JP2008269964A - Method for manufacturing electroluminescent element - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a method for manufacturing an EL (electroluminescent) element capable of preventing a mixture of dust and pasting right after a light-emitting layer is applied and securing an auxiliary electrode space after pasting and maintaining its quality by cutting a substrate and an organic layer without damaging a mating electrode after pasting. <P>SOLUTION: In the manufacturing method for an electroluminescent element in which the electroluminescent element in a structure laminated by at least a first substrate, a first electrode, an electroluminescent layer, a second electrode, and a second substrate in that order is manufactured as two members separated in an intermediate portion in this structure and the electroluminescent element is formed by pasting both members, a half-cut is applied on at least one substrate at an electrode side, and upon making use of a groove caused by the half-cut, at least one electrode is exposed by removing an unnecessary section after pasting both members. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a method for manufacturing an electroluminescence element by a bonding method, and more particularly to a method for bonding members and an easy method for taking out electrodes.

  Conventionally, in a method of manufacturing an electroluminescence element by bonding two members, there is no technique for bonding a light emitting surface using rolls of plastic materials, which has been a development target in the industry. Until now, since the cut base materials are pasted together, it was easy to secure the auxiliary electrode space at the time of pasting.

  However, it is difficult to secure an electrode space in advance when the light emitting surfaces are bonded using rolls of plastic material.

  In order to secure electrode space, if cutting or other treatment is performed before bonding, the chance of mixing dust, dust, etc. increases, so bonding is performed immediately after applying the light-emitting layer for the purpose of preventing dust contamination. It is necessary.

  In addition, it is necessary to secure an auxiliary electrode space after pasting, and in securing the auxiliary electrode space after pasting, it is easy to maintain quality without damaging the electroluminescence layer and electrode layer, and the other electrode layer, etc. It was a challenge to do this (with good productivity).

  So far, no method has been found that can minimize dust contamination by the bonding method and can easily secure the auxiliary electrode space after bonding.

  Therefore, the purpose of the present invention is to prevent contamination by mixing the light emitting layer immediately after the light emitting layer application, to ensure an auxiliary electrode space after the bonding, and without damaging the partner electrode after the bonding. An object of the present invention is to provide a method for manufacturing an electroluminescence element capable of maintaining the quality by cutting the substrate.

  The above object of the present invention is achieved by the following means.

  1. Two electroluminescent elements having a structure in which at least a first base material, a first electrode, an electroluminescent layer, a second electrode, and a second base material are stacked in this order are separated by an intermediate portion of the structure. In the manufacturing method of the electroluminescent element which manufactures as a member and bonds both members and forms an electroluminescent element, after the half cut is given to the electrode side of at least one base material, and after bonding both members A method for producing an electroluminescent element, wherein an unnecessary portion is removed using a groove by half-cut to expose at least one of the electrodes.

  2. 2. The method for producing an electroluminescent element according to 1, wherein the half-cut method is laser light, a hot blade or a half-cut blade.

  3. 3. The method for producing an electroluminescent element according to 1 or 2, wherein both the first base material and the second base material are half-cut.

  4). 4. The method for producing an electroluminescent element according to any one of 1 to 3, wherein at least one of the first substrate and the second substrate is made of a plastic film.

  5. The method for producing an electroluminescent element according to any one of claims 1 to 4, wherein at least one of the first base material or the second base material comprises a roll-shaped long sheet.

  6). The method for producing an electroluminescent element according to any one of 1 to 5, wherein half cut of the first base material or the second base material is 30% to 90% with respect to the thickness direction.

  7. After forming a cut in each base material by inserting a half-cut blade in at least one of the first base material or the second base material, an electrode is formed on each of the first base material and the second base material, Forming an electroluminescence layer on at least one electrode of the first base material and the second base material, and then bonding the first base material and the second base material with the electrodes facing each other. A method of manufacturing an electroluminescent element characterized by the above.

8). After forming an electrode on each of the first substrate and the second substrate, a half-cut blade is inserted into at least one substrate to form a cut, and the first substrate and the second substrate each formed with an electrode Forming an electroluminescent layer on at least one electrode of the substrate;
A method for producing an electroluminescent element, wherein the first substrate and the second substrate are bonded together with electrodes facing each other.

  9. 9. The method for producing an electroluminescent element according to any one of 1 to 8, wherein the first base material and the second base material are cut in a state where the grooves by the half cut are orthogonal to each other.

  10. The method for producing an electroluminescent element according to any one of 2 to 9, wherein the edge angle of the half-cut blade is 20 ° to 70 °.

  11. The method for producing an electroluminescent element according to any one of 2 to 10, wherein the half-cut blade is a roll-shaped rotary blade having a blade edge on the surface.

  12 The method for producing an electroluminescent element according to any one of 1 to 11, wherein the electroluminescent element is an organic electroluminescent element.

  According to the present invention, in the production of an organic electroluminescence (EL) element by a bonding method using a roll-shaped long sheet, after bonding, an unnecessary portion is easily removed to remove an auxiliary electrode space (auxiliary electrode bonding portion). ) Can be formed easily and without loss of quality, and roll-to-roll of organic EL elements can be produced.

  Hereinafter, the best mode for carrying out the present invention will be described in detail.

  The present invention provides an electroluminescent element having a structure in which at least a first base material, a first electrode, an electroluminescent layer, a second electrode, and a second base material are stacked in this order, and an intermediate layer of the stacked structure. Is manufactured as two members separated by a part, and is a method for manufacturing an electroluminescent element in which both members are bonded to form an electroluminescent element, and at least one of the base materials is subjected to a half cut In addition, after half-cutting, both members are bonded together, and unnecessary portions are removed using a groove formed by half-cutting on the substrate to expose at least one of the electrodes.

  In the present invention, the electroluminescence layer refers to a layer constituting an electroluminescence element that is sandwiched between the first electrode and the second electrode. In the organic electroluminescence element, for example, it is laminated and sandwiched between both electrodes. It refers to a layer such as a hole injection layer, a hole transport layer, a light emitting layer, or an electron transport layer.

  The present invention will be described using an organic electroluminescence element.

  For example, a first member that is an anode on a first substrate, a first member in which an electroluminescence layer, for example, a hole injection layer, a hole transport layer, a light emitting layer, or the like is laminated, and a second substrate The second electrode serving as the cathode, the electron transport layer, and the second member laminated with the light emitting layer are bonded to each other on the surface of the organic layer, and the first substrate / first electrode / electroluminescence layer / second A sealed electroluminescent device having a structure in which the electrode / second substrate is laminated in this order is manufactured.

  The electroluminescent layers stacked in a predetermined order are arbitrary up to which intermediate layer is formed on the first substrate and up to which layer is formed on the second substrate. As described above, the light-emitting layers may not necessarily be bonded to each other (the same layers) as described above. For example, an electroluminescent layer such as a hole injection layer, a hole transport layer, and a light emitting layer is laminated on a first base material, and a second electrode and an electron transport layer are laminated on the second base material. May be combined.

  In the present invention, by forming a groove by half-cut from the bonding surface side before bonding, unnecessary part removal (formation of the auxiliary electrode bonding part) is easily performed after bonding without damaging the quality. It is a feature.

(Preferred embodiment)
As a preferred embodiment, first, for example, an organic electroluminescence (EL) element having a configuration comprising a first substrate / anode / hole transport layer / light emitting layer / electron transport layer / cathode / second substrate. The manufacturing method was shown.

  In FIG. 1, each process of manufacture by the bonding method of an organic EL element is shown with a block diagram.

  In FIG. 1, first, a first electrode (anode) is formed on a first substrate (substrate 1). After forming the first electrode, a hole transport layer is formed, and a light emitting layer is further formed to produce a first member (anode member).

  A second electrode (cathode) is formed on the second base material (base material 2). Further, after the second electrode is formed, an electron transport layer is formed thereon to produce a cathode member. Each electrode can be formed under optimum conditions using vacuum conditions such as vacuum deposition or sputtering. On the other hand, the electroluminescent layer is preferably formed from the viewpoint of productivity, and a normal die coater, an ink jet method, a printing method, or the like is suitable.

  In this way, the first member (anode member) in which the first electrode, the hole transport layer, and the light emitting layer are formed on the first base material, and the second electrode and the electron transport layer are formed on the second base material. About the 2nd member (cathode member) which was made, the base material is half-cut from the electrode layer side and cut.

  Half-cutting is sufficient for only one substrate when the auxiliary electrode space is to be exposed only on one substrate.

  The base material 1 and the base material 2 that have been half-cut are stacked so that the electrodes face each other in a form sandwiching the organic EL layer, and are adhered and bonded together.

  What is necessary is just to make it stick together under pressure, the pressure should just be the range of 0.1 Mpa-10 Mpa, and as a specific means, types, such as a pressure roll and a press apparatus, are not ask | required. Moreover, it is preferable to heat to the temperature near the glass transition temperature of the organic layer used as a bonding surface and below a glass transition temperature.

  After pasting, the cut portion was cut and the half-cut portion was used to cut it here to remove unnecessary portions, to expose the electrode layer, and as an auxiliary electrode space, an auxiliary electrode was produced here and then sealed. When connected to the power supply via the auxiliary electrode, electroluminescence is observed.

  In FIG. 2, a more specific embodiment is shown about the manufacturing method of the electroluminescent element of this invention which half-cuts and bonds a base material.

  In FIG. 2, both the first base material and the second base material include a sheet supply process, a coating / drying process, and a half-cut process, and the first member and the second member formed thereby are further bonded. It includes a process and an individual cutting process.

  As a 1st base material, the base material sheet with an electrode which formed ITO beforehand (for example, a polyethylene terephthalate film) is used, and in a sheet | seat supply process, this is unwound from the supply roll 11, and it sends to an application | coating and drying process. The coating is performed using, for example, an extrusion type coater head 21, and an electroluminescence layer (EL layer) coating solution is supplied to the coating layer 21 and coated on the substrate. Although only one coater head is shown here, a hole transport layer coating solution or a light emitting layer coating solution is supplied, and a hole transport layer and a light emitting layer are formed by coating. In the figure, the drying step is omitted.

  In addition, a polyethylene terephthalate film or the like in which a vapor-deposited aluminum layer or the like is formed in advance as one second base material is unwound from the supply roll 12 and sent to the coating / drying process in the same manner. For example, an electron transport layer forming coating solution is supplied, applied, and dried to form an electron transport layer on the substrate. A second member (cathode member) is thus produced. Again, only the coater head 22 is shown and the drying process is omitted.

  The first layer is formed by separating the constituent layers of the organic EL element at the intermediate portion so as to constitute the organic EL element after being bonded onto the electrodes of the first base material and the second base material. After producing the second member, in the half cut step, the first member (first base material) and the second member (second base material) are pasted using the roll-shaped rotary blades 31 and 32, respectively. Half cut from the mating surface.

  The roll-shaped rotary blade 31 for half-cutting the first substrate has a blade (pinnacle) on the surface along the rotation axis direction of the roll. On the other hand, the roll-shaped rotary blade 32 that half-cuts the second substrate is formed with a blade along the rotation direction (conveyance direction) of the roll surface.

  As a result, the first substrate is half-cut perpendicular to the sheet conveyance direction, and the second substrate is half-cut parallel to the conveyance direction.

  The roll-shaped rotary blade is formed by sticking a sheet-shaped pinnacle die having a blade edge on the surface of the roll. The sheet-like pinnacle die (shown in FIG. 3) is a sheet-like die having a sharp pointed blade on the surface of the base sheet. The sheet-like die is attached to a rotating roll as a roll-shaped rotary blade having a blade edge on the surface. Use. The sheet-shaped pinnacle die is formed by etching a base material having a thickness of 1 to several mm to form a sharp blade as shown in the figure. The base thickness (d) of the pinnacle die is 0.1 to 0.2 mm, the blade edge angle (θ) is 20 ° to 70 °, the blade height (l) is 0.3 to 0.6 mm, and the blade thickness is 0.1 mm. It is about 38 mm to 1.2 mm. A base sheet on which a sharp blade is formed on such a surface is fixed to a 500 to several thousand gauss magnet roll and used as a roll-shaped rotary blade.

  FIG. 3 shows the roll-shaped rotary blade 4 in which the blade direction is set parallel to the roll axial direction. However, in the roll-shaped rotary blade 5, the blade is perpendicular to the roll axial direction along the transport direction. Set and use.

  The half cut of the first base material or the second base material is preferably set in a range of 30% to 90% with respect to the thickness direction, but the half cut is performed by pressing that can surely cut the base material. The depth of the cut can be adjusted by adjusting the clearance between, for example, a metal roll (copper) serving as a backup roll for the roll-shaped rotary blade, or by using a laying plate having a predetermined thickness. it can.

  Thus, the 1st board | substrate (1st member) and the 2nd board | substrate (2nd member) which were each half-cut in the direction orthogonal to each other are closely_contact | adhered and bonded by the pressure roll 4 in the bonding process. The As described above, a pressure roll 4 having a pressure in the range of 0.1 MPa to 10 MPa, for example, a laminator of about 0.5 Pa can be used.

  In the individual cutting step, the elements formed by being closely adhered and bonded are individually cut into unit elements of a predetermined size including a half cut groove by punching or the like (FIG. 2).

  As shown in FIG. 4, the element individually cut to a predetermined size has a half-cut base, and the auxiliary electrode mounting part is exposed by bending off the cut portion by half-cut and peeling off unnecessary portions. I can do it.

  FIG. 4 shows a state in which an unnecessary portion of the first member is peeled off by the half cut groove of the first member to expose the electrode portion (auxiliary electrode mounting portion) of the second member. FIG. 4 (1) shows a place where the first member and the second member having a half cut interval are bonded together, and FIG. 4 (2) shows a place where the unnecessary part of the first member is folded and peeled off at the half cut portion. FIG. 4 (3) shows that the auxiliary electrode attachment portion of the electrode layer is exposed after the first member is peeled off and then the organic layer on the second member is scraped or removed by washing or the like. Next, an auxiliary electrode, for example, a metal foil (copper foil, aluminum foil, etc.) is attached to form an auxiliary electrode (FIG. 4 (4)).

  By treating the second member in the same manner as the first member in a direction of 90 degrees (orthogonal direction), both the first member and the second member can expose the auxiliary electrode attachment portion of the electrode layer.

  FIG. 4 (6) shows that the first base material (first member) and the second base material (second member) are both half-cut grooves, and unnecessary parts are peeled off. The place which exposed is shown with the perspective view.

  The auxiliary electrode can be formed by attaching a metal sheet, a metal tape, or the like in addition to the metal foil.

  After the auxiliary electrode is manufactured, it can be sealed. After the auxiliary electrode is formed, the first substrate and the second substrate may be sealed with an adhesive leaving the portion where the auxiliary electrode portion can be connected to the power supply circuit (FIG. 4 (5)).

  After sealing, electroluminescence is observed if connected to a power source via the auxiliary electrode.

  The half cut can be performed using a roll-shaped rotary blade, but can be cut using a laser beam such as a carbon dioxide gas laser or a YAG laser. Moreover, you may cut with heat with a hot blade.

  Moreover, although the said half cut puts 30%-90% notch with respect to the thickness direction of a base material, the form in which the perfect penetration part hole continued like a perforation may be sufficient. A similar cut can be made along the perforation. A perforation may be formed so that 30% to 90% of the cut line is constituted by through holes.

  Moreover, in the said embodiment, the half cut of the 1st base material and the 2nd base material is performed after forming the organic EL layer in the said embodiment, and making it the 1st member and the 2nd member, You may perform in the other location of the manufacturing process of the electroluminescent element by the bonding method, for example, after forming an electrode on a base material.

  In addition, after half-cutting the base material, an auxiliary film may be laminated to form an electrode and an organic EL layer in order to maintain strength. FIG. 5 is a block diagram showing an example of the manufacturing process of the present invention other than the above embodiment.

  In the step shown in FIG. 5 (1), electrodes (anode and cathode) are formed on the base material 1 (first base material) and the base material 2 (second base material), respectively, and then half cut is performed. The luminescence layer is formed separately on two base materials, and the first member and the second member are produced respectively. Then, the two members are bonded together, and then unnecessary portions are removed and sealed in the half-cut groove. An electrode is formed.

  In the step shown in FIG. 5 (2), after the base material 1 and the base material 2 are half-cut, an auxiliary film is laminated on the surface opposite to the half-cut surface. By laminating the auxiliary film, the base material can be reinforced to prevent deformation or breakage of the half cut portion, and deformation of the base material can be suppressed in roll conveyance, winding and the like in the subsequent steps. After laminating the auxiliary film, an electrode is formed on each of the base material 1 and the base material 2, an organic electroluminescence layer is formed separately on each base material, and the produced first member and second member are bonded. After bonding, the auxiliary film is removed, unnecessary portions are removed from the respective base materials at the half-cut portions, and sealing is performed to form auxiliary electrodes.

  Here, as the auxiliary film, for example, an adhesive layer is provided on a resin film of about several μm to 10 μm, which will be described later, used as a base material. In the step shown in FIG. Lamination is performed using a material film and a laminator. However, for example, the film may be formed after the first electrode is formed, or may not necessarily be after the half cut. In any case, since it has an auxiliary film laminated on the back surface of the base material, it is difficult for the half-cut portion to be folded or deformed in the post-process, preventing the base material from being folded or deformed during electrode formation or organic EL layer formation, The uniformity of the formed film can be maintained.

  In the present invention, an electroluminescent element having a structure in which at least a first base material, a first electrode, an electroluminescent layer, a second electrode, and a second base material are stacked in this order is provided as an intermediate portion of the structure. Are manufactured as two members separated by 1 and both members are bonded to form an electroluminescence element, but an electroluminescence layer is formed only on one of the first substrate and the second substrate. You may paste. In the case of an organic EL element, all of the organic layers are arranged on either the first base material or the second base material, and the other has only the electrode layer.

  Various organic layer configurations of the organic EL element have been proposed in addition to the above. For example, on the support, the simplest structure such as anode / hole injection / transport layer / light emitting layer / electron injection / transport layer / cathode, etc. There are also forms composed of a layer structure such as an anode / light emitting layer / cathode, and in any form, a first base material and a second base material separated between any of the layers are prepared and used. Paste.

  The film thickness of each organic layer and each thin film in these organic EL elements ranges from 1 nm to several μm, but these organic layers are formed separately on the first substrate and the second substrate, The organic EL element of this invention is formed by bonding.

  For each of the above functional layers, known literature can be referred to.

  Therefore, in the first base material and the second base material, the organic layer structure on each base material may be separated at any part of the organic EL layer structure.

  The organic EL element has a configuration in which one or a plurality of organic layers are laminated between electrodes. For example, the organic EL device has the above-described configuration. In addition to the above, an electron blocking layer, a hole blocking layer, a buffer layer, etc. Necessary layers are appropriately laminated in a predetermined layer order, and carriers such as holes and electrons injected from both electrodes are smoothly moved.

  In each of these organic layers constituting the organic EL device, the organic light emitting material contained in the light emitting layer includes aromatic heterocyclic compounds such as carbazole, carboline, diazacarbazole, triarylamine derivatives, stilbene derivatives, polyarylenes. , Aromatic condensed polycyclic compounds, aromatic heterocondensed ring compounds, metal complex compounds, etc., and single oligo compounds or composite oligo compounds thereof, but the present invention is not limited thereto, and widely known Materials can be used.

  The layer (film forming material) may preferably contain about 0.1 to 20% by mass of a dopant in the light emitting material. Examples of the dopant include known fluorescent dyes such as perylene derivatives and pyrene derivatives, and in the case of phosphorescent light emitting layers, for example, tris (2-phenylpyridine) iridium, bis (2-phenylpyridine) (acetylacetonate). A complex compound such as an orthometalated iridium complex represented by iridium, bis (2,4-difluorophenylpyridine) (picolinato) iridium, and the like is similarly contained in an amount of about 0.1 to 20% by mass. The thickness of the light emitting layer ranges from 1 nm to several hundred nm.

  Examples of materials used in the hole injection / transport layer include phthalocyanine derivatives, heterocyclic azoles, aromatic tertiary amines, polyvinyl carbazole, polyethylene dioxythiophene / polystyrene sulfonic acid (PEDOT: PSS), and the like. Polymer materials such as conductive polymers are also used for the light emitting layer, for example, carbazole-based light emitting materials such as 4,4′-dicarbazolylbiphenyl, 1,3-dicarbazolylbenzene, (di ) Low molecular light emitting materials represented by pyrene-based light emitting materials such as azacarbazoles, 1,3,5-tripyrenylbenzene, polymer light emitting materials represented by polyphenylene vinylenes, polyfluorenes, polyvinyl carbazoles, etc. Etc.

  Examples of the electron injection / transport layer material include metal complex compounds such as 8-hydroxyquinolinate lithium and bis (8-hydroxyquinolinate) zinc, and nitrogen-containing five-membered ring derivatives listed below. That is, oxazole, thiazole, oxadiazole, thiadiazole or triazole derivatives are preferred. Specifically, 2,5-bis (1-phenyl) -1,3,4-oxazole, 2,5-bis (1-phenyl) -1,3,4-thiazole, 2,5-bis (1 -Phenyl) -1,3,4-oxadiazole, 2- (4′-tert-butylphenyl) -5- (4 ″ -biphenyl) 1,3,4-oxadiazole, 2,5-bis ( 1-naphthyl) -1,3,4-oxadiazole, 1,4-bis [2- (5-phenyloxadiazolyl)] benzene, 1,4-bis [2- (5-phenyloxadiazolyl) -4-tert-butylbenzene], 2- (4'-tert-butylphenyl) -5- (4 "-biphenyl) -1,3,4-thiadiazole, 2,5-bis (1-naphthyl) -1 , 3,4-thiadiazole, 1,4-bis [2- (5-phenyl) Asiazolyl)] benzene, 2- (4′-tert-butylphenyl) -5- (4 ″ -biphenyl) -1,3,4-triazole, 2,5-bis (1-naphthyl) -1,3,4 -Triazole, 1,4-bis [2- (5-phenyltriazolyl)] benzene and the like.

  The film thickness of the organic EL element and each organic layer is required to be about 0.05 to 0.3 μm, and preferably about 0.1 to 0.2 μm.

  Moreover, as a formation method of an organic layer (organic electroluminescence layer), application | coating, printing, etc. are preferable as mentioned above.

  As the coating, spin coating, transfer coating, extrusion coating and the like can be used. In consideration of material use efficiency, a method capable of applying a pattern such as transfer coating and extrusion coating is preferable, and transfer coating is particularly preferable.

  Moreover, screen printing, offset printing, inkjet printing, etc. can be used for printing. As the display element, a thin film, a small element size, and high-precision high-definition printing such as offset printing and inkjet printing are preferable in consideration of overlapping RGB patterns.

  Each organic material has its own solubility characteristics (solubility parameters, ionization potential, polarity), and there are limitations on the solvents that can be dissolved. In this case, since the solubility is different from each other, the concentration cannot be generally determined. However, the type of the solvent used in the present invention is suitable for the above conditions depending on the organic EL material to be formed. May be selected from known solvents, for example, halogenated hydrocarbon solvents such as dichloromethane, dichloroethane, chloroform, carbon tetrachloride, tetrachloroethane, trichloroethane, chlorobenzene, dichlorobenzene, chlorotoluene, dibutyl ether, tetrahydrofuran, Ether solvents such as dioxane and anisole, alcohol solvents such as methanol, ethanol, isopropanol, butanol, cyclohexanol, 2-methoxyethanol, ethylene glycol, glycerin, benzene, toluene, xylene, ethylben Aromatic hydrocarbon solvents such as hexane, paraffin solvents such as hexane, octane, decane and tetralin, ester solvents such as ethyl acetate, butyl acetate and amyl acetate, N, N-dimethylformamide, N, N-dimethylacetamide Amide solvents such as N-methylpyrrolidone, ketone solvents such as acetone, methyl ethyl ketone, cyclohexanone and isophorone, amine solvents such as pyridine, quinoline and aniline, nitrile solvents such as acetonitrile and valeronitrile, thiophene, carbon disulfide And sulfur-based solvents such as

  In addition, the solvent which can be used is not restricted to these, You may mix and use 2 or more types of these as a solvent.

  Among these, preferable examples of the organic EL material are different depending on each functional layer material. However, as a good solvent, for example, an aromatic solvent, a halogen solvent, an ether solvent, and the like are preferable. Aromatic solvents and ether solvents. Examples of the poor solvent include alcohol solvents, ketone solvents, paraffin solvents, and the like. Among them, alcohol solvents and paraffin solvents are used.

  In the present invention, it is preferable to previously form the first electrode on the first substrate and the second electrode on the second substrate, and an optimum process such as vapor deposition can be used for electrode formation. The electrodes are preferably formed in a roll-to-roll form using a resin film.

  Of the two electrodes, those having a work function larger than 4 eV are suitable as the conductive material used for the anode for injecting holes, such as silver, gold, platinum, palladium and their alloys, oxidation Metal oxides such as tin, indium oxide and ITO, and organic conductive resins such as polythiophene and polypyrrole are used. It is preferable that it is translucent, and ITO is preferable as a transparent electrode. As a method for forming the ITO transparent electrode, mask vapor deposition or photolithography patterning can be used, but is not limited thereto.

  As the conductive material used as the cathode, those having a work function smaller than 4 eV are suitable, such as magnesium and aluminum. Typical examples of the alloy include magnesium / silver and lithium / aluminum. The formation method can be mask vapor deposition, photolithography patterning, plating, printing, or the like, but is not limited thereto.

  In the present invention, glass or a transparent resin film is used as the substrate. A transparent resin film is used as a base material for performing at least one half cut. Transparent resin films include polyethylene, ethylene-vinyl acetate copolymer, ethylene-vinyl alcohol copolymer, polypropylene, polystyrene, polymethyl methacrylate, polyvinyl chloride, polyvinyl alcohol, polyvinyl butyral, nylon, polyether ether ketone. , Polysulfone, polyethersulfone, tetrafluoroethylene-perfluoroalkyl vinyl ether copolymer, polyvinyl fluoride, tetrafluoroethylene-ethylene copolymer, tetrafluoroethylene-hexafluoropropylene copolymer, polychlorotrifluoroethylene, Polyesters such as polyvinylidene fluoride, polyethylene terephthalate, polyethylene naphthalate, polycarbonate, polyurethane, polyimide Polyetherimide, polyimide, polypropylene, and a resin film having a thickness of 50Myuemu～1000myuemu.

  In the case of a resin film, when a film in which a gas barrier layer is formed on the above resin film such as a silica vapor deposition film or an alumina vapor deposition film is used, an element having a further improved sealing property against moisture, oxygen and the like can be produced. Moreover, as a base material on the side from which light emission is not extracted, a metal laminate film or the like can also be used as a gas barrier film.

  As described above, in the method of manufacturing an electroluminescent element, an electroluminescent layer is manufactured as two members separated at an intermediate portion of the structure on the first base material and the second base material, and bonded together. By using a groove formed by half-cutting in advance before bonding, by removing unnecessary parts of the base material after bonding, there is little dust mixing to perform bonding immediately after layer formation, and auxiliary after bonding An electrode space can be easily secured, and a manufacturing method that does not damage other electrodes after bonding can be obtained.

It is a block diagram of each process of manufacture by the bonding method of an organic EL element. It is a figure which shows the more concrete embodiment of the element manufacturing method of this invention which half-cuts and bonds a base material. It is a schematic diagram of a sheet-like pinnacle die and a roll-shaped rotary blade. A mode that an unnecessary part is peeled off by a half cut groove | channel and an electrode part is exposed is shown. It is a block diagram which shows the other example of a manufacturing process of this invention.

Explanation of symbols

11, 12 Supply roll 21, 22 Coater head 31, 32 Roll-shaped rotary blade 4 Pressure roll

Claims (12)

Two electroluminescent elements having a structure in which at least a first base material, a first electrode, an electroluminescent layer, a second electrode, and a second base material are stacked in this order are separated by an intermediate portion of the structure. In the manufacturing method of the electroluminescent element which manufactures as a member and bonds both members and forms an electroluminescent element, after the half cut is given to the electrode side of at least one substrate, and after bonding both members A method for producing an electroluminescent element, wherein an unnecessary portion is removed using a groove by half-cut to expose at least one of the electrodes. 2. The method of manufacturing an electroluminescent element according to claim 1, wherein the half-cut method is laser light, a hot blade or a half-cut blade. 3. The method of manufacturing an electroluminescent element according to claim 1, wherein both the first base material and the second base material are half-cut. The method for manufacturing an electroluminescent element according to any one of claims 1 to 3, wherein at least one of the first substrate and the second substrate is made of a plastic film. 5. The method of manufacturing an electroluminescent element according to claim 1, wherein at least one of the first base material and the second base material is a roll-shaped long sheet. 6. The method of manufacturing an electroluminescent element according to claim 1, wherein a half cut of the first base material or the second base material is 30% to 90% with respect to the thickness direction. After forming a cut in each base material by inserting a half-cut blade in at least one of the first base material or the second base material, an electrode is formed on each of the first base material and the second base material, Forming an electroluminescent layer on at least one electrode of the first substrate and the second substrate;
A method for producing an electroluminescent element, wherein the first substrate and the second substrate are bonded together with electrodes facing each other. After forming an electrode on each of the first substrate and the second substrate, a half-cut blade is inserted into at least one substrate to form a cut, and the first substrate and the second substrate each formed with an electrode Forming an electroluminescent layer on at least one electrode of the substrate;
A method for producing an electroluminescent element, wherein the first substrate and the second substrate are bonded together with electrodes facing each other. The groove | channel by the half cut of a 1st base material and a 2nd base material is bonded in the state orthogonal, The manufacturing method of the electroluminescent element of any one of Claims 1-8 characterized by the above-mentioned. The method of manufacturing an electroluminescent element according to any one of claims 2 to 9, wherein the edge angle of the half-cut blade is 20 ° to 70 °. The method for producing an electroluminescent element according to any one of claims 2 to 10, wherein the half-cut blade is a roll-shaped rotary blade having a blade edge on the surface. The method of manufacturing an electroluminescent element according to claim 1, wherein the electroluminescent element is an organic electroluminescent element.

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