JP2008103585A - Area light emitting organic el member, article provided with the same, and method of manufacturing the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an organic EL display panel of a simple area light emitting type which has an anode, an EL layer, and a cathode (cathode electrode) laminated on a substrate in this order, which acts to collectively emit light of whole or part of a predetermined area as an image when a predetermined voltage is applied between the anode and the cathode, and which avoids luminescence failure in the organic EL display panel having a through hole formed in its display area by punching. <P>SOLUTION: In the organic EL member of an area light emitting type, an insulating layer having such a thickness as capable of blocking emitted light and having one or more openings is provided between an anode and a cathode so that application of a voltage between the anode and the cathode causes areas of the openings of the insulating layer as light emission areas to collectively emit light. In a region as a use target, a through hole not in contact with a metal part of the cathode is provided. <P>COPYRIGHT: (C)2008,JPO&INPIT

Description

  The present invention relates to a simple area light emitting organic EL member used for POP (Point Of Purchase advertising), an article provided with the area light emitting organic EL member, and a method for manufacturing the area light emitting organic EL member In particular, an area light emitting organic EL display panel provided with a through-hole portion not in contact with a metal pattern of a cathode (cathode electrode), an article provided with the area light emitting organic EL display panel, and an area The present invention relates to a method for manufacturing a light-emitting organic EL display panel.

In recent years, various types of display panels have been developed as display devices become lighter, larger, and more refined. As a display panel that stably displays individual characters and designs with high brightness, simple area light emission such as POP is possible. Type EL display panels have come to be used from the standpoint of merits such as being a solid-state element and self-luminous.
An electroluminescence element (hereinafter referred to as an EL element) is an element that emits light by applying an electric field to a fluorescent compound or injecting a charge or a hole. This EL element is self-luminous and has high visibility. It is high and has a feature such as excellent impact resistance because it is a completely solid element.
Among them, an organic EL element using an organic compound as a fluorescent material has high emission efficiency such as high luminance emission even at a low voltage of less than 10 V applied voltage, and can emit light with a simple element structure. There are advantages such as high brightness and long life.
In addition, the organic EL element is a laminated structure in which a hole transport layer, a light emitting layer, and an electron injection layer are mainly formed between an anode and a cathode, and each layer can be formed with a thickness of nanometer unit. There is an advantage that it is easy to reduce the thickness and weight.
Furthermore, each of these layers can be manufactured by applying a coating solution in which a polymer material is dissolved, so that it is possible to apply a manufacturing method that applies a printing method to paper or a manufacturing method that applies an ink jet method. There is also.

As an area light emitting organic EL display panel, the insulating layer is patterned to emit light uniformly over the entire light emitting area, or organic EL is emitted using an active matrix or passive matrix, and the gray scale is controlled using a complex circuit. Some types are available.
The type that uniformly emits light in the entire light emitting area is described in Japanese Patent Application Laid-Open No. 2004-111158 (Patent Document 1) and Japanese Patent Application Laid-Open No. 2002-231446 (Patent Document 2). A gray scale cannot be expressed in an organic EL panel that emits light.
Further, when organic EL is caused to emit light using an active matrix or a passive matrix, a moving image display or the like is possible, but there is a problem that a gray scale must be controlled using a complicated circuit.
JP 2004-111158 A JP 2002-231446 A

Under such circumstances, an anode, an EL layer, and a cathode (cathode electrode) are laminated on a base material in this order, and a predetermined voltage is applied to the anode and the cathode to emit light as a whole or a part of a predetermined area. In addition, in a simple area light emission type area light emission type organic EL display panel, various uses other than the use of POP (Point Of Purchase advertising) are being studied.
For example, in an exhibition or product, it may be used for a display panel that needs to have a through hole in order to look into it or smell it.
However, when opening the through hole with the solid metal forming the cathode, the anode and the EL layer due to impact, light emission failure due to separation of the EL layer and the cathode, and oxygen from the gap generated during the hole preparation, There is a problem that the EL layer deteriorates due to the influence of water or the like, and the light emission failure occurs due to oxidation of the cathode.

As described above, recently, an anode, an EL layer, and a cathode (cathode electrode) are laminated in this order on a base material, and a predetermined voltage is applied to the anode and the cathode so that all or a part of a predetermined area is batched. A simple area emission type organic EL display panel that emits light as an image, and a display panel that needs to be provided with a through hole is also considered. When punched with a solid metal that forms a hole to form a through hole, light emission failure due to separation of the anode and the EL layer, the EL layer and the cathode due to impact, and a gap generated during the hole preparation Therefore, the EL layer deteriorates due to the influence of oxygen, water, and the like, and light emission failure occurs due to oxidation of the cathode.
The present invention corresponds to this, and an anode, an EL layer, and a cathode (cathode electrode) are laminated in this order on a substrate, and a predetermined voltage is applied to the anode and the cathode so that all or a part of a predetermined area is formed. A simple area emission type organic EL display panel that emits light as an image, and an organic EL display panel in which a through-hole is formed by punching in the display area. It is what.

In the area light emitting organic EL member of the present invention, an anode, an EL layer (also referred to as an electroluminescent layer), and a cathode (cathode electrode) are laminated in this order on a base material, An insulating layer having a thickness capable of preventing light emission at the time of light emission and having one or more openings is provided between the anode and the cathode, and a voltage is applied between the anode and the cathode so that each opening region of the insulating layer is formed. The light emitting area is an area light emitting type organic EL member that emits light from each light emitting area in a lump, and a through hole portion that is not in contact with the metal portion of the cathode is provided in the region to be used. It is characterized by this.
And it is said area light emission type organic EL member, Comprising: The said base material is a flexible plastic base material, It is characterized by the above-mentioned.
In addition, in the area light emitting organic EL member according to any one of the above, the through hole portion is formed by punching.
Further, any one of the above-mentioned area light emitting organic EL members, which is a member for a display panel, and comprises light, a figure, or a combination thereof by light emission of each light emitting area. A display pattern is configured.
Alternatively, any one of the above-described area light emitting organic EL members, which is a light source member.

The method for producing an area light emitting organic EL member according to the present invention is a method for producing an area light emitting organic EL member for producing the area light emitting organic EL member according to any one of claims 1 to 6. After laminating an anode, an EL layer, and a cathode (cathode electrode) in this order on a substrate, a through hole is formed by punching from the cathode side, and patterning formation of the metal part of the cathode (cathode electrode) A masking method is used to form a film so as not to come into contact with the through-hole forming region for forming the through-hole.
A method for producing an area light emitting organic EL member according to the present invention is a method for producing an area light emitting organic EL member, wherein the area light emitting organic EL member according to any one of claims 1 to 6 is produced. Then, using a base material in which a through-hole portion has been formed in advance, an anode, an EL layer, and a cathode (cathode electrode) are laminated on the base material in this order, and patterning formation of the metal portion of the cathode (cathode electrode) Is characterized in that a film is formed by using a masking method so as not to come into contact with the through-hole forming region for forming the through-hole portion.

(Function)
The area light emitting organic EL member of the present invention has such a structure, and an anode, an EL layer, and a cathode (cathode electrode) are laminated on the base material in this order, and a predetermined voltage is applied to the anode and the cathode. An organic EL member of a simple area emission type organic EL member that emits light as a whole image or a part of a predetermined area, and in which a through hole is formed by punching in the predetermined target area It is possible to provide an EL member having no light emission failure.
Specifically, by providing a through-hole part that is not in contact with the metal part of the cathode (cathode electrode) in the area to be used, when the through-hole part is opened, prevention of light emission failure due to peeling due to impact, Under the influence of oxygen, water, etc. from the gaps produced during the production of the part, it is possible to prevent the EL layer from deteriorating and the light emission failure due to the oxidation of the cathode.
In particular, the base material is a flexible plastic base material, and can be used by being attached to an article on a non-planar surface by adopting the form of the invention of claim 2, and thermal change or external force It is possible to use it in response to the wide range of uses.
Moreover, the said through-hole part can be made into a thing with good productivity by setting it as the form of invention of Claim 3 made by punching.
When used as a member for a display panel, the entire use target area can be collectively displayed as an image, which is effective.
Usually, a display pattern composed of characters, figures, or a combination thereof is formed by light emission of each light emitting area.
Alternatively, it may be used as a light source member.
In addition, as described above, in the region to be used, it is a through-hole part that is not in contact with the metal part of the cathode (cathode electrode). The EL layer is not deteriorated and the cathode is not oxidized due to peeling and the influence of oxygen, water, etc. from the gap between the holes.

In the method of manufacturing the area light emitting organic EL member of the present invention, the anode, the EL layer, and the cathode (cathode electrode) are laminated in this order on the base material, and the anode and the cathode are formed. An organic EL member of a simple area light-emitting type organic EL member that emits light as an image by applying a predetermined voltage, and in which a through hole is formed in the predetermined area. With the EL member, it is possible to provide a method for manufacturing an organic EL member free from light emission defects.
Examples of the area-emitting organic EL member to be manufactured include those for display panels and light sources.

As described above, in the present invention, in particular, an anode, an EL layer, and a cathode (cathode electrode) are laminated in this order on a base material, and a predetermined voltage is applied to the anode and the cathode so that all or a part of a predetermined area is formed. A simple area emission type organic EL display panel that emits light as an image, and an organic EL display panel in which a through-hole is formed by punching in the predetermined area, and there is no light emission defect area It has become possible to provide a light-emitting organic EL display panel and an article using such an area light-emitting organic EL display panel.
At the same time, it is possible to provide a method for manufacturing such an area light emission type organic EL display panel.

Embodiments of the present invention will be described with reference to the drawings.
FIG. 1A is a schematic plan view showing a state in which a characteristic part of one example of an embodiment of the area light emitting organic EL member of the present invention is seen through from the cathode side, and FIG. 1A is a cross-sectional view taken along line A1-A2, FIG. 1C is a view showing a mask used for forming a cathode film shown in FIG. 1A, and FIG. 2A is an area of the present invention. FIG. 2B is a schematic cross-sectional view showing an example of the laminated state of the light-emitting organic EL member, and FIG. 2B is an enlarged cross-sectional view of the light-emitting portion showing the patterning of the insulating layer in an easy-to-understand manner. (D) is a cross-sectional view of the light emitting part having EL layers of various layer structures. FIGS. 4 (a) and 4 (b) are each an article 1 with the area light emitting organic EL member of the present invention attached thereto. It is the figure which showed the example.
In addition, in FIG. 4, the arrow has shown the movement to the upper side of an attachment part.
1-4, 1 is an area light emission type organic EL display panel, 2 is a flexible substrate (also simply referred to as a substrate), 3 is a barrier layer, 4 is an anode, 5 is an EL layer, and 5a is an organic light emitting device. The body layer, 6 is a cathode (also referred to as a metal part), 7 is a barrier layer, 8 is a flexible sealing substrate, 9 is an insulating layer (also referred to as an insulating layer part here, photoresist), 9A is an opening, 10 is a sealing agent, 20 is a light emitting part, 21 is a hole transport layer, 22 is an organic light emitter layer, 23 is an electron transport layer, 24 is an organic light emitter layer / hole transport layer, and 25 is an electron transport layer / organic light emitting. Body layer, 30 is a through-hole part, 40 is a mask, 41 is a shielding part, 42 is an opening part, 60 is an article (attached to an area light emitting organic EL member), 61 is an installation part, 62 is an attachment part, and 63 is area light emission Type organic EL member (also referred to as area light emitting type organic EL display panel), 63a is a light emitting portion, 63b is a through-hole portion, and 70 is Area emission organic EL member attached) article 71 is cylindrical portion, 72 is a through hole, 73 is a light emitting portion.

First, an example of an embodiment of the area light emitting organic EL member of the present invention will be described with reference to FIG.
The area emission type organic EL member of this example is a member for a display panel, and an anode 4, an EL layer 5, and a cathode (cathode electrode) 6 are laminated on the flexible substrate 2 in this order, An insulating layer 9 having at least one opening is provided between the anode 4 and the EL layer 5 with a thickness capable of preventing light emission at the time of light emission in the region where the anode 4 and the cathode 6 are provided. 6 is applied, and the light emitting areas are collectively emitted by using the region of each opening 9A of the insulating layer 9 as a light emitting area.
In particular, the whole has a layer structure shown in FIG. 2A, and a through hole 30 that is not in contact with the metal part of the cathode 6 is provided in the region to be used. ), A schematic plan view showing a state seen through from the cathode 6 side corresponds to FIG.
The through hole 30 is formed by stacking the anode 4, the insulating layer 9, the EL layer 5, and the cathode (cathode electrode) 6 in this order on the flexible plastic substrate 2, and then punching out from the cathode side. The patterning of the metal portion of the cathode (cathode electrode) 6 is performed by using a masking method so as not to contact the through-hole forming region where the through-hole portion 30 is formed.
For example, in the case of the cathode 6 having a shape as shown in FIG. 1A, masking is performed with a metallic mask 40 made of stainless steel or the like having a shielding portion 41 and an opening 42 as shown in FIG. A film is formed by sputtering or the like.

And the display pattern which consists of a character, a figure, or these combination is comprised by light emission of each light emission area.
Alternatively, a non-light emitting area other than the light emitting area constitutes a display pattern made up of characters, figures, symbols, or a combination thereof.
The region of the opening 9A of the insulating layer 9 shown in FIG. 2B corresponds to the light emitting area, and the region covered by the other insulating layer is a non-light emitting region.
Examples of the patterning of the insulating layer 9 include a method of patterning a photosensitive material layer (also referred to as a resist) by a photolithography method.

Next, each part will be described.
(Flexible substrate 2)
The flexible base material 2 is provided on the surface on the viewer side in the area light emitting organic EL member for the display panel of this example.
Therefore, the flexible substrate 2 has a display pattern (hereinafter referred to as “characters”) composed of characters, figures, symbols, or combinations thereof displayed as a light emitting display region or a non-light emitting region when the EL layer 5 emits light. The transparency is such that an observer can easily visually recognize.
As the flexible substrate 2, a film-shaped resin substrate or a thin glass plate having a thickness of about 100 μm or less and a protective plastic plate or a protective plastic layer is used.
Such a base material is preferably used as a base material for a light-emitting display panel that can be mounted or installed on various objects because it has excellent flexibility and can be rounded or bent.

The resin material for forming the flexible substrate 2 is not particularly limited as long as it has sufficient flexibility as a substrate for a light-emitting display panel in the state after formation. , Polyethylene, polypropylene, polyvinyl chloride, polyvinyl fluoride, polystyrene, ABS resin, polyamide, polyacetal, polyester, polycarbonate, modified polyphenylene ether, polysulfone, polyarylate, polyetherimide, polyamideimide, polyimide, polyphenylene sulfide, liquid crystal Polyester, polyethylene terephthalate, polybutylene terephthalate, polyethylene naphthalate, polyoxymethylene, polyethersulfone, polyetheretherketone, polyacrylate, acrylonitrile-styrene resin, Phenol resins, urea resins, melamine resins, unsaturated polyester resins, epoxy resins, polyurethane, silicone resin, amorphous polyolefins, and the like.
Other resin materials can be used as long as they satisfy the conditions that can be used for light-emitting display panels, and are copolymerized using two or more types of monomers that are starting materials for the above-described resins. It may be a copolymer obtained.

Of these resinous substrates, those having good solvent resistance and heat resistance, and those having good gas barrier properties such as water vapor and oxygen are more preferred, depending on the application.
When a resin material with good gas barrier properties is used, the barrier layer 3 described later can be omitted, but in the light emitting display panel of the present invention, the flexible substrate 2 on which the barrier layer 3 is formed is used. preferable.
The flexible substrate 2 is manufactured by extrusion molding or the like so as to be a film-like substrate having a thickness of 50 to 200 μm.

In addition, a thin glass plate having a thickness of about 100 μm or less and provided with a protective plastic plate or a protective plastic layer is excellent in flexibility and can be rounded or bent. Used.
At this time, it is more preferable to use a protective plastic plate or a protective plastic layer having a good gas barrier property.

By setting the thickness of the flexible base material 2 within the above range, preferable flexibility can be imparted to the light emitting display panel.
When the obtained light-emitting display panel is installed in a complicated shape or used as a display device of a portable device, the light-emitting display panel can be thinned to 50 μm to 100 μm to 400 μm. It is possible to realize the thinness unique to the light-emitting display panel for advertisement.

(Barrier layer 3)
The barrier layer 3 is a layer that acts to block moisture (water vapor) and oxygen that adversely affect the life and light emitting performance of the organic EL layer 5.
The barrier layer 3 is not an essential layer in the light-emitting display panel of the present invention, but is a layer that is preferably formed between the flexible substrate 2 and the first electrode 4 described above.
This barrier layer 3 also needs to be transparent, like the flexible base 2 described above.

As the barrier layer 3, an inorganic oxide thin film is preferably applied.
Examples of the inorganic oxide include silicon oxide, aluminum oxide, titanium oxide, yttrium oxide, germanium oxide, zinc oxide, magnesium oxide, calcium oxide, boron oxide, strontium oxide, barium oxide, lead oxide, zirconium oxide, sodium oxide, Examples thereof include lithium oxide and potassium oxide, and one or more of these can be used.
Among these, silicon oxide, aluminum oxide, or titanium oxide is preferably used. Moreover, silicon nitride can be mentioned as things other than an inorganic oxide.
The thickness of the barrier layer 3 provided in the area light emitting organic EL display panel of this example is preferably 0.01 to 0.5 μm.

The barrier layer 3 is formed between the flexible substrate 2 and the first electrode 4 described above, for example, on the flexible substrate 2 by a physical vapor deposition method such as a reactive sputtering method or a vacuum vapor deposition method.
As a film forming apparatus for the barrier layer 3, a vapor deposition apparatus capable of performing physical vapor deposition while transporting the above-described film-like flexible substrate 2 by roll-to-roll is used.

(Anode 4, cathode 6)
The anode 4 and the cathode 6 are essential layers provided for applying an electric field to the EL layer 5 described later.
In this example, the electrode provided on the flexible substrate 2 side as viewed from the EL layer 5 is the anode 4, and the electrode provided on the flexible sealing substrate 8 side is the cathode 6.
About transparency, either one or both of an anode and a cathode is comprised so that it may have a light transmittance.
Specifically, like the flexible base material 2 and the barrier layer 3 described above, it is preferable that at least the anode on the viewer side has transparency.
On the other hand, the cathode 6 is not necessarily transparent, but it is preferable that the cathode 6 is also transparent when characters and the like are to be displayed from the back side opposite to the viewer side in FIG.

Examples of the anode 4 include thin film electrode materials such as indium tin oxide (ITO), indium oxide, indium zinc oxide (IZO), gold, and polyaniline.
Among these, indium tin oxide (ITO) and indium zinc oxide (IZO), which are transparent oxides, are preferably used.

As the cathode 6, in addition to the above-mentioned transparent electrode material made of indium tin oxide (ITO), indium oxide, indium zinc oxide (IZO), gold, polyaniline, etc., magnesium alloy (MgAg etc.), aluminum alloy (AlLi, AlCa, AlMg etc.) or metallic calcium.
When the cathode 6 is also required to be transparent, the same transparent electrode as the anode 4 is formed.

  When the anode is used, it is preferably formed of a conductive material having a high work function so that holes can be easily injected (for example, indium tin oxide (ITO)). In order to facilitate, it is preferable to form the conductive material with a small work function (for example, metallic calcium).

  The thickness of each of the anode 4 and the cathode 6 is preferably 0.005 to 0.5 μm, and is usually provided adjacent to the EL layer 5 by a sputtering method, a vacuum deposition method, or the like.

The anode 4 may be formed on the entire surface or may be formed in a pattern so as to correspond to the position where the EL layer 5 is formed.
The cathode 6 may be formed in a solid shape other than the through-hole portion 30 formation region, or may be formed in a pattern shape so as to correspond to the position where the EL layer 5 is formed.
The patterned electrode is formed by etching with a photosensitive resist after being formed on the entire surface.

(EL layer 5)
The EL layer 5 is an essential layer in the light emitting display panel.
Examples of the configuration of the EL layer 5 include various layer configurations as shown in FIGS. 3 (a) to 3 (d).
The EL layer 5 shown in FIG. 3A is an embodiment in which an organic light emitting layer 5a exclusively including an organic light emitting body (also referred to as an organic fluorescent light emitting body) is formed as an EL layer 5 between the electrodes. In the EL layer 5 shown in (b), a hole transport layer 21 made of a hole transport material is formed on the anode side of the organic light emitter layer 22, and an electron transport made of an electron transport material is made on the cathode side of the organic light emitter layer 22. In the EL layer 5 shown in FIG. 3C, an organic light-emitting layer 24 having the properties of a hole transport layer is formed, and the organic light-emitting layer 24 is formed on the cathode side. The EL layer 5 shown in FIG. 3D is an embodiment in which the electron transport layer 23 is formed. The organic light emitter layer 25 having the properties of the electron transport layer is formed, and the anode side of the organic light emitter layer 25 is formed. In this embodiment, the hole transport layer 21 is formed.

Although not shown, the EL layer 5 has a stacked structure of a hole transport material / organic light emitter mixed layer formed by mixing at least a hole transport material and an organic light emitter, and an electron transport layer. It may also be a laminated structure of a mixed layer of an organic light emitter / electron transport material formed by mixing at least an organic light emitter and an electron transport material, and a hole transport layer.
Furthermore, the EL layer 5 may be composed of a mixed layer in which at least three of a hole transport material, an organic light emitter, and an electron transport material are mixed.

Although the azo compound generally used as the organic EL layer is used for the organic light emitter layer 22 containing the organic light emitter, an azo compound to which another organic light emitter is added may be used.
Such other organic light emitters include pyrene, anthracene, naphthacene, phenanthrene, coronene, chrysene, fluorene, perylene, perinone, diphenylbutadiene, coumarin, styryl, pyrazine, aminoquinoline, imine, diphenylethylene, merocyanine, quinacridone or rubrene, Or what is normally used as organic light-emitting bodies, such as these derivatives, can be mentioned.
The organic light emitting layer is formed using an organic light emitting layer forming coating solution containing such a compound.

Examples of hole transport materials include phthalocyanine, naphthalocyanine, porphyrin, oxadiazole, triphenylamine, triazole, imidazole, imidazolone, pyrazoline, tetrahydroimidazole, hydrazone, stilbene or butadiene, or derivatives thereof. Those commonly used can be used.
Also, commercially available as a composition for forming a hole transport layer, for example, poly (3,4) ethylenedioxythiophene / polystyrene sulfonate (abbreviation PEDOT / PSS, manufactured by Bayer, trade name: Baytron P AI4083, marketed as an aqueous solution. .) Etc. can also be used as hole transport materials.
The hole transport layer is formed using a coating liquid for forming a hole transport layer containing such a compound.

  As an electron transport material, anthraquinodimethane, fluorenylidenemethane, tetracyanoethylene, fluorenone, diphenoquinone oxadiazole, anthrone, thiopyran dioxide, diphenoquinone, benzoquinone, malononitrile, niditrobenzene, nitroanthraquinone, anhydrous What is normally used as an electron transport material, such as maleic acid or perylenetetracarboxylic acid, or a derivative thereof, can be used. The electron transport layer is formed using a coating liquid for forming an electron transport layer containing such a compound.

The formation of the EL layer 5 is performed by, for example, separating the organic light-emitting layer forming coating liquid, the hole transporting layer forming coating liquid, and the electron transporting layer forming coating liquid as described above in accordance with the lamination mode illustrated in FIG. It is performed by injecting into a predetermined position divided by.
Examples of the injection means include a dispenser method of dropping using a dispenser, an ink jet method, a spin coating method, and a printing method. In the present invention, the EL layer is preferably formed under a roll-to-roll manufacturing condition by a printing method such as gravure printing, offset / gravure printing, and inkjet printing.
In particular, the method of separately printing by the ink jet printing method is preferably applied because it can be applied without contacting the base material, so that the base material is not damaged, and a plate is not required and the degree of freedom is high.
By forming the EL layer by these printing methods, productivity can be further improved.
Each injected coating liquid is subjected to a heat treatment such as a vacuum heat treatment according to a normal means.
The thickness of the EL layer 5 composed of each of the above-described lamination modes is preferably in the range of 0.1 to 2.5 μm.

Note that the partition wall (not shown) forms a region divided for each emission color on the plane of the light emitting display panel.
A hole transport layer forming coating liquid, an organic light emitting layer forming coating liquid, an electron transport layer forming coating liquid, or the like is injected into the region divided by the partition walls in accordance with the configuration of the EL layer.
As a partition material, various materials conventionally used as a partition material, for example, a photosensitive resin, an active energy ray curable resin, a thermosetting resin, a thermoplastic resin, and the like can be used.
As a partition formation means, it can be formed by means suitable for the partition material employed, and for example, it can be formed by using a thick film printing method or by patterning using a photosensitive resist.

(Sealant 10)
The sealing agent 10 is the above-described flexible sealing material, and the gap between the organic EL element 20 including the EL layer 5 and the flexible sealing substrate 8 is not present. And for the purpose of improving the sealing performance.
As the sealant 10, various commonly used ones can be used, but an epoxy resin-based thermosetting adhesive or an acrylic resin-based UV curable adhesive can be preferably used.

  In addition, since the sealing agent 10 has barrier property depending on the kind, without providing the plastic sealing base material 8 and the barrier layer 7 which will be described later, one side of the EL layer 20 (opposite to the observer side). ) May be composed only of this sealant.

Even if the sealing agent 10 is directly formed on the entire surface of the organic EL element 20, the sealing agent surface is applied on the organic EL element 20 after being formed on the flexible sealing substrate 8. You may form so that it may adhere.
The sealant is preferably formed as thin as possible within a range in which the gap can be filled, and the thickness and the like are appropriately adjusted.
The curing means differs depending on whether it is a thermosetting type or a UV curable type, and can be cured based on the respective curing conditions.

This sealant 10 is preferably provided on the entire surface of the EL element.
In the case of a conventional frame-like coating applied to a glass substrate, if a force such as bending the panel is applied after the sealing substrate is bonded, the vicinity of the center of the sealing substrate may come into contact with the element. However, such a problem can be prevented by providing the sealant 10 on the entire surface.
Therefore, the organic EL display obtained by forming the sealant on the entire surface does not have voids inside, so it prevents unnecessary distortion and tension even when it is rolled or bent. Thus, problems such as abnormal contact inside the EL element can be suppressed.
Moreover, since the sealing agent itself has a barrier property, by providing the sealing agent over the entire surface to increase the sealing degree, it is possible to further suppress moisture permeability and air permeability and improve the protection of the element. be able to.

(Barrier layer 7)
The barrier layer 7 is not an essential layer in the light emitting display panel of the present invention, but is a layer preferably provided on the flexible sealing substrate 8 side as shown in FIGS.
The barrier layer 7 is formed between the flexible sealing substrate 8 and the second electrode 6, more specifically, between the flexible sealing substrate 8 and the sealing agent 10 described above. The same effects as the barrier layer 3 described above are exhibited.
Moreover, although it does not specifically limit about the material to be used, The same thing as the above-mentioned barrier layer 3 can be used preferably.

  The barrier layer 7 is formed on a flexible sealing substrate 8 described later by a physical vapor deposition method such as a reactive sputtering method or a vacuum vapor deposition method. As a film forming apparatus for the barrier layer 7, a vapor deposition apparatus capable of physical vapor deposition while transporting a film-like flexible sealing substrate 8 to be described later by roll-to-roll is used.

(Flexible sealing substrate 8)
The flexible sealing substrate 8 is the above-described flexible sealing material. In the light emitting display panel of the present invention, as shown in FIG. 2, the flexible sealing substrate 8 is provided on the surface opposite to the viewer side. Is.
When the light emitting display panel of the present invention is observed only from one side, the flexible sealing substrate 8 is not required to be transparent, but when observed from both sides, the flexible sealing substrate 8 It is preferable that the material 8 has transparency.
By setting it as the transparent flexible sealing base material 8, an observer can also visually recognize a character etc. also from the back side.

As the flexible sealing substrate 8, a film-shaped resin substrate is used.
A film-like resin base material is excellent in flexibility and can be rolled or bent, and thus is preferably used as a base material for a light-emitting display panel that can be mounted or installed on various objects. Since the forming material and the forming method are the same as those of the flexible base 2 described above, the description thereof is omitted here.
In addition, it is preferable that it is 50-200 micrometers similarly to the above-mentioned flexible base material 2, and the thickness of the flexible sealing base material 8 can provide preferable flexibility to a light emission display panel.

(Insulating layer 9)
The insulating layer 9 is a layer that determines a light emitting region, and is patterned between the anode 4 and the cathode 6. And the light emitting area emits light, and a display pattern composed of characters, figures, symbols, or a combination thereof is formed. The non-light-emitting area other than the light-emitting area constitutes a display pattern made up of characters, figures, symbols, or a combination thereof.
That is, since the insulating layer 9 provided between the two electrodes cuts off the voltage applied between the two electrodes, even if an organic EL element is formed between the two electrodes, the light emission in that region is prevented. Acts as follows.
Therefore, the region where the insulating layer is patterned is a non-light emitting region.
On the other hand, in the light emitting area in which the insulating layer is not formed, since both electrodes are in contact with both sides of the EL layer, the EL element to which voltage is applied from both electrodes emits light and acts to exert an appealing effect.
The light emitting area or non-light emitting area defined by the insulating layer is preferably a display pattern composed of characters, figures, symbols, or a combination thereof.
If an insulating layer is formed so that such a display pattern is displayed, an excellent appeal effect can be given to a specific display pattern made up of characters, figures, symbols, or combinations thereof.

Such an insulating layer 9 may be laminated on the anode side or the cathode 6 side, and is not particularly limited.
Since the resist material used is usually transparent, there is almost no visibility even if it is patterned, and the insulating layer itself does not affect the visibility of the light-emitting display panel.

Below, the formation method of the display pattern by an insulating layer is demonstrated in detail.
As a material for forming the insulating layer 9, a photosensitive resin composition used as a resist material is preferably used.
The photosensitive resin composition may be a positive photosensitive resin composition or a negative photosensitive resin composition. Examples of the positive photosensitive resin composition include those having a photodegradable and soluble quinonediazide photosensitive resin as a main component.
In addition, as the negative photosensitive resin composition, for example, a photodegradable crosslinked azide photosensitive resin, a photolytic insoluble diazo photosensitive resin, a photodimerization cinnamate photosensitive resin, a photopolymerization type Examples thereof include an unsaturated polyester photosensitive resin, a photopolymerizable acrylate resin, or a cationic polymerization resin.
In these photosensitive resin compositions, a photopolymerization initiator, a sensitizing dye, and the like can be blended as necessary.

The insulating layer 9 is formed in a predetermined pattern by applying the above-described photosensitive resin composition to the entire surface of any electrode, performing pattern exposure, and developing.
Specifically, first, the photosensitive resin composition described above is formed on the entire surface of the electrode by spin coating, and the photosensitive resin composition is exposed with a mask pattern.
Exposure, ultra-high pressure mercury lamp, high pressure mercury lamp, carbon arc, a light source such as a xenon arc or metal halide lamp is used, 0.1~10,000mJ / cm ^2, preferably by ultraviolet irradiation 10~1,000mJ / cm ² Done.

When the positive photosensitive resin composition is used, the exposed portion is solubilized, so that the exposed portion is dissolved and removed by development.
And the part which is not exposed remains as an insulating layer of a predetermined pattern.
On the other hand, when the negative photosensitive resin composition is used, the exposed portion is insolubilized, so that the unexposed portion is dissolved and removed by development.
The exposed portion remains as an insulating layer having a predetermined pattern.
Although the thickness of an insulating layer is arbitrarily adjusted according to the insulation resistance intrinsic | native to resin which comprises the insulating layer, Usually, it exists in the range of 0.5-3.0 micrometers.

  The area light emitting organic EL member of this example has been described above. However, as long as the object and effect of the present invention are not impaired, a mode in which functional layers other than the above-described layers are provided may be used. Examples of such a functional layer include a low refractive index layer, a reflective layer, a light absorption layer, and the like used in ordinary organic EL elements or light-emitting display panels.

In the area light emitting organic EL member of the present invention, the thickness of the base material and the layer described above may be adjusted so that the total thickness is 400 μm or less, preferably 200 μm or less, and 50 μm or more. preferable.
The area light emitting organic EL member having a thickness within such a range is flexible and can be rolled or bent, and can be installed in a complicated shape when viewed as an electric decoration panel.
When the thickness of the area light emitting organic EL member exceeds 400 μm, the flexibility may be slightly inferior.
Further, when the area light emitting organic EL member has a thickness of less than 50 μm, it is easily affected by a decrease in barrier properties and heat and stress between processes.

In the area light emission type organic EL member of the present invention, the laminate structure composed of at least a flexible substrate and an anode on one side of the EL layer 5, and at least a cathode and a flexible sealing material on the other side. It is preferable that the laminated structure to have the same or similar expansion coefficient.
By doing so, even if an external factor such as heating is added during the manufacturing process of the light emitting display panel, adverse effects such as distortion of the light emitting display panel are less likely to appear.
Here, by making the stacked structure on one side of the EL layer 5 and the stacked structure on the other side the same or substantially the same in terms of the number of layers, material, thickness, etc. Even if an additional factor is added, since the distortion generated on both sides is balanced, adverse effects such as distortion of the obtained light-emitting display panel can be reduced.

In addition, in the manufacturing process of the area light emitting organic EL member of this example, by forming each layer by a wet method, it becomes possible to continuously manufacture the light emitting display member that can be supplied to the market with a price setting that is easily accepted by the market. Can be provided.
For example, the flexible base material 2 and the flexible sealing base material 8 on which the barrier layers 3 and 7 are formed by the continuous vapor deposition method are prepared in advance, and the flexible base material 2 has the first layer on the barrier layer 3 side. One electrode 4 is formed by a sputtering method, an EL layer 5 is formed on the first electrode 4 by a printing method, a second electrode 6 is formed on the EL layer 5 by a vacuum deposition method, and the second electrode 6 is formed. A sealing agent 10 is applied and formed thereon, and a flexible sealing substrate 8 having a barrier layer 7 is provided on the sealing agent 10.
By adopting such a wet method in many processes, a light emitting display panel can be manufactured by a roll-to-roll continuous manufacturing method with excellent productivity.

As described above, the area light emitting organic EL member of this example for a display panel has been described, but the area light emitting organic EL member of the present invention is not limited to the display panel.
The use as a mere light source is also mentioned.
Examples of the use of the area light emitting organic EL member of the present example include an article 60 used by attaching the area light emitting organic EL member 63 of the present example to the installation portion 61 as shown in FIG. .
When the area light emitting organic EL member 63 is attached so as to cover the upper side of the container-like attachment part 62, for example, when the lower side of the container-like attachment part 62 is accommodated in the installation part 61 at a predetermined position In addition, the area light emitting organic EL member 63 emits light, and moves as shown in FIG. 4A when the attachment portion 62 is moved upward and does not fit in the installation portion 61 at a predetermined position. As a result, the voltage source for light emission is switched off so that the light emission display is not performed.
As what is built in the container-like attachment part 62, soap and cosmetics are mentioned, for example, those smells can be sniffed from a through-hole part, and it is used for sales promotion etc.
Moreover, as shown in FIG.4 (b), the article 60 which attaches and uses the area light emission type organic EL member 63 of this example so that the cross-sectional direction of the cylinder of the cylinder part 71 may be covered is also mentioned.
In this case, when the inside of the cylindrical portion is viewed from the through-hole portion 72, the area light emitting organic EL member 73 of this example is used as a light source.
In addition to these, a mode in which the area light emitting organic EL member of this example is attached to the card and the frame is made to emit light is also included.

FIG. 1A is a schematic plan view showing a state in which a characteristic part of one example of an embodiment of the area light emitting organic EL member of the present invention is seen through from the cathode side, and FIG. FIG. 1C is a cross-sectional view taken along line A1-A2 of FIG. 1A, and FIG. 1C is a view showing a mask used for film formation of the cathode shown in FIG. FIG. 2A is a schematic cross-sectional view showing an example of the laminated state of the area light emitting organic EL members of the present invention, and FIG. 2B is an enlarged cross-sectional view of the light emitting portion showing the patterning of the insulating layer in an easy-to-understand manner. It is. FIG. 3A to FIG. 3D are cross-sectional views of light emitting units having EL layers having various layer structures. 4 (a) and 4 (b) are diagrams showing an example of an article provided with the area light emitting organic EL member of the present invention.

Explanation of symbols

1 Area-emitting organic EL display panel 2 Flexible substrate (also simply referred to as substrate)
3 Barrier layer 4 Anode 5 EL layer 5a Organic light emitter layer 6 Cathode (also called metal part)
7 Barrier layer 8 Flexible sealing substrate 9 Insulating layer (also referred to as insulating layer portion, here photoresist)
9A Opening 10 Sealant 20 Light Emitting Part 21 Hole Transport Layer 22 Organic Light Emitter Layer 23 Electron Transport Layer 24 Organic Light Emitter Layer / Hole Transport Layer 25 Electron Transport Layer / Organic Light Emitter Layer 30 Through Hole 40 Mask 41 Shielding Part 42 Opening 60 (Area light emitting organic EL member attached) Article 61 Installation part 62 Attached part 63 Area light emitting organic EL member (also referred to as area light emitting organic EL display panel)
63a Light-emitting part 63b Through-hole part 70 (Attached to area light-emitting organic EL member) Article 71 Tube part 72 Through-hole part 73 Light-emitting part

Claims (9)

  An anode, an EL layer, and a cathode (cathode electrode) are laminated in this order on a substrate, and an opening is formed between the anode and the cathode in a region to be used with a thickness capable of preventing light emission during light emission. An area-emitting organic material in which an insulating layer having one or more is provided, a voltage is applied between the anode and the cathode, and each light-emitting area is caused to emit light collectively by using each aperture area of the insulating layer as a light-emitting area. An area-emitting organic EL member, which is an EL member, wherein a through-hole portion that is not in contact with the metal portion of the cathode is provided in the region to be used.   2. The area light emitting organic EL member according to claim 1, wherein the base material is a flexible plastic base material.   3. The area light emitting organic EL member according to claim 1, wherein the through hole is formed by punching. 4.   The area light emitting organic EL member according to any one of claims 1 to 3, wherein the area light emitting organic EL member is a member for a display panel.   5. The area light emitting organic EL member according to claim 4, wherein a display pattern composed of characters, figures, or a combination thereof is formed by light emission of each light emitting area. .   4. The area light emitting organic EL member according to claim 1, wherein the area light emitting organic EL member is a light source member.   An area light emitting organic EL member-attached article, comprising the area light emitting organic EL member according to any one of claims 1 to 6.   A method for producing an area light emitting organic EL member according to any one of claims 1 to 6, wherein an anode, an EL layer, and a cathode (cathode electrode) are formed on a substrate. Are stacked in this order, and then a through hole is formed by punching. The patterning of the metal part of the cathode (cathode electrode) is performed using a masking method in the through part forming region where the through hole is formed. A method for producing an area light emitting organic EL member, wherein the film is formed so as not to contact.   A method for producing an area light emitting organic EL member according to any one of claims 1 to 6, wherein a base material in which a through-hole is formed in advance is used. An anode, an EL layer, and a cathode (cathode electrode) are laminated in this order on a material, and the metal part of the cathode (cathode electrode) is patterned using a masking method to form the through hole. A method for manufacturing an area light-emitting organic EL member, wherein the film is formed so as not to contact a formation region.

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