JP2001223075A - Organic electroluminescence device and manufacturing method of the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an organic EL device and manufacturing method of the same by which respective organic EL elements with their own luminous color can be formed with microscopic pattern and high luminance, suitable for color display, can be obtained. SOLUTION: The organic EL device comprises the first electrode 31R, a pigment translation and diffusion part 33R where the first organic pigment 42R is introduced by translation and diffusion, and the second electrode. The first organic pigment 42R is contained in the first pigment layer 40R and the first organic pigment 42R in the first pigment layer 40R can be translated and diffused to a polymeric luminous layer 32 by heating with a laser beam 50 selectively. Assuming that the first organic pigment 42R is an organic pigment for red, organic pigments for green and blue can also be translated and diffused to the polymeric luminous layer 32 by the heating with the laser beam 50.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an organic electroluminescence device (hereinafter, simply referred to as an organic EL device) and a method of manufacturing the same, and more particularly to an organic EL device most suitable for constructing a color display panel and a method of manufacturing the same.

[0002]

2. Description of the Related Art Recently, word processors, display panels of personal computers, portable telephones and PHSs have been developed.
2. Description of the Related Art Organic EL devices have been attracting attention as display panels, display panels for in-vehicle audio, and the like. In particular, research and development of high-performance organic EL devices that emit light with high luminance when driven at a low voltage have been conducted. FIGS. 29 and 30 are sectional structural views of the organic EL device disclosed in Japanese Patent Application Laid-Open No. 7-220871.

The organic EL device shown in FIG. 29 comprises a glass substrate 100, an ITO (indium-tin oxide) transparent electrode 101 on the surface of the glass substrate 100, an organic layer 102 on the surface of the ITO transparent electrode 101, And a metal electrode 103 on the surface of the organic layer 102. The ITO transparent electrode 101 is used as an anode (anode electrode), and the metal electrode 103 is used as a cathode (cathode electrode). The metal electrode 103 is formed of a metal having a small work function, such as lithium or magnesium, or an alloy thereof. The organic layer 102 is formed of a polymer material, a low-molecular material, a metal complex, or the like, and is formed by application from a solution, vacuum deposition, or the like. The organic layer 102 of the organic EL device shown in FIG. 29 is a single layer, and light emitted from the organic layer 102 when a voltage is applied between the ITO transparent electrode 101 and the metal electrode 103 emits light from the ITO transparent electrode 101 and the glass substrate. 100 can be emitted.

On the other hand, in the organic EL device shown in FIG.
The organic layer 102 between the first electrode 01 and the metal electrode 103 is composed of a hole transport layer 102H and an electron transport layer 102E.
By applying a predetermined voltage between the ITO transparent electrode 101 and the metal electrode 103, holes are injected from the ITO transparent electrode 101 into the hole transport layer 102H, and the metal electrode 10
From 3, electrons are injected into the electron transport layer 102 </ b> E. The holes injected into the hole transport layer 102H are
The electrons move inside, and the holes are injected again into the electron transport layer 102E. The electron transporting layer 102E also serves as a light emitting layer, and electrons injected from the metal electrode 103 into the electron transporting layer 102E move through the electron transporting layer 102E to form the hole transporting layer 10E.
Not injected into 2H. Since holes injected into the electron transport layer 102E, that is, the holes injected into the light-emitting layer hardly move in the light-emitting layer, the holes and the electrons that have moved through the light-emitting layer form an interface between the hole-transport layer 102H and the light-emitting layer. Coupling occurs in the vicinity, and light emission occurs. The light emitted inside the organic layer 102 is generated by the IT like the organic EL device shown in FIG.
Light can be emitted through each of the O transparent electrode 101 and the glass substrate 100.

[0005] The color of light emitted from this type of organic EL device is determined by the color of light emitted from the light emitting layer, and is monochromatic (monochromatic).

[0006]

However, in the above-mentioned organic EL device and its manufacturing method, the following points have not been considered.

In order to extract light as a full-color display outside the organic EL device, it is necessary to form three types of fine organic EL elements that emit red, green, and blue light as one pixel. Organic EL
Since the element does not have water resistance and solvent resistance, it cannot be patterned by photolithography and etching, and is usually manufactured using a vacuum evaporation method or a coating method. However, for example, in a vacuum vapor deposition method, it is necessary to arrange the vapor deposition mask and the glass substrate in a non-contact manner and without any gap. Further, in order to secure the mechanical strength of the evaporation mask itself, the evaporation mask needs to have an appropriate thickness. Therefore, organic E
It is difficult to form a fine opening pattern corresponding to the L element on the evaporation mask. Further, it is necessary to perform the alignment between the glass substrate and the deposition mask with high accuracy. Therefore, miniaturization of the organic EL element has been extremely difficult in the vacuum deposition method.

Further, in the vacuum vapor deposition method, it is necessary to align the glass substrate and the vapor deposition mask every time an organic EL element which emits light of each color is formed. Further, when replacing the vapor deposition mask for each color, it is necessary to decompress the inside of the vacuum vessel and release it to the atmosphere. Therefore, organic EL
The productivity of the device was very poor.

On the other hand, in the coating method, the organic EL of each color is used.
In manufacturing the elements, it is necessary to previously form a bank (a member having a function such as a bank or a bank) between the elements so that the organic materials forming the organic EL elements of each color do not mix with each other. Further, each time the organic material of each color is injected into the bank, long-time low-temperature baking is required. Therefore, the productivity of the organic EL device has been extremely poor.

In order to solve such a technical problem,
A white light-emitting layer is formed by dispersing at least one kind or several kinds of dyes in a polymer so as to emit white light while covering the visible light region as widely as possible, and combining this white light-emitting layer and a color filter. 2. Description of the Related Art An organic EL device designed to extract an arbitrary emission color has been proposed. In such an organic EL device, a fine pattern is not required for the light emitting layer itself, and a red, green, and blue color filter of a color filter is formed in a fine pattern to form a fine pixel array. There are features such as can be.

However, the light emitting layer of the organic EL device can obtain high efficiency in monochromatic light emission, but it is extremely difficult to obtain high efficiency in light emission of a wide spectrum, and most of the light emitted from the light emitting layer is colored. Each light emission color could not be obtained at practical luminance because the light was absorbed by the filter. Therefore, it has been difficult at present to produce a practical color display panel using an organic EL device.

Further, in this type of organic EL device, a color filter is separately required, which causes a problem that the manufacturing cost and the product cost of the color display panel are increased.

The present invention has been made to solve the above problems. Therefore, an object of the present invention is to provide an organic EL device capable of forming an organic EL element of each emission color in a fine pattern and obtaining a high luminance suitable for color display in the organic EL element of each emission color. And a method for producing the same.

It is a further object of the present invention to provide an organic EL device capable of reducing product cost and a method for manufacturing the same.

Further, an object of the present invention is to manufacture an organic EL device capable of forming an organic EL element of each emission color in a fine pattern and easily manufacturing an organic EL element of a fine pattern. Is to provide a way.

It is a further object of the present invention to provide a method of manufacturing an organic EL device which can improve the yield in manufacturing.

It is a further object of the present invention to provide a method for manufacturing an organic EL device which can reduce the production cost.

[0018]

In order to solve the above-mentioned problems, a first feature of the present invention is a step of forming a first electrode on a substrate and a step of forming a polymer light-emitting layer on the first electrode. Forming, forming a dye layer containing an organic dye on the polymer light emitting layer, and transferring and diffusing the organic dye of the dye layer to the polymer light emitting layer in a region corresponding to the first electrode. A method for manufacturing an organic EL device includes a step of forming a diffusion section, a step of removing a dye layer, and a step of forming a second electrode on the dye transfer diffusion section.

In the method for manufacturing an organic EL device according to the first aspect of the present invention, it is possible to form a dye transfer diffusion portion in which an organic dye is transferred and diffused in a fine pattern from the dye layer to the polymer light emitting layer. . For example, in a fine pattern of about several μm to several tens μm,
Organic dyes can be transferred and diffused. Further, since color mixing between the organic dyes does not occur between the dye transfer / diffusion portions, a bank between the organic EL devices as in the related art is not required, and the separation distance between the dye transfer / diffusion portions (for example, between the organic EL devices) is reduced. Can be reduced. Therefore, by using organic dyes of several colors, organic EL elements of each emission color can be easily formed in a fine pattern.
An organic EL device having fine pixels can be manufactured. Further, since the dye transfer diffusion portion can be formed by directly transferring and diffusing an organic dye to the polymer light emitting layer, the surface state of the dye transfer diffusion portion does not change,
It is possible to manufacture an organic EL device having high luminance, which maintains optical characteristics and is suitable for color display. Furthermore, by directly transferring and diffusing an organic dye to the polymer light emitting layer to form a dye transfer / diffusion portion, a conventional color filter is not required, so that the number of parts can be reduced, and The manufacturing cost of the EL device can be reduced. As a result, the manufacturing cost of the organic EL device can be reduced, so that the product cost of the organic EL device can be reduced.

Furthermore, the organic E according to the first feature of the present invention
In the manufacturing method of the L device, the manufacturing process of forming the polymer light emitting layer and the dye layer and the manufacturing process of transferring and diffusing the organic dye of the dye layer into the polymer light emitting layer are formed by separate independent manufacturing processes. can do. In the manufacturing process of the polymer light emitting layer, the uniformity of film thickness, pinhole-free property of the film, no defect, etc. are independently controlled, and in the manufacturing process of the dye layer, the uniformity of film thickness, the concentration of organic dye, In a manufacturing process in which defect-freeness and the like are independently managed and an organic dye is migrated and diffused, migration diffusion conditions (for example, temperature and time), alignment accuracy, and the like can be independently managed. Optimization can be achieved, and a high-quality polymer light-emitting layer, a dye layer, and a dye transfer / diffusion portion with high quality can be formed. The organic EL device forms a dye layer on the polymer light emitting layer formed by such separate and independent manufacturing processes, and the organic dye contained in the dye layer corresponds to the region of the first electrode. A dye transfer diffusion portion (organic EL device) having a predetermined emission color in a fine pattern can be easily manufactured only by transferring and diffusing it to the molecular light emitting layer.

According to a second feature of the present invention, the step of forming the dye transfer diffusion portion in the method for manufacturing an organic EL device according to the first feature of the present invention is performed by: Is heated at least to transfer and diffuse the organic dye in the dye layer into the polymer light emitting layer to form a dye transfer diffusion portion.

In the method for manufacturing an organic EL device according to the second aspect of the present invention, at least a region substantially corresponding to a heated portion of the dye layer, preferably the dye layer and the polymer light emitting layer (the first electrode is formed by The organic dye can be selectively transferred and diffused from the dye layer to the polymer light emitting layer only in the corresponding region) to form a dye transfer diffusion portion. That is, by setting the region to be heated in a fine pattern, an organic EL element having a predetermined pattern and a predetermined emission color can be formed. Further, since the organic dye can be transferred and diffused into the polymer light emitting layer in the region corresponding to the first electrode only by heating, it is not necessary to use a vacuum deposition method or a coating method as in the related art. Since it is not necessary to use a lithography technique or an etching technique, a method of manufacturing an organic EL device that can further reduce the number of steps in a manufacturing process can be realized. Further, the step of transferring and diffusing the organic dye from the dye layer to the polymer light emitting layer can be performed in a predetermined gas atmosphere, for example, in an inert gas atmosphere by a dry method. A method for manufacturing an organic EL device that can be manufactured can be realized.

A third feature of the present invention is that the dye layer is heated with a laser beam in the method for manufacturing an organic EL device according to the second feature of the present invention.

In the method for manufacturing an organic EL device according to the third aspect of the present invention, the irradiation energy distribution can be made uniform, and the boundary between the dye transfer diffusion portion and the periphery thereof can be made relatively clear. Therefore, an organic EL element having a fine pattern can be formed.

A fourth feature of the present invention is that, in the method for manufacturing an organic EL device according to the third feature of the present invention, a step of forming a mask layer having a threshold value on laser light transmission and non-transmission on the dye layer. Further comprising the step of forming a dye transfer diffusion portion, by heating the dye layer with a laser beam transmitted through the mask layer in a region corresponding to the first electrode,
That is, the organic dye of the dye layer is transferred and diffused into the polymer light emitting layer to form a dye transfer diffusion portion. here,
The “mask layer” is used to mean a mask layer that can transmit a laser beam when the irradiation energy is equal to or higher than a threshold, and does not transmit a laser beam when the irradiation energy is equal to or lower than the threshold.
As the “mask layer”, for example, a thermochromic layer, a photochromic layer, or the like can be practically used.

In the method of manufacturing an organic EL device according to the fourth aspect of the present invention, laser light whose irradiation energy is less than a threshold value, in particular, unnecessary regions in a region around a dye transfer diffusion portion (for example, an organic EL device). Since the laser beam is removed and the boundary between the dye transfer diffusion portion and its surroundings can be made clearer, an organic EL element having a fine pattern can be formed. Further, it is possible to prevent contamination of a region other than the dye transfer / diffusion portion due to sublimation, bumping, and the like generated by irradiating the dye layer with the laser light.

A fifth feature of the present invention is that the heating of the dye layer in the method for manufacturing an organic EL device according to the second feature of the present invention is performed by a thermal head accompanied by pressurization. Here, it is preferable that the “thermal head” includes a heating element corresponding to the first electrode.

In the method for manufacturing an organic EL device according to the fifth aspect of the present invention, the same effect as that obtained by the method for manufacturing an organic EL device according to the second aspect of the present invention is obtained by using a thermal head. It can be easily realized. That is, an organic EL element having a fine pattern corresponding to the size of the heating element of the thermal head can be easily formed.

A sixth feature of the present invention is that the method for manufacturing an organic EL device according to the fifth feature of the present invention further comprises a step of forming a film on the dye layer to prevent diffusion of the organic dye in the dye layer. The step of forming a dye transfer / diffusion portion is performed by pressing and heating a dye layer with a thermal head with a film interposed in a region corresponding to the first electrode, so that the organic dye of the dye layer is To form a dye transfer / diffusion section by transfer / diffusion. Here, the `` film '' is a film which, when the dye layer is heated by the thermal head, can be transferred and diffused to the polymer light emitting layer side before the organic dye of the dye layer is diffused to the thermal head side. Used in the sense. For example, a resin film having a glass transition temperature higher than the glass transition temperature of the polymer light emitting layer can be practically used for the “film”.

In the method for manufacturing an organic EL device according to the sixth aspect of the present invention, the diffusion and the like of the organic dye from the dye layer can be prevented by the film. In addition, maintenance work can be reduced.

A seventh feature of the present invention is that a step of forming a plurality of first electrodes adjacent to each other on a substrate;
Forming a polymer light-emitting layer on the electrode, and forming a first dye layer containing a first organic dye on the polymer light-emitting layer, and forming a first dye layer in a region corresponding to the first electrode in the first region. Forming a first dye transfer diffusion portion by transferring and diffusing the first organic dye of the first dye layer into the polymer light emitting layer; removing the first dye layer; Forming a second dye layer containing a second organic dye, and transferring and diffusing the second organic dye of the second dye layer to the polymer light emitting layer in a region corresponding to the first electrode in the second region. Forming a second dye transfer diffusion section, removing the second dye layer, forming a third dye layer containing a third organic dye on the polymer light emitting layer, The third organic dye in the third dye layer is transferred to and diffused in the polymer light-emitting layer in the region corresponding to the first electrode in the region of the third dye. Forming a row diffusion, removing the third dye layer, and forming a second electrode common to each color on the first, second and third dye transfer diffusions. And a method of manufacturing an organic EL device.

Here, the terms "first organic dye, second organic dye and third organic dye" are used as expressions meaning organic dyes having the three primary colors of light. The three primary colors are red, green, and blue. For example, the “first organic dye” is a red organic dye, the “second organic dye” is a green organic dye, and the “third organic dye” is a blue organic dye. It is. Therefore, for example, the “first organic layer” is a dye layer containing a red organic dye, the “second organic layer” is a dye layer containing a green organic dye, and the “third organic layer” is a blue organic dye. It is a dye layer containing. Further, for example, a “first region” is a region where a dye transfer diffusion unit (organic EL element) that emits red light is disposed, a “second region” is a region where a dye transfer diffusion unit that emits green light is disposed, and the “third region” is a third region. The “region” is a region where the dye transfer diffusion portion that emits blue light is arranged.

In the method for manufacturing an organic EL device according to the seventh aspect of the present invention, in addition to the effects obtained by the method for manufacturing an organic EL device according to the first aspect of the present invention, a plurality of colors having different colors are provided. Since the dye transfer / diffusion portion can be provided, organic EL elements of a plurality of emission colors can be formed, and an organic EL device most suitable for constructing a color display panel can be manufactured.

According to an eighth aspect of the present invention, there is provided a method for manufacturing an organic EL device according to any one of the first to seventh aspects of the present invention, wherein the first electrode on the substrate and the first An organic light-emitting layer formed on the first electrode, a dye transfer diffusion portion formed by transferring and diffusing an organic dye to the polymer light-emitting layer, and a second electrode formed on the dye transfer diffusion portion on the first electrode. This is an EL device.

In the organic EL device according to the eighth aspect of the present invention, similarly to the method for manufacturing an organic EL device according to the first aspect of the present invention, a dye transfer / diffusion section in which an organic dye is introduced in a fine pattern. (For example, an organic EL element), and a conventional bank is not required between the dye transfer / diffusion portions, so that the separation distance between the dye transfer / diffusion portions can be reduced. Therefore, an organic EL device having fine pixels can be realized. Furthermore, a high-luminance organic EL device suitable for color display can be realized. Further, since a conventional color filter is not required, the number of components can be reduced, and an organic EL device having a simple structure can be realized. Furthermore, since the number of parts can be reduced, an organic EL device with low product cost can be provided.

[0036]

Embodiments of the present invention will be described below in detail with reference to the drawings.

(First Embodiment) A first embodiment of the present invention relates to an organic EL device in which an organic dye in a dye layer is transferred and diffused into a polymer light emitting layer by heating by irradiation with a laser beam, and its manufacture. The method is explained.

Device Structure: FIG. 1 is a sectional structural view of an organic EL device according to the first embodiment of the present invention. As shown in FIG. 1, an organic EL device 1 according to a first embodiment of the present invention includes a plurality of first electrodes 31R, 31G, and 31B arranged adjacent to each other on a substrate 2; A plurality of dyes formed on the bases 31R, 31G, 31B, respectively, and organic dyes of different colors are selectively supplied from the outside in regions corresponding to the first electrodes 31R, 31G, 31B and introduced by migration diffusion. Migration diffusion parts 33R, 33G, 33B, and dye migration diffusion parts 33R,
And a common second electrode 34 on 33G and 33B. Organic E according to the first embodiment of the present invention
In the L device 1, the dye transfer diffusion unit 33R is formed as an organic EL element 30R that emits red light, and the dye transfer diffusion unit 33G is an organic EL element 30G that emits green light.
The dye transfer / diffusion portion 33B is formed as an organic EL element 30B that emits blue light.
A total of three organic EL elements 30R, 30G, and 30B that emit red, green, and blue light, respectively, constitute a pixel 3 that performs one color display. The organic EL device 1 is configured to construct, for example, a color display panel.

The substrate 2 is formed as a base of a color display panel in which a plurality of pixels 3 are arranged in a matrix or in a staggered manner. The substrate 2 includes the organic E of the pixel 3.
In order to extract emitted light of each color from each of the L elements 30R, 30G, and 30B, a transparent glass substrate such as a quartz glass substrate can be practically used. Substrate 2
Corresponds to a specific example of the “substrate” according to the present invention.

The first electrode 31R is formed as an anode (anode electrode) of the organic EL element 30R that emits red light, and similarly, the first electrode 31G is formed as an anode of the organic EL element 30G that emits green light. And the first electrode 31
B is formed as an anode of the organic EL element 30B that emits blue light. On the other hand, the second electrode 34 is formed of the organic EL.
Each of the elements 30R, 30G, and 30B is formed as a common cathode (cathode electrode).

For each of the first electrodes 31R, 31G, 31B, for example, an indium tin oxide (ITO) thin film as a transparent electrode can be practically used. This ITO thin film is formed with a thickness of, for example, 80 nm to 120 nm, and each of the first electrodes 31R, 31G, 31B has a width dimension (minimum dimension of a plane pattern) of, for example, 10 μm.
Set to about. Therefore, the size of the pixel 3 of one unit of three colors of red, green and blue can be set to, for example, about 30 μm. As explained in the manufacturing method described later,
Since the organic EL device 1 according to the first embodiment of the present invention is formed using laser light, the organic EL device 1 has a fine size corresponding to the spot diameter of the laser light, for example, a fine size of about 1 μm. The size of the pixel 3 can be reduced. The first electrodes 31R, 31G, 31B
All correspond to a specific example of the “first electrode” according to the present invention.

On the first electrodes 31R, 31G, 31
B, the dye transfer diffusion sections 33R, 33
A transparent or almost transparent polymer light emitting layer 32 is formed as a base for G and 33B. The polymer light emitting layer 32 has a substantially transparent polyvinyl carbazole (PVCz) having a thickness of, for example, about 50 nm to 100 nm.
Thin films can be used practically. Since the PVCz thin film emits light broadly from the ultraviolet light region to the visible light region, energy is easily transferred to the dopant of each color, and is a suitable host material for the organic EL device 1.
Further, as the polymer light emitting layer 32, a polyphenylenevinylene (PPV) derivative thin film, a polyfluorene derivative thin film, a polythiophene derivative thin film, or the like can be practically used. The polymer material of the polymer light-emitting layer 32 is not limited to the case where it is used as a single light-emitting layer. And the like can be mixed to form a hole transport layer.

The dye transfer / diffusion portion 33R of the organic EL element 30R that emits red light is provided in a region corresponding to the first electrode 31R in the polymer light emitting layer 32 (substantially in the same pattern as the first electrode 31R). It is preferably formed by selectively introducing a red organic dye supplied from the outside by transfer diffusion. Examples of the red organic dye include pyran derivatives such as Nile Red and DCM1;
Fluorescent dye materials such as squarylium derivatives, porphyrin derivatives, chlorin derivatives, eurolysine derivatives and the like can be used practically.

The dye transfer / diffusion portion 33G of the organic EL element 30G that emits green light is located in a region corresponding to the first electrode 31G in the polymer light emitting layer 32 (similarly, the first electrode 31G and the It is preferably the same pattern.), Which is formed by selectively introducing a green organic dye supplied from the outside by transfer diffusion. Green organic dyes include, for example, coumarin derivatives such as coumarin 6;
A fluorescent dye material such as a quinacridone derivative can be used practically.

The dye transfer / diffusion portion 33B of the organic EL element 30B that emits blue light is located in a region corresponding to the first electrode 31B in the polymer light emitting layer 32 (similarly, the first electrode 31B It is preferably the same pattern.), And is formed by selectively introducing a blue organic dye supplied from the outside by transfer diffusion. As the blue organic dye, for example, a coumarin derivative such as coumarin 47 or a fluorescent dye material such as tetraphenylbutadiene or perylene can be practically used.

The dye transfer / diffusion portions 33R, 33
G and 33B are both “dye transfer diffusion part” according to the present invention.
This corresponds to one specific example. Also, red, green,
Each of the blue organic dyes corresponds to a specific example of each of the “organic dye”, “first organic dye”, “second organic dye”, and “third organic dye” according to the present invention. It is.

As the second electrode 34, for example, an aluminum thin film or an aluminum alloy thin film containing an appropriate additive can be practically used as a metal electrode. This aluminum thin film or aluminum alloy thin film is, for example, 8
It is formed with a thickness of 0 nm to 120 nm. The second electrode 34 shown in FIG. 1 is formed as a common electrode (wiring) for each of the plurality of organic EL elements 30R, 30G, and 30B arranged in the left-right direction. Note that the second electrode 3
Reference numeral 4 corresponds to a specific example of the “second electrode” according to the present invention.

Manufacturing Process: Next, a method of manufacturing the organic EL device according to the first embodiment of the present invention will be described. 2 to 10 are process cross-sectional views of the organic EL device 1 according to the first embodiment of the present invention.

(1) First, as shown in FIG.
A substrate 2 serving as a base of the device 1 and made of a transparent glass substrate is prepared.

(2) As shown in FIG. 3, a plurality of first electrodes 31R, 31G and 31B are formed on the surface of the substrate 2. Here, the first electrode 31R is a red organic EL element 3
Similarly, the first electrode 31G is formed in the second region G on the substrate 2 forming the green organic EL element 30G, and the first electrode 31G is formed in the first region R on the substrate 2 forming the OR. The electrode 31B is formed in a third region B on the substrate 2 on which the blue organic EL element 30B is formed. One set of first electrodes 3
1R, 31G and 31B are formed in portions corresponding to the formation region of one pixel 3, and one set of first electrodes is formed for each formation region of a plurality of pixels 3 arranged in a matrix (or staggered). 31R, 31G and 31B are formed. The first electrodes 31R, 31G, and 31B are all formed of the same conductive layer and the same conductive material. For example, the first electrodes 31R, 31G, and 31B can be formed by forming an ITO thin film by a sputtering method and patterning the ITO thin film by etching using a mask formed by a photolithography technique. .

The first region R corresponds to the “first region R” according to the present invention.
The second region G corresponds to one specific example of the "second region" according to the present invention, and the third region B corresponds to one specific example of the "third region" according to the present invention.

(3) As shown in FIG. 4, the first electrode 31
The polymer light emitting layer 32 is formed on the entire surface of the substrate 2 including the surfaces of R, 31G, and 31B. In the first embodiment of the present invention, the polymer light emitting layer 32 is formed of a transparent or almost transparent PVCz thin film as described above. The PVCz thin film is applied on the substrate 2 with a uniform thickness by, for example, a coating (spin coating) method, and after the coating, the PVCz thin film is dried. In addition, the PVCz thin film can be formed by any one of a dipping method, a casting method, a wet coating method such as a Langmuir project (LB) method, and a vacuum deposition method instead of the coating method. In any of these film forming methods, since the polymer light emitting layer 32 is formed on the entire surface of the substrate 2, any of these film forming methods does not hinder the fine processing. As a solvent used in the wet coating method, for example, chloroform, dichloromethane and the like can be practically used.

(4) Next, the first dye layer 4 including the red first organic dye 42R on the entire surface of the polymer light emitting layer 32
OR is formed (see FIG. 5A). First dye layer 40
As described above, Neil Red or the like can be practically used as the organic dye contained in R. First dye layer 4
0R can be formed by using a solution in which the first organic dye 42R is directly dissolved, and forming a film by a wet coating method such as a coating method, a dip method, a casting method, and a Langmuir-Blodget method similarly to the polymer light emitting layer 32. it can. The thickness of the first dye layer 40R can be formed, for example, in a range of about 10 nm to 100 nm. The first dye layer 40R formed by such a film forming method can be formed with a uniform thickness without unevenness. As the solvent used in the wet coating method, a solvent in which the first organic dye 42R is soluble and the polymer light emitting layer 32 is insoluble and does not affect the surface shape can be used. For this type of solvent, for example, ethanol, propanol, methanol, hexane, acetone and the like can be practically used.

The first dye layer 40R can be formed by a vacuum evaporation method, and can be formed by a printing method such as an ink jet printing method and a gravure printing method.

(5) As shown in FIG. 5A, a first mask layer 41R is formed on the entire surface of the first dye layer 40R. The first mask layer 41R has a function of transmitting a laser beam when the irradiation energy is equal to or higher than a threshold, and not transmitting the laser beam 50 when the irradiation energy is equal to or lower than the threshold. That is, the first mask layer 41 </ b> R is such that only the portion where the irradiation energy is high at the irradiation center portion of the laser beam 50 is
Can be transmitted, and the laser beam 50 in a portion where the irradiation energy is low in a region deviated from the irradiation center of the laser beam 50
Is cut, and the boundary of the irradiation area can be sharpened. Further, the first mask layer 41
R has a function as a protective mask for preventing contamination of an area other than an irradiation position (transition diffusion area) due to sublimation, bumping, or the like due to irradiation of the laser beam 50.

First mask layer 4 having such a function
For 1R, a thermochromic layer composed of a leuco dye and a fixing agent, a photochromic layer composed of fulgides, diarylethenes, chalcones, and naphthothioindigos can be practically used. As the thermochromic layer, the photochromic layer, and the like, those formed by any of a dry method and a wet method can be used. The first mask layer 41R is, for example, 100 nm to 500 nm.
It is formed with a thickness of about nm. Here, the first mask layer 41R corresponds to a specific example of “mask layer” according to the present invention.

In the method for manufacturing an organic EL device according to the first embodiment of the present invention, as shown in FIG. 5B, the first mask layer 41R is made up of the first dye layer 40R.
It can be formed with a film 45 interposed therebetween.
This film 45 can easily transfer and diffuse the organic dye of the first dye layer 40R to the polymer light emitting layer 32,
In addition, diffusion of the organic dye into the first mask layer 41R can be prevented. Specifically, the glass transition temperature of the film 45 is preferably set to a value higher than the glass transition temperatures of the first dye layer 40R and the polymer light emitting layer 32.
For example, when the polymer light emitting layer 32 is formed of a PVCz thin film as described above, the glass transition temperature of the PVCz thin film is 1
Since the temperature is 73 ° C., the glass transition temperature of the film 45 is 1
The temperature is set to be higher than 73 ° C. As the film 45 having such a glass transition temperature, for example, a resin film such as polyimide can be practically used, and it is preferable that the film is formed to have a thickness of, for example, about 2 μm to 20 μm.

(6) As shown in FIG. 6, in the region corresponding to the first electrode 31R in the first region R, that is, in the formation region of the organic EL element 30R that emits red light, the first mask layer The first dye layer 40R is selectively irradiated with laser light 50 through 41R. By the irradiation of the laser beam 50, the first organic dye 42R of the first dye layer 40R can be transferred and diffused into the polymer light emitting layer 32. The layer 32 can form the dye transfer diffusion portion 33R.

Here, the transfer diffusion means the first dye layer 40
By heating R, preferably the first dye layer 4
By heating the OR and the polymer light emitting layer 32,
Molecular movement such as liquefaction or sublimation of the first organic dye 42R becomes active, and at the same time, the first dye layer 40R and the polymer light emitting layer 32 are also heated to or near the glass transition temperature point to bond between molecules. And the first organic dye 42R of the first dye layer 40R passes through the molecular contact interface between the first dye layer 40R and the polymer light emitting layer 32.
It is used to mean that it is dissolved (doped). That is, the transition diffusion is performed in the first dye layer 40R and the first organic dye 42R of the first dye layer 40R in substantially the same region as the heated region of the polymer light emitting layer 32.
Can be dissolved in the polymer light emitting layer 32. In the first embodiment of the present invention, a PVCz thin film is used for the polymer light emitting layer 32, and the glass transition temperature Tg of the PVCz thin film is 173 ° C. as described above. Is heated by the laser beam 50 to about 170 ° C. to 185 ° C. Further, the area of the irradiation area of the laser beam 50, that is, the spot diameter is about 1 by the optical system.
Since it can be easily adjusted to about μm, the dye transfer / diffusion portion 33R can be formed in a fine pattern. Further, since the first mask layer 41R is formed on the first dye layer 40R, it is possible to form the dye transfer diffusion portion 33R having a clear outline boundary.

FIG. 11 is a schematic configuration diagram of an organic dye transfer device used in the first embodiment of the present invention. As shown in FIG. 11, the transfer diffusion can be performed by the organic dye transfer device 6. The organic dye transfer device 6 includes a carriage 60 for mounting and holding the substrate 2, a carriage driving unit 61 for moving the carriage 60 in the X and Y directions, a laser light oscillation unit 62, and a laser light driving source 63.
A pulse control circuit unit 64, a polygon mirror 65,
It is configured to include at least a polygon mirror rotation control unit 66 and an optical system 67.

In the organic dye transfer device 6, the carriage 60 moves the substrate 2 stepwise by the carriage driving unit 61 at least in the X direction perpendicular to the paper surface with the same high precision as the arrangement pitch of the pixels 3. Can be. For example, when the arrangement pitch of the pixels 3 is 30 μm, the carriage 60 can be moved every 30 μm.
The laser light oscillating section 62 oscillates the laser light 50 necessary for the transition diffusion by supplying power from the laser light driving source 63. The pulse control circuit section 64 controls power supply from the laser light drive source 63 to the laser light oscillating section 62, and the laser light oscillating section 62 sequentially and intermittently transmits laser light to regions corresponding to the plurality of first electrodes. 50 is irradiated. The laser light oscillating unit 62 can be appropriately selected according to various conditions such as a required laser output and a required absorption wavelength range such as a semiconductor laser, a gas laser, a solid laser, and a liquid laser. The rotation of the polygon mirror 65 is controlled by a polygon mirror rotation control unit 66, so that the laser beam 50 oscillated from the laser beam oscillation unit 62 can be scanned on the substrate 2 in the Y direction. In the first embodiment of the present invention, an imaging lens is used for the optical system 67, and the laser beam 50 reflected by the polygon mirror 65 is converged to a spot diameter corresponding to the size of the first electrode 31R. It has become so.

FIG. 12 is a diagram showing the relationship among laser light irradiation time, organic dye concentration, and irradiation power. As shown in FIG. 12, the first dye layer 40 of the red first organic dye 42R is formed.
The transition diffusion concentration from R to the polymer light-emitting layer 32 tends to increase as the laser light irradiation time increases, and increases as the irradiation power increases. Immediately after the start of the irradiation of the laser beam 50, a sufficient temperature rise cannot be obtained in the first dye layer 40R, so that the organic dye concentration shows a low value. The organic dye concentration tends to increase as the laser light irradiation time increases. In the organic dye transfer device 6 according to the first embodiment of the present invention, the organic dye concentration after irradiating the laser light 50 for a certain period of time is set so as to be in a saturated region which is not influenced by the change of the laser light irradiation time. Transition diffusion is performed using the laser beam irradiation time. In addition, the tendency shown in FIG.
The same applies to each of the organic dye 42G and the blue third organic dye 42B.

The organic dye transfer operation of the organic dye transfer device 6 shown in FIG. 11 is performed as follows. First, the carriage 6
The substrate 2 on which the polymer light emitting layer 32, the first organic layer 40R containing the first organic dye 42R and the first mask layer 41R are already formed is placed and held on the substrate 2, and the organic Move the carriage 60 to the dye transfer start position
To move. By the pulse control circuit section 64, the laser light drive source 63 can intermittently excite the laser light oscillation section 62, and the laser light oscillation section 62 can oscillate the laser light 50 in pulses. The laser beam 50 is reflected by the polygon mirror 65, and the reflected laser beam 50 passes through the optical system 67, passes through the first mask layer 41R on the substrate 2, and has at least the first dye layer 40R and the high dye layer 40R. The molecular light emitting layer 32 is irradiated (see FIG. 6). This laser beam 50
Is selectively applied only to a region of the first region R corresponding to the first electrode 31R. The first organic dye 42R of the first dye layer 40R is transferred and diffused into the polymer light emitting layer 32 by the heat generated by the irradiation of the laser beam 50, and the first organic dye 42R is transferred and diffused in red. The dye transfer diffusion portion 33 </ b> R that emits light at the same time can be formed. The laser beam 50 transmits through the first mask layer 41R on the order of μs, and several m when the thickness of the first dye layer 40R is several μm.
Since heat is transmitted to the polymer light emitting layer 32 in the order of s, and the first dye layer 40R and the polymer light emitting layer 32 are heated almost instantaneously, one transition diffusion can be performed instantaneously.
The polygon mirror 6 is controlled by the polygon mirror rotation controller 66.
5, the laser beam 50 is scanned in the Y direction, and a plurality of dye transfer / diffusion portions 33R are sequentially formed in a region corresponding to each of the plurality of first electrodes 33R arranged in the Y direction. can do. Laser light 50
After the scanning of one row in the Y direction is completed, the carriage 60 is moved by the pitch of the pixel 3 in the X direction by the carriage driving unit 61, and thereafter the laser beam 50 is similarly scanned in the Y direction to perform a plurality of dye transfer diffusion. The portions 33R are sequentially formed. In this way, the dye transfer diffusion portions 33R can be formed in all the first regions R on the substrate 2.

(7) Dye transfer / diffusion section 3 that emits red light
After all the 3Rs are formed, the first mask layer 41R and the first dye layer 40R are sequentially removed. Especially the first
The dye layer 40R is removed by a solvent that does not dissolve the polymer light emitting layer 32 during the removal.

(8) Next, the second dye layer 4 containing the green second organic dye 42G on the entire surface of the polymer light emitting layer 32
0G is formed (see FIG. 7). For example, the same resin film as that of the first dye layer 40R can be practically used for the second dye layer 40G. It is set similarly. Second organic dye 42G contained in second dye layer 40G
A coumarin derivative such as coumarin 6 can be used practically, and the second dye layer 40G is used as the first dye layer 40G.
Like R, the film can be formed by a wet coating method such as a coating method.

(9) As shown in FIG. 7, the second dye layer 4
A second mask layer 41G is formed on the entire surface on 0G. Second
The first mask layer 41G is similar to the first mask layer 41R.
When the irradiation energy is equal to or higher than the threshold, the laser beam can be transmitted. When the irradiation energy is equal to or lower than the threshold, the laser beam is not transmitted. Further, the second mask layer 41G
Has a function as a protective mask for preventing contamination of an area other than the irradiation position due to sublimation, bumping, or the like due to laser light irradiation.

(10) As shown in FIG. 8, the second region G
In a region corresponding to the first electrode 31G, that is, in a region where the organic EL element 30G that emits green light is formed, the second dye layer 40G is selectively irradiated with the laser beam 50 through the second mask layer 41G. By the irradiation of the laser beam 50, the second organic dye 42G of the second dye layer 40G can be transferred and diffused into the polymer light emitting layer 32, and the dye transfer diffusion obtained by transferring and diffusing the second organic dye 42G. The portion 33G can be formed. Irradiation with the laser beam 50 is performed using the organic dye transfer device 6 shown in FIG.

(11) After all of the dye transfer diffusion portions 33G that emit green light are formed, the second mask layer 41G,
Each of the second dye layers 40G is sequentially removed.

(12) Next, a third dye layer 40B containing the blue third organic dye 42B is formed on the entire surface of the polymer light emitting layer 32 (see FIG. 9). For the third dye layer 40B, for example, a resin film similar to the first dye layer 40R and the second dye layer 40G can be practically used, and the thickness of the third dye layer 40B is the first dye layer. The thickness is set in the same manner as the thickness of the dye layer 40 and the second dye layer 40G. As described above, a coumarin derivative such as coumarin 47 can be practically used as the third organic dye 42B included in the third dye layer 40B, and the third dye layer 40B is formed of the first organic dye 42B. Like the dye layer 40R and the second dye layer 40G, the film can be formed by a wet coating method such as a coating method.

(13) As shown in FIG. 9, a third mask layer 41B is formed on the entire surface of the third dye layer 40B. The third mask layer 41B includes the first mask layer 41R and the second mask layer 41B.
As in the case of the mask layer 41G, when the irradiation energy is equal to or larger than the threshold, the laser beam can be transmitted, and when the irradiation energy is equal to or smaller than the threshold, the laser beam is not transmitted. Further, the third mask layer 41B has a function as a protective mask for preventing contamination of a region other than the irradiation position due to sublimation, bumping, or the like due to irradiation with laser light.

(14) As shown in FIG. 10, in the region corresponding to the first electrode 31B in the third region B, that is, in the formation region of the organic EL element 30B that emits blue light,
The third dye layer 40B is selectively irradiated with the laser beam 50 through the mask layer 41B. By the irradiation of the laser light 50, the third organic dye 42B of the third dye layer 40B can be transferred and diffused into the polymer light emitting layer 32, and the dye transfer diffusion obtained by transferring and diffusing the third organic dye 42B Part 33B
Can be formed. Irradiation with the laser beam 50 is performed using the organic dye transfer device 6 shown in FIG. 11 described above and in the same procedure as the procedure for forming the dye transfer diffusion portions 33R and 33G.

(15) After all the dye transfer / diffusion portions 33B for emitting blue light are formed, the third mask layer 41B,
Each of the third dye layers 40B is sequentially removed.

FIG. 13 is a plan view during the manufacturing process of the organic EL device 1 (after the completion of the migration diffusion process).
As shown in FIG. 13, in the first region R of the polymer light emitting layer 32 on the substrate 2, the red dye transfer diffusion portion 33 </ b> R
Are arranged at an arrangement pitch on the short side of the pixels 3 in the Y direction (scanning direction of the laser beam 50), and are arranged at an arrangement pitch on the long sides of the pixels 3 in the X direction (moving direction of the carriage 60). Similarly, in the second region G of the polymer light emitting layer 32 on the substrate 2, the green dye transfer / diffusion portions 33 </ b> G are arranged at the shorter pitch of the pixels 3 in the Y direction, and are arranged in the X direction. 3 at an arrangement pitch on the longitudinal side. Substrate 2
In the third region B of the upper polymer light-emitting layer 32, the blue dye transfer / diffusion portions 33B are arranged at the arrangement pitch on the short side of the pixel 3 in the Y direction and on the long side of the pixel 3 in the X direction. They are arranged at an arrangement pitch.

In the first embodiment of the present invention, as described above, the red dye transfer diffusion portion 33R, the green dye transfer diffusion portion 33G, and the blue dye transfer diffusion portion 33B are formed in this order. However, the present invention is not necessarily limited to this order.

(16) Then, as shown in FIG. 1 described above, a second electrode 34 is formed on each surface of the dye transfer / diffusion portions 33R, 33G and 33B. Second electrode 34
Is formed, for example, by forming an aluminum thin film or an aluminum alloy thin film by a sputtering method and patterning it into a required shape. Further, the second electrode 34 may be formed by, for example, an evaporation method. The organic EL device 1 according to the first embodiment of the present invention is completed by forming the second electrode 34 and, if necessary, forming a protective film on the second electrode 34. be able to.

In the first embodiment of the present invention, as shown in FIG.
Although the case where the pixels 3 having 3G and 33B are regularly arranged in the X direction and the Y direction has been described, the present invention relates to the arrangement of the pixels 3 in the Y direction next to the arrangement of the pixels 3 in the X direction. The arrangement pattern of the pixels 3 may be staggered by shifting the arrangement pitch in the direction by one-third (corresponding to one dye transfer diffusion part) or two-thirds (corresponding to two dye transfer diffusion parts). The arrangement pattern of such staggered pixels 3 is such that the carriage driving unit 61 moves the carriage 60 in the Y direction by one third or two thirds of the pixel pitch without changing the irradiation start position of the laser beam 50. By shifting, it can be easily manufactured.

As described above, in the method of manufacturing the organic EL device 1 according to the first embodiment of the present invention, the first dye layer 40R is applied to the polymer light emitting layer 32 in a fine pattern. The dye transfer / diffusion portion 33R obtained by transferring and diffusing the organic dye 42R can be formed. Similarly, a dye transfer diffusion portion 33G in which the second organic dye 42G is transferred and diffused in a fine pattern from the second dye layer 40G to the polymer light emitting layer 32 can be formed, and the third dye layer 40B
Thus, a dye transfer diffusion portion 33B in which the third organic dye 42B is transferred and diffused in a fine pattern in the polymer light emitting layer 32 can be formed. Further, the dye transfer diffusion sections 33R, 3R
Since there is no color mixing between the organic dyes between 3G and 33B, there is no need for a bank between the organic EL elements as in the prior art, and the dye transfer / diffusion units 33R, 33G, 3G
3B, that is, between the organic EL elements 30R and 3R.
The separation distance between each of 0G and 30B can be reduced. Therefore, the first organic dye 42 of several colors is used.
By using R, the second organic dye 42G and the third organic dye 42B, the organic EL element 30R of each emission color can be used.
Since each of 30G and 30B can be easily formed in a fine pattern, the organic E having the fine pixels 3 can be easily formed.
The L device 1 can be manufactured.

Further, the dye transfer diffusion sections 33R, 33G,
33B can be formed by directly transferring and diffusing each of the first organic dye 42R, the second organic dye 42G, and the third organic dye 42B to the polymer light emitting layer 32. Diffusion units 33R, 33G, 33
There is no change in the surface state of each of B, the optical characteristics are maintained, and a high-brightness organic EL device 1 suitable for color display can be manufactured. Further, the polymer light emitting layer 32
First, the first organic dye 42R and the second organic dye 42R
G and the respective third organic dyes 42B are transferred and diffused to form the dye transfer diffusion portions 33R, 33G, and 33B, respectively, thereby eliminating the need for a conventional color filter, thereby reducing the number of components. The manufacturing cost of the organic EL device 1 can be reduced. As a result, the manufacturing cost of the organic EL device 1 can be reduced, so that the product cost of the organic EL device 1 can be reduced.

Further, in the method of manufacturing the organic EL device 1 according to the first embodiment of the present invention, the polymer light emitting layer 32, the first dye layer 40R, the second dye layer 40G, and the third dye The manufacturing process for forming the layer 40B, the first organic dye 42R of the first dye layer 40R, and the second dye layer 40
G of the second organic dye 42G and third of the third dye layer 40B.
And the manufacturing process of transferring and diffusing each of the organic dyes 42 </ b> B into the polymer light emitting layer 32 can be formed by separate independent manufacturing processes. In the manufacturing process of the polymer light emitting layer 32, the uniformity of the film thickness, the pinhole-free property of the film, the defect-free property and the like are independently managed, and the first dye layer 4 is formed.
In the manufacturing process for forming the 0R, the second dye layer 40G, and the third dye layer 40B, the uniformity of the film thickness, the concentration of the organic dye, the defect-freeness, and the like are independently controlled, and the manufacturing process in which migration and diffusion are further performed. Can independently control the transfer diffusion conditions (eg, temperature and time), alignment accuracy, etc., so that each manufacturing process can be optimized, and a high-quality and high-quality polymer light emitting layer can be achieved. 3
2, the first dye layer 40R, the second dye layer 40G, the third dye layer 40B, and the dye transfer diffusion portions 33R, 33G, 3
3B can be formed. The organic EL device 1 includes a first dye layer 40 on the polymer light emitting layer 32 formed by such separate independent manufacturing processes.
R is formed, and the first organic dye 42R included in the first dye layer 40R is transferred and diffused into the polymer light-emitting layer 32 in correspondence with the region of the first electrode 31R. Dye transfer diffusion portion 33R having red emission color
(Organic EL element 30R) can be easily manufactured. Similarly, a second dye layer 40G is formed on the polymer light emitting layer 32.
Is formed, and the second organic dye 42G included in the second dye layer 40G is transferred and diffused into the polymer light emitting layer 32 in correspondence with the region of the first electrode 31G, and a predetermined green color is formed in a fine pattern. Transfer diffusion part 33G having a luminescent color of
(Organic EL element 30G) can be easily manufactured. Similarly, a third dye layer 40B is formed on the polymer light emitting layer 32, and the third organic dye 42B included in the third dye layer 40B is made to correspond to the region of the first electrode 31B. The dye transfer diffusion section 3 having a predetermined blue light emission color in a fine pattern only by being transferred and diffused into the molecular light emitting layer 32
3B (organic EL element 30B) can be easily manufactured.

Further, in the method of manufacturing the organic EL device 1 according to the first embodiment of the present invention, at least the first dye layer 40R, the second dye layer 40G, and the third dye layer 40B, preferably The first dye layer 40R, the second dye layer 40G, the third dye layer 40B, and the region substantially corresponding to the heated portion of the polymer light emitting layer 32 (the first electrode 31
R, 31G, and 31B) selectively from the first dye layer 40R to the first organic dye 42R.
From the second dye layer 40G to the second organic dye 42G,
The third organic dye 42B is transferred from the third dye layer 40B to the polymer light emitting layer 32 and diffused into the dye transfer diffusion section 3
Each of 3R, 33G, and 33B can be formed. That is, by setting the region to be heated to a fine pattern, the organic EL element 30R having a fine pattern of red emission color, the organic EL element 30G having a green emission color, and the organic EL element having a blue emission color 30B can be formed.

Further, the first electrode 31 is heated only by heating.
The first organic dye 42R, the second organic dye 42G, and the third organic dye 42B can be transferred and diffused into the polymer light emitting layer 32 in the regions corresponding to R, 31G, and 31B, respectively. It is not necessary to use a vacuum deposition method or a coating method as described above, and it is not necessary to use a photolithography technique or an etching technique, so that the manufacturing of the organic EL device 1 can further reduce the number of manufacturing processes. The method can be realized. Further, each of the first organic dye 42R of the first dye layer 40R, the second organic dye 42G of the second dye layer 40G, and the third organic dye 42B of the third dye layer 40B is a polymer light emitting layer. Since the step of shifting to 32 can be performed in a predetermined gas atmosphere by a dry method, for example, in an inert gas atmosphere, the organic EL element 30 having a red emission color can be used.
It is possible to realize a method of manufacturing the organic EL device 1 that can easily manufacture each of the organic EL element 30G having the R and green emission colors and the organic EL element 30B having the blue emission color.

Further, in the method for manufacturing the organic EL device 1 according to the first embodiment of the present invention, the heating of each of the first dye layer 40R, the second dye layer 40G, and the third dye layer 40B is performed. Is performed with the laser beam 50, the irradiation energy distribution can be made uniform, and the dye transfer diffusion section 33
Since the boundary between each of R, 33G, and 33B and the periphery thereof can be made relatively clear, each of the organic EL elements 30R, 30G, and 30B having a fine pattern can be formed.

Further, in the organic dye transfer device 6,
Since the laser beam 50 can be scanned over a wide range in the Y direction by the polygon mirror 65, the organic EL device 1 optimal for constructing a large-screen color display panel can be manufactured.

The organic EL according to the first embodiment of the present invention
In the method of manufacturing the device 1, transmission of the laser beam 50,
By further providing a step of forming each of the first mask layer 41R, the second mask layer 41G, and the third mask layer 41B having a threshold value for opacity, the laser beam 50 whose irradiation energy does not reach the threshold value is provided. In particular, the dye transfer diffusion sections 33R, 3
Unnecessary laser light 50 that spreads in the surrounding area of each of 3G and 33B is removed, and dye transfer diffusion sections 33R and 33R are removed.
Since the boundary between each of G and 33B and the periphery thereof can be made clearer, each of the organic EL elements 30R, 30G and 30B having a fine pattern can be formed. Further, the laser light 50 is applied to the first dye layer 4.
By irradiating each of 0R, the second dye layer 40G, and the third dye layer 40B, sublimation, bumping, etc. occur.
It is possible to prevent contamination of areas other than the dye transfer diffusion sections 33R, 33G, and 33B.

Further, in the method of manufacturing the organic EL device 1 according to the first embodiment of the present invention, a plurality of dye transfer diffusion portions 33R, 33G and 33B of different colors are used.
, The organic EL elements 30R, 30G, and 30B of a plurality of emission colors can be formed, and the organic EL device 1 optimal for constructing a color display panel can be manufactured.

In the organic EL device 1 according to the first embodiment of the present invention, similar to the effect obtained by the method of manufacturing the organic EL device 1 according to the first embodiment of the present invention, finer EL device 1 having a simple pixel 3
Can be realized. Further, it is possible to realize a high-brightness organic EL device 1 suitable for color display.
Further, the organic EL device 1 having a simple structure can be realized. Further, the organic EL device 1 having a low product cost can be provided.

First Modification: From the first modification to the fifth modification of the first embodiment of the present invention, examples of an organic EL device having another sectional structure excellent in luminous efficiency are described. It is for explanation.

FIG. 14 shows a first embodiment of the first embodiment of the present invention.
It is sectional drawing of the organic EL device which concerns on the modification of FIG.
As shown in FIG. 14, the organic EL device 1 according to the first modification has a positive electrode between the entire surface of the substrate 2 including the first electrodes 31R, 31G, and 31B and the polymer light emitting layer 32. The hole injection layer 35 is provided. That is, the organic EL element 30R for emitting red light includes the first electrode 31R, the hole injection layer 35 on the first electrode 31R, and the red first organic dye 42R on the hole injection layer 35. The dye transfer diffusion part 33R that has been transferred and diffused, and the second electrode 34 on the dye transfer diffusion part 33R.
It is comprised including. Similarly, the organic EL element 30G for emitting green light includes a first electrode 31G, a hole injection layer 35 on the first electrode 31G, and a green second organic dye 42G on the hole injection layer 35. And the second electrode 34 on the dye transfer diffusion portion 33G.
It is comprised including. In the organic EL element 30B emitting blue light, the first electrode 31B, the hole injection layer 35 on the first electrode 31B, and the blue third organic dye 42B on the hole injection layer 35 migrate and diffuse. Dye transfer diffusion part 33B
And a second electrode 34 on the dye transfer diffusion section 33B.

In the organic EL device 1 according to the first modification of the first embodiment of the present invention thus configured, the organic EL device 1 according to the first embodiment of the present invention is obtained. In addition to the effects obtained, the provision of the hole injection layer 35 can further improve the light emission efficiency.

The organic EL device 1 according to the first modification may further include a hole transport layer in addition to the hole injection layer 35.

Second Modification: FIG. 15 is a sectional structural view of an organic EL device according to a second modification of the first embodiment of the present invention. As shown in FIG. 15, the organic EL device 1 according to the second modified example has a structure in which the second electrode 34 extends from the polymer light emitting layer 32 between the entire surface on the polymer light emitting layer 32 and the second electrode 34. Toward the electron transport layer 36 and the electron injection layer 37
Are sequentially provided. That is, the organic EL element 30R for emitting red light is provided with the first electrode 31R,
A dye transfer / diffusion portion 33R where the red first organic dye 42R on the first electrode 31R is transferred / diffused, an electron transport layer 36 on the dye transfer / diffusion portion 33R, and an electron injection layer 37 on the electron transport layer 36. And a second electrode 34 on the electron injection layer 37. Similarly, organic E of green emission color
The L element 30G includes a first electrode 31G and a first electrode 31.
A dye transfer diffusion portion 33G in which the green second organic dye 42G on G is transferred and diffused; an electron transport layer 36 on the dye transfer diffusion portion 33G; an electron injection layer 37 on the electron transport layer 36;
And a second electrode 34 on the electron injection layer 37. The organic EL element 30B for emitting blue light includes a first electrode 31B, a dye transfer diffusion portion 33B in which the blue third organic dye 42B on the first electrode 31B is transferred and diffused,
The electron transport layer 36 on the dye transfer diffusion part 33B, the electron injection layer 37 on the electron transport layer 36, and the second
Electrodes 34.

In the organic EL device 1 according to the second modification of the first embodiment of the present invention thus configured, the organic EL device 1 according to the first embodiment of the present invention is obtained. In addition to the effects obtained, the provision of the electron transport layer 36 and the electron injection layer 37 can further improve the luminous efficiency.

Third Modification: The organic EL device 1 according to the third modification of the first embodiment of the present invention is different from the organic EL device 1 according to the first modification shown in FIG. The hole injection layer 35 (and the hole transport layer) and the second layer shown in FIG.
The organic EL device 1 according to the modification example includes the electron transport layer 36 and the electron injection layer 37. In the organic EL device 1 according to the third modification of the first embodiment of the present invention configured as described above, the luminous efficiency can be further improved.

Fourth Modification: An organic EL device 1 according to a fourth modification of the first embodiment of the present invention is designed to improve the luminous efficiency or the spectral conversion efficiency as shown in FIG. 15 and the hole injection layer 35 (and the hole transport layer) other than the polymer light emitting layer 32 of the organic EL device 1 or the electron injection layer 36 or the electron transport layer 37 of the organic EL device 1 shown in FIG. Similarly to the method of transferring and diffusing the organic dye to the polymer light emitting layer 32, the organic dye is
Are transferred and diffused.

Fifth Modification: The organic EL device 1 according to a fifth modification of the first embodiment of the present invention is different from the polymer light emitting layer 32 and other layers, for example, the first modification. The hole injection layer 35, the electron injection layer 36, and the electron transport layer 37 according to the second modified example are obtained by doping a low-molecular material having a carrier transport property such as electrons or holes. The doping of the low-molecular material can be performed simultaneously with the transfer diffusion of the organic dye or in a separate step. By doping the polymer light emitting layer 32 and the like with a low molecular material as described above, the organic EL device 1 having excellent carrier transport efficiency, light emission efficiency, and the like can be realized. Further, the thickness of the organic EL layer (organic E
Since the carrier transport molecule concentration can be increased without particularly increasing the height of each of the L elements 31R, 30, and G30B), the organic EL device 1 having excellent luminous efficiency can be realized.

Sixth Modification: A sixth modification of the first embodiment of the present invention and a seventh modification which will be described later are directed to an organic EL device provided with a circuit for controlling light emission of an organic EL element.
5 illustrates the L device. FIG. 16 is a sectional structural view of an organic EL device according to a sixth modification of the first embodiment of the present invention, and FIG. 17 is a circuit diagram of a circuit for controlling light emission of one pixel of the organic EL device shown in FIG. It is.

In the organic EL device 1 according to the sixth modification of the first embodiment of the present invention, as shown in FIG. Is performed by the light emission control circuit 80. The light emission control circuit 80 is disposed at the intersection of a select line SL and a data line DL extending orthogonally to each other, and includes a thin film transistor Tr1 for pixel selection and a capacitor C
And a series circuit.

As shown in FIGS. 17 and 16, the thin film transistor Tr1 of the light emission control circuit 80 is
0 and the first main electrode 71 connected to the select line SL
, A second main electrode 72 connected to one electrode 73 of the capacitor C, an insulator 74 on the channel region 70, and a control electrode 75 on the insulator 74. Channel region 70, first main electrode 71, second main electrode 72
Are formed of a gate material such as a silicon polycrystalline thin film and a silicon amorphous thin film in the same layer. Control electrode 75
Is formed of a gate material such as a silicon polycrystalline thin film, a silicon amorphous thin film, a refractory metal silicide thin film, or a refractory metal thin film in an upper layer different from the channel region 70 and the like. For the select line SL, the gate material or a metal material such as an aluminum thin film or an aluminum alloy thin film can be practically used.

The capacitance element C includes one electrode 73 and the electrode 7
3 and the other electrode 7 on the dielectric film 76
7 are provided. The electrode 77 is a first electrode 31R of the organic EL element 30R, a second electrode 31G of the organic EL element 30G, or a first electrode 3 of the organic EL element 30B.
1B. Electrode 73
Are formed of the same gate material in the same layer as the channel region 70 and the like. As the dielectric film 76, for example, a silicon oxide film can be practically used. The electrode 77 is formed of, for example, the same gate material or metal material in the same layer as the select line SL.

The light emission control circuit 80 is formed on the substrate 2,
Each of the organic EL elements 30R, 30G, and 30B is arranged on the light emission control circuit 80 with an insulating film 79 interposed therebetween. As the insulating film 79, for example, a silicon oxide film can be practically used. An organic EL device 1 according to a sixth modification of the first embodiment of the present invention has a substrate 2
Since a transparent glass substrate is employed, the light emission direction is on the substrate 2 side (the lower side in the figure) as shown by the arrow in FIG.

In the organic EL device 1 according to the sixth modification of the first embodiment of the present invention, a light emission control circuit 81 having a circuit configuration shown in FIG. 18 can be employed. That is, the light emission control circuit 81 performs the first pixel selection.
Series circuit of the thin film transistor Tr1 and the capacitor C, the power line PL and the organic EL element 30R, 30G or 30
B and a second thin film transistor Tr2 controlled by the first thin film transistor Tr1. The specific device structure of the second thin film transistor Tr2 is substantially the same as the thin film transistor Tr1 shown in FIG.

Seventh Modification: FIG. 19 is a sectional structural view of an organic EL device according to a seventh modification of the first embodiment of the present invention. An organic EL device 1 according to a seventh modification of the first embodiment of the present invention includes, as shown in FIG.
Organic E according to a sixth modification of the first embodiment of the present invention
In the L device 1, an opaque, for example, silicon single crystal substrate is used as the substrate 2, and the organic EL elements 30R, 30G,
30B each of the first electrodes 31R, 31G, 31B
An electrode material such as an aluminum thin film is used as a cathode, and the second electrode 34 is formed using an electrode material such as an indium tin oxide thin film as an anode.

In the organic EL device 1 according to the seventh modification of the first embodiment of the present invention, as shown by an arrow in FIG. 19, the light emission direction is on the second electrode 34 side (in the figure). ,
(Upper side), the material of the substrate 2 is not limited to a transparent glass substrate, and a silicon single crystal substrate and other wiring substrate materials can be used. As the substrate 2, an insulating substrate or the like can be used in addition to the silicon single crystal substrate.

Eighth Modification: In the method of manufacturing the organic EL device 1 according to the eighth modification of the first embodiment of the present invention, the first dye layer 40R, the second dye layer 40G,
Each of the third dye layers 40B can be formed by printing an organic dye paste using a thermoplastic plastic as a binder on the polymer light emitting layer 32 by a dry gravure printing method. A first dye layer 40R, a second dye layer 40G formed by such a gravure printing method,
Each of the third dye layers 40B is inexpensive in terms of manufacturing cost, and is excellent in productivity of the organic EL device 1.
Polystyrene, polymethyl methacrylate (PMMA), or the like can be practically used as the thermoplastic plastic as a binder. First dye layer 40R, second dye layer
Each of the third dye layer 40G and the third dye layer 40B can be formed to a thickness of, for example, about 1 μm to 3 μm, and has high quality of the first dye layer 40R and the second dye layer 40G without thickness unevenness. The third dye layer 40B can be formed.

Ninth Modification: In the method of manufacturing an organic EL device 1 according to a ninth modification of the first embodiment of the present invention, the first dye layer 40R, the second dye layer 40G,
Each of the third dye layers 40B can be formed by printing a solution in which an organic dye is dissolved on the polymer light emitting layer 32 by a wet photoengraving method such as gravure coating or die coating. As in the eighth modification, each of the first dye layer 40R, the second dye layer 40G, and the third dye layer 40B formed by such a photoengraving method is inexpensive in terms of manufacturing cost. Therefore, the productivity of the organic EL device 1 is excellent.

(Second Embodiment) In a second embodiment of the present invention, an organic EL device 1 according to the first embodiment of the present invention and an organic dye of the dye layer in the method for manufacturing the same are transferred to a thermal head. This explains an example in which the dye is transferred and diffused into the polymer light emitting layer to form a dye transfer / diffusion portion. The cross-sectional structure of the organic EL device according to the second embodiment of the present invention is substantially the same as the cross-sectional structure of the organic EL device 1 according to the first embodiment of the present invention shown in FIG. Since it is formed, the description here is omitted. In addition, unless otherwise specified, the functions and materials of each part of the organic EL device according to the second embodiment of the present invention will be described. The same functions and materials are used.

Manufacturing Process: FIGS. 20 to 25 are manufacturing process diagrams of the organic EL device according to the second embodiment of the present invention.

(1) First, as shown in FIG. 2 described above, a substrate 2 serving as a base of the organic EL device 1 is prepared, and as shown in FIG. One electrode 31R, 31G and 31B is formed. As in the manufacturing process of the organic EL device 1 according to the first embodiment of the present invention, the first electrode 31R is a red organic EL element 30R.
Is formed in a first region R on the substrate 2 on which the first organic EL element 30G is formed. The first electrode 31G is formed in a second region G on the substrate 2 on which the green organic EL element 30G is formed. It is formed in a third region B on the substrate 2 on which the blue organic EL element 30B is formed. That is, a set of first electrodes 31
R, 31G, and 31B are formed in portions corresponding to the formation region of one pixel 3.

(2) As shown in FIG. 4, the polymer light emitting layer 32 is formed on the entire surface of the substrate 2 including the surfaces of the first electrodes 31R, 31G and 31B.

(3) As in the method for manufacturing the organic EL device 1 according to the first embodiment of the present invention, as shown in FIG. The first dye layer 40R containing the dye 42R is formed.

(4) Next, a film 45 is disposed on the first dye layer 40R (see FIG. 21). Film 45
Means that when the first dye layer 40R is heated by the thermal head 92, the first organic dye 42R of the first dye layer 40R is diffused toward the polymer light emitting layer 32 before the first organic dye 42R is diffused toward the thermal head 92. It can be transferred and diffused. That is, the film 45 includes the first pigment layer 40R.
Thus, the first organic dye 42 can be prevented from diffusing, and the thermal head 92 can be prevented from being stained or deteriorated. For the film 45, it is preferable to use, for example, a resin film that has a glass transition temperature higher than the glass transition temperature of the polymer light emitting layer 32 and does not allow the first organic dye 42R to diffuse by heating during transition diffusion. Specifically, the film 45 has, for example, 2 μm to 2 μm.
A long (tape) -like polyethylene terephthalate (PET) film, polyethylene naphthalate film, polyimide film or the like having a thin film thickness of about 0 μm can be practically used.

Subsequently, as shown in FIG. 21, in a region of the first region R corresponding to the first electrode 31R, at least the first dye layer 40R is interposed by the heating element 94R of the thermal head 92 with the film 45 interposed therebetween. Is pressed and heated to transfer and diffuse the first organic dye 42R of the first dye layer 40R to the polymer light emitting layer 32, thereby forming a dye transfer diffusion portion 33R in which the first organic dye 42R is transferred and diffused. . PVCz is applied to each of the first dye layer 40R and the polymer light emitting layer 32.
If a thin film is used, the glass transition point T of the PVCz thin film
Since g is 173 ° C., each of the first dye layer 40R and the polymer light emitting layer 32 is 180 ° C. or less due to the heating element 94R.
Heated to about 185 ° C.

FIG. 26 is a schematic configuration diagram of an organic dye transfer device used in the second embodiment of the present invention.

As shown in FIG. 26, the transfer diffusion can be performed by the organic dye transfer device 9. The organic dye transfer device 9 takes up a carriage 90 for mounting and holding the substrate 2, a carriage driving unit 91 for moving the carriage 90 in the X direction, and a supply roll 46A for supplying the film 45 and the film 45. Take-up roll 4
6B, a roll driving unit 96 for rotating the take-up roll 46B, a thermal head 92 having heating elements 94 (94R, 94G and 94B) for performing transition diffusion, and a heating element 94.
And a head driving unit 93 that moves the thermal head 92 up and down in the Z direction (vertical direction). As shown in FIG. 27, in the thermal head 92, the heating element 94
Heating element 94R that pressurizes and heats the dye layer 40R,
Heating element 94G for pressing and heating the dye layer 40G of
A plurality of heating elements 94B for pressing and heating the dye layer 40B are arranged as a set in the Y direction. Actually, these heating elements 94R, 94R of the thermal head 92 are used.
G and 94B are both formed of similar resistors.
When the first dye layer 40R is pressed and heated, the heating element 94 is used.
R is applied only to the heating element 94G when the second dye layer 40G is pressed and heated.
When pressurizing and heating OB, only the heating element 94B is energized. The plurality of first heating elements 94R are arranged on the substrate 2 in the Y direction (direction perpendicular to the paper surface).
Corresponding to each of the electrodes 31R. Similarly, the heating element 94G individually corresponds to the plurality of first electrodes 31G arranged on the substrate 2 in the Y direction, and the heating element 94B corresponds to the plurality of first electrodes 31 arranged on the substrate 2 in the Y direction. 31B individually. Heating element 94R, 94
Both G and 94B are heated for each color by supplying current from the heating element control unit 95 (by supplying electricity), and the heating temperature can be adjusted by the supply time and supply current amount.

FIG. 28 is a diagram showing the relationship between the heating time (heating time) of the heating element 94, the heating current (current flowing amount), and the transition diffusion concentration (doping concentration). Thermal head 9
As the heating time of the second heating element 94 increases, the transfer diffusion density of the red first organic dye 42R from the first dye layer 40R to the polymer light emitting layer 32 tends to increase.
Further, by sequentially increasing the heating current i1 → i2 → i3 of the heating element 94, the transfer diffusion density of the red first organic dye 42R from the first dye layer 40R to the polymer light emitting layer 32 tends to increase. It is in. By controlling the heating time and the heating current using the tendency shown in FIG. 28, that is, by controlling the conduction time and the conduction current amount of the heating element 94 of the thermal head 92, the transfer diffusion of the polymer light emitting layer 32 is controlled. The concentration can be easily and accurately controlled.
In the initial stage of the start of energization of the heating element 94, since the temperature of the heating element 94 is low, the energizing time and / or the amount of energizing current are adjusted slightly larger. In a middle or late stage after a certain time has elapsed from the start of energization, the temperature of the heating element 94 is high, so that the energization time and / or the amount of energization current are adjusted slightly lower. Such adjustment is automatically performed by a microprocessor included in the heating element control unit 95. Note that the relationship between the heating time, the heating current, and the transfer diffusion concentration shown in FIG. 28 is the same for each of the green second organic dye 42G and the blue third organic dye 42B described later.

In FIGS. 26 and 27, the organic dye transfer operation of the organic dye transfer device 9 is performed as follows.
First, the substrate 2 on which the polymer light emitting layer 32 and the first dye layer 40R are already formed is placed and held on the carriage 90,
The carriage 90 is moved by the carriage drive unit 91 so that the heating element 94R of the heating element 94 of the thermal head 92 faces the organic dye transfer start position on the substrate 2. Substrate 2
Of the first dye layer 40R and the heating element 9 of the thermal head 92
A film 45 supplied from the supply roll 46A and taken up by the take-up roll 46B is arranged between the film 45 and the feed roll 4B. The thermal head 92 is lowered by the head driving unit 93, the heating element 94R of the thermal head 92 is pressed against the substrate 2 with the film 45 interposed, and the heating element control unit 95 starts energization of the heating element 94R. The heating element 94R presses and heats the first dye layer 40R and the polymer light emitting layer 32 with the film 45 interposed therebetween, and as shown in FIG. 21, the first organic dye 42R of the first dye layer 40R. Is transferred to and diffused into the polymer light emitting layer 32 to form the dye transfer / diffusion portion 33R including the red first organic dye 42R.

When the thickness of the film 45 is about several μm, the first organic dye 42R can be transferred and diffused into the polymer light emitting layer 32 in a very short time of several ms. In addition, the first organic dye 42R can be selectively transferred and diffused in the region of the first dye layer 40R and the polymer light emitting layer 32 which are pressurized and heated by the heating element 94R. The heating element 94R itself can be manufactured using photolithography technology and etching technology in semiconductor manufacturing technology, and thus can be formed by fine processing of several μm to several tens μm. In particular,
The heating element 94R can be formed with a width dimension of, for example, about 40 μm, which is equivalent to that of the first electrode 31R. Therefore, a green dye transfer diffusion part 33G and a blue dye transfer diffusion part 33B, which will be described later, are added to the red dye transfer diffusion part 33R, and one pixel 3 is formed by a total of three color dye transfer diffusion parts 33R, 33G and 33B. However, the size of one pixel 3 is 120 μm.
It can be formed with a fine size of about m to 150 μm.

Then, as shown in FIG. 27, in one row in the Y direction, the transfer diffusion is completed, and after the dye transfer diffusion portion 33R including the red first organic dye 42R is formed, the transfer to the heating element 94R is performed. Of the thermal head 9
The carriage 90 is moved while the carriage 2 is pressed.
1 moves in the X direction by the pixel pitch (the pitch of the first electrode 31R), and moves the thermal head 9 onto the first dye layer 40R and the polymer light emitting layer 32 at the next organic dye transfer position.
2 is arranged. Thereafter, transfer diffusion is repeatedly performed in the same manner as described above, and a dye transfer diffusion portion 33R including the first organic dye 42R of red color can be formed on the substrate 2 in the X direction.

(5) Dye transfer diffusion section 3 for emitting red light
After all of the 3Rs are formed, the substrate 2 is removed from the organic dye transfer device 9, and the first dye layer 40R on the substrate 2 is removed. In particular, the first dye layer 40R is selectively removed with respect to the polymer light-emitting layer 32 by using a solvent that does not dissolve the polymer light-emitting layer 32, such as ethanol, when removing the first dye layer 40R.

(6) Next, similarly to the method of manufacturing the organic EL device 1 according to the first embodiment of the present invention, as shown in FIG. A second dye layer 40G containing the second organic dye 42G is formed.

(7) Then, the substrate 2 on which the second dye layer 40G is formed is attached to the organic dye transfer device 9, and the film 45 is disposed on the second dye layer 40G (see FIG. 23). Subsequently, as shown in FIG. 23, in a region corresponding to the first electrode 31G in the second region G, at least the second dye layer 40G is pressed by the heating element 94G of the thermal head 92 with the film 45 interposed therebetween. Then, the second organic dye 42G of the second dye layer 40G is transferred and diffused into the polymer light emitting layer 32 to form the dye transfer diffusion portion 33G in which the second organic dye 42G is transferred and diffused. .

(8) Dye transfer diffusion section 3 for emitting green light
After all of the 3G are formed, the substrate 2 is removed from the organic dye transfer device 9, and the second dye layer 40G on the substrate 2 is removed. In particular, the second dye layer 40G is selectively removed with respect to the polymer light emitting layer 32 by a solvent that does not dissolve the polymer light emitting layer 32 at the time of removal.

(9) Next, similarly to the method of manufacturing the organic EL device 1 according to the first embodiment of the present invention, as shown in FIG. A third dye layer 40B containing the third organic dye 42B is formed.

(10) Then, the substrate 2 on which the third dye layer 40B is formed is attached to the organic dye transfer device 9, and the third dye layer
The film 45 is disposed on the dye layer 40B (see FIG. 25). Subsequently, as shown in FIG. 25, in a region corresponding to the first electrode 31B in the third region B, at least the third dye layer 40B is pressed by the heating element 94B of the thermal head 92 with the film 45 interposed therebetween. Then, the third organic dye 42B of the third dye layer 40B is transferred and diffused into the polymer light emitting layer 32 to form a dye transfer diffusion portion 33B in which the third organic dye 42B is transferred and diffused. .

(11) After all the dye transfer / diffusion portions 33B that emit blue light are formed, the substrate 2 is removed from the organic dye transfer device 9, and the third dye layer 40B on the substrate 2 is removed. In particular, the third dye layer 40B is selectively removed with respect to the polymer light emitting layer 32 by a solvent that does not dissolve the polymer light emitting layer 32 at the time of removal.

(12) As in the case of the organic EL device 1 according to the first embodiment of the present invention shown in FIG. 1, the second surface of the dye transfer diffusion portions 33R, 33G, 33B Is formed. By forming the second electrode 34 and, if necessary, forming a protective film on the second electrode 34, the organic EL device 1 according to the second embodiment of the present invention is completed. be able to.

In the second embodiment of the present invention, as shown in FIG.
Although the case where the pixels 3 having 3G and 33B are regularly arranged in the X direction and the Y direction is described, the present invention is, as described in the organic EL device 1 according to the first embodiment described above. The arrangement pattern of the pixels 3 may be staggered.

As described above, the method for manufacturing the organic EL device 1 according to the second embodiment of the present invention is obtained by the method for manufacturing the organic EL device 1 according to the first embodiment of the present invention. In addition to the effect obtained, the first dye layer 40
R, the second dye layer 40G, and the third dye layer 40B are each heated by the thermal head 92 with pressurization, so that the heating elements 94 (94R, 94R) of the thermal head 92 are heated.
G or 94B), and each of the organic EL elements 30R, 30G, and 30B having a fine pattern can be easily formed.

Further, in the method for manufacturing the organic EL device 1 according to the second embodiment of the present invention, the first organic dye 42R and the second dye layer 40G of the first dye layer 40R are provided.
Forming a film 45 for preventing the diffusion of the third organic dye 42B of the second organic dye 42G and the third organic dye 42B of the third dye layer 40B. Effort can be reduced.

In the organic EL device 1 according to the second embodiment of the present invention, the first to ninth modified examples of the first embodiment of the present invention are used. be able to.

(Other Embodiments) Although the present invention has been described with reference to the above embodiments, it should not be understood that the description and drawings constituting a part of this disclosure limit the present invention. From this disclosure, various alternative embodiments, examples, and operation techniques will be apparent to those skilled in the art.

For example, in the method of manufacturing the organic EL device 1 according to the first embodiment, the first mask layer 41R, the second mask layer 41G, and the third mask layer 41B
Instead of forming each of the above, like the film layer 45 used in the method of manufacturing the organic EL device 1 according to the second embodiment, the mask layer is supplied by the supply-side roll and is supplied by the winding-side roll. You may make it wind up.

Further, the present invention may be an organic EL device 1 combining at least two of the first to ninth modifications of the first embodiment or a method of manufacturing the same.

As described above, the present invention naturally includes various embodiments and the like not described herein. Therefore, the technical scope of the present invention is defined only by the invention specifying matters according to the appropriate claims.

[0135]

According to the present invention, a dye layer containing an organic dye is formed, and a dye transfer / diffusion portion for transferring and diffusing the organic dye of the dye layer to the polymer light emitting layer is provided.
It is possible to provide an organic EL device capable of forming an element in a fine pattern and obtaining high luminance suitable for color display in an organic EL element of each emission color, and a method for manufacturing the same.

Further, since the present invention does not require a color filter or a bank for separating organic EL elements, it is possible to provide an organic EL device capable of reducing the number of parts and the product cost.

Further, according to the present invention, by performing transition diffusion with laser light, organic EL elements of each emission color can be formed in a fine pattern, and an organic EL element having a fine pattern can be easily manufactured. And a method of manufacturing an organic EL device that can be provided.

Further, according to the present invention, by performing transfer diffusion with a thermal head, organic EL elements of each emission color can be formed in a fine pattern, and an organic EL element having a fine pattern can be easily manufactured. Organic EL that can be used
A method for manufacturing a device can be provided.

Further, the present invention can provide a method of manufacturing an organic EL device capable of improving a manufacturing yield.

Further, the present invention can provide a method for manufacturing an organic EL device capable of reducing the production cost.

[Brief description of the drawings]

FIG. 1 is a sectional structural view of an organic EL device according to a first embodiment of the present invention.

FIG. 2 is a process sectional view of the organic EL device according to the first embodiment of the present invention.

FIG. 3 is a process sectional view of the organic EL device following FIG. 2;

FIG. 4 is a process sectional view of the organic EL device following FIG. 3;

5A is a process sectional view of the organic EL device following FIG. 4, and FIG. 5B is a process sectional view of another example of the organic EL device following FIG.

FIG. 6 is a process sectional view of the organic EL device following FIG. 5;

FIG. 7 is a process sectional view of the organic EL device following FIG. 6;

FIG. 8 is a process sectional view of the organic EL device following FIG. 7;

FIG. 9 is a process sectional view of the organic EL device, following FIG. 8;

FIG. 10 is a process sectional view of the organic EL device following FIG. 9;

FIG. 11 is a schematic configuration diagram of an organic dye transfer device according to the first embodiment of the present invention.

FIG. 12 is a diagram illustrating a relationship among laser light irradiation time, organic dye concentration, and irradiation power according to the first embodiment of the present invention.

FIG. 13 is a plan view of the organic EL device during a manufacturing process according to the first embodiment of the present invention.

FIG. 14 is a sectional structural view of an organic EL device according to a first modification of the first embodiment of the present invention.

FIG. 15 is a sectional structural view of an organic EL device according to a second modification of the first embodiment of the present invention.

FIG. 16 is a sectional structural view of an organic EL device according to a sixth modification of the first embodiment of the present invention.

FIG. 17 is a circuit diagram of a circuit that performs light emission control of an organic EL device according to a sixth modification of the first embodiment of the present invention.

FIG. 18 is a circuit diagram of another circuit that performs light emission control of the organic EL device according to the sixth modification of the first embodiment of the present invention.

FIG. 19 is a circuit diagram of a circuit that performs light emission control of an organic EL device according to a seventh modification of the first embodiment of the present invention.

FIG. 20 is a process sectional view of the organic EL device according to the second embodiment of the present invention.

FIG. 21 is a process sectional view of the organic EL device, following FIG. 20;

FIG. 22 is a process sectional view of the organic EL device, following FIG. 21;

FIG. 23 is a process sectional view of the organic EL device, following FIG. 22;

FIG. 24 is a process sectional view of the organic EL device, following FIG. 23;

FIG. 25 is a process sectional view of the organic EL device, following FIG. 24;

FIG. 26 is a schematic configuration diagram of an organic dye transfer device according to a second embodiment of the present invention.

FIG. 27 is a schematic top view of a main part of the organic dye transfer device shown in FIG. 26;

FIG. 28 is a diagram showing a relationship among a heating time, a heating current, and a transfer diffusion concentration of a heating element of a thermal head according to a second embodiment of the present invention.

FIG. 29 is a sectional structural view of an organic EL device according to the related art.

FIG. 30 is a sectional structural view of an organic EL device according to a conventional technique.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Organic EL device 2 Substrate 3 Pixel 30R, 30G, 30B Organic EL element 31R, 31G, 31B 1st electrode 32 Polymer light emitting layer 33R, 33G, 33B Dye transfer diffusion part 34 2nd electrode 35 Hole injection layer 36 Electron injection layer 37 Electron transport layer 40R, 40G, 40B Dye layer 41R, 41G, 41B Mask layer 42R, 42G, 42B Organic dye 45 Film 46A, 46B Roll 50 Laser light 6,9 Organic dye transfer device 60,90 Carriage 61, 91 Carriage drive unit 62 Laser light oscillation unit 63 Laser light drive source 64 Pulse control circuit unit 65 Polygon mirror 66 Polygon mirror rotation control unit 92 Thermal head 63 Head drive unit 64, 64R, 64G, 64B Heating element 65 Heating element control unit 66 Roll drive 80, 81 Light emission control circuit Tr1, Tr2 Thin film transistor C Capacitance element DL Data line SL Select line PL Power supply line

 ──────────────────────────────────────────────────続 き Continued on the front page F term (reference) 3K007 AB02 AB04 AB18 BA06 CA00 CA01 CB01 DA00 DB03 EB00 FA00 FA01 5C094 AA08 AA10 AA42 AA43 AA44 AA60 BA02 BA27 CA19 DA09 EA05 EB02

Claims (8)

[Claims] A step of forming a first electrode on the substrate; a step of forming a polymer light emitting layer on the first electrode; and forming a dye layer containing an organic dye on the polymer light emitting layer. And, in a region corresponding to the first electrode, a step of forming a dye transfer diffusion portion by transferring and diffusing the organic dye of the dye layer to a polymer light emitting layer; and removing the dye layer; Forming a second electrode on the dye transfer diffusion section. 2. The step of forming the dye transfer diffusion section,
In a region corresponding to the first electrode, at least the dye layer is heated to transfer and diffuse the organic dye of the dye layer to the polymer light emitting layer to form a dye transfer diffusion portion. The method for manufacturing an organic electroluminescent device according to claim 1. 3. The method according to claim 2, wherein the heating of the dye layer is performed by a laser beam. 4. Transmitting the laser light on the dye layer,
Forming a mask layer having a threshold value for opacity, wherein the step of forming the dye-migration-diffusion portion comprises, in a region corresponding to the first electrode, a laser beam transmitted through the mask layer; 4. The organic electroluminescent device according to claim 3, wherein the step of heating the layer causes the organic dye of the dye layer to migrate and diffuse into the polymer light emitting layer to form a dye migration diffusion part. Method. 5. The method according to claim 2, wherein the heating of the dye layer is performed by a thermal head accompanied by pressurization. 6. The method according to claim 1, further comprising: forming a film on the dye layer to prevent migration and diffusion of the organic dye in the dye layer, wherein the step of forming the dye transfer diffusion portion corresponds to the first electrode. A step of forming a dye transfer diffusion part by diffusing an organic dye of the dye layer into a polymer light emitting layer by pressing and heating the dye layer with the thermal head through the film in the region. The method for manufacturing an organic electroluminescent device according to claim 5, wherein 7. A step of forming a plurality of first electrodes adjacent to each other on a substrate; a step of forming a polymer light emitting layer on the plurality of first electrodes; and a step of forming a polymer light emitting layer on the polymer light emitting layer. Forming a first dye layer containing one organic dye, and transferring and diffusing the first organic dye of the first dye layer to the polymer light emitting layer in a region of the first region corresponding to the first electrode; Forming a first dye transfer diffusion portion by removing the first dye layer; forming a second dye layer containing a second organic dye on the polymer light emitting layer; Forming a second dye transfer diffusion portion by transferring and diffusing the second organic dye of the second dye layer into the polymer light emitting layer in a region corresponding to the first electrode in a second region; Removing the second dye layer; and a third dye layer containing a third organic dye on the polymer light emitting layer Is formed, and the third organic dye of the third dye layer is transferred and diffused into the polymer light emitting layer in a third region corresponding to the first electrode, thereby forming a third dye transfer / diffusion portion. Removing the third dye layer; and forming a second electrode common to each color on the first, second, and third dye transfer diffusion sections. A method for producing an organic electroluminescent device, characterized by: 8. A first electrode on a substrate, and a polymer light emitting layer on the first electrode, using the method of manufacturing an organic electroluminescence device according to claim 1. An organic dye, wherein a dye transfer / diffusion portion in which an organic dye is transferred / diffused in the polymer light emitting layer and a second electrode on the dye transfer / diffusion portion are formed on the first electrode. Electroluminescence device.