JP2009211828A - Illuminating device and method of manufacturing illuminating device - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an illuminating device with light and dark points due to joints suppressed, and to provide a method of manufacturing the same. <P>SOLUTION: The illuminating device 30 includes: an organic light-emitting element 10 having flexibility with an organic light-emitting layer 3 arranged in a state pinched by an positive electrode 2 and a negative electrode 4 on a substrate 1 and sealed with a sealing plate 7 together with the positive electrode 2 and the negative electrode 4, and with an positive electrode terminal 2a and a negative electrode terminal 4a exposed from the sealing plate 7; and a nearly cylindrical support substrate 20 having a notched part 20a along an axis direction. The organic light-emitting element 10 is arranged folded on the surface of the support substrate 20, with the positive electrode terminal 2a and the negative electrode terminal 4a arranged in the vicinity of the notched part 20a. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to a lighting device using an organic light emitting element and a method for manufacturing the lighting device, and more particularly, to a lighting device and a method for manufacturing the lighting device that improve the occurrence of light and darkness due to the next.

  In recent years, lighting devices using organic EL (EL) elements as organic light-emitting elements have been developed for practical use. 2. Description of the Related Art Conventionally, an organic EL element sealed with sealing glass or the like in order to protect an organic light emitting unit or an electrode is known (for example, see Patent Document 1).

  FIG. 7 shows an example of a conventional organic EL element structure. In a conventional organic EL element, an anode 52 formed by laminating on a glass substrate 51, a light emitting layer 53, and a cathode 54 insulated from the anode 52 via an insulating layer 55 are formed by a sealing plate 57 made of glass. The sealing material 56 is adhesively sealed on the glass substrate 51.

When the above-described organic EL element is used to illuminate a wide range, it is necessary to arrange a plurality of organic EL elements side by side. However, as shown in FIG. 7, the organic EL element has a light emitting region on the substrate 51 side of the light emitting layer 53 and a non-light emitting region on the substrate 51 side of the sealing material 56. There is a problem that light and darkness is caused by the non-light emitting region in the light, and the dark portion looks like a stripe shape, so that a sense of unity cannot be obtained in the light.
JP 2007-128726 A

  The objective of this invention is providing the manufacturing method of the illuminating device and illuminating device which improved generation | occurrence | production of the brightness by the next.

  According to one aspect of the present invention for achieving the above object, an organic light emitting layer sandwiched between an anode and a cathode is disposed on a substrate, and the organic light emitting layer is sealed with a sealing plate together with the anode and the cathode. A flexible organic light-emitting element having an anode terminal and a cathode terminal exposed from the sealing plate, and a substantially cylindrical support substrate having a cutout portion along the axial direction, the organic light-emitting element comprising: A lighting device is provided, wherein the lighting device is bent on the surface of the support substrate, and the anode terminal and the cathode terminal are arranged in the vicinity of the notch.

  According to another aspect of the present invention for achieving the above object, a step of forming an anode and an organic light emitting layer on a substrate, a step of forming an insulating layer and a cathode, and forming an insulating layer and a sealing plate are formed. An organic light emitting device, a step of forming a notch in a cylindrical member to form a support substrate, and a step of bending the organic light emitting device and attaching it to the surface of the support substrate. A manufacturing method is provided.

  According to the illumination device and the method of manufacturing the illumination device of the present invention, it is possible to improve the occurrence of light and darkness due to the next.

  Hereinafter, a lighting device according to an embodiment of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic, differ from actual ones, and also include portions having different dimensional relationships and ratios between the drawings.

[First embodiment]
(Structure of lighting device)
As shown in FIGS. 1 and 2, the lighting device according to the first embodiment of the present invention includes an organic light emitting layer 3 sandwiched between an anode 2 and a cathode 4 on a substrate 1. 4, the organic light emitting layer 3 is sealed with a sealing plate 7, the anode terminal 2 a and the cathode terminal 4 a are exposed from the sealing plate 7, and a flexible organic light emitting element 10, and a notch along the axial direction. The organic light emitting device 10 is bent on the surface of the support substrate 20 and the anode terminal 2a and the cathode terminal 4a are disposed in the vicinity of the notch 20a. In FIG. 1, the cross-sectional structure of the organic light emitting element 10 is omitted.

 In the first embodiment, the plurality of organic light emitting elements 10 are arranged adjacent to each other along the axial direction of the support substrate 20.

  As shown in FIG. 2A, the organic light emitting element 10 is formed by sequentially laminating an anode 2, an organic light emitting layer 3, and a cathode 4 on a substrate 1. The anode 2 and the cathode 4 are insulated through insulating layers 5 and 6, the anode 2 has an anode terminal 2 a arranged with the anode 2 extended, and the cathode 4 has the cathode 4 arranged with an extension. Cathode terminals 4a are respectively formed. A portion sandwiched between the anode 2 and the cathode 4 of the organic light emitting layer 3 is a light emitting region. FIG. 2A shows a cross-sectional structure view taken along the line II of FIG.

  As shown in FIG. 2B, the organic light emitting element 10 has a substantially square shape in plan view, and an anode terminal 2a and a cathode are formed on the whole or a part of the outer edges of one pair of opposing sides. Terminal 4a is arranged. As will be described later, when the plurality of organic light emitting devices 10 are arranged on the support substrate 20, the anode terminal 2a and the cathode terminal 4a side are arranged on the notch portion 20a side and adjacent to the other pair of opposite sides. The organic light emitting device 10 is disposed. Thereby, since the light emitting region is close at the next between the organic light emitting elements 10 in the axial direction of the support substrate 20, the occurrence of light and darkness at the next portion is reduced.

  The surface of the organic light emitting device 10 on the cathode 4 side is sealed by the sealing plate 7 except for the anode terminal 2a and the cathode terminal 4a.

  Since the illumination device 30 is configured such that light is extracted from the substrate 1 side, the substrate 1 is a transparent substrate that has flexibility and transmits light. Examples of the material of the substrate 1 include transparent resins such as polycarbonate and polyethylene terephthalate, and glass. The thickness is preferably about 50 to 500 μm, for example.

  As with the substrate 1, the anode 2 can transmit light and has a thickness of, for example, a transparent electrode of ITO (indium-tin oxide) having a thickness of about 150 to 160 nm.

  A gas barrier layer (schematically illustrated) is preferably disposed between the substrate 1 and the anode 2. Thereby, the invasion of water vapor that causes deterioration of the lifetime of the organic light emitting device 10 can be prevented. Examples of the gas barrier layer include metal oxides such as silicon oxide and aluminum oxide, or metal nitrides such as aluminum nitride and silicon nitride.

  In the organic light emitting layer 3, a hole transport layer, a light emitting portion, and an electron transport layer are sequentially laminated from the substrate 1 side.

  The hole transport layer is for smoothly transporting holes injected from the anode 2 to the light emitting portion, and has a thickness of, for example, about NPB (N, N-di (naphthalyl) -N of about 60 nm. N-diphenyl-benzylidene).

The electron transport layer is for smoothly transporting electrons injected from the cathode 4 to the light emitting portion, and is made of, for example, Alq ₃ (aluminum quinolinol complex) having a thickness of about 35 nm.

The light emitting portion is for emitting light by recombination of injected holes and electrons. For example, a coumarin compound (C ₅₄₅ T), which is a luminescent species, is doped with, for example, about 1% and has a thickness of For example, it is made of Alq _{3 of} about 30 nm.

  In addition, you may comprise the organic light emitting layer 3 using layers other than the said positive hole transport layer and an electron carrying layer, for example, a positive hole injection layer, an electron injection layer, etc.

  The cathode 4 is made of aluminum having a thickness of about 150 nm, for example.

  The sealing plate 7 protects the anode 2, the cathode 4, and the organic light emitting layer 3, seals them, and has flexibility. Examples of the material of the sealing plate 7 include glass, metals such as stainless steel (SUS) and copper, ceramics, resins, and the like. The thickness is preferably about 50 to 500 μm, for example.

  Since the substrate 1 and the sealing plate 7 have flexibility, the organic light emitting element 10 has good flexibility. Accordingly, as described later, the organic light emitting element 10 can be bent and easily attached to the support substrate 20 when the lighting device 30 is manufactured.

  The support substrate 20 is for arranging and supporting the plurality of organic light emitting elements 10. The support substrate 20 has a substantially cylindrical shape, and a notch 20a is formed along the axial direction. The size of the notch 20a is, for example, about 1/16 to 1/4 of the circumference in a cross-sectional view.

  The support substrate 20 also has a function of a heat radiating plate for radiating heat generated in the organic light emitting element 10.

  The material of the support substrate 20 is not particularly limited as long as the thermal conductivity is good, for example. For example, a metal, resin, etc. are mentioned. Preferably, copper or aluminum is used. The thickness is about 1 to 10 mm, for example.

(Operating principle)
The operation principle of the lighting device according to the first embodiment of the present invention is as follows.

  First, a constant voltage is applied between the anode 2 and the cathode 4 from the external electrode (illustrated) through the anode terminal 2 a and the cathode terminal 4 a of the organic light emitting device 10. As a result, holes are injected from the anode 2 into the light emitting part through the hole transport layer, and electrons are injected from the cathode 4 into the light emitting part through the electron transport layer. Then, the holes and electrons injected into the light emitting portion recombine to emit light. The emitted light is emitted to the outside through the substrate 1.

(Production method)
3 and 4 are diagrams illustrating a method of manufacturing the lighting device according to the first embodiment of the present invention.

  The manufacturing method of the lighting device according to the present embodiment includes the step of forming the anode 2 and the organic light emitting layer 3 on the substrate 1, the step of forming the insulating layer 5 and the cathode 4, the insulating layer 6 and the sealing plate 7. Forming the organic light-emitting element 10 by forming the cut-out portion 20a in the cylindrical member, forming the support substrate 20, and folding the organic light-emitting element 10 on the surface of the support substrate 20 And have.

  Below, a manufacturing process is explained in full detail.

(A) First, as shown in FIG. 3A, after patterning and etching the anode 2 on the substrate 1, a gas barrier layer (illustrated) made of silicon oxide or the like is formed by a vacuum deposition method or the like.

  Next, the organic light-emitting layer 3 is formed by sequentially forming a hole transport layer, a light-emitting portion, and an electron transport layer using a vacuum deposition apparatus or the like.

(B) Next, as shown in FIG. 3B, after the insulating layer 5 made of SiO ₂ is formed by a CVD (Chemical Vapor Deposition) method or the like, the cathode 4 is formed by sputtering or the like.

(C) Next, as shown in FIG. 3C, after forming the insulating layer 6 made of SiO ₂ by the CVD method or the like, the sealing plate 7 is removed by sputtering or the like except the anode terminal 2a and the cathode terminal 4a. It is formed on the surfaces of the cathode 4 and the insulating layers 5 and 6.

(D) Next, as shown in FIG. 4D, the notch 20a is formed along the axial direction on the cylindrical member made of aluminum using a cutting device or the like, and the support substrate 20 is manufactured. The support substrate 20 can be formed by bending a flat plate made of aluminum using a press brake or the like to form a cylindrical support substrate 20 having a notch 20a.

(E) Next, as shown in FIG. 4E, the organic light emitting device 10 is bent, and the surface of the organic light emitting device 10 on the sealing plate 7 side is attached to the surface of the support substrate 20 with an adhesive or the like. wear. Then, a plurality of organic light emitting devices 10 are attached adjacent to each other along the axial direction of the support substrate 20, the anode terminal 2 a and the cathode terminal 4 a are connected by an external terminal (schematically illustrated) such as a clip, and the support substrate 20. By connecting the connection wiring in the internal space, the lighting device 30 as shown in FIG. 1 is completed.

  In such an illuminating device 30, since the light emitting regions of the organic light emitting element 10 are arranged close to each other, good luminance can be obtained even at the next portion, and the illuminating device 30 having a sense of unity with light can be obtained.

  Further, since the support substrate 20 is made of a heat conductive member, the heat generated from the organic light emitting element 10 can be efficiently removed.

  Further, since the internal space of the support substrate 20 can be used as a wiring space, the wiring portion can be hidden, and the aesthetics are excellent.

  According to the illumination device and the method for manufacturing the illumination device according to the present embodiment, it is possible to improve the occurrence of light and darkness due to the next.

[Second Embodiment]
As shown in FIG. 5, the lighting device according to the second embodiment of the present invention further includes a substantially flat support member 21 arranged through the notch 20 a from the inner wall of the support substrate 20. Since other configurations are the same as those of the first embodiment, description thereof is omitted. In FIG. 5, the cross-sectional structure of the organic light emitting element 10 is omitted.

  The support member 21 supports the support substrate 20 and locks the support substrate 20 to an external locking portion (illustrated schematically). The support member 21 has a flat plate shape and has a thickness of about 1 to 10 mm, for example.

  The support member 21 also has a function of a heat sink for radiating heat generated in the organic light emitting element 10.

 The support member 21 is not particularly limited as long as the material has good thermal conductivity. For example, a metal, resin, etc. are mentioned. Preferably, copper or aluminum is used.

  The manufacturing method of the lighting device according to the second embodiment is different from the manufacturing method according to the first embodiment in the method of forming the support member 21, and is otherwise the same as in the first embodiment. Therefore, a duplicate description is omitted.

  In the manufacturing method of the lighting device according to the second embodiment, a flat plate-like support member 21 made of aluminum is joined to the inner wall of the support substrate 20 with an adhesive or the like, and is formed so as to penetrate the notch 20a. By doing so, the illumination device 30A can be manufactured.

  Alternatively, it is also possible to form the cylindrical support substrate 20 by bending both wings of a plate made of aluminum having a T-shaped cross section using a press brake or the like, and to integrally form the support substrate 20 and the support member 21. .

  According to the second embodiment, since the support member 21 is disposed through the notch 20a from the inner wall of the support substrate 20, the support substrate 20 can be stably installed at a desired location.

 In addition, according to the second embodiment, since the support member 21 has heat conductivity, heat generated in the organic light emitting element 10 can be radiated well through the support substrate 20.

  According to the illumination device and the method for manufacturing the illumination device according to the present embodiment, it is possible to improve the occurrence of light and darkness due to the next.

[Third embodiment]
As shown in FIG. 6, the lighting device according to the third embodiment of the present invention is a reflection member 22 arranged on the end surface of the support member 21 so as to cover the upper side of the support substrate 20 so as to face the notch 20 a. Have Since other configurations are the same as those of the second embodiment, description thereof will be omitted. In FIG. 6, the cross-sectional structure of the organic light emitting element 10 is omitted.

  The reflection member 22 is for reflecting the light emitted from the organic light emitting element 10 toward the upper side of the notch 20a. The reflecting member 22 preferably has a substantially arc-shaped cross section so as to cover the upper portion of the support substrate 20 so as to face the notch 20a. The thickness is, for example, about 1 to 10 mm.

  Further, the reflection member 22 also has a function of a heat radiating plate for radiating heat generated in the organic light emitting element 10.

 The reflective member 22 is not particularly limited as long as the material has good light reflectivity and good thermal conductivity. For example, a metal, resin, etc. are mentioned. Preferably, copper or aluminum is used. When resin or the like is used, a metal film or the like may be disposed on the inner surface of the reflecting member 22 (the surface facing the notch portion 20a) to enhance the light reflectivity.

  The manufacturing method of the lighting device according to the third embodiment is different from the manufacturing method according to the second embodiment in the method of forming the reflecting member 22, and the other is the same as in the second embodiment. Therefore, a duplicate description is omitted.

  In the method of manufacturing the lighting device according to the third embodiment, the lighting device 30B can be manufactured by bonding the reflecting member 22 to the end surface of the support member 21 via an adhesive.

  According to the third embodiment, since the reflection member 22 is disposed so as to cover the upper portion of the support substrate 20 so as to face the notch portion 20a, the light is emitted from the organic light emitting element 10 toward the upper side of the notch portion 20a. Light can be reflected efficiently.

 Further, according to the third embodiment, since the reflection member 22 has heat conductivity, heat generated in the organic light emitting element 10 can be radiated well through the support substrate 20 and the support member 21.

  According to the illumination device and the method for manufacturing the illumination device according to the present embodiment, it is possible to improve the occurrence of light and darkness due to the next.

[Other embodiments]
The present invention has been described in detail with the first to third embodiments described above. However, for those skilled in the art, the present invention is limited to the first to third embodiments described in the present specification. Obviously it is not. The present invention can be implemented as modifications and changes without departing from the spirit and scope of the present invention defined by the description of the scope of claims. Therefore, the description of the present specification is for illustrative purposes and does not have any limiting meaning to the present invention. Hereinafter, modified embodiments in which the first to third embodiments described above are partially modified will be described.

  For example, it is possible to change dimensions such as the thickness of each layer and the constituent materials.

  In the lighting device according to the first embodiment described above, the support substrate 20 has been described as having a substantially cylindrical shape, but the cylinder may be formed in a curved tube shape. Thereby, it is possible to enhance the aesthetics and to increase the degree of freedom with respect to the arrangement location.

  In the illuminating device according to the second embodiment described above, the description has been made with the flat support member 21 disposed on the support substrate 20, but instead of the flat support member 21, both end portions or notches of the support substrate 20 are provided. A support member that supports the support substrate 20 may be provided as appropriate near the portion 20a.

  In the lighting device according to the third embodiment described above, the reflecting member 22 has been described as having a substantially arc-shaped cross section, but the cross section is changed to a linear shape or a polygonal line shape as appropriate. Also good.

The typical partially broken perspective view of the illuminating device which concerns on the 1st Embodiment of this invention. It is explanatory drawing of the organic light emitting element which concerns on the 1st Embodiment of this invention, Comprising: (a) Typical sectional structure drawing, (b) Typical plan view. It is explanatory drawing of the manufacturing method of the illuminating device which concerns on the 1st Embodiment of this invention, Comprising: (a) Process drawing which forms the anode 2 and the organic light emitting layer 3 on the board | substrate 1, (b) The insulating layer 5 and Process drawing which forms the cathode 4, (c) Process drawing which forms the insulating layer 6 and the sealing board 7. FIG. It is explanatory drawing of the manufacturing method of the illuminating device which concerns on the 1st Embodiment of this invention, Comprising: (d) Process drawing which forms the support substrate 20, (e) Process drawing which attaches the organic light emitting element 10 to the support substrate 20 . The typical partially broken perspective view of the illuminating device which concerns on the 2nd Embodiment of this invention. The typical cross-section figure of the illuminating device which concerns on the 3rd Embodiment of this invention. The typical cross-section figure of the illuminating device using the conventional organic EL element.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Board | substrate 2 ... Anode 2a ... Anode terminal 3 ... Organic light emitting layer 4 ... Cathode 4a ... Cathode terminal 5,6 .... Insulating layer 7 ... Sealing board 10 ... Organic light emitting element 20 Support substrate 20a Notch 21 Support member 22 Reflective member 30, 30A, 30B Lighting device

Claims (6)

An organic light emitting layer sandwiched between an anode and a cathode is disposed on the substrate, the organic light emitting layer is sealed together with the anode and the cathode with a sealing plate, and the anode terminal and the cathode terminal are exposed from the sealing plate, An organic light emitting device having flexibility;
A substantially cylindrical support substrate having a cutout portion along the axial direction, and the organic light emitting element is arranged to be bent on the surface of the support substrate, and the anode terminal and the cathode terminal are arranged in the vicinity of the cutout portion. A lighting device characterized by being arranged in   The lighting device according to claim 1, further comprising a substantially flat support member disposed through the notch from an inner wall of the support substrate.   The lighting device according to claim 2, wherein the support substrate and the support member are made of a heat conductive member.  The lighting device according to claim 1, wherein the plurality of organic light emitting elements are arranged adjacent to each other along the axial direction of the support substrate.  5. The lighting device according to claim 2, further comprising: a reflection member disposed on an end surface of the support member so as to cover the upper portion of the support substrate so as to face the notch portion. Forming an anode and an organic light emitting layer on a substrate;
Forming an insulating layer and a cathode;
Forming an insulating layer and a sealing plate to produce an organic light emitting device;
Forming a notch in the cylindrical member to form a support substrate;
A step of bending the organic light emitting element and attaching it to the surface of the support substrate.

Images