, using the device. However, OLED layers may be deposited. In principle, the device is also suitable for MOCVD.
An exemplary embodiment of the invention is explained below with reference to accompanying drawings, which show the following:
The device illustrated in the drawings is composed of a process chamber 1 which is closed gas-tight with respect to the surroundings, a gas supply unit 21 situated above the process chamber 1, and a gas inlet element 4, situated in the process chamber 1 and supplied with process gases which may be transported via carrier gases into the process chamber. The process chamber 1 may be evacuated by means of a vacuum pump, not illustrated.
A mask storage chamber 2 is illustrated to the left of the process chamber 1 in
By use of the drive device 25 illustrated in
The gas inlet element is heated to temperatures between 200° and 400° using a heater, not illustrated. In other processes, however, the gas inlet element 4 may be heated to higher process temperatures. In the exemplary embodiment, the shielding plate 11 has a three-layer design. The plate 18 facing the gas inlet element 4 is a glass plate 1 mm thick. A foil 100 μm thick made of a highly reflective material, in particular a metal, especially Invar, gold, or aluminum, is situated between this glass plate 18 and a lower quartz glass plate 20, which may have a thickness between 8 mm and 10 mm. The foil 19 is floatingly-mounted between the glass plate and the quartz glass plate 20 due to the different thermal expansion properties. The emissivity of the foil in the range of the thermal radiation is less than 0.1.
By means of the shielding plate 11, the thermal radiation emitted by the gas inlet element 4 is shielded in the direction of the susceptor 5 or the substrate 12 situated on the susceptor.
The susceptor 5 has a cooling device by means of which the surface temperature of the susceptor 5 may be cooled to temperatures between −80° C. and 20° C. The substrate 12 is held at a cooled temperature as a result of the substrate resting on a cooled surface of the susceptor 5.
As discussed above, the shielding plate 11 forms the transport element by means of which a mask 10, 10′, 10″, 10″′ may be brought from the magazine 9 of the mask storage chamber 2 into the process chamber 1. For this purpose, the masks 10 or mask frames, not illustrated in the drawings, have counter-mountings which are able to cooperate with clamping elements 17 of the shielding plate 11, which are only schematically illustrated in
The mode of operation of the device is as follows:
At the same time, the magazine 9 is lowered in the direction of the arrow P2 illustrated in
In a subsequent step the shielding plate 11, driven by the drive device 25, moves on the rails 15, through the loading opening 6, and back into the mask storage chamber 2, where it moves into a pocket in which a mask 10 is present.
The shielding plate 11 then reaches its position illustrated in
The susceptor 5 is then moved upwardly in the direction of the arrow P1 in
Lastly, the shielding plate 11 is moved from the process chamber 1 into the storage chamber 2, so that the process position illustrated in
The gas supply unit 21 is able in particular to supply the gas inlet element 4 with a monomer, which is transported by a carrier gas. This monomer has the property of condensing at low temperatures. When the monomer meets the cooled substrate surface of the substrate 12, it condenses there and polymerizes to form a polymer.
Without cooling of the gas inlet element, after the coating process is completed, the shielding plate 11 is brought from the process position illustrated in
Another substrate 12′ may then be brought into the process chamber 1 with the aid of a substrate holder 13′ in order to be coated in the previously described manner.
The device is also suited for depositing OLEDs or semiconductor layers, for example using the MOCVD process.
All features disclosed are (in themselves) pertinent to the invention. The disclosure content of the associated/accompanying priority documents (copy of the prior application) is also hereby included in full in the disclosure of the application, including for the purpose of incorporating features of these documents in claims of the present application. The subsidiary claims in their optional subordinated formulation characterize independent inventive refinement of the prior art, in particular to undertake divisional applications based on these claims.
Number | Date | Country | Kind |
---|---|---|---|
10 2010 000 447.2 | Feb 2010 | DE | national |
Filing Document | Filing Date | Country | Kind | 371c Date |
---|---|---|---|---|
PCT/EP2011/051793 | 2/8/2011 | WO | 00 | 10/24/2012 |