JP2005079075A - Organic electroluminescent element and its manufacturing method - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an organic electroluminescent element restraining growth of alteration of an organic layer such as a dark spot in the organic layer. <P>SOLUTION: This organic electroluminescent element is so structured that the organic layer 20 is caught between a positive electrode 10 and a negative electrode 30; a light extraction surface 41 is set at least on the side of one-side electrode; and light emitted from the organic layer 20 is extracted to the outside from the extraction surface 41. The organic layer 20 is divided into a plurality of sections 22 by a plurality of separators 21 in a surface direction nearly parallel to the extraction surface 41. Each separator 21 is non-conductive, and physically connected to both the electrodes 10 and 30. The electrodes 10 and 30 are each formed so as to be electrically connected to the organic layer 20 in each section 22, and so as to cover the organic layer 20 and the separators 21. <P>COPYRIGHT: (C)2005,JPO&NCIPI

Description

  The present invention relates to an organic electroluminescent element and a method for producing the element.

  A display device using an organic electroluminescent element has attracted attention because of its excellent display performance. An organic electroluminescent element emits light when a predetermined voltage is applied between an anode and a cathode that are stacked with an organic layer interposed therebetween.

  On the other hand, it is known that an organic electroluminescent element is easily deteriorated in organic layers and electrodes due to moisture, oxygen and the like in an external atmosphere. As a typical alteration, an alteration (abnormality) called a dark spot, in which a portion that does not emit light even when an electric current is applied, is known.

  Therefore, in order to prevent alteration of the organic electroluminescent element, conventional techniques for protecting the organic electroluminescent element with a substrate, a sealing film (passivation film), a sealing can, and the like have been proposed. In other words, this conventional technique is a sealing technique that prevents the entry of moisture, oxygen, and the like from the outside atmosphere.

  As the sealing technique, for example, an organic organic electroluminescent device in which an anode and a cathode are laminated at least through a light emitting layer is sealed on the outer periphery of an dissolved liquid containing an adsorbent and having a dissolved oxygen concentration of 1 ppm or less. There is a conventional technique for providing a stop layer (see, for example, Patent Document 1).

There has also been proposed a moisture barrier film that can be applied to an organic electroluminescence display of a resin substrate (see, for example, Non-Patent Document 1).
Japanese Patent Laid-Open No. 9-35868 (paragraphs [0011] to [0014] of FIG. 1, FIG. 1) Jun Sugimoto, 2 others, “Development of organic electroluminescence film display”, PIONEER R & D, vol. 11, no. 3, p. 48-56

  However, even if the sealing technique as described above is adopted, it is not possible to completely prevent the deterioration in the organic electroluminescent element.

It is also known that once a deteriorated part such as a dark spot is generated, the periphery of this part is similarly changed.
For example, when an organic electroluminescence device in which a dark spot is generated is further left, a dark spot is first generated concentrically around the dark spot portion (the dark spot grows).

  There are various reasons for this. For example, because the chemical structure or three-dimensional structure of a substance present in a denatured location changes from the normal state, it is difficult for the substance adjacent to this to exist in a normal state or in a layout that is easily denatured. It is thought that the material is altered by the exchange of electrons from the altered material. Thereby, it can be considered that the adjacent substance is altered, the adjacent substance is also altered, and the alteration spreads. Also, it can be considered due to other factors.

  For any reason, when an organic electroluminescent element is altered, the problem is that this phenomenon propagates around the altered part, that is, the area of the altered part increases. There is a problem of (growing).

The problem to be solved by the present invention is to provide an organic electroluminescent device that suppresses the growth of alterations in the organic layer, such as dark spots in the organic layer.
Moreover, another subject of this invention is providing the manufacturing method of the said organic electroluminescent element.

  In order to achieve the above object, an organic electroluminescent device according to the present invention has an organic layer sandwiched between a pair of electrodes, a light extraction surface is set on at least one electrode side, and light emitted from the organic layer. Is taken out from the light extraction surface. The organic layer is divided into a plurality of sections by a plurality of separators in a plane direction substantially parallel to the light extraction surface. Each separator is non-conductive and is physically connected to both electrodes. Both electrodes are provided so as to be electrically connected to the organic layer in each section and to cover the organic layer and the separator.

Note that the separator is preferably thinner as it approaches one electrode from the other electrode.
Further, the shape of the section projected onto a plane parallel to the light extraction surface may be a substantially square shape.
Furthermore, when the first electrode is configured in a substantially rectangular shape and projected onto a plane parallel to the light extraction surface, the direction of each side in the shape of the partition, and the direction of each side in the outer periphery of the first electrode Are preferably approximately 45 degrees.

In the method of manufacturing an organic electroluminescent element according to the present invention, an organic layer is sandwiched between a pair of electrodes, a light extraction surface is set on at least one electrode side, and light emitted from the organic layer is emitted from the light extraction surface. This is a manufacturing method of an element taken out to the outside, and is manufactured by the following steps (a) to (c).
(A) A plurality of non-conductive separators are provided on a first electrode provided substantially parallel to the light extraction surface, and a plurality of sections are formed in the normal direction of the light extraction surface by the separators. Process.
(B) A step of providing an organic layer in each compartment.
(C) A step of providing a second electrode so as to cover the organic layer and the separator.

  In the manufacturing method, the separator is thinned from one end to the other end, and the step (a) is such that the one end side of the separator is the first electrode side. It is good also as a process of providing.

  In the manufacturing method, in the step (a), after the separator is further provided, the separator may be processed so that the first electrode side is thicker than the other end side.

In these manufacturing methods, in the step (a), a separator may be provided so that the shape when the section is projected on a plane parallel to the light extraction surface is substantially rectangular. Further, a separator may be provided so that the shape when the section is projected on a plane parallel to the light extraction surface is approximately square.
In this case, the shape when the first electrode is projected on a surface parallel to the light extraction surface may be substantially rectangular, and the step (a) may be performed as follows.
Step (a): The direction of each side on the outer periphery of the partition and the direction of each side on the outer periphery of the first electrode when projected onto a plane parallel to the light extraction surface are approximately 45 degrees. A separator is provided.

  In the above manufacturing method, in the step (b), when the organic layer is provided by discharging the material for forming the organic layer in a direction substantially the same as the diagonal line in the shape of the partition when projected onto a plane parallel to the light extraction surface. Good.

In each of the above manufacturing methods, in the step (b), the organic layer may be provided by discharging the organic layer forming material from a plurality of positions.
In the step (b), the organic layer may be provided by discharging the organic forming material from a plurality of positions on a substantially straight line and moving the straight line relative to the first electrode.
When such a manufacturing method is adopted, it is preferable that the discharge direction of the organic layer forming material is approximately the same direction.

ADVANTAGE OF THE INVENTION According to this invention, the organic electroluminescent element which suppresses the growth of a dark spot etc. in an organic layer, ie, suppresses the propagation of alteration in an organic layer can be provided.
Moreover, the manufacturing method of the said organic electroluminescent element can be provided.

Hereinafter, the organic electroluminescent element (organic EL element) according to the present embodiment will be described in detail with reference to the drawings. In addition, a manufacturing method and a preferable manufacturing method of the organic EL element will be described together.
1 to 16, the same or similar components are denoted by the same reference numerals. Each drawing schematically shows the structure of the organic EL element according to the present embodiment, and the film thickness and the like are different from those of the actual organic EL element.
First, the configuration of the organic EL element according to this embodiment will be described.

"Constitution"
As shown in FIG. 1, the organic EL element 1 is a full-surface light emitting element in which an organic layer 20 is sandwiched between an anode 10 and a cathode 30, and the anode 10, the organic layer 20, and the cathode 30 are formed on a substrate 4. The organic EL devices are sequentially stacked. In FIG. 1, the cathode 30 is indicated by a broken line in order to explain the structure of the organic layer 20.

  The organic layer 20 is divided into a plurality of sections 22 by a plurality of separators 21. In addition, each electrode 10, 30 is provided so as to be electrically connected to the organic layer 20 in each section 22, cover the organic layer 20 and the separator 21, and not be exposed to the outside.

  In the following description, the organic EL element 1 will be described based on a bottom emission type organic EL device that extracts light emitted from the organic layer 20 from the anode 10 side, that is, the substrate 4 side. Therefore, the light extraction surface is a surface 41 opposite to the surface 42 on which the organic EL element 1 is laminated on the substrate 4.

Note that the organic EL element may be configured as a top emission type element, or may be configured as an element that extracts light from both the substrate 4 side and the opposite side of the substrate 4. When there are a plurality of light extraction surfaces like the latter, at least one surface may be set as the light extraction surface 41 in the following description to design the organic EL element 1.
Of course, an organic EL device in which the cathode 30, the organic layer 20, and the anode 10 are stacked in this order on the substrate 4 may be used.
First, the separator 21 will be described in detail.

<Separator 21>
As described above, the organic layer 20 is a layer containing an organic light emitting material, and is divided into a plurality of sections 22 by a plurality of separators 21 in a plane direction substantially parallel to the light extraction surface 41.

  The separator 21 is a member that partitions the organic layers 20 in each compartment 22 so as not to be physically connected to each other. Therefore, as shown in the sectional view of FIG. 2, at least one end is connected to the anode 10 and the other end is connected to the cathode 30. Further, the anode 10 and the cathode 30 are made non-conductive so as not to be electrically connected. The sectional structure of this element is as shown in FIG. That is, the end portion (end surface) of the separator 21 is in contact with each of the electrodes 10 and 30.

In addition, as shown in the cross-sectional view of FIG. 4, a configuration in which a part of the separator 21 enters the electrode can also be adopted. For example, one end may be inside the anode 10 as shown in (a), the other end may be inside the cathode 30 as shown in (b), and both ends are inside as shown in (c). Each may be contained in the electrodes 10 and 30.
However, even if any configuration is employed, a configuration that penetrates the electrode cannot be employed. If the separator 21 penetrates the electrode, the electrode is isolated, the corresponding organic layer does not emit light, or the current path becomes longer than the other electrodes. This is because it becomes lower than the electrode, and the magnitude of the current flowing through the organic layer 20 changes for each section 22.

  Thus, each separator 21 according to the present embodiment is non-conductive, one end is connected to anode 10, the other end is connected to cathode 30, and anode 10 and cathode 30 are connected to each other. Not penetrated.

  The width B of the separator 21 shown in FIG. 2 is better as it is thinner than the width S of the section, and is generally set to about 2 μm to 10 μm. This is because if the width B of the separator 21 is too thick, the separator 21 may be visually confirmed in the manufactured organic EL element 1. In addition, in the same display area, the surface area of the organic layer 20 (the area corresponding to the square of the width S) is narrower than that of the organic EL element 1 having a small width B, and more current is obtained to obtain the same luminance. This is because the luminance becomes low when the current of the same magnitude is applied.

The shape of the separator 21 may be any shape as long as the above-described function can be realized. Generally, as shown in FIGS. 1, 2, and 4, a plate shape having a width B is used. (Cuboid shape).
In addition, a shape such as a wedge shape or a quasi-taper shape, for example, is preferably adopted in which the width of the separator becomes thinner as it approaches the cathode 10 from the anode 30 as shown in the sectional view of FIG. When such a shape is adopted, when the organic EL element 1 is manufactured as described later, the possibility that the anode 10 and the cathode 30 are in contact with each other can be extremely reduced, or a special device for preventing a short circuit. This is because it is not necessary to elaborate.

The shape of the section 22 is preferably rectangular when projected onto the light extraction surface 41 (or a plane parallel to the surface, the same applies hereinafter) as shown in the perspective view of FIG. 1 or the front view of FIG. , A regular triangle or a regular hexagon, and more preferably a square.
This is because if the shape of the section 22 is a rectangle or the like, the sections 22 having the same shape can be spread without gaps. Moreover, if the shape of the section 22 is a square, a regular triangle, or a regular hexagon, when the organic EL element 1 is manufactured, the length of the side (the size of the section) that prevents the section 22 from being visually confirmed is as follows. There is no need to be limited to the length of the longest side such as a rectangle.
If the shape of the section 22 is a square, a regular triangle, or a regular hexagon, and if the length twice the side of the section 22 is a length that cannot be visually confirmed when the organic EL element 1 is manufactured, one separator is obtained. Even if damaged or missing, the section 22 is not visually confirmed. For this reason, the yield of a finished product can also be raised.

The length S of one side of the section 22 shown in FIG. 2 is preferably a length that the section 22 cannot be confirmed when the produced organic EL element 1 is viewed. Such a length is generally about 300 μm or less, and is about 500 μm or less when a diffusion plate or a prism sheet is disposed on the light extraction surface 41 of the organic EL element 1.
Further, even when the shape of the section 22 is a square or the like and one separator is missing and two adjacent sections are electrically connected, this section is visually observed in the manufactured organic EL element 1. In order not to be able to confirm in step 1, the length of one side may be set to a length equal to or less than half of the above length. That is, the length is preferably about 250 μm or less when a diffusion plate or the like is used, and about 150 μm or less when a diffusion plate or the like is not used.

  In addition, when the anode 10 as the first electrode is rectangular and the section 22 is rectangular, preferably square, the shape projected on the light extraction surface 41 is when projected onto the light extraction surface 41, The direction of each side in the shape of the section 22 and the direction of each side in the outer periphery of the anode 10 may be set to have a relationship of approximately 45 degrees. When designed in this way, as described later, the organic EL element 1 can be efficiently manufactured even if a small manufacturing apparatus is used.

  The material for forming the separator 21 is not particularly limited as long as it is a non-conductive material so as not to electrically connect the organic layers 20 of the adjacent sections 22, but for example, 2 MV / cm or more A material having a dielectric strength of 1 is preferable. Moreover, it is preferable that it is a material which does not affect the organic layer 20 and the electrodes 10 and 30 (it does not change in quality). Furthermore, as described above, since the width B is fine and it is preferable to shape the wedge B or the like, a material that can be easily processed, for example, that can be etched can be desirably employed.

Examples of the material include a transparent polymer, an oxide, and glass.
More specifically, preferred transparent polymers include polyimide, fluorinated polyimide, fluororesin, polyacrylate, polyquinoline, polyoxadiazol, polyolefin having a cyclic structure, polyarylate, and polycarbonate. -Todo, polysulfone, ladder-type polysiloxane and the like.
Further, as preferable oxides, SiO ₂ , Al ₂ O ₃ , Ta ₂ O ₃ , Si ₃ N ₄ , fluorine-added SiO ₂ , MgO, YbO _{3, and the} like are given as preferable examples of materials that can be etched. Can do.
Furthermore, in addition to the above-described materials, a photosensitive photoresist and its cured product can be exemplified.

However, since the organic layer 20 and the like are easily deteriorated by water, oxygen, or the like, the water content is 0.1% by weight or less, and the gas permeability coefficient (JIS K7126) is 1 × 10 ⁻¹³ cc · cm / cm ² · s ·. It is preferable to employ a material having a cmHg or less. Examples of such materials include inorganic oxides, inorganic nitrides, or compositions of both.
Next, other components will be described.

<Organic layer 20>
The organic layer 20 is a layer that is the anode 10 that is the first electrode and is provided in the section 22 that is divided by the separator 21. The organic layer 20 is a known layer configuration and a known one in a known organic EL element. What is necessary is just to make it the layer of material, and it can manufacture with a well-known manufacturing method.

That is, the organic layer 20 only needs to realize at least the following functions. The organic layer 20 may have a laminated structure, and each layer may have any of the functions, or a single layer may realize the following functions.
-Electron injection function Function to inject electrons from the electrode (cathode). Electron injection.
-Hole injection function A function for injecting holes (holes) from the electrode (anode). Hole injection property.
-Carrier transport function A function to transport at least one of electrons and holes. Carrier transportability.
The function of transporting electrons is called an electron transport function (electron transportability), and the function of transporting holes is called a hole transport function (hole transportability).
-Luminescence function A function that emits light when returning to the ground state by recombining injected and transported electrons and carriers to generate excitons (in an excited state).

  Therefore, in the organic layer 20, a region (light emitting region) sandwiched between the surface in contact with the anode 10 and the surface in contact with the cathode 30 emits light by the above function.

  For example, the organic layer 20 may be configured by providing layers in the order of a hole transport layer, a light emitting layer, and an electron transport layer from the anode 10 side.

  The hole transport layer is a layer that transports holes from the anode to the light emitting layer. Examples of the material for forming the hole transport layer include metal phthalocyanines such as copper phthalocyanine and tetra (t-butyl) copper phthalocyanine and metal-free phthalocyanines, quinacridone compounds, 1,1-bis (4-di-p- Tolylaminophenyl) cyclohexane, N, N′-diphenyl-N, N′-bis (3-methylphenyl) -1,1′-biphenyl-4,4′-diamine, N, N′-di (1-naphthyl) ) -N, N'-diphenyl-1, 1'-biphenyl-4, 4'-diamine and other low molecular weight materials such as polyamines, polyaniline and other high molecular weight materials, polythiophene oligomer materials, etc. Of hole transport materials.

  The light-emitting layer is a layer that emits light when the holes transported from the anode side and the electrons transported from the cathode side are recombined to be in an excited state and return from the excited state to the ground state. As the material of the light emitting layer, a fluorescent material or a phosphorescent material can be employed. Further, a dopant (fluorescent material or phosphorescent material) may be contained in the host material.

  Examples of the material for forming the light emitting layer include 9,10-diallylanthracene derivative, pyrene derivative, coronene derivative, perylene derivative, rubrene derivative, 1,1,4,4-tetraphenylbutadiene, tris (8-quinolinola). -To) aluminum complex, tris (4-methyl-8-quinolinolato) aluminum complex, bis (8-quinolinolato) zinc complex, tris (4-methyl-5-trifluoromethyl-8-quinolinolato) Aluminum complex, tris (4-methyl-5-cyano-8-quinolinolato) aluminum complex, bis (2-methyl-5-trifluoromethyl-8-quinolinolato) [4- (4-cyanophenyl) phenola -To] aluminum complex, bis (2-methyl-5-cyano-8-quinolinolato) [4- (4-cyanophen L) phenolate] aluminum complex, tris (8-quinolinolato) scandium complex, bis [8- (para-tosyl) aminoquinoline] zinc complex and cadmium complex, 1,2,3,4-tetraphenylcyclopentadiene , Pentaphenylcyclopentadiene, poly-2,5-diheptyloxy-para-phenylene vinylene, coumarin phosphor, perylene phosphor, pyran phosphor, anthrone phosphor, porphyrin phosphor, quinacridone phosphor Low molecular weight materials such as N, N'-dialkyl-substituted quinacridone phosphor, naphthalimide phosphor, N, N'-diaryl-substituted pyrrolopyrrole phosphor, polyfluorene, polyparaphenylene vinylene, polythiophene Other existing light emitting materials can be used. In the case of adopting a host / guest type configuration, a host and a guest (dopant) may be appropriately selected from these materials.

  The electron transport layer is a layer that transports electrons from the cathode 30 to the light emitting layer. Examples of the material for forming the electron transport layer include 2- (4-bifinylyl) -5- (4-tert-butylphenyl) -1,3,4-oxadiazol, 2,5-bis (1-naphthyl). ) -1,3,4-oxadiazol and oxadiazol derivatives, bis (10-hydroxybenzo [h] quinolinolato) beryllium complexes, triazole compounds and the like.

  It should be noted that the organic layer 20 can naturally be provided with a layer that can be used for a known organic electroluminescence layer, such as a buffer layer, a hole blocking layer, an electron injection layer, and a hole injection layer. These layers can also be provided by a known production method using a known material.

<Anode 10>
The anode 10 is an electrode that injects holes into the organic layer 20, and is provided so as to cover the separator 21 and the organic layer 20. That is, it is provided so as not to be exposed outside the element.
The material for forming the anode 10 may be any material that imparts the above-described properties to the anode 10, and generally known materials such as metals, alloys, electrically conductive compounds, and mixtures thereof are selected. It is manufactured so that the work function of the contacting surface (surface) is 4 eV or more.

Examples of the material for forming the anode 10 include the following.
Metal oxides and metal nitrides such as ITO (indium-tin-oxide), IZO (indium-zinc-oxide), tin oxide, zinc oxide, zinc aluminum oxide, titanium nitride;
Metals such as gold, platinum, silver, copper, aluminum, nickel, cobalt, lead, chromium, molybdenum, tungsten, tantalum, niobium;
These metal alloys and copper iodide alloys,
Conductive polymers such as polyaniline, polythiophene, polypyrrole, polyphenylene vinylene, poly (3-methylthiophene), and polyphenylene sulfide.

  When the anode 10 is provided closer to the light extraction side than the organic layer 20 as in this embodiment, the anode 10 is generally set so that the transmittance for the extracted light is greater than 10%. When extracting light in the visible light region, ITO having high transmittance in the visible light region is preferably used.

  Further, unlike the present embodiment, when configured as a top emission type element and the anode 10 is used as a reflective electrode, it has the performance of reflecting the light extracted to the outside among the above materials. The material is appropriately selected, and generally a metal, an alloy, or a metal compound is selected.

The anode 10 may be formed of only one kind of material as described above, or may be formed by mixing a plurality of materials. Moreover, the multilayer structure which consists of several layers of the same composition or a different composition may be sufficient.
When the resistance of the anode 10 is high, an auxiliary electrode may be provided to lower the resistance. The auxiliary electrode is an electrode in which a metal such as copper, chromium, aluminum, titanium, an aluminum alloy, or a laminate thereof is partially provided on the anode 10.

  Although the film thickness of the anode 10 depends on the material used, it is generally about 5 nm to 1 μm, preferably about 10 nm to 1 μm, more preferably about 10 nm to 500 nm, particularly preferably about 10 nm to 300 nm, desirably 10 nm to 200 nm. Selected by range.

The anode 10 is formed by a known thin film forming method such as a sputtering method, an ion plating method, a vacuum vapor deposition method, a spin coat method, or an electron beam vapor deposition method using the above-described materials.
The sheet electrical resistance of the anode 10 is preferably set to several hundred Ω / □ or less, more preferably about 5 to 50 Ω / □.

Further, the surface may be subjected to UV ozone cleaning or plasma cleaning.
In order to suppress the occurrence of short circuits and defects in the organic EL element, the surface roughness may be controlled to 20 nm or less as a mean square value by a method of reducing the particle size or a method of polishing after film formation.

<Cathode 30>
The cathode 30 is an electrode for injecting electrons into the organic layer 20 (electron transport layer in the above-described layer configuration), and covers the separator 21 and the organic layer 20 so as not to be exposed to the outside of the device, like the anode 10. .
As a material for forming the cathode 30, a metal, an alloy, or an electrically conductive compound having a work function of, for example, less than 4.5 eV, generally 4.0 eV or less, typically 3.7 eV or less in order to increase electron injection efficiency. And mixtures thereof are employed.

  Examples of the electrode material as described above include lithium, sodium, magnesium, gold, silver, copper, aluminum, indium, calcium, tin, ruthenium, titanium, manganese, chromium, yttrium, aluminum-calcium alloy, and aluminum-lithium alloy. , Aluminum-magnesium alloys, magnesium-silver alloys, magnesium-indium alloys, lithium-indium alloys, sodium-potassium alloys, magnesium / copper mixtures, aluminum / aluminum oxide mixtures, and the like. Moreover, the material employable as a material used for an anode can also be used.

  When the cathode 30 is used as a light-reflecting electrode in a bottom emission type element as in the present embodiment, a material having the ability to reflect light extracted outside is appropriately selected from the above materials. Generally, a metal, an alloy, or a metal compound is selected.

  In addition, when the cathode 30 is provided on the light extraction side of the light emitting layer, the cathode 30 is generally set so that the transmittance for the extracted light is larger than 10%. For example, the cathode 30 is transparent to an ultra-thin magnesium-silver alloy. An electrode formed by stacking various conductive oxides is used. Further, in this cathode, a buffer layer to which copper phthalocyanine or the like is added is preferably provided between the cathode 30 and the organic layer 20 in order to prevent the light emitting layer from being damaged by plasma when the conductive oxide is sputtered. .

  The cathode 30 may be formed of the above materials alone or a plurality of materials. For example, when 5% to 10% of silver or copper is added to magnesium, the cathode 30 can be prevented from being oxidized, and the adhesion of the cathode 30 to the organic layer 20 can be improved.

Further, the cathode 30 may have a multilayer structure including a plurality of layers having the same composition or different compositions.
For example, the following structure may be used.
In order to prevent oxidation of the cathode 30, a protective layer made of a metal having corrosion resistance is provided on a portion of the cathode 30 that is not in contact with the organic layer 20.
For example, silver or aluminum is preferably used as the material for forming the protective layer.

In order to reduce the work function of the cathode 30, an oxide, fluoride, metal compound, or the like having a small work function is inserted into the interface portion between the cathode 30 and the organic layer 20.
For example, a material in which the cathode 30 is made of aluminum and lithium fluoride or lithium oxide is inserted in the interface portion is also used.

The cathode 30 can be formed by a known thin film deposition method such as a vacuum deposition method, a sputtering method, an ionization deposition method, an ion plating method, or an electron beam deposition method.
The sheet electrical resistance of the cathode 30 is preferably set to several hundred Ω / □ or less.

<Other layers>
As a matter of course, the organic EL element 1 can employ known layers and configurations other than those described above. For example, the configuration described below can be particularly preferably employed.

(Protective layer: passivation film, sealing can)
In order to protect the organic layer 20 and the like from the outside air, the first organic EL element 1 may be protected by a passivation film or a sealing can.

  The passivation film is a protective layer (sealing layer) provided on the side opposite to the substrate 4 in order to prevent the organic EL element 1 from coming into contact with oxygen or moisture. Examples of the material used for the passivation film include organic polymer materials, inorganic materials, and photocurable resins. The material used for the protective layer may be used alone, Or you may use together. The protective layer may have a single layer structure or a multilayer structure. The thickness of the passivation film may be a thickness that can block moisture and gas from the outside.

  Examples of organic polymer materials include fluorinated resins such as chlorotrifluoroethylene polymer, dichlorodifluoroethylene polymer, a copolymer of chlorotrifluoroethylene polymer and dichlorodifluoroethylene polymer, polymethyl methacrylate Acrylic resins such as polyethylene and polyacrylate, epoxy resins, silicone resins, epoxy silicone resins, polystyrene resins, polyester resins, polycarbonate resins, polyamide resins, polyimide resins, polyamideimide resins, polyparaxylene resins , Polyethylene resin, polyphenylene oxide resin and the like.

  Examples of the inorganic material include polysilazane, diamond thin film, amorphous silica, electrically insulating glass, metal oxide, metal nitride, metal carbonide, metal sulfide and the like.

  The sealing can is a member constituted by a sealing member such as a sealing plate or a sealing container for blocking moisture and oxygen from the outside. The sealing can may be installed only on the electrode side on the back side (the side opposite to the substrate 4) or may cover the entire organic EL element 1. The thickness, the size, the thickness, and the like of the sealing member are not particularly limited as long as the organic EL element 1 can be sealed and external air can be blocked. As a material used for the sealing member, glass, stainless steel, metal (aluminum, etc.), plastic (polychlorotrifluoroethylene, polyester, polycarbonate, etc.), ceramic, etc. can be used.

  When installing the sealing member on the organic EL element 1, a sealing agent (adhesive) may be used as appropriate. When covering the organic EL element 1 whole with a sealing member, you may heat-seal sealing members without using a sealing agent. As the sealant, an ultraviolet curable resin, a thermosetting resin, a two-component curable resin, or the like can be used.

  Note that a moisture absorbent may be inserted into the space between the passivation film or the sealing can and the organic EL element 1. The moisture absorbent is not particularly limited, and specific examples include barium oxide, sodium oxide, potassium oxide, calcium oxide, sodium sulfate, calcium sulfate, magnesium sulfate, phosphorus pentoxide, calcium chloride, magnesium chloride, copper chloride, cesium fluoride. , Niobium fluoride, calcium bromide, vanadium bromide, molecular sieve, zeolite, magnesium oxide and the like.

  Further, an inert gas may be enclosed in the passivation film or the sealing can. The inert gas refers to a gas that does not react with the organic EL element 1, and for example, a rare gas such as helium or argon or a nitrogen gas can be employed.

(Insulating layer)
In order to prevent the anode 10 and the cathode 30 from being short-circuited, an insulating layer may be provided on the outer periphery of the organic layer 20. In addition, in the partition 22, an insulating layer may be provided in a portion where the organic layer 20 is not provided (a portion that cannot be provided or a portion that cannot be provided).
As a material for forming an insulating layer, a material for forming an insulating portion employed in a known organic EL element can be appropriately employed. For example, the materials listed as materials for forming the separator 21 are employed. You can also. As a forming method, a known forming method can be adopted, and for example, a sputtering method, an electron beam evaporation method, a CVD method, or the like can be adopted.

(Auxiliary electrode)
It is naturally possible to provide an auxiliary electrode. The auxiliary electrode is provided so as to be electrically connected to the anode 10 and / or the cathode 30 and is made of a material having a lower volume resistivity than the electrode to be connected. If the auxiliary electrode is formed of such a material, it becomes possible to reduce the volume resistivity of the entire electrode provided with the auxiliary electrode, and the maximum difference in the magnitude of the current flowing to each point constituting the organic layer 20 is determined. The size can be reduced as compared with the case where no auxiliary electrode is provided.

Examples of the material for forming the auxiliary electrode include tungsten (W), aluminum (Al), copper (Cu), silver (Ag), molybdenum (Mo), tantalum (Ta), gold (Au), and chromium (Cr). , Titanium (Ti), neodymium (Nd), and alloys thereof.
Specific examples of these alloys include alloys such as Mo—W, Ta—W, Ta—Mo, Al—Ta, Al—Ti, Al—Nd, and Al—Zr. Further, as the material of the auxiliary wiring layer, which is a compound of metal and _{silicon, TiSi 2, ZrSi 2, HfSi} 2, VSi 2, NbSi 2, TaSi 2, CrSi 2, WSi 2, CoSi 2, NiSi 2, PtSi Pd ₂ Si and the like are also preferable. Moreover, the structure which laminated | stacked these metals and * silicon compounds, respectively may be sufficient.

The auxiliary electrode may be a single-layer film made of the above materials, but it is also preferable to use two or more types of multilayer films in order to improve the stability of the film. Such a multilayer film can be formed using the above metals or their alloys. For example, in the case of three layers, Ta layer and Cu layer and Ta layer, and Ta layer and Al layer and Ta layer, in the case of two layers, Al layer and Ta layer, Cr layer and Au layer, Cr layer and Al layer, and A combination of an Al layer and a Mo layer can be given.
Here, the stability of the film refers to a property that can maintain a low volume resistivity and is not easily corroded by a liquid or the like used for the treatment during etching. For example, when the auxiliary electrode is made of Cu or Ag, the auxiliary electrode may have a low volume resistivity but may be easily corroded. On the other hand, the stability of the auxiliary electrode is enhanced by laminating a metal with excellent corrosion resistance, such as Ta, Cr, Mo, etc., on the upper and / or lower part of the metal film made of Cu or Ag. be able to.

In general, the thickness of the auxiliary electrode is preferably set to a value within the range of 100 nm to several tens of μm, and more preferably set to a value within the range of 200 nm to 5 μm.
The reason for this is that when the film thickness is less than 100 nm, the resistance value increases, which is not preferable as the auxiliary electrode. On the other hand, when the film thickness exceeds several tens of μm, it becomes difficult to flatten and the organic EL element 1 may be defective. Because there is.

For example, the width of the auxiliary electrode is preferably a value within a range of 2 μm to 1,000 μm, and more preferably a value within a range of 5 μm to 300 μm.
The reason is that if the width is less than 2 μm, the resistance of the auxiliary electrode may be increased. On the other hand, if the width exceeds 100 μm, extraction of light to the outside may be hindered. .
Next, the substrate 4 will be described.

<Substrate 4>
The substrate 4 is a mainly plate-like member that supports the organic EL element 1. The organic EL element 1 is generally manufactured as an organic EL device supported by the substrate 4 because the constituent layers are very thin.

Since the substrate 4 is a member on which the organic EL element 1 is laminated, the substrate 4 preferably has planar smoothness.
Further, when the substrate 4 is on the light extraction side with respect to the organic layer 20, it is transparent to the extracted light. Since the organic EL element 1 is a bottom emission type element, the substrate 4 is transparent, and the plane 41 opposite to the plane 42 in contact with the organic EL element 1 of the substrate 4 is a light extraction surface.

  A known substrate can be used as the substrate 2 as long as it has the performance described above. In general, a ceramic substrate such as a glass substrate, a silicon substrate, or a quartz substrate, or a plastic substrate is selected. Moreover, the board | substrate etc. which formed metal foil in the metal substrate and the support body are used. Furthermore, a substrate made of a composite sheet in which a plurality of substrates of the same or different types are combined can be used.

In the above example, an organic EL device in which the anode 10, the organic layer 20, and the cathode 30 are sequentially stacked on the substrate 4 is shown. However, a configuration in which the cathode 30, the organic layer 20, and the cathode 10 are sequentially stacked on the substrate 4 is also possible. Naturally it can be adopted. Further, as described above, it is natural that the organic EL device 1 may not be configured as the organic EL device but may be configured as the organic EL element 1 that does not include the substrate 4. In this case, the organic EL element 1 may be manufactured without using the substrate 4 from the beginning, or after the organic EL device is manufactured, the substrate 4 is deleted by a known substrate stripping technique such as etching. May be manufactured.
Next, a method for manufacturing the organic EL element 1 will be described. In the following description, an example in which the organic EL element 1 is manufactured on the substrate 4 is shown.

"Production method"
The organic EL element 1 can be realized by appropriately combining a known method for manufacturing an organic EL element as described above and a known fine processing technique for providing a separator.
For example, it can be produced as shown in FIGS.

First, as shown in (a), a layer of an anode 10 as a first electrode is formed on one surface 42 of the substrate 4 by using the above-described anode forming material, and the above-described known anode. It is produced by a forming method.
After the anode 10 is manufactured, the separator 21 is formed on the surface of the anode 10 that is not in contact with the substrate, using the above-described material for forming a separator, using a known fine processing method, as shown in FIG. Are provided, and the section 22 is manufactured.
After producing the compartment 22, as shown in (c), the organic layer 20 is produced in the compartment 22 using the organic layer 20 forming material by the known organic layer 20 forming method as described above.
After the organic layer 20 is produced, as shown in (d), the above-described known material for forming the cathode 30 is used so that the organic layer 20 and the separator 21 are not exposed to the outside of the device. The cathode 30 is formed by the cathode 30 film forming method.
The organic EL element 1 can be produced through the above steps.

  In the organic EL element 1 manufactured as described above, the organic layer 20 is sandwiched between the pair of electrodes 10 and 30. The organic layer 20 is divided into a plurality of areas 22 by a plurality of separators 21, and each separator 21 is non-conductive and physically connects both electrodes 10 and 30. . Both electrodes 10 and 30 are provided over at least the entire light emitting region so that the organic layer 20 and the separator 21 are not exposed to the outside of the element 1. Since the organic EL element 1 is a full surface light emitting element, both electrodes 10 and 30 are provided so as to cover all the compartments 22.

Since the structure of the organic EL element 1 can be appropriately changed as described above, the manufacturing method may be appropriately changed according to the structure to be employed.
For example, in the case where an insulating layer is provided around the organic layer 20, a material for forming an insulating layer as described above is replaced with a known insulating material as described above between the steps of FIGS. 6 (c) and 6 (d). What is necessary is just to provide using a layer formation method.
Further, when providing a passivation film or a sealing can, these protective layers are formed by a known passivation film manufacturing method or a sealing can manufacturing method as described above after the step shown in FIG. What is necessary is just to provide.
Below, an example suitable for manufacture of the organic EL element 1 is shown.

<Production Example 1>
The manufacturing example 1 shown in FIG. 7 is different from the manufacturing method shown in FIG. 6 in that the step shown in FIG. 7B is adopted instead of the step shown in FIG. 6B.
In the step shown in FIG. 7 (b), the thickness of the separator 21 is increased by using, for example, a wedge-shaped separator 21 that is thinner from one end side to the other end side. It arrange | positions so that it may become the anode 10 side which is a 1st electrode. Other steps may be performed in the same manner as the manufacturing example shown in FIG. That is, the process shown in FIG. 7A corresponds to the process shown in FIG. 6A, the process shown in FIG. 7C corresponds to the process shown in FIG. 6C, and FIG. The steps shown correspond to the steps shown in FIG.

  In this way, by employing the separator 21 that is thick on the anode 10 side and thin on the cathode 30 side, when the organic layer 20 is formed in the step shown in FIG. Even if the attaching direction does not substantially coincide with the normal direction of the light extraction surface 41, the organic layer 20 can be spread in the compartment 22. For example, as shown in FIG. 8, when the organic layer 20 forming material is laminated from a direction deviating from the normal line H of the light extraction surface 41 (A direction in the figure), the shadow of the separator 21 in the compartment 22 is obtained. Therefore, the organic layer 20 can be provided on the entire surface of the anode 10.

  In the above description, the anode 10 is formed when the organic layer 20 forming material is applied from a direction that does not coincide with the normal line of the light extraction surface 41 as in the direction A in FIG. It does not indicate that the organic layer 20 is not formed on the entire upper surface. In the manufacturing method shown in FIG. 6, the viscosity of the material for forming the organic layer 20 is set to an appropriate value, or the time provided between the step shown in FIG. 6B and the step shown in FIG. Or the like, the material also moves to the place where the material for forming the organic layer 20 was not laminated on the anode 10, and as a result, the organic layer 20 can be provided on the entire surface of the anode 10. .

  Further, as described above, if an insulating layer is provided on the anode 10 where the organic layer 20 is not laminated, a short circuit between the anode 10 and the cathode 30 can be prevented. The timing of providing this insulating layer is after the step shown in FIG. 6C in the manufacturing example of FIG. Note that the direction in which the organic layer 20 is ejected can be set or determined by the organic layer 20 forming apparatus, and therefore the portion where the organic layer is not formed on the anode 10 is substantially the same in each section 22. Therefore, an insulating layer may be provided in advance in each compartment 22 where the organic layer is not formed, and then the organic layer 20 may be laminated.

  The separator 21, which becomes thinner from one end side to the other end side, can be manufactured by using a well-known fine processing technique such as a photolithography method, a dry etching method, or a wet etching method.

<Production Example 2>
The manufacturing method shown in FIG. 9 is the same as the manufacturing method shown in FIG. 6 except that the steps of FIGS. 9B1 to 9B3 are sequentially performed instead of the step of providing the section 22 of FIG. In the same manner as described above, a section 22 is formed by a separator 21 which is thick on the anode 10 side which is the first electrode and thin on the cathode 30 side which is the second electrode. After the process shown in (b3) is completed, the processes shown in FIGS. 6C and 6D are sequentially performed. Hereinafter, the steps illustrated in FIG. 9B1 to (B3) will be described in detail.

  In the step shown in FIG. 9 (b1), as in the step shown in FIG. 6 (b), the separator forming material 21 ′ is provided on the anode 10 and then the separator precursor 21 ′. The photoresist F is placed on the upper side (the side opposite to the anode 10). Then, in the step shown in FIG. 9 (b2), the separator 21 having a shape as shown in the figure can be obtained by performing undercutting on the separator 21 by wet etching or dry etching. . Thereafter, by removing the photoresist F in (b3), a separator 21 having the same shape as the separator in Manufacturing Method Example 1 is obtained.

  When a dry etching method is employed in the step shown in (b2), an etching solution that does not affect the anode 10 is employed, the anode 10 is protected from the etching solution, and the separator 21 is shaped, The protection of the anode 10 may be removed.

  In addition to the manufacturing method shown in FIG. 9, after the separator 21 is provided on the anode 10, the separator 21 can be shaped into the shape described above. Hereafter, each manufacturing method is demonstrated using FIGS. 10-13. 10 to 13, only the process shown in FIG. 6B is changed. Therefore, the processes shown in FIGS. 6A, 6 </ b> C, and 6 </ b> D are illustrated and described. Is omitted.

The method shown in FIG. 10 is a manufacturing method using a sandblast method.
After the anode 10 is formed on the substrate 4, as shown in (b1), a separator forming material 21 'is laminated on the anode 10 and solidified. Thereafter, the dry film resist D is laminated on the separator precursor 21 'as shown in (b2), and the resist is put on the separator precursor 21' as shown in (b3) to (b4). Exposure and development so that D remains. More specifically, the resist mask D is formed to be approximately the same size as the size of the separator 21 on the cathode 30 side at the position where the separator 21 is provided. After forming the resist mask D, unnecessary separator 21 material is ground by sandblasting as shown by arrow E in (b5), and the dry film resist is peeled off as shown in (b6). -The data 21 can be produced. In addition, after the step shown in (b5), the anode 10 may be subjected to plasma cleaning or UV ozone cleaning in order to planarize the surface of the anode 10.

The method shown in FIG. 11 is a manufacturing method using a material for forming a separator as described above and having a function as a photosensitive resin.
After forming the anode 10 on the substrate 4, as shown in (b1), a separator forming material 21 'is laminated on the anode 10 and solidified. Thereafter, as shown in (b2), pattern exposure is performed at the position where the separator 21 is provided, whereby the separator 21 having the shape shown in (b3) can be obtained.

The method shown in FIG. 12 is a manufacturing method in which the photoresist method can be adopted even if the material for forming the separator 21 does not have a function as a photosensitive resin.
After the anode 10 is formed on the substrate 4, the dry film resist D is laminated on the anode 10 as shown in (b1). Then, as shown in (b2), the position where the separator 21 is provided is exposed and developed, and as shown in (b3), a cavity (mold) C made of resist is produced at that position. Then, as shown in (b4), the mold C produced as described above is filled with a material for forming a separator as described above and solidified, and a dry film resist is stripped as shown in (b5). By doing so, the same separator 21 as described above can be manufactured.

The method shown in FIG. 13 is a manufacturing method in which the separator 21 is manufactured by repeatedly applying a material for forming the separator 21 by a printing method such as a screen printing method.
After forming the anode 10 on the substrate 4, as shown in (b1) to (b4), the material for forming the separator 21 is sequentially printed. Thereby, as shown in (b4), the separator 21 similar to the above can be produced.

<Production Example 3>
Production method example 3 shows a production method example in which the organic layers 20 in adjacent compartments 22 are extremely less likely to be electrically connected when the shape of the compartments 22 is rectangular as described above, preferably square. . In the present manufacturing method example, the organic EL element 1 is basically manufactured in the same manner as the manufacturing method shown in FIG. The difference from the manufacturing method of FIG. 6 is that the organic layers in FIG. 6C are stacked as follows.

  FIG. 14A shows a front view of the organic EL element 1 intermediate body in which the separator 21 is provided on the anode 10 as viewed from the separator 21 side. As shown in this figure, each section 22 divided by the separator 21 has a substantially rectangular shape when projected onto the light extraction surface 41.

  In the manufacturing method example 3, when an organic layer is stacked on this intermediate, the material for forming the organic layer 20 is discharged (applied) and stacked in a direction L substantially the same as the diagonal direction of the section 22. More specifically, when projected onto the light extraction surface 41 (or a plane parallel to the surface), the material for forming the organic layer 20 is discharged in the direction L substantially the same as the diagonal line in the shape of the section 22, and the organic layer 20 is formed.

  FIG. 14B shows the state of the organic layer 20 formed as described above. As shown in this figure, the organic layer 20 is laminated on the separator 21 (on the cathode 30 side). However, since the partition 22 has a portion N where the separator 21 is a wall and the organic layer 20 is not formed and a formed portion M, the organic layer 20 in each partition 22 is formed as shown in the figure. There is no electrical connection with the organic layer 20 in the adjacent compartment 22.

In addition, in the portion N where the organic layer 20 was not provided in the above manufacturing method,
・ As described above, an insulating layer is provided,
・ Establishing an insulating layer in advance
-After the said process, you may laminate | stack the organic layer 20 anew in the said part N so that it may not connect with the organic layer 20 on the separator 21. FIG. In this case, the stacking direction (material discharge direction) when projected onto the light extraction surface 41 is opposite to the material discharge direction B for forming the organic layer 20 and the organic material on the separator 21 is organic. In order not to be connected to the layer 20, the stacking amount (discharge amount) may be controlled.

In combination with the manufacturing method shown in manufacturing method example 1 and manufacturing method example 2, separator 21 that becomes thinner as it approaches cathode 30 from anode 10 is used, and separator 21 has a portion N where the material for forming organic layer 20 is not laminated. A base (anode 10 side end) may be provided. Thereby, there is no need to provide a step of providing an insulating layer or to laminate the material for forming the organic layer 20 in a plurality of times.
Further, the material for forming the organic layer 20 laminated on the separator 21 may be deleted.

<Production Example 4>
In the manufacturing method example 4, when the organic layer 20 in FIG. 6C is formed in the manufacturing method shown in FIG. 6, the organic layer 20 is formed by discharging materials for forming the organic layer 20 from a plurality of positions. That is, a plurality of discharge nozzles are provided in a device that discharges the material for forming the organic layer 20, and the material for forming the organic layer 20 is discharged onto the anode 10 from each nozzle. Thereby, the time required for the process shown in FIG. 6C can be shortened.

  If the discharge directions of the nozzles are substantially the same, the organic layer 20 in each section 22 can be formed substantially uniformly.

Further, when the manufacturing method example 3 is combined and the shape of the section 22 when projected onto the light extraction surface 41 is a rectangle, preferably a square, and the discharge direction of the nozzle is set to the diagonal direction of the section 22, they are adjacent as described above. The possibility that the organic layer 20 in the section 22 is electrically connected can be extremely reduced, and the state (film thickness and the like) of the organic layer 20 in each section 22 can be made substantially uniform.
Naturally, Production method example 1, Production method example 2, and other modified examples can be appropriately combined.

<Production Example 5>
The production method example 5 is different from the production method example 4 in that the organic layer 20 is formed using a device in which nozzles in a device for discharging the material for forming the organic layer 20 are arranged on a substantially straight line. That is, the material for forming the organic layer 20 is discharged from a plurality of positions on a substantially straight line so that the straight line in which the nozzles are arranged moves relative to the anode 10. Thereby, like the example 4 of manufacturing method, the time which the process shown in FIG.6 (c) requires can be shortened.

  If the discharge directions of the nozzles are substantially the same, the state of the organic layer 20 in each compartment 22 can be made substantially uniform.

Further, when the manufacturing method example 3 is combined and the shape of the section 22 when projected onto the light extraction surface 41 is a rectangle, preferably a square, and the discharge direction of the nozzle is set to the diagonal direction of the section 22, they are adjacent as described above. The possibility that the organic layer 20 in the section 22 is electrically connected can be extremely reduced, and the state (film thickness and the like) of the organic layer 20 in each section 22 can be made substantially uniform.
Of course, like the manufacturing method example 4, the above-mentioned various manufacturing methods and known organic EL device manufacturing methods, such as the manufacturing method example 1, can be appropriately combined.

Thus, when using the organic layer 20 forming material discharge device in which nozzles having substantially the same discharge direction are arranged on a substantially straight line, the anode 10 is provided in a substantially rectangular shape, and the separator 21 is set as follows. It is good to provide.
The shape of the section 22 when projected onto a plane parallel to the light extraction surface 41 is a rectangle, preferably a square.
The direction of each side in the shape of the partition 22 and the direction of each side on the outer periphery of the anode 10 when projected onto a plane parallel to the light extraction surface 41 are set to be approximately 45 degrees.

  For example, as shown in FIG. 15A, with respect to an organic EL element intermediate in which a separator 21 having the above conditions is provided on a rectangular anode 10, the direction in which the nozzles in the apparatus are aligned is defined as the anode 10. It is preferable to discharge the material for forming the organic layer 20 by moving the apparatus in a direction substantially perpendicular to the direction in which the nozzles are arranged on a plane parallel to the anode 10. The nozzle may be set so that the ejection direction for forming the organic layer 20 is substantially the same as the one side direction when projected onto the light emitting surface 41.

When manufactured in this way, the following effects can be obtained.
-The possibility that the organic layers 20 in the adjacent compartments 22 are electrically connected can be extremely low.
Since the shape of the section 22 when projected onto the light extraction surface 41 is rectangular and the material for forming the organic layer 20 can be discharged in the diagonal direction of this shape, the organic layer in the adjacent section 22 as described above. This is because the possibility of connecting 20 is extremely low.
The state of the organic layer 20 such as the film thickness in each compartment 22 can be made substantially the same.
This is because the ejection direction of each nozzle is substantially the same.
-Time required for the process shown in FIG.
This is because a plurality of nozzles are used.
The size of the organic layer 20 forming material discharge device can be reduced.
For example, as shown in FIG. 15B, when the direction of each separator 21 and the direction of the side on the outer periphery of the anode 10 are substantially the same when projected onto the light extraction surface 41, Thus, in order to apply the material for forming the organic layer 20 from the diagonal direction of the section 22, the width of the device G ′ must be equal to or larger than the diagonal line of the anode 10.
On the other hand, when the separator 21 is provided as shown in FIG. 15A, the width of the device G can be approximately the same as the length of one side of the anode 10.
Accordingly, it is possible to reduce the size and length of the device, more specifically, the portion of the device where the nozzle is provided.
Next, the operation of the organic EL element 1 will be described.

<Action>
In the organic EL element 1, when the anode 10 and the cathode 30 are connected to an external drive circuit (not shown) and a voltage is applied between both electrodes, holes are transferred from the anode 10 to the organic layer 20, and holes are transferred from the cathode 30 to the organic layer 20. Each is injected with electrons. And as mentioned above, an organic layer emits light because both recombine.

When the organic layer 20 is altered in a certain section 22 such as a dark spot, the alteration propagates only to the organic layer 20 in the section 22. That is, the growth of alteration stops within the compartment 22. This is because the organic layer 20 is divided into a plurality of sections 22 by the separator 21 and the organic layers 20 in the adjacent sections 22 are not physically connected.
Next, the effect obtained by the organic EL element 1 and the effect obtained by the manufacturing method will be described. In addition, although it does not describe below about each effect described in the said description, it is natural that each is acquired.

"effect"
-The device life can be extended.
An organic EL element can be altered, such as a dark spot, and if it grows (if it propagates to the surroundings), it can be used substantially even if other parts can emit light. Can not.
On the other hand, the organic EL device according to the present embodiment is limited to the area where the dark spot is generated even if the alteration such as a dark spot occurs in the organic layer even if the range in which the alteration propagates is the maximum. Therefore, there are few problems in use if other sections are alive. Therefore, the element can be used for a long time.

-Yield can be improved.
Deterioration such as dark spots also occurs in the manufacturing process.
On the other hand, the organic EL element according to the present embodiment does not grow to a size larger than the section even when the deterioration occurs, so that the ratio of elements that can be used as products can be increased.

<Modification>
Hereinafter, modified examples of the organic EL element 1 will be described. In addition, it is natural that each modification described in the above description can also be adopted as appropriate, and not only one modification but also a combination of a plurality of modifications may be employed within a range not contradicting each other. Of course it is possible.

<Modification 1>
Although the organic EL element 1 is a full surface light emitting element, the above-described technology is adopted for a pixel constituting a display employing a passive matrix method or an active matrix method, or a sub-pixel (organic EL element) constituting the pixel. It is also possible to do.

For example, in a display in which one pixel is configured by red, blue, and green sub-pixels (organic EL elements), each sub-pixel may be divided into a plurality of areas 22 by a separator 21. That is, each sub-pixel includes a plurality of organic layers 20 divided into a plurality of areas 22 by a plurality of separators 21, and the anode and the cathode are configured to be connected to the organic layers 20 in each area 22, respectively. To do.
By dividing in this way, even if alteration occurs in one area 22, the subpixel is not completely unusable.

<Modification 2>
At least one end of the separator 21 may be embedded in the electrode, and the portion embedded in the electrode may have conductivity.
For example, as shown in FIG. 16, the separator 21 is provided so as to be pushed into the anode 10, and a part or all of the part 21 b located in the anode 10 in the separator 21, more specifically, the surface side of the part 21 b Conductivity may be imparted to the side that contacts the anode 10. If the portion 21b is formed of a material whose volume resistivity is lower than that of the anode 10, the separator 21 can also serve as an auxiliary electrode. As a material constituting this portion 21b, any of the materials mentioned as the materials for forming the auxiliary electrode can be adopted as appropriate.

The separator 21 precursor formed of the auxiliary electrode forming material is pushed into the anode 10 as shown in FIG. 16, and then the portion 21a that has not been pushed into the anode 10 is oxidized. By making it non-conductive, a configuration equivalent to the above configuration can be realized.
Further, in the separator 21 precursor formed of the auxiliary electrode forming material, the portion 21a that is not pushed into the anode 10 is made non-conductive similarly to the above, and the portion 10b is pushed into the anode 10. A separator 21 may be arranged.

  As described above, if the end 21b of the separator 21 has a function as an auxiliary electrode, it is not necessary to provide the auxiliary electrode. Further, the position where the separator 21 is provided is originally a position where the organic layer 20 is not provided, that is, a position which does not contribute to light emission, so that the separator 21 does not have a function as an auxiliary electrode. However, the total surface area of the organic layer 20 does not change.

  That is, without changing the total surface area, the volume resistivity of the electrode can be reduced, or the potential difference between a portion close to the terminal connected to the external drive circuit and a portion far from the terminal can be reduced. This makes it possible to reduce luminance unevenness and the like.

<Modification 3>
The shape of the anode 10 as a whole and the shape of each section 22 may not be a strict rectangle, but may be, for example, a rounded shape or a rounded shape. Each side does not need to be a strict straight line. For example, even if a part has a curved portion or one side is a curved line as a whole, if the shape is actually equivalent to a rectangle, This shape is also included in the rectangular concept in this specification.

  In addition, when the corners of the anode 10 and the section 22 are rounded or rounded, it is possible to alleviate the phenomenon of electric power concentration at the corners.

It is the perspective view which showed typically the structure of the organic EL element 1 which concerns on this Embodiment. In this figure, in order to explain the configuration of the organic layer 20 and the separator 21 in detail, the cathode 30 is indicated by a broken line. 2 is a cross-sectional view schematically showing a cross-sectional configuration of a main part of the organic EL element 1. FIG. FIG. 3 is a front view schematically showing a state where the organic EL element 1 is viewed from the side opposite to the substrate 4. 6 is a cross-sectional view schematically showing another arrangement position of the separator 21 in the organic EL element 1. FIG. (A) has shown typically the separator 21 embed | buried in the cathode 30 as a 2nd electrode. (B) has shown typically the separator 21 embed | buried in the anode 10 as a 1st electrode. (C) schematically shows a state in which the separator 21 is embedded in both the anode 10 and the cathode 30. In either case, the separator 21 does not penetrate the electrode. 6 is a cross-sectional view schematically showing another shape of the separator 21 in the organic EL element 1. FIG. The separator 21 shown in this figure has a cross-sectional shape that becomes thinner from the anode 10 as the first electrode toward the cathode 30 as the second electrode. 3 is a cross-sectional view schematically showing a first production example of the organic EL element 1. FIG. 5 is a cross-sectional view schematically showing a second production example of the organic EL element 1. FIG. FIG. 8 is a cross-sectional view of an essential part showing in more detail the process of FIG. 7C for explaining the operation and effect of the organic EL element 1 manufactured by the manufacturing example shown in FIG. It is principal part sectional drawing for demonstrating the 1st example of manufacture of the organic EL element which has the separator 21 shown in FIG. Steps (b1) to (b3) in this figure are steps that replace the step (b) in FIG. It is principal part sectional drawing for demonstrating the 2nd manufacturing example of the organic EL element which has the separator 21 shown in FIG. Steps (b1) to (b6) in this figure are steps that replace step (b) in FIG. It is principal part sectional drawing for demonstrating the 3rd example of manufacture of the organic EL element which has the separator 21 shown in FIG. Steps (b1) to (b3) in this figure are steps that replace the step (b) in FIG. It is principal part sectional drawing for demonstrating the 4th example of manufacture of the organic EL element which has the separator 21 shown in FIG. Steps (b1) to (b5) in this figure are steps that replace the step (b) in FIG. It is principal part sectional drawing for demonstrating the 5th example of manufacture of the organic EL element which has the separator 21 shown in FIG. Steps (b1) to (b4) in this figure are steps that replace step (b) in FIG. FIG. 6 is a front view of a main part for explaining a preferred method for manufacturing the organic layer 22 when the section 22 in the organic EL element 1 is rectangular. This figure shows an example in which the material for forming the organic layer 20 is applied in the diagonal direction of the shape of the section 22 when projected onto the light extraction surface, and the organic EL element 1 produced in this way is shown in FIG. Shows the effect. It is a figure for demonstrating the conditions for reducing the manufacturing apparatus of the organic EL element 1 and manufacturing the organic EL element which has a very favorable performance. FIG. 6 is a cross-sectional view of a main part for explaining a modification of the organic EL element 1.

Explanation of symbols

1: Organic EL element 4: Substrate (in the embodiment, a transparent substrate)
10: First electrode (in the embodiment, an anode)
20: Organic layer 21: Separator 22: Partition 30: Second electrode (cathode in the embodiment)
41: Surface on which the organic EL element 1 is provided on the substrate 42: Surface opposite to the surface 41 (light extraction surface in the embodiment)

Claims (14)

An organic electroluminescent element in which an organic layer is sandwiched between a pair of electrodes, a light extraction surface is set on at least one electrode side, and light emitted from the organic layer is extracted from the light extraction surface to the outside ,
The organic layer is divided into a plurality of sections by a plurality of separators in a plane direction substantially parallel to the light extraction surface,
Each separator is non-conductive and is physically connected to both electrodes,
Both electrodes are provided so as to be electrically connected to the organic layer in each section and to cover the organic layer and the separator, respectively. The organic electroluminescent device according to claim 1,
2. The organic electroluminescent element according to claim 1, wherein the separator is thinner as it approaches one electrode from the other electrode. The organic electroluminescent element according to claim 1 or 2,
The organic electroluminescence device according to claim 1, wherein a shape of the section projected onto a plane parallel to the light extraction surface is substantially square. The organic electroluminescent device according to claim 3, wherein
At least one of the electrodes is generally rectangular,
The direction of each side in the shape of the section when projected onto a plane parallel to the light extraction surface and the direction of each side in the outer periphery of the substantially rectangular electrode have a relationship of approximately 45 degrees. Organic electroluminescent element characterized. An organic electroluminescent element manufacturing method in which an organic layer is sandwiched between a pair of electrodes, a light extraction surface is set on at least one of the electrodes, and light emitted from the organic layer is extracted from the light extraction surface to the outside Because
(A) providing a plurality of non-conductive separators on the first electrode and forming a plurality of sections by the separators;
(B) providing an organic layer in each of the compartments;
(C) providing a second electrode so as to cover each organic layer and each separator, and a method for producing an organic electroluminescent element. It is a manufacturing method of the organic electroluminescent element of Claim 5,
The separator is thinner from one end to the other,
In the step (a), the separator is provided so that one end side of the separator is on the first electrode side. It is a manufacturing method of the organic electroluminescent element of Claim 5,
In the step (a), after the separator is further provided, the separator is processed so that the first electrode side is thicker than the other end side. . It is a manufacturing method of the organic electroluminescent element according to any one of claims 5 to 7,
In the step (a), a separator is provided so that the shape of the section when projected onto a plane parallel to the light extraction surface is substantially rectangular. It is a manufacturing method of the organic electroluminescent element according to any one of claims 5 to 7,
In the step (a), a separator is provided so that the shape of the section when projected onto a plane parallel to the light extraction surface is approximately square. It is a manufacturing method of the organic electroluminescent element according to claim 8 or 9,
The first electrode has a substantially rectangular shape when projected onto a plane parallel to the light extraction surface,
In the step (a), the direction of each side on the outer periphery of the section and the direction of each side on the outer periphery of the first electrode when projected onto a plane parallel to the light extraction surface are approximately 45 degrees. A method of manufacturing an organic electroluminescent element, wherein each separator is provided so as to be in a relationship. It is a manufacturing method of the organic electroluminescent element according to any one of claims 8 to 10,
In the step (b), an organic layer is provided by discharging an organic layer forming material in a direction substantially the same as a diagonal line in the shape of the section when projected onto a plane parallel to the light extraction surface. Manufacturing method of organic electroluminescent element. It is a manufacturing method of the organic electroluminescent element according to any one of claims 5 to 11,
In the step (b), an organic layer is provided by discharging an organic layer forming material from a plurality of positions. It is a manufacturing method of the organic electroluminescent element according to any one of claims 5 to 11,
In the step (b), an organic layer is provided by discharging organic forming materials from a plurality of positions on a substantially straight line and moving the straight line relative to the first electrode. Manufacturing method of electroluminescent element. It is a manufacturing method of the organic electroluminescent element according to claim 12 or 13,
The method for producing an organic electroluminescent element, wherein the discharge direction of the organic layer forming material at each position is substantially the same direction.

Images