JP2001257072A - Manufacturing method of organic el display device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a manufacturing method of organic electroluminescence display device that enables to reduce time of manufacturing process and manufacturing cost. SOLUTION: The manufacturing method of this organic EL display device comprises formation of a transparent electrode layer 3 and a positive hole transporting layer 5 on a transparent substrate 1, and further comprises a first layer forming process S1 to form in plane a luminous layer 7 on a layer formed substrate 21 separate from the transparent substrate 1, a heat transfer process S2 to heat-transfer the luminous layer 7 formed on the layer formed substrate 21 partially to the transparent substrate 1 in accordance with the pattern shape of the luminous layer 7 formed on the transparent substrate 1, and a second layer forming process S3 to form an electron transporting layer 9 and a rear face electrode layer 11 on the transparent substrate 1 formed with the luminous layer 7.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

[0001] 1. Field of the Invention [0002] The present invention relates to a method for manufacturing an organic EL (electroluminescent) display device.

[0002]

2. Description of the Related Art FIG. 8 shows an organic E which is a background art of the present invention.
It is a figure which shows the structure of L display apparatus typically. As shown in FIG. 8, the organic EL display device includes a transparent substrate 1 such as a glass substrate, and at least a transparent electrode layer 3 on the transparent substrate 1.
A plurality of layers are stacked so as to constitute the hole transport layer 5, the light emitting layer 7, the electron transport layer 9, the back electrode layer 11, and the like. The transparent electrode layer 3, the hole transport layer 5, the light emitting layer 7, the electron transport layer 9, and the back electrode layer 11 are formed on the transparent substrate 1 in the order described.

Here, the transparent electrode layer 3 is formed of a transparent conductive material such as indium tin oxide (ITO), the hole transport layer 5 is formed of an amine compound or the like, and the light emitting layer 7 is formed of aluminum quinol. The electron transport layer 9 is formed of an organic compound such as a complex, the electron transport layer 9 is formed of a zinc dinuclear complex or the like, and the back electrode layer 11 is formed of a metal such as aluminum. The portion of the transparent substrate 1 where the plurality of layers are laminated is formed by a metal casing 13 for moisture prevention or the like.
To form an organic EL display device.

When a voltage is applied to the organic EL display device using the transparent electrode layer 3 as a positive electrode and the back electrode layer 11 as a cathode, the positive electrode injected into the light emitting layer 7 from the transparent electrode layer 3 via the hole transport layer 5. The holes and the electrons injected into the light emitting layer 7 from the back electrode layer 11 via the electron transport layer 9 are recombined in the light emitting layer 7, and when the organic molecules excited by the electrons transit to the ground state, Light 15 having a wavelength is emitted.

[0005] The layers formed on the transparent substrate 1 include:
Although not shown in FIG. 8, a far layer for preventing injection of holes and electrons to generate light is included in a portion of the light emitting layer 7 other than a portion corresponding to a predetermined light emitting pattern. ing. This far layer is interposed in any part between the transparent electrode layer 3 and the back electrode layer 11.

In the conventional manufacturing method of such an organic EL display device, each layer formed on the transparent substrate 1 is formed by vapor deposition in order from the transparent electrode layer 3.
Also, the transparent electrode layer 3, the back electrode layer 11, and the light emitting layer 7
Is formed in accordance with the pattern shape of the light emitting portion, the driving method of the light emitting portion, and the like.In the conventional manufacturing method, the pattern is formed using a mask at the time of vapor deposition, or by using an etching method. The pattern is formed.

[0007]

However, in the above-described conventional manufacturing method, each layer formed on the transparent substrate 1 is formed on the transparent substrate 1 in order from the transparent electrode layer 3, so that a predetermined number of layers are formed. When forming a layer, the layer cannot be formed unless all layers on the transparent substrate 1 side than the layer are formed on the transparent substrate 1, and all the layers are formed on the transparent substrate 1. However, there is a problem that it takes a long time to increase the cost of the manufacturing process.

In particular, when the organic EL display device performs display with a plurality of emission colors, the light emitting layer 7 is divided into a plurality of partial emission regions having a predetermined pattern shape, and each of the partial emission regions is divided into a plurality of partial emission regions. It is necessary to be formed from an organic material that emits light of a color corresponding to the emission color. On the other hand, in the above-mentioned conventional manufacturing method, since the light emitting layer 7 is formed by evaporating an organic material on the transparent substrate 1, the light emitting layer 7 having the partial light emitting region corresponding to each emission color is formed. In this case, it is necessary to sequentially deposit an organic material corresponding to each light emission color on the transparent substrate 1 for each light emission color while performing patterning, and it takes a long time to form the light emitting layer 7.

In view of the above problems, an object of the present invention is to provide a method of manufacturing an organic EL display device which can shorten the manufacturing process and reduce the cost.

[0010]

The technical means for achieving the above object is to form at least a transparent electrode layer, a hole transport layer, a light emitting layer, an electron transport layer, and a back electrode layer on a transparent substrate. A method for manufacturing an organic EL display device in which a plurality of layers are stacked, wherein each of the layers is formed on the transparent substrate in order from a layer on a side of the transparent substrate, and other than the transparent electrode layer of the plurality of layers. At least one of
Forming one layer on a film-forming substrate other than the transparent substrate, and transferring the layer formed on the film-forming substrate onto the transparent substrate, thereby forming the plurality of layers on the transparent substrate. Are laminated.

Preferably, the layer formed on the substrate on which the film is to be formed is the light emitting layer, and the light emitting layer is formed planarly on the substrate on which the film is to be formed. The transfer of the layer onto the transparent substrate is performed by causing a part of the planarly formed light emitting layer on the substrate on which the film is to be formed to correspond to the pattern shape of the light emitting layer formed on the transparent substrate. This is preferably done by partial transfer onto the top.

Preferably, the transfer of the layer formed on the substrate on which the film is formed onto the transparent substrate is performed by heating the layer formed on the substrate on which the film is formed. It is preferable that the heat transfer is performed by transferring the image onto a substrate.

Further, preferably, the light emitting layer provided in the organic EL display device has a plurality of partial light emitting regions having a predetermined pattern shape for emitting light of different colors from each other. The light-emitting region is a portion in which a portion corresponding to the predetermined pattern shape is partially transferred onto the transparent substrate from a surface formed on the film-forming substrate different from each other for each light-emitting color. Is good.

[0014]

FIG. 1 is a flowchart showing a process of manufacturing an organic EL display device to which a method of manufacturing an organic EL display device according to an embodiment of the present invention is applied. In addition,
The organic EL display device to which this manufacturing method is applied is substantially the same in configuration as the organic EL display device shown in FIG. 8 except for the manufacturing method, and the corresponding parts are denoted by the same reference numerals. The description of the configuration and the like is omitted.

As shown in FIG. 1, the manufacturing process according to this manufacturing method includes a first film forming structure S1 and a thermal transfer process S2.
And a second film forming step S3.

In a first film forming step S1, as shown in FIG. 2, a transparent electrode layer 3 and a hole transport layer 5 are formed on a transparent substrate 1.
Is formed in the order of the transparent electrode layer 3 and the hole transport layer 5 by an evaporation method using a resistance heating method or the like.

In the first film forming step S1, as shown in FIG. 3, other than the transparent substrate 1 as shown in FIG. A predetermined organic material is planarly applied or vapor-deposited on one or a plurality of sheet-like base materials 21 to form the light-emitting layer 7 in a planar manner. In the case of coating, the organic material is dissolved in a predetermined solvent, and the solution is applied to the film-forming substrate 21 by a method such as spin coating or spraying, and then the solvent is evaporated to form the light-emitting layer 7. It is formed on the substrate 21.

The next thermal transfer step S2
In order to perform the thermal transfer of the light emitting layer 7, it is necessary to use a material having heat resistance. Further, when the light emitting layer 7 is formed on the film-forming substrate 21 by coating, the film-forming substrate 21 needs to have chemical resistance to a solvent or the like to be used. In the present embodiment, a sheet member made of a fluororesin is used as the substrate 21 on which the film is to be formed.

Further, an organic EL to which this manufacturing method is applied
When the display device performs display with a plurality of emission colors, in the first film-forming step S1, the light-emitting layers 7 that emit light of different emission colors are planarly arranged on the different deposition base materials 21. The light-emitting layers 7 having different emission colors
Are formed in the number of required emission colors.

In the subsequent thermal transfer step S3, as shown in FIG. 4, the light-emitting layer 7 formed on the base material 21 is replaced with the transparent substrate 1 on which the transparent electrode layer 3 and the hole transport layer 5 are formed.
It is superimposed on top and thermally transferred onto the transparent substrate 1 by the thermal transfer machine 23.

The thermal transfer machine 23 has a thermal transfer pattern 23a (see FIG. 5) having a convex surface on the contact surface (lower surface) with the substrate 21 to be formed.
And a heater 23c for heating the pressing portion 23b. The pressing portion 23b heated by the heater 23c is
Thermal transfer is performed by pressing (pressing) the film-forming base material 21 superposed thereon.
The thermal transfer pattern 23a of the pressing portion 23b is formed corresponding to the pattern shape of the light emitting layer 7 to be formed on the transparent substrate 1 by thermal transfer.

The heated pressing portion 23b is
Is pressed, the portion corresponding to the thermal transfer pattern 23a of the light emitting layer 7 is partially heated over the deposition target substrate 21,
After being softened (or melted) and adhered (transferred) onto the transparent substrate 1 and then separating the substrate 21 from the transparent substrate 1, as shown in FIG. 6, the thermal transfer pattern 23a of the pressing portion 23b is formed. Is formed on the transparent substrate 1 in a pattern shape corresponding to. The transferred light emitting layer 7 is cured by cooling and fixed on the transparent substrate 1.

Here, the organic E to which this production method is applied
When the L display device performs display with a plurality of emission colors, the emission layer 7 of the organic EL display device includes a plurality of partial emission regions having a predetermined pattern shape that emit light of different colors. Must be provided. For this reason, in this case, in this thermal transfer step S2, the pressing portion 23b is replaced with a pressing portion 23b having a thermal transfer pattern 23a corresponding to the pattern shape of the partial light emitting region of each emission color,
While replacing the film-forming substrate 21 with the film-forming substrate 21 on which the light-emitting layers 7 corresponding to the predetermined luminescent colors are formed, thermal transfer is performed one by one for each required luminescent color. It is necessary to form each partial light emitting region corresponding to a light emission color on the transparent substrate 1.

In the subsequent second film forming step, the electron transport layer 9 and the back electrode layer 1 are formed on the transparent substrate 1 on which the light emitting layer 7 is formed.
1 is formed in the order of the electron transport layer 9 and the back electrode layer 11 by an evaporation method using a resistance heating method or the like. Then, if necessary, the plurality of layers 3, 5, 7, and
As shown in FIG. 8, the portion where the layers 9 and 11 are formed is sealed with a metal casing 13 for moisture proof and the like to constitute an organic EL display device.

As described above, according to the embodiment, the light-emitting layer 7 is formed on the film-forming substrate 21 different from the transparent substrate 1, and the light-emitting layer 7 is separated from the film-forming substrate 21. Since the thermal transfer is performed on the transparent substrate 1, a film forming step of forming the transparent electrode layer 3 and the hole transport layer 5 on the transparent substrate 1 and a light emitting layer 7 is formed on the substrate 21 on which the film is to be formed Can be performed simultaneously and in parallel, and the manufacturing process can be shortened and cost can be reduced.

The transfer of the light emitting layer 7 formed on the substrate 21 on the transparent substrate 1 is performed by transferring a part of the light emitting layer 7 formed on the substrate 21 on a plane. Since the transfer is performed by partially transferring the light emitting layer 7 on the transparent substrate 1 in accordance with the pattern shape of the light emitting layer 7 formed on the transparent substrate 1, it is easier and faster than the conventional mask evaporation method or etching method. The pattern formation of the light emitting layer 7 can be performed.

Further, since the transfer of the light emitting layer 7 formed on the substrate 21 on which the film is to be formed onto the transparent substrate 1 is performed by thermal transfer, the transfer can be easily performed.

An organic EL to which this manufacturing method is applied
When the display device performs display with a plurality of luminescent colors, the luminescent layer 7 corresponding to each luminescent color is formed in advance on each of the deposition base materials 21, and each of the deposition base materials is formed. By merely partially transferring the light emitting layers of each light emitting color formed on 21 onto the transparent substrate 1 according to the pattern shape, the partial light emitting areas corresponding to each light emitting color of the light emitting layer 7 can be formed. Therefore, as compared with the conventional case in which the film forming process of each partial light emitting region of the light emitting layer 7 is performed on the transparent substrate 1 by the number of luminescent colors, the manufacturing process is significantly shortened and the cost is reduced. Can be achieved.

In this embodiment, only the light emitting layer 7 is provided.
The method of forming on the film-forming base material 21 which is different from the transparent substrate 1 and then transferring it onto the transparent substrate 1 is applied, but a plurality of layers 3, 5, 7, and 9,11
A transfer forming method may be applied to an arbitrary layer (including the insulating layer) other than the transparent electrode layer 3. It is considered that, among the layers to which the formation method by transfer can be applied, the transfer by thermal transfer is suitable for the light emitting layer 7, the hole transport layer 5, and the insulating layer.

[0030]

According to the first aspect of the present invention, at least one layer other than the transparent electrode layer among the plurality of layers is formed on the transparent substrate in order from the layer on the transparent substrate side. Since it is formed on a deposition target substrate other than the substrate, and the layer formed on the deposition target substrate is transferred onto a transparent substrate, the process of forming each layer, which is generally time-consuming, is generally performed on the transparent substrate. And on a deposition target substrate other than the transparent substrate at the same time, and the manufacturing process can be shortened and cost can be reduced.

According to the second aspect of the present invention, the transfer of the light emitting layer formed on the substrate on which the film is to be formed onto the transparent substrate is performed on the light emitting layer formed on the substrate on which the film is to be formed. Is partially transferred onto the transparent substrate in accordance with the pattern shape of the light emitting layer formed on the transparent substrate.
The pattern formation of the light emitting layer can be performed easily and in a short time as compared with the conventional mask evaporation method and etching method.

According to the third aspect of the present invention, the layer formed on the substrate on which the film is to be formed is transferred onto the transparent substrate by thermal transfer, so that the transfer can be easily performed.

According to the fourth aspect of the present invention, a luminescent layer corresponding to each luminescent color is previously formed on each film-forming substrate, and each luminescent layer formed on each film-forming substrate is formed. Since the light emitting layer of the light emitting color is only partially transferred onto the transparent substrate according to the pattern shape, the partial light emitting region corresponding to each light emitting color of the light emitting layer is formed, as in the related art, Compared to performing the film forming process of each partial light emitting region of the light emitting layer on the transparent substrate by the number of emission colors, the manufacturing process can be significantly shortened and cost can be reduced.

[Brief description of the drawings]

FIG. 1 is a flowchart showing a manufacturing process of an organic EL display device to which an organic EL display device manufacturing method according to an embodiment of the present invention is applied.

FIG. 2 is an explanatory diagram of the manufacturing process of FIG.

FIG. 3 is an explanatory view of the manufacturing process of FIG. 1;

FIG. 4 is an explanatory view of the manufacturing process of FIG. 1;

FIG. 5 is an explanatory view of the manufacturing process of FIG. 1;

FIG. 6 is an explanatory diagram of the manufacturing process of FIG. 1;

FIG. 7 is an explanatory diagram of the manufacturing process in FIG. 1;

FIG. 8 is a diagram schematically showing a configuration of an organic EL display device as a background art of the present invention.

[Explanation of symbols]

 DESCRIPTION OF SYMBOLS 1 Transparent substrate 3 Transparent electrode layer 5 Hole transport layer 7 Light emitting layer 9 Electron transport layer 11 Back electrode layer 21 Deposition base material 23 Thermal transfer machine

 ────────────────────────────────────────────────── ─── Continuation of the front page (72) Inventor Takanori Ito 1-7-10 Kikuzumi, Minami-ku, Nagoya-shi, Aichi F-term in Harness Research Institute, Inc. (reference) 3K007 AB18 CA01 CB01 DA01 DB03 EB00 FA01 5C058 AA12 BA35

Claims (4)

[Claims] A transparent electrode layer on a transparent substrate;
A method for manufacturing an organic EL display device in which a plurality of layers each constituting a hole transport layer, a light emitting layer, an electron transport layer, and a back electrode layer are stacked, wherein each layer is formed on the transparent substrate on the transparent substrate side. While forming in order from the layer, at least one layer other than the transparent electrode layer of the plurality of layers is formed on a deposition target substrate other than the transparent substrate, and on the deposition target substrate. A method for manufacturing an organic EL display device, wherein the plurality of layers are stacked on the transparent substrate by transferring the formed layer onto the transparent substrate. 2. The layer formed on the substrate on which the film is to be formed is the light emitting layer; the light emitting layer is formed planarly on the substrate on which the film is to be formed; Is transferred onto the transparent substrate, a part of the planarly formed light emitting layer on the substrate on which the film is formed is formed on the transparent substrate in accordance with the pattern shape of the light emitting layer formed on the transparent substrate. 2. The method for manufacturing an organic EL display device according to claim 1, wherein the method is performed by partially transferring the organic EL display device. 3. The transfer of the layer formed on the substrate on which the film is to be formed onto the transparent substrate includes heating the layer formed on the substrate on which the film is to be formed and heating the layer on the transparent substrate. 3. The method for manufacturing an organic EL display device according to claim 1, wherein the method is performed by thermal transfer for transferring to an organic EL display. 4. The light emitting layer provided in the organic EL display device includes a plurality of partial light emitting regions having a predetermined pattern shape for emitting light of different colors, and each of the partial light emitting regions is Wherein a portion corresponding to the predetermined pattern shape is partially transferred onto the transparent substrate from those formed two-dimensionally on the film-forming base material, which are different from each other for each emission color. The method for manufacturing an organic EL display device according to claim 2.