JP2003045647A - Electroluminescent lamp and its manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a variable size electroluminescent lamp avoiding uneven brightness even if large in light-emission size, and capable of being divided into desired shapes. SOLUTION: A conductive layer 3 is formed by screen printing along approximately the overall peripheral edge of a transparent electrode 2 formed on a transparent film 1 and a light-emitting layer 4 is formed on the transparent electrode 2 except on the conductive layer 3. After a reflective insulating layer 5 is formed on separate metallic foil (back electrode 6) by use of a roll coater, they are cut into a predetermined configuration and size, with the light-emitting layer and the reflecting insulating layer facing and bonded to each other by thermocompression.

Description

Detailed Description of the Invention

[0001]

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to an electroluminescent lamp which can easily cope with various emission sizes and a method for manufacturing the same.

[0002]

2. Description of the Related Art In recent years, portable electronic devices such as mobile phones and PHSs have been rapidly spread with the progress of information society.
These electronic devices are equipped with a liquid crystal display,
A small and thin electroluminescent lamp is used as a backlight. Further, the electroluminescent lamp is also used as a light source for a display device other than liquid crystal such as various figures, characters, and symbols.

As described above, since the applications are various, electroluminescent lamps of various emission sizes are required. For this reason, conventional electroluminescent lamps have been manufactured sequentially from the first step to the last step for different sizes, but there are many common steps, resulting in waste and high cost.

Therefore, as a countermeasure, an electroluminescent lamp of a relatively large size is manufactured, and an electroluminescent lamp of an arbitrary size can be promptly provided by cutting the electroluminescent lamp into a required size in the final step. Electroluminescent lamps have been developed. As this type of electroluminescent lamp, for example, Japanese Patent Application Laid-Open No. 7-
There is one described in Japanese Patent No. 94277. This electroluminescent lamp 100 has a planar structure seen from the back electrode side shown in FIG.
It has a cross-sectional structure of a main part of the light emitting portion shown in FIG. In FIG. 13, a light emitting layer 103 in which a zinc sulfide phosphor is dispersed in a fluororesin binder is formed on a transparent electrode 102 such as ITO vapor-deposited on a PET film 101, and barium titanate is added to the fluororesin. A dielectric layer 104 dispersed in a system binder is formed, and a back electrode 105 is formed thereon. The back electrode 105 is printed on the dielectric layer 104 using an ink in which carbon powder is mixed with a fluororesin-based binder (for example, a copolymer of vinylidene fluoride and propylene hexafluoride), heated and dried. Has been formed.

As shown in FIG. 12, the shape of the back electrode 105 is such that a plurality of lead terminals 105a are formed in the outer peripheral portion, and the lead terminals of the transparent electrode 102 are alternately arranged along the entire circumference next to the lead terminals 105a. 102a
Are formed. On the lead terminal 102a, the lead electrode 102b is formed by printing at the same time as the back electrode 105 by using the same ink as the back electrode 105. The electroluminescent lamp 100 can be divided into an arbitrary shape including a pair of lead terminals.

However, in the electroluminescent lamp 100 shown in FIGS. 12 and 13, since the lead-out terminal 102a for the transparent electrode and the lead-out terminal 105a for the rear electrode are provided over the entire circumference, the lead-out terminal 102a for the transparent electrode (particularly, There is a problem that the area of the lead terminal electrode 102b) becomes small and it is difficult to connect the lead wire from the drive circuit to the lead terminal 102a of the transparent electrode.

Therefore, as a countermeasure, JP-A-9-27391
An improved electroluminescent lamp is disclosed in the publication. This electroluminescent lamp 200 has a planar structure seen from the back electrode side shown in FIG. 14 and a sectional structure taken along line EE shown in FIG. IT deposited on the PET film 201
A light emitting layer 203 is formed on the transparent electrode 202 such as O while avoiding the outer peripheral portion over the entire circumference, and a dielectric layer 204 is formed thereon.
A back electrode 205 formed by mixing carbon powder with a polyester resin is formed thereon. Back electrode 2
On 05, a low resistance conductive pattern 20 such as silver paste is provided.
6 are printed in a grid pattern as shown in FIG. The outermost peripheral portion of the conductive pattern 206 is the back electrode terminal portion 206a. In addition, a slit portion 205a is formed in a cross shape in the conductive pattern 206 at the center. A carbon layer 207, which is a mixture of carbon powder and polyester resin, is formed on the entire circumference of the transparent electrode 202 with a predetermined width, and a transparent electrode terminal portion 208 made of silver paste or the like is formed on the carbon layer 207. Is printed over the entire circumference. Connect the lead wire (not shown) from the drive circuit to the transparent electrode terminal 2
08 and the back electrode terminal portion 206a are connected to light the electroluminescent lamp 200. Since these terminals have a large area, it is easy to connect the lead wires. Further, by cutting along the slit portion 205a, an electroluminescent lamp having a small light emission size can be obtained.

[0008]

By the way, in the above-mentioned variable size electroluminescent lamp 100, since the material of the back electrode 105 is a mixture of carbon powder and fluororesin, the back electrode 105 has a large resistance value. . Therefore, when a voltage is applied, a considerable voltage drop occurs in the back electrode, causing uneven brightness. On the other hand, also in the electroluminescent lamp 200, since the back electrode 205 is a mixture of carbon powder and polyester resin, the resistance value is also large. Since the low-resistance conductive pattern 206 of silver paste or the like is formed in a grid pattern on the back electrode 205, the voltage drop is smaller than that of the electroluminescent lamp 100, and the uneven brightness is reduced.
As the light emitting area increases, the uneven brightness cannot be ignored.

By the way, in recent years, the demand for variable size electroluminescent lamps having a large light emission size is rapidly increasing in the market. As the light emission size increases, even the improved electroluminescent lamp 200 has a problem that the size of the back electrode also increases, the voltage drop increases, and the uneven brightness cannot be ignored.

Therefore, the present invention has been made in view of the above-mentioned problems, and is a variable size electroluminescent lamp capable of eliminating uneven brightness even if the light emitting size is large and dividing into an arbitrary shape, and a method for manufacturing the same. Is provided.

[0011]

An electroluminescent lamp according to claim 1, wherein a conductive layer is formed over substantially the entire circumference of the peripheral portion of the transparent electrode formed on the transparent substrate, and the conductive layer is avoided. The light emitting layer and the reflective insulating layer are laminated on the transparent electrode, and the back electrode made of a metal foil is formed on the reflective insulating layer. With this configuration, the transparent electrode terminal portion 3A is formed in a strip shape over substantially the entire circumference, and the back electrode terminal portion 6A is continuously formed inside the transparent electrode terminal portion 3A as a part (for example, a peripheral portion) of the back electrode. Since it is formed, it is possible to obtain an electroluminescence lamp having a pair of terminal portions 3A and 6A regardless of the shape of the cut. In addition, the transparent electrode terminal portion 3
Since A is not divided, individual transparent electrode terminal portions 3
A sufficient area of A can be secured. For this reason, the area of the connection portion of the transparent electrode lead can be increased, the connection is easy, and it is suitable for an electroluminescence lamp having a large light emitting area and a large current. on the other hand,
Since the back electrode is made of metal foil, the resistance value is sufficiently low,
Since the voltage drop loss is extremely small, uneven brightness does not occur. Moreover, since the back electrode terminal portion 6A can be used at any place on the back electrode, there is no limitation in the formation place and area,
Connection of the back electrode lead is also easy.

Further, in the electroluminescent lamp according to the present invention, a conductive layer is formed over substantially the entire periphery of the transparent electrode formed on the transparent substrate, and the conductive layer is formed on the conductive layer at predetermined intervals. A plurality of insulating layers are formed, a light emitting layer and a reflective insulating layer are stacked on the transparent electrode while avoiding the conductive layer, and a back electrode made of a metal foil is formed on the reflective insulating layer. To do.
Also in this configuration, since the transparent electrode terminal portion 3A and the back electrode terminal portion 6A are formed over substantially the entire circumference,
No matter what shape is cut, a pair of terminals 3A, 6A
It is possible to obtain an electroluminescent lamp having Moreover, since the back electrode is made of a metal foil, the resistance value is sufficiently low and the voltage drop loss is extremely small, so that uneven brightness does not occur.
Further, since the back electrode lead can be led out through the insulating layer, the insulation between the back electrode lead and the conductive layer can be secured, and the back electrode lead does not need to be insulated.

Further, in the electroluminescent lamp according to the present invention, a conductive layer is formed over substantially the entire circumference of the peripheral portion of the transparent electrode formed on the transparent substrate, and the transparent electrode is avoided while avoiding the conductive layer. A light emitting layer is formed on the light emitting layer, a reflective insulating layer and a back electrode made of a metal foil are laminated on the light emitting layer, and a plurality of convex portions are formed on the peripheral edge of the reflective insulating layer, the convex portions being the conductive layer. It is characterized by being extended above. Also in this structure, the same effect as that of the electroluminescent lamp according to the second aspect can be obtained.

Further, in the electroluminescent lamp according to the present invention, a conductive layer is formed over substantially the entire circumference of the peripheral portion of the transparent electrode formed on the transparent substrate, and the conductive layer is formed on the conductive layer at predetermined intervals. A plurality of insulating layers are formed, a light emitting layer is formed on the transparent electrode while avoiding the conductive layer, and a laminated body of a reflective insulating layer and a back electrode made of a metal foil is formed on the light emitting layer. A plurality of protrusions are formed on a peripheral portion of the body, and the protrusions extend on the insulating layer. Also in this structure, the same effect as that of the electroluminescent lamp according to the second aspect can be obtained. Furthermore, since the convex portion of the reflective insulating layer and the insulating layer are interposed between the metallic foil of the convex portion and the conductive layer, there is a double insulating effect.

The electroluminescent lamp according to claim 5 is parallel to the electroluminescent lamp according to claim 1 or a conductive layer and a back electrode of the electroluminescent lamp obtained by cutting the electroluminescent lamp into an arbitrary shape. In addition, the transparent electrode lead and the back electrode lead are connected in the longitudinal direction. With this configuration,
It is possible to provide a lead take-out structure capable of sufficiently securing the area of the connecting portion.

An electroluminescent lamp according to claim 6 is the electroluminescent lamp according to claim 2 or claim 3, or a conductive layer of the electroluminescent lamp obtained by cutting these electroluminescent lamps into an arbitrary shape. A transparent electrode lead and a back electrode lead are respectively connected to the back electrode, and the back electrode lead is provided via an insulating layer or a reflective insulating layer convex portion. . With this configuration, insulation between the back electrode lead and the conductive layer can be ensured, so that there is no need to perform insulation processing on the back electrode lead.

An electroluminescent lamp according to a seventh aspect is the electroluminescent lamp according to the fifth aspect, characterized in that the transparent electrode lead and the back electrode lead are flat cables. With this configuration, it is possible to provide a lead extraction structure that is easy to connect and compact.

The method for manufacturing an electroluminescent lamp according to claim 8 is the method for manufacturing an electroluminescent lamp according to claim 1, wherein the peripheral portion of the transparent electrode formed on the transparent substrate is substantially formed. Screen-printing a conductive layer around the entire circumference, screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer, and printing a reflective insulating layer on substantially the entire surface of a separate metal foil And a step of cutting the metal foil on which the reflective insulating layer is formed into a shape that avoids the conductive layer, and a step of facing the light emitting layer and the reflective insulating layer to each other by thermocompression bonding. Characterize. In this manufacturing method, since the light emitting layer 4 and the reflective insulating layer 5 using the same binder are thermocompression bonded, the adhesion between both layers is very good, and the brightness and the brightness distribution are excellent. In addition, since the reflective insulating layer can be printed by a roll coater, the process is easier than screen printing, the printing speed is fast, and mass productivity is excellent.

The method for manufacturing an electroluminescent lamp according to claim 9 is the method for manufacturing an electroluminescent lamp according to claim 2, wherein the peripheral portion of the transparent electrode formed on the transparent substrate is substantially formed. Screen-printing a conductive layer around the entire circumference, screen-printing a plurality of insulating layers on the conductive layer at predetermined intervals, and screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer. And a step of printing a reflective insulating layer on substantially the entire surface of a separate metal foil, a step of cutting the metal foil having a reflective insulating layer formed into a shape that avoids the conductive layer, the light emitting layer and the reflective layer. And a step of facing the insulating layer and thermocompression-bonding them together. Also in this manufacturing method, the same operational effects as those of the manufacturing method according to the eighth aspect are exhibited.

The method for manufacturing an electroluminescent lamp according to claim 10 is the method for manufacturing an electroluminescent lamp according to claim 3, wherein the peripheral portion of the transparent electrode formed on the transparent substrate is substantially formed. Screen-printing a conductive layer around the entire circumference, screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer, and a reflective insulating layer on the light-emitting layer and a part of the conductive layer. A screen-printing step, in particular, a step of screen-printing the reflective insulating layer in a shape in which a plurality of convex portions provided on the peripheral edge of the reflective insulating layer are extended on the conductive layer, and The method is characterized by including a step of cutting into a shape that avoids the conductive layer, and a step of facing the reflective insulating layer and the metal foil to each other and thermocompression-bonding them together. According to this manufacturing method, since the convex portion of the reflective insulating layer is substituted for the insulating layer 8, the step of forming the insulating layer 8 is unnecessary, and there is an advantage that the number of steps is reduced as compared with the manufacturing method according to claim 9.

The method for manufacturing an electroluminescent lamp according to claim 11 is the method for manufacturing an electroluminescent lamp according to claim 4, wherein the peripheral portion of the transparent electrode formed on the transparent substrate is substantially Screen-printing a conductive layer around the entire circumference, screen-printing a plurality of insulating layers on the conductive layer at predetermined intervals, and screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer. And a step of printing a reflective insulating layer on substantially the entire surface of a separate metal foil, a step of cutting the metal foil on which the reflective insulating layer is formed into a shape having a convex portion at a peripheral portion, the light emitting layer and the And a reflective insulating layer facing each other, and the reflective insulating layer of the convex portion and the insulating layer facing each other are bonded together by thermocompression bonding. Also in this manufacturing method, the same operational effects as those of the manufacturing method according to the eighth aspect are exhibited.

[0022]

BEST MODE FOR CARRYING OUT THE INVENTION A first embodiment of an electroluminescent lamp of the present invention will be described with reference to the drawings. FIG. 1 is a plan view of an electroluminescent lamp 10 having a large area such as an A3 size, and FIG. 2 is a sectional view taken along the line AA. The structure is characterized in that a conductive layer 3 made of a low-resistance conductive paste such as a silver paste is formed in a strip shape over substantially the entire circumference of the peripheral portion of the transparent electrode 2 formed on the transparent film 1. The light emitting layer 4, the reflective insulating layer 5, and the back electrode 6 are laminated on the transparent electrode 2 inside the layer 3, and the back electrode 6 is made of a metal foil such as an aluminum foil having a very low resistance. That is what is being done. A protective layer 7 made of an insulating resin such as an epoxy resin or a phenol resin, an insulating film or the like is formed on a portion of the back electrode 6 excluding the peripheral portion. Therefore, an arbitrary portion of the conductive layer 3 can be used as the transparent electrode terminal portion 3A, and an arbitrary portion of the peripheral portion of the back electrode 6 can be used as the back electrode terminal portion 6A. The transparent electrode terminal portion 3A and the back electrode terminal portion 6A are arranged in parallel along each side. Here, the substantially entire circumference of the peripheral portion of the transparent electrode 2 is about 70% or more of the length of the entire circumference before division. If the substrate is rectangular, it corresponds to three or more sides. In the electroluminescent lamp after the division, as a matter of course, the transparent electrode terminal portion does not exist substantially all around. There is a pair of terminal portions on at least one side, depending on how to divide. Further, the protective layer 7 may be omitted in some cases.

As described above, the electroluminescent lamp 10 of the present invention is
The transparent electrode terminal portion 3A is continuously formed over substantially the entire circumference, and the back electrode terminal portion 6A is continuously formed inside the transparent electrode terminal portion 3A, so that it can be cut into any shape. It is possible to obtain a small size electroluminescent lamp having a pair of terminal portions 3A and 6A. Also, the area of each transparent electrode terminal portion 3A can be sufficiently secured. Therefore, the transparent electrode leads can be easily connected and the area of the lead connecting portion can be increased, so that the electroluminescent lamp having a large light emitting area and a large current can be sufficiently supported. On the other hand, since the back electrode is made of a metal foil, the resistance value is sufficiently low and the voltage drop loss is extremely small, so that uneven brightness does not occur. Moreover, since the back electrode terminal portion 6A is not limited in the formation location and area, the back electrode lead can be easily connected.

Next, the lead takeout structure of the electroluminescent lamp 10 before division will be described with reference to the drawings. Figure 3 (a)
FIG. 3 is a plan view of a main part of a flexible flat cable in which two flat transparent electrode leads 11 and a back electrode lead 12 are arranged in parallel. The connecting portions 11a and 12a of the same size are exposed, and the lead portions 11b and 12b are sandwiched by the upper and lower insulating resin films 13. Connection part 11a, 1
As shown in FIG. 3 (b), 2a is adhered to the conductive layer 3 (terminal portion 3A) and the back electrode 6 (terminal portion 6A) of the electroluminescent lamp 10 along the longitudinal direction by a conductive adhesive or the like. ing. The length of the connection portions 11a and 12a can be selected to be a sufficient length along the conductive layer 3 and the back electrode 6, and a necessary connection area can be secured. Transparent electrode lead 11, back electrode lead 12
Since the lead portions 11b and 12b are covered with the insulating resin film 13, they do not short-circuit even if they contact the conductive layer 3 and the back electrode 6, respectively. By using such a flat cable, it is possible to easily take out thin leads.

FIG. 4 is a perspective view of an essential part showing another lead take-out structure. The transparent electrode lead 14 is formed by molding a slightly thick metal plate as shown in the figure, and includes a connecting portion 14a and a lead portion 14b having one end extended. The back electrode lead 15 is also made of the same material, and the connecting portion 15
It is composed of a and a lead portion 15b. The connection method is such that a spring (not shown) is used to connect the connection portions 14a and 15a to the terminal portion 3.
Press contact with A and 6A respectively. Especially, the lead portion 15b is
As shown in the drawing, the notch is formed so as not to come into contact with the conductive layer 3 to cause a short circuit. This structure has a large mechanical strength and can increase the area of the connection portion, and is therefore suitable for an electroluminescent lamp having a large current area. As a modified example, the connection portion may have the same shape as the terminal portion and may be pressed against the entire terminal portion.

Next, the lead-out structure of the divided electroluminescent lamp will be described with reference to the drawings. FIG. 5 is a plan view showing the lead-out structure for one electroluminescent lamp 10A, in which the electroluminescent lamp 10 is divided into four along the two-dot chain line in FIG. 1 as an example. In the electroluminescent lamp 10A after the division, the pair of terminal portions 3A and 6A are both orthogonal to the side formed by the cutting, and therefore, by leading both leads in parallel with the terminal portion, it is not necessary to take a short circuit prevention measure. Moreover, the connecting portion can be lengthened to increase the area.
Therefore, a simple linear metal foil can be used for the lead. The transparent electrode lead 16 includes a connecting portion 16a and a lead portion 16
and the connecting portion 16a is connected to the transparent electrode terminal portion 3A via a conductive adhesive (not shown).
Similarly, the back electrode lead 17 also comprises a connecting portion 17a and a lead portion 17b having the same shape and size, and the connecting portion 17a is connected to the back electrode terminal portion 6A via a conductive adhesive. Further, the flat cable shown in FIG. 3A can be used as the other lead, or the pressure contact type lead shown in FIG. 4 can be used.

Next, a method of manufacturing the electroluminescent lamp 10 having the above structure will be described with reference to FIGS. (1) A transparent conductive film is prepared by depositing a transparent electrode 2 such as ITO on the transparent film 1. A band-shaped conductive layer 3 is formed over substantially the entire circumference of the peripheral portion of the transparent electrode 2 by screen printing using a low-resistance silver paste. (2) Next, the light emitting layer 4 having a thickness of 20 to 60 μm (the optimum thickness is 30 to 40 μm) is formed on the transparent electrode 2 by screen printing using the light emitting layer ink in a pattern avoiding the conductive layer 3. To do. The light emitting layer ink is prepared so that the weight ratio of the zinc sulfide phosphor to the fluororesin binder is 1 to 4 (the optimum ratio is 2 to 3). (3) Next, on a metal foil (which will become the back electrode 6) such as an aluminum foil having a thickness of 50 to 100 μm, the ink for a reflective insulating layer is used to form a roll coater with a thickness of 30 to 60 μm.
The reflective insulating layer 5 having a thickness (the optimum thickness is 45 to 50 μm) is printed. In the reflective insulating layer ink, the weight ratio of barium titanate to the fluororesin binder is 1 to 4 (the optimum ratio is 2 to
Formulated in 3). (4) Next, the metal foil on which the reflective insulating layer 5 is printed is cut to a standard size. A known cutting device can be used. shape,
The size is substantially the same as that of the light emitting layer 4. (5) Next, the light emitting layer 4 formed in the step (2) and the reflective insulating layer 5 of the metal foil cut to a fixed size in the step (4) are faced to each other and thermocompression-bonded by a hot press, a laminator, or the like, and attached. To match.

In this manufacturing method, the light emitting layer 4 and the reflective insulating layer 5 are used.
The adhesiveness with is very good because the same binder is used. Further, since the reflective insulating layer can be printed by a roll coater, the process is easier and mass productivity is excellent as compared with screen printing.

As a modified example 1 of this manufacturing method, the reflective insulating layer 5 and the light emitting layer 4 are laminated and printed on a metal foil by a roll coater and cut into a predetermined size (for example, a size smaller than the inner size of the conductive layer 3). After that, there is a method in which the light emitting layer 4 is thermocompression bonded to the transparent electrode 2 on which the conductive layer 3 has been formed and then bonded. In addition, as a modified example 2, a reflective insulating layer 5 is screen-printed on the light-emitting layer 4 screen-printed on the transparent electrode 2 in the step (2), and a separate metal foil on which nothing is printed. There is also a method of pasting. Which manufacturing method is used is appropriately selected in consideration of various conditions.

Next, a second embodiment of the electroluminescent lamp of the present invention will be described with reference to the drawings. FIG. 6 is a plan view of a main part of the electroluminescent lamp 20, and FIG. 7 is a sectional view taken along line BB. The structure is characterized in that the conductive layer 3 made of a low-resistance conductive paste such as a silver paste is formed in a strip shape over substantially the entire periphery of the transparent electrode 2, and the conductive layer 3 and the transparent electrode in the vicinity thereof are formed. A plurality of insulating layers 8 are formed at predetermined intervals so as to cross the conductive layer 3 and divide the conductive layer 3, and the conductive layer is provided between the insulating layers 8 and 8. 3 is exposed, and this exposed portion serves as the transparent electrode terminal portion 3A, and the light emitting layer 4 is provided on the transparent electrode 2 in a region (a region indicated by a broken line in FIG. 6) that avoids the conductive layer 3. That is, the reflective insulating layer 5 and the back electrode 6 are laminated and formed thereon, and in particular, the back electrode 6 is made of a metal foil such as an aluminum foil having a very low resistance. An arbitrary portion of the peripheral portion of the back electrode 6 becomes the back electrode terminal portion 6A. The description of the protective layer 7 is omitted (the same applies to the following embodiments).

The transparent electrode lead 18 suitable for the electroluminescent lamp 20 having the above structure is, for example, a T-shaped metal foil. The connecting portion 18a at one end is adhered to the transparent electrode terminal portion 3A with a conductive adhesive to be led out. A T-shaped metal foil is also suitable for the back electrode lead 19, the connection portion 19a at one end is connected to the back electrode terminal portion 6A, and the lead portion 19b is overlaid on the insulating layer 8 and led out to the outside. The insulating layer 8 can ensure insulation between the back electrode lead 19 and the conductive layer 3. Also, FIG.
It is also possible to lead out along the longitudinal direction of the conductive layer 3 and the back electrode 6 using the flat cable of FIG. 4, the pressure contact type lead of FIG. 4, the metal foil lead of FIG.

As described above, the electroluminescent lamp 20 of the present invention is
Since the transparent electrode terminal portions 3A are formed at intervals over substantially the entire circumference of the peripheral portion and the back electrode terminal portions 6A are continuously formed inside the transparent electrode terminal portions 3A, the transparent electrode terminal portions 3A are cut into any shape. Even so, it is possible to obtain an electroluminescence lamp having a pair of terminal portions 3A and 6A. In particular, since only the transparent electrode terminal portion 3A is formed as a terminal portion on the outer periphery of the peripheral edge portion, it is possible to sufficiently secure the area of each transparent electrode terminal portion 3A. Therefore, it is easy to connect the transparent electrode leads, and there is no problem in connection area. On the other hand, since the back electrode 6 is made of a metal foil, the resistance value is sufficiently low and the voltage drop loss is extremely small, so that the uneven brightness does not occur. Moreover, since the back electrode terminal portion 6A is not limited in the formation location and area, the back electrode lead can be easily connected. In particular, since the insulating layer 8 can ensure the insulation between the back electrode lead 19 and the conductive layer 3, it is not necessary to subject the back electrode lead 19 itself to an insulating treatment.

A method of manufacturing the electroluminescent lamp 20 having the above structure will be described with reference to FIGS. (1) A transparent conductive film is prepared by depositing a transparent electrode 2 such as ITO on the transparent film 1. A band-shaped conductive layer 3 is formed over substantially the entire circumference of the peripheral portion of the transparent electrode 2 by screen printing using a low-resistance conductive paste such as silver paste. (2) Next, a plurality of rectangular insulating layers 8, 8 ... Are formed on the conductive layer 3 at predetermined intervals by screen printing using an insulating resin such as epoxy resin or phenol resin. (3) Next, the light emitting layer 4 is formed on the transparent electrode 2 by screen printing using the light emitting layer ink in a pattern (a region indicated by a broken line in FIG. 6) avoiding the conductive layer 3. The thickness and ink composition are the same as in the first embodiment. (4) On the other hand, a metal foil such as an aluminum foil having a thickness of 50 to 100 μm is prepared, and one surface of the metal foil is coated with a roll coater using the ink for the reflective insulation layer to form a reflective insulation film having a thickness of 30 to 60 μm (the optimum thickness is 45 to 50 μm). Print layer 5. The thickness and ink composition are the same as in the first embodiment. (5) Next, the metal foil on which the reflective insulating layer 5 is formed is cut into a regular size. A known cutting device can be used. The shape and size are the same as or slightly larger than those of the light emitting layer 4. (6) Next, the reflective insulating layer 5 and the light emitting layer 4 are faced to each other and bonded by thermocompression bonding with a hot press, a laminator or the like.

In this manufacturing method, the light emitting layer 4 and the reflective insulating layer 5 are used.
The adhesiveness with is very good because the same binder is used. Further, since the reflective insulating layer can be printed by a roll coater, the process is easier and the mass productivity is superior to the screen printing.

As a modified example 1 of this manufacturing method, the reflective insulating layer 5 and the light emitting layer 4 are laminated and printed on a metal foil by a roll coater and cut into a predetermined size (for example, a size smaller than the inner size of the conductive layer 3). After that, there is a method in which the light emitting layer 4 is thermocompression bonded to the transparent electrode 2 on which the conductive layer 3 has been formed and then bonded. In addition, as a modified example 2, a reflective insulating layer 5 is screen-printed on the light-emitting layer 4 screen-printed on the transparent electrode 2 in the step (2), and a separate metal foil on which nothing is printed. There is also a method of pasting. Which manufacturing method is used is appropriately selected in consideration of various conditions.

Next, a third embodiment of the electroluminescent lamp of the present invention will be described with reference to the drawings. FIG. 8 is a plan view of a main part of the electroluminescent lamp 30, and FIG. 9 is a sectional view taken along the line CC. The structure is characterized in that the peripheral portion of the reflective insulating layer 5 is extended to form a convex portion 5A, and the convex portion 5A covers a part of the conductive layer 3 to substitute for the insulating layer 8 of the second embodiment. Is. Therefore, the step of forming the insulating layer 8 becomes unnecessary. The other structure is similar to that of the second embodiment. The lead take-out structure is the same as in the case of using the T-shaped lead shown in FIG.
In addition, the flat cable of FIG. 3, the pressure contact type lead of FIG.
It is also possible to lead out along the longitudinal direction of the conductive layer 3 and the back electrode 6 by using the metal foil lead shown in FIG.

A method of manufacturing the electroluminescent lamp 30 having the above structure will be described with reference to FIGS. (1) A transparent conductive film is prepared by depositing a transparent electrode 2 such as ITO on the transparent film 1. A band-shaped conductive layer 3 is formed over substantially the entire circumference of the peripheral portion of the transparent electrode 2 by screen printing using a low-resistance silver paste. (2) Next, the light emitting layer 4 is formed on the transparent electrode 2 by screen printing in a pattern (a region shown by a broken line in FIG. 8) avoiding the conductive layer 3. The thickness and ink composition are the first
This is the same as the embodiment. (3) Next, the reflective insulating layer 5 is screen-printed so as to cover the light emitting layer 4 in a pattern having a plurality of convex portions 5A shown in FIG. The convex portion 5A includes the conductive layer 3 and the transparent electrode 2 in the vicinity thereof.
To cover. The thickness and ink composition are the same as in the first embodiment. (4) On the other hand, a separate piece of metal foil such as aluminum foil is cut to a fixed length. The shape and size are shapes that avoid the conductive layer, are substantially the same as the light emitting layer 4, and are slightly smaller than the main body portion (the portion excluding the convex portions 5A) of the reflective insulating layer. (5) Next, the metal foil cut into the same size as the light emitting layer and the reflective insulating layer 5 are faced to each other and bonded by thermocompression bonding with a hot press, a laminator or the like.

The advantage of this manufacturing method is that the step of forming the insulating layer 8 which is the step (2) of the second embodiment becomes unnecessary,
This means that the number of steps is reduced as a whole as compared with the second embodiment.

Next, a fourth embodiment of the electroluminescent lamp of the present invention will be described with reference to the drawings. FIG. 10 is a plan view of an essential part of the electroluminescent lamp 40, and FIG. 11 is a sectional view taken along the line DD. The structure is characterized in that the conductive layer 3 made of a low-resistance conductive paste such as silver paste is formed in a strip shape over substantially the entire periphery of the transparent electrode 2, and the conductive layer 3
, A plurality of insulating layers 8 are formed at predetermined intervals so as to cross the conductive layer 3 and the transparent electrode in the vicinity thereof, and the conductive layer 3 is divided.
The conductive layer 3 between the first and second electrodes is exposed, and the exposed portion serves as the transparent electrode terminal portion 3A. On the other hand, the peripheral portion of the laminated body of the back electrode 6 made of metal foil and the reflective insulating layer 5 Has a convex-concave shape and a convex portion 6 ′ is formed, and the reflective insulating layer 5 (or the laminated body of the light emitting layer 4 and the reflective insulating layer 5) of the convex portion 6 ′ is laminated on the insulating layer 8. That is what is being done. The convex portion 6'is used as the back electrode terminal portion 6A. The lead take-out structure is the same as in the case of using the T-shaped lead shown in FIG. Further, the flat cable of FIG. 3, the pressure contact type lead of FIG. 4, the metal foil lead of FIG. 5, and the like can be used to lead out along the longitudinal direction of the conductive layer 3 and the back electrode 6.

As described above, the electroluminescent lamp 40 of the present invention is
Since the transparent electrode terminal portion 3A and the back electrode terminal portion 6A are formed in order over substantially the entire circumference of the peripheral portion, no matter what shape is cut, a pair of terminal portions 3A, 6A is formed. It is possible to obtain an electroluminescent lamp having Back electrode terminal 6
The insulation between A and the conductive layer 3 can be sufficiently ensured by the insulation layer 8 and the reflective insulation layer 5 (the light emitting layer 4 is also added in some cases). There is no need to insulate the back electrode lead itself. On the other hand, since the back electrode 6 is made of a metal foil, the resistance value is sufficiently low and the voltage drop loss is extremely small, so that the uneven brightness does not occur.

A method of manufacturing the electroluminescent lamp 40 having the above structure will be described with reference to FIGS. (1) A transparent conductive film is prepared by depositing a transparent electrode 2 such as ITO on the transparent film 1. A band-shaped conductive layer 3 is formed over substantially the entire circumference of the peripheral portion of the transparent electrode 2 by screen printing using a low-resistance conductive paste such as silver paste. (2) Next, a plurality of rectangular insulating layers 8, 8 ... Are formed on the conductive layer 3 at predetermined intervals by screen printing using an insulating resin such as epoxy resin or phenol resin. (3) Next, the light emitting layer 4 is formed on the transparent electrode 2 by screen printing using the light emitting layer ink in a pattern (a region indicated by a broken line in FIG. 10) avoiding the conductive layer 3. The thickness and ink composition are the same as in the first embodiment. (4) On the other hand, a metal foil such as an aluminum foil having a thickness of 50 to 100 μm is prepared, and one surface of the metal foil is coated with a roll coater using the ink for the reflective insulation layer to form a reflective insulation film having a thickness of 30 to 60 μm (the optimum thickness is 45 to 50 μm). Print layer 5. The reflective insulating layer ink is prepared so that the weight ratio of barium titanate to the fluororesin binder is 1 to 4 (the optimum ratio is 2 to 3). (5) Next, the metal foil on which the reflective insulating layer 5 is formed is cut in a pattern having a concave and convex peripheral portion to form a convex portion 6 '. The reflective insulating layer 5 also has the same pattern. (6) Next, the reflective insulating layer 5, the light emitting layer 4, and the convex portion 6 '
Of the reflective insulating layer and the insulating layer 8 of
Thermolaminate with a laminator, etc.

In this manufacturing method, the light emitting layer 4 and the reflective insulating layer 5 are used.
The adhesiveness with is very good because the same binder is used. Further, since the reflective insulating layer can be printed by a roll coater, the process is easier and mass productivity is excellent as compared with screen printing.

As a modified example of this manufacturing method, the reflective insulating layer 5 and the light emitting layer 4 are laminated and printed on a metal foil by a roll coater, the peripheral portion is cut with an uneven pattern, and the conductive layer 3 is separately formed.
There is a method in which the transparent conductive film on which the insulating layer 8 is formed is bonded by thermocompression bonding. Which manufacturing method is used is appropriately selected in consideration of various conditions.

[0044]

According to the electroluminescent lamp of the present invention, a conductive layer is formed over substantially the entire periphery of the transparent electrode, and a light emitting layer and a reflective insulating layer are laminated on the transparent electrode while avoiding the conductive layer. It is basically that a back electrode made of a metal foil is formed on the reflective insulating layer. With this configuration, the transparent electrode terminal portion and the back electrode terminal portion are formed so as to be exposed over substantially the entire circumference, so that no matter which shape is cut, there is a brightness unevenness having a pair of terminal portions. It is possible to obtain an electroluminescent lamp that does not include

The method of manufacturing the electroluminescent lamp of the present invention is as follows.
A step of screen-printing a conductive layer over substantially the entire periphery of the transparent electrode formed on the transparent substrate, a step of screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer, and a separate body The step of printing a reflective insulating layer on substantially the entire surface of the metal foil, the step of cutting the metal foil having the reflective insulating layer formed into a predetermined shape, and thermocompression bonding the light emitting layer and the reflective insulating layer facing each other. It is basically provided with a laminating step. In this manufacturing method, since the light emitting layer and the reflective insulating layer using the same binder are thermocompression bonded, the adhesion between both layers is extremely good, and the brightness and the brightness distribution are excellent. In addition, since the reflective insulating layer can be printed by a roll coater, the process is easier than screen printing, the printing speed is fast, and mass productivity is excellent.

[Brief description of drawings]

FIG. 1 is a plan view for explaining the structure of the electroluminescent lamp according to the first embodiment of the present invention.

FIG. 2 is a sectional view of the electroluminescence lamp shown in FIG. 1 taken along the line AA.

FIG. 3 is a plan view of a main part showing a lead take-out structure of the electroluminescence lamp shown in FIG. 1 ((a) is a flat cable, (b) is a take-out structure).

FIG. 4 is a perspective view of a main part showing another lead extraction structure of the electroluminescence lamp shown in FIG.

FIG. 5 is a plan view showing a lead-out structure of a divided electroluminescent lamp.

FIG. 6 is a plan view of a main part for explaining the structure of the electroluminescence lamp according to the second embodiment of the present invention.

7 is a cross-sectional view of the electroluminescence lamp shown in FIG. 6 taken along the line BB.

FIG. 8 is a plan view of relevant parts for explaining the structure of the electroluminescence lamp according to the third embodiment of the present invention.

9 is a sectional view of the electroluminescence lamp shown in FIG. 8 taken along the line C-C.

FIG. 10 is a plan view of relevant parts for explaining the structure of the electroluminescence lamp according to the fourth embodiment of the present invention.

11 is a sectional view of the electroluminescence lamp shown in FIG. 10, taken along the line D-D.

FIG. 12 is a plan view of a main part of a conventional variable size electroluminescent lamp.

FIG. 13 is a cross-sectional view of main parts of the electroluminescence lamp shown in FIG.

FIG. 14 is a plan view of a main part of another conventional variable size electroluminescent lamp.

15 is a sectional view of the electroluminescence lamp shown in FIG. 14 taken along the line EE.

[Explanation of symbols]

1 transparent film 2 transparent electrode 3 Conductive layer 3A Transparent electrode terminal 4 Light emitting layer 5 Reflective insulation layer 5A Convex portion of reflective insulating layer 6 Back electrode (metal foil) 6A Rear electrode terminal 6'Protruding part of a laminated body of a back electrode and a reflective insulating layer 7 protective layer 8 insulating layers 10, 20, 30, 40 electroluminescent lamp 11, 14, 16, 18 Transparent electrode lead 12, 15, 17, 19 Back electrode lead 13 Insulating resin film

Claims (11)

[Claims] 1. A conductive layer is formed on substantially the entire circumference of a transparent electrode formed on a transparent substrate, and a light emitting layer and a reflective insulating layer are laminated on the transparent electrode while avoiding the conductive layer. An electroluminescent lamp in which a back electrode made of a metal foil is formed on the reflective insulating layer. 2. A transparent electrode formed on a transparent substrate, a conductive layer is formed over substantially the entire circumference of a peripheral portion, and a plurality of insulating layers are formed on the conductive layer at predetermined intervals. An electroluminescent lamp in which a light emitting layer and a reflective insulating layer are laminated on a transparent electrode while avoiding the above, and a back electrode made of a metal foil is formed on the reflective insulating layer. 3. A transparent electrode formed on a transparent substrate, wherein a conductive layer is formed over substantially the entire circumference of a peripheral portion of the transparent electrode, and a light emitting layer is formed on the transparent electrode while avoiding the conductive layer. An electroluminescent lamp in which a reflective insulating layer and a back electrode made of a metal foil are laminated on top of the reflective insulating layer, and a plurality of convex portions are formed on the peripheral edge of the reflective insulating layer, and the convex portions extend on the conductive layer. 4. A conductive layer is formed on substantially the entire circumference of a peripheral portion of a transparent electrode formed on a transparent substrate, and a plurality of insulating layers are formed on the conductive layer at predetermined intervals. By avoiding the above, a light emitting layer is formed on the transparent electrode, and a laminated body of a reflective insulating layer and a back electrode made of a metal foil is formed on the light emitting layer,
An electroluminescent lamp in which a plurality of convex portions are formed on a peripheral portion of the laminated body, and the convex portions extend on the insulating layer. 5. The electroluminescent lamp according to claim 1, or a transparent electrode lead and a back electrode which are parallel and longitudinal to a conductive layer and a back electrode of the electroluminescent lamp obtained by dividing the electroluminescent lamp into an arbitrary shape. An electroluminescent lamp, which is connected to a lead. 6. The electroluminescent lamp according to claim 2 or claim 3, or a conductive electrode and a back electrode of the electroluminescent lamp obtained by dividing these electroluminescent lamps into arbitrary shapes, a transparent electrode lead and a back surface, respectively. An electroluminescent lamp, which is connected to an electrode lead, and the back electrode lead is provided via an insulating layer or a convex portion of a reflective insulating layer. 7. The electroluminescent lamp according to claim 5, wherein the transparent electrode lead and the back electrode lead are flat cables. 8. The method for manufacturing an electroluminescent lamp according to claim 1, wherein a conductive layer is screen-printed over substantially the entire circumference of the peripheral edge of the transparent electrode formed on the transparent substrate,
The step of screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer, the step of printing a reflective insulating layer on substantially the entire surface of a separate metal foil, and the step of printing the reflective insulating layer-formed metal foil on the conductive layer. A method of manufacturing an electroluminescent lamp, comprising: a step of cutting into a shape that avoids the above; 9. A method for manufacturing an electroluminescent lamp according to claim 2, wherein a conductive layer is screen-printed over substantially the entire circumference of the peripheral portion of the transparent electrode formed on the transparent substrate,
Screen-printing a plurality of insulating layers on the conductive layer at predetermined intervals, screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer, and reflecting on almost the entire surface of a separate metal foil. A step of printing an insulating layer, a step of cutting the metal foil having a reflective insulating layer formed into a shape avoiding the conductive layer,
A method of manufacturing an electroluminescent lamp, comprising the steps of facing the light emitting layer and the reflective insulating layer and thermocompression-bonding them together. 10. The method for manufacturing an electroluminescent lamp according to claim 3, wherein a conductive layer is screen-printed over substantially the entire circumference of the peripheral portion of the transparent electrode formed on the transparent substrate, A step of screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer; and a step of screen-printing a reflective insulating layer on the light-emitting layer and a part of the conductive layer, wherein A step of screen-printing a plurality of convex portions provided on the peripheral portion of the layer in a shape extending on the conductive layer;
Cutting the metal foil into a shape that avoids the conductive layer,
A method of manufacturing an electroluminescent lamp, comprising the steps of facing the reflective insulating layer and the metal foil and thermocompression-bonding them together. 11. A method of manufacturing an electroluminescent lamp according to claim 4, wherein a conductive layer is screen-printed over substantially the entire periphery of the transparent electrode formed on the transparent substrate. Screen-printing a plurality of insulating layers on the conductive layer at predetermined intervals, screen-printing a light-emitting layer on the transparent electrode while avoiding the conductive layer, and reflecting on almost the entire surface of a separate metal foil. A step of printing an insulating layer, a step of cutting the metal foil on which a reflective insulating layer is formed into a shape having a convex portion at a peripheral portion, facing the light emitting layer and the reflective insulating layer, and A method of manufacturing an electroluminescent lamp, comprising a step of facing a reflective insulating layer and the insulating layer and thermocompression-bonding them together.