JP2011233341A - Method for manufacturing organic electroluminescent lighting device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a method for manufacturing an organic electroluminescent lighting device, which can improve manufacturing yield in a film formation process and hold an interval between substrates at a fixed value in a sealing process.SOLUTION: The method includes: a first film formation process for forming an anode film 2 on the surface of a transparent substrate 1; a spacer formation process for forming a plurality of spacers 3 which are arranged like a frame so as to continuously or intermittently surround the whole or a part of the surface of the anode film 2 and of which heights are higher than that of the anode film 2 and are the same height each other; a second film formation process for forming an organic light-emitting film 4 which covers the surface of the anode film 2 on the inside of the plurality of spacers 3 and of which height is lower than that of the plurality of spacers 3; a third film formation process for forming a cathode film 5 which covers the surface of the organic light-emitting film 4 and of which height is lower than that of the plurality of spacers 3; a seal part formation process for forming a seal part 6 which covers the plurality of spacers 3 and continuously surrounds the outer periphery of the organic light-emitting film 4 through the cathode film 5; and a sealing process for attaching a sealing substrate 7 to the plurality of spacers 3 in the sealing part 6 to cover an inner space 8.

Description

  The present invention relates to a method for manufacturing an organic electroluminescent lighting device using a light emitting element in which an organic light emitting film is sandwiched between an anode film and a cathode film as a light source.

  A main manufacturing process of an organic electroluminescence lighting device using a light emitting element sandwiching an organic light emitting film between an anode film and a cathode film as a light source includes a film forming process and a sealing process. The film forming process is a manufacturing process in which a light emitting element is formed by sequentially laminating an anode film, an organic light emitting film, and a cathode film on the surface of a transparent substrate. A sealing process is a manufacturing process which interrupts | blocks a light emitting element from external air. In the organic electroluminescence lighting device manufactured through these manufacturing steps, moisture may enter the device as the sealed portion deteriorates with time. In this case, since the organic light emitting film is sensitive to moisture, a region that does not emit light (dark spot) may be generated, and the light emitting area may be reduced (shrink). Therefore, the sealing process is an important manufacturing process. In the sealing process, generally, a sealing substrate is disposed facing a transparent substrate on which a light emitting element is mounted. The sealing substrate is disposed at a predetermined interval with respect to the transparent substrate so as not to damage the light emitting element. A seal portion is formed between the transparent substrate and the sealing substrate, and the light emitting element is shielded from outside air by the seal portion and the sealing substrate. Patent Document 1 discloses a method for manufacturing an organic electroluminescence lighting device having such a sealing step.

  In the method for manufacturing an organic electroluminescence lighting device disclosed in Patent Document 1, a rib structure projecting from a surface of a sealing substrate (a substrate on which a color filter element is mounted) is formed by a photolithography method. ing. In the sealing step, the rib structure is attached to the substrate on which the light emitting element is mounted. As a result, the distance between the substrate on which the light emitting element is mounted and the sealing substrate can be kept constant.

JP 2008-235089 A

  In the film forming process which is the main manufacturing process of the organic electroluminescence lighting device together with the sealing process, the organic light emitting film is generally deposited on the surface of the anode film using a shadow mask having an opening. At this time, in order to accurately deposit the organic light emitting film on the target region, it is desirable to bring the shadow mask close to the anode film. However, if the shadow mask is too close to the anode film, the organic light emitting film may be formed in a state where the shadow mask is in contact with the anode film. In this case, there is a concern that the number of defective products in which the anode film is damaged due to the contact with the shadow mask increases and the manufacturing yield decreases. Although Patent Document 1 discloses a technique for keeping a distance between substrates constant by providing a rib structure on the sealing substrate side, a technique for coping with a decrease in manufacturing yield in the above-described film formation process is disclosed. Not disclosed.

  Accordingly, an object of the present invention is to provide a method of manufacturing an organic electroluminescence lighting device that can improve the manufacturing yield in the film forming process and can maintain a constant spacing between the substrates in the sealing process. To do.

  In order to achieve the above object, an organic electroluminescence lighting device according to the present invention includes a first film forming step of forming an anode film on the surface of a transparent substrate, and all or part of the surface of the anode film continuously. Or a spacer forming step of forming a plurality of spacers that are arranged in a frame shape so as to intermittently surround and have a height from the surface of the transparent substrate that is higher than the anode film and the same height as each other; A second organic light-emitting film is formed by using a shadow mask, covering the surface of the anode film inside the plurality of arranged spacers and having a height from the surface of the transparent substrate lower than that of the plurality of spacers. A film forming step, a third film forming step for covering the surface of the organic light emitting film and forming a cathode film having a height from the surface of the transparent substrate lower than that of the plurality of spacers, and the plurality of spacers. And coating the cathode film A sealing part forming step of continuously forming a sealing part surrounding the outer periphery of the organic light emitting film; and a sealing substrate is attached to the plurality of spacers by the sealing part, and the sealing part is provided above the cathode film. And a sealing step of covering the enclosed internal space with the sealing substrate.

  According to the present invention, the height from the surface of the transparent substrate is increased between the first film forming step for forming the anode film and the second film forming step for forming the organic light emitting film. There is a spacer forming step of forming a spacer whose height is higher than that of the anode film. Therefore, when the organic light emitting film is formed using the shadow mask in the second film forming step, the contact between the shadow mask and the anode film is avoided by the spacer. Thereby, since the organic light emitting film can be formed without damaging the anode film, the manufacturing yield in the film forming process is improved. Further, since the sealing substrate is attached to the spacer in the sealing step, the distance between the transparent substrate and the sealing substrate is kept constant by the spacer.

It is a flowchart which shows the procedure of the manufacturing method of the organic electroluminescent illuminating device of this invention. It is sectional drawing for demonstrating the 1st film-forming process in the manufacturing method of the organic electroluminescent illuminating device of this invention. It is a figure for demonstrating the spacer formation process in the manufacturing method of the organic electroluminescent illuminating device of this invention. It is sectional drawing for demonstrating the 2nd film-forming process in the manufacturing method of the organic electroluminescent illuminating device of this invention. It is sectional drawing for demonstrating the 3rd film-forming process in the manufacturing method of the organic electroluminescent illuminating device of this invention. It is a figure for demonstrating the seal | sticker part formation process in the manufacturing method of the organic electroluminescent illuminating device of this invention. It is a figure for demonstrating the sealing process in the manufacturing method of the organic electroluminescent illuminating device of this invention. It is a figure which shows other embodiment of the manufacturing method of the organic electroluminescent illuminating device of this invention. It is a figure which shows other embodiment of the manufacturing method of the organic electroluminescent illuminating device of this invention. FIG. 10 is a cross-sectional view taken along the cutting line shown in FIG. 9.

  An embodiment of a method for producing an organic electroluminescence lighting device of the present invention will be described. FIG. 1 is a flowchart showing the procedure of the method for manufacturing the organic electroluminescence lighting device of the present invention. Hereafter, each process is demonstrated according to the flowchart of FIG.

  First, the first film forming step (step S1) will be described. FIG. 2 is a cross-sectional view for explaining the first film formation step. As shown in FIG. 2, the first film formation step is a step of forming the anode film 2 on the surface of the transparent substrate 1. The transparent substrate 1 is a glass substrate or a plastic substrate. The anode film 2 is mainly made of ITO (Indium Tin Oxide), IZO (Indium Zinc Oxide), or the like.

  Next, a spacer formation process (step S2) is demonstrated. FIG. 3 is a diagram for explaining the spacer forming step. FIG. 3A is a plan view. FIG. 3B is a cross-sectional view taken along a cutting line AA shown in FIG. As shown in FIG. 3, the spacer forming step is a step of forming a plurality of spacers 3 having a height from the surface of the transparent substrate 1 higher than that of the anode film 2 and the same height as each other (FIG. 3B). reference). The plurality of spacers 3 are arranged in a frame shape so as to intermittently surround a part of the surface of the anode film 2 (see FIG. 3A). In the present embodiment, the spacer 3 is made of resin and is formed by a photolithography method. Therefore, as shown to Fig.3 (a), the several spacer 3 can be arrange | positioned by arbitrary density in arbitrary positions. As a result, the plurality of spacers 3 can be arranged so as not to aggregate at specific locations on the surface of the transparent substrate 1. In the present invention, the plurality of spacers 3 may be arranged so as to surround the entire surface of the anode film 2 in a frame shape. In the present invention, the plurality of spacers 3 may be disposed so as to continuously surround the surface of the anode film.

  Next, the second film forming step (step S3) will be described. FIG. 4 is a diagram for explaining the second film forming step. FIG. 4A is a plan view. FIG. 4B is a cross-sectional view taken along the cutting line AA shown in FIG.

  As shown in FIG. 4, in the second film forming step, the surface of the anode film 2 is covered inside the plurality of spacers 3 arranged in a frame shape (see FIG. 4A), and the height from the transparent substrate 4 is increased. This is a step of forming the organic light emitting film 4 having a length lower than that of the spacer 3 (see FIG. 4B). The organic light emitting film 4 is deposited on the surface of the anode film 2 using a shadow mask. At this time, since the spacer 3 having a height higher than that of the anode 2 is formed from the transparent electrode 1, the contact between the shadow mask and the anode film 2 can be prevented by the spacer 3. The material of the organic light emitting film 4 is not particularly limited and may be the same as the conventional one.

  Next, the third film forming step (step S4) will be described. FIG. 5 is a diagram for explaining the third film forming step. FIG. 5A is a plan view. FIG. 5B is a cross-sectional view taken along the cutting line AA shown in FIG. As shown in FIG. 5, the third film forming step is a step of forming a cathode film 5 that covers the surface of the organic light emitting film 4 and has a height from the surface of the transparent substrate 1 lower than that of the spacer 3.

  Next, the seal part forming step (step S5) will be described. FIG. 6 is a view for explaining a seal portion forming step. FIG. 6A is a plan view. FIG. 6B is a cross-sectional view taken along the cutting line AA shown in FIG. As shown in FIG. 6, the seal portion forming step is a step of forming a seal portion 6 that covers the spacer 3 and continuously surrounds the outer periphery of the organic light emitting film 4 with the cathode film 5 interposed therebetween.

  Next, the sealing step (Step S6) will be described. FIG. 7 is a cross-sectional view for explaining the sealing step. As shown in FIG. 7, in the sealing step, the sealing substrate 7 is attached to the spacer 3 with the seal portion 5, and the internal space 8 surrounded by the seal portion 5 is covered with the sealing substrate 7 above the cathode film 5. It is a process.

  As described above, in the present embodiment, from the surface of the transparent substrate 1 between the first film forming step for forming the anode film 2 and the second film forming step for forming the organic light emitting film 4. There is a spacer forming step of forming a spacer 3 having a height higher than that of the anode film 2. Therefore, the contact between the shadow mask and the anode film 2 is avoided by the spacer 3 when the organic light emitting film 4 is formed using the shadow mask in the second film forming step. Thereby, since the organic light emitting film 4 can be formed without damaging the anode film 2, the manufacturing yield in the film forming process is improved. Further, since the sealing substrate 7 is attached to the spacer 3 in the sealing step, the distance between the transparent substrate 1 and the sealing substrate 7 is kept constant by the spacer 3.

  In the present embodiment, a hygroscopic material 9 is attached to the surface of the sealing substrate 7 that contacts the internal space 8. Therefore, even if moisture enters the internal space 8 due to deterioration of the sealing substrate 7 and the seal portion 6 with time, the moisture can be absorbed by the hygroscopic material 9, so that the progress of the deterioration of the organic light emitting film 4 can be stopped. It becomes possible.

  In the present embodiment, as shown in FIG. 4B, the side surface portion of the anode film 2 is compared with the thickness of the organic light emitting film 4 covering the upper surface portion of the anode film 2 in the second film formation step. The covering organic light emitting film 4 is thin. Then, as shown in FIG. 5B, in the third film forming step, the upper surface portion and the side surface portion of the anode film 2 are covered with the cathode film 5. Therefore, when a high electric field is generated between the anode film 2 and the cathode film 5, in the organic light emitting film 4, the portion covering the side surface portion of the anode film 2 is insulated compared to the portion covering the upper surface portion of the anode film 2. It becomes easy to destroy.

  Therefore, in the present invention, as shown in FIG. 8, a step of forming an anode edge cover 10 that covers the side surface of the anode film 2 and has a lower insulating height than the spacer 3 from the surface of the transparent substrate 1. You may have. FIG. 8 is a diagram showing another embodiment of the method for producing an organic electroluminescent lighting device of the present invention. FIG. 8A is a plan view. FIG. 8B is a cross-sectional view taken along the cutting line AA shown in FIG.

  When manufacturing an organic electroluminescence lighting device in which the anode edge cover 10 is formed, by forming the anode edge cover 10 having insulation so as to cover the side surface portion of the anode film 2 in the spacer forming step, the second In the film forming process, the side surface portion of the anode film 2 is covered with the organic light emitting film 4 through the anode edge cover 10 (see FIG. 8B). Therefore, even when a high electric field is generated between the side surface portion of the anode film 2 and the cathode film 5, the voltage applied to the organic light emitting film 4 is relaxed by the anode edge cover 10. Thereby, the portion of the organic light emitting film 4 that covers the side surface portion of the anode film 2 via the anode edge cover 10 is less likely to break down. Furthermore, in the present invention, the spacers 3 having different heights from the surface of the transparent substrate 1 and the anode edge cover 10 may be simultaneously formed using a gray tone mask or a half tone mask having a semi-transmissive region. . Thereby, compared with the case where each of the spacer 3 and the anode edge cover 10 is formed separately, the number of processes can be reduced.

  Moreover, in this invention, in order to manufacture the organic electroluminescent illuminating device provided with the several light emitting element, as shown to FIG. 9, FIG. 10, the process of forming the element separation rib 11 provided with insulation is shown. You may have. FIG. 9 is a plan view showing another embodiment of the method for producing an organic electroluminescent lighting device of the present invention. In FIG. 9, a part of the cathode film 5 is omitted for easy understanding of the layout of the element isolation ribs 11. FIG. 10 is a cross-sectional view taken along the cutting line shown in FIG. FIG. 10A is a cross-sectional view taken along the cutting line CC shown in FIG. FIG. 10B is a cross-sectional view taken along the cutting line DD shown in FIG.

  In the case of manufacturing an organic electroluminescence lighting device in which the element isolation ribs 11 are formed, first, in the first film formation step, the plurality of anode films 2 are formed separately from each other. After that, in the spacer forming step, between the plurality of anode films 2 on the surface of the transparent substrate 1, the element isolation ribs whose height from the surface of the transparent substrate 1 is higher than the plurality of anode films 2 and lower than the spacer 3. 11 is formed. At this time, the spacers 3 having different heights from the surface of the transparent substrate 1 and the element isolation ribs 11 may be simultaneously formed using the above-described gray tone mask or half tone mask. As a result, the number of steps can be reduced as compared with the case where the spacer 3 and the element isolation rib 11 are individually formed. After the element isolation ribs 11 are formed, the surfaces of the plurality of anode films 2 are individually covered with the plurality of organic light emitting films 4 in the second film forming step. Thereafter, the surfaces of the plurality of organic light emitting films 4 are individually covered with the cathode film 5 in the third film forming step. Thereby, a plurality of light emitting elements are completed.

  When manufacturing the organic electroluminescence lighting device including the anode edge cover 10 or the element separation rib 11 described above, each of the anode edge cover 10 and the element separation rib 11 has a height from the surface of the transparent substrate 1. Is lower than the spacer 3, it is also possible to use the sealing substrate 7 to which the above-described hygroscopic material 9 is attached in the sealing step.

DESCRIPTION OF SYMBOLS 1 Transparent substrate 2 Anode film 3 Spacer 4 Organic light emitting film 5 Cathode film 6 Seal part 7 Sealing substrate 8 Internal space 9 Hygroscopic material 10 Anode edge cover 11 Element isolation rib

Claims (4)

A first film forming step of forming an anode film on the surface of the transparent substrate;
Arranged in a frame shape so as to surround all or part of the surface of the anode film continuously or intermittently, and the height from the surface of the transparent substrate is higher than that of the anode film and a plurality of same heights. A spacer forming step of forming a spacer of
An organic light emitting film that covers the surface of the anode film inside the plurality of spacers arranged in a frame shape and is lower than the plurality of spacers from the surface of the transparent substrate is formed using a shadow mask. A second film forming step,
A third film forming step of covering the surface of the organic light emitting film and forming a cathode film having a height from the surface of the transparent substrate lower than that of the plurality of spacers;
A seal part forming step of covering the plurality of spacers and forming a seal part that continuously surrounds the outer periphery of the organic light emitting film through the cathode film;
A sealing step of attaching a sealing substrate to the plurality of spacers at the sealing portion, and covering the internal space surrounded by the sealing portion above the cathode film with the sealing substrate. Manufacturing method.   The manufacturing method of the organic electroluminescent illuminating device of Claim 1 with which the hygroscopic material is attached to the surface which contact | connects the said internal space in the said sealing substrate.   In the spacer formation step, a gray-tone mask or a half-tone mask is used as the anode edge cover that covers the side surface portion of the anode film and has a lower insulating height than the plurality of spacers from the surface of the transparent substrate. The manufacturing method of the organic electroluminescent illuminating device of Claim 1 or 2 formed simultaneously with these spacers. In the first film formation step, a plurality of anode films are formed apart from each other,
In the spacer forming step, the insulating layer is located between the plurality of anode films on the surface of the transparent electrode, and is higher than the plurality of anode films and insulated from the plurality of spacers. Forming element isolation ribs having the same properties as the spacers using a gray-tone mask or a half-tone mask;
In the second film forming step, the surfaces of the plurality of anode films are individually covered with a plurality of organic light emitting films,
The manufacturing method of the organic electroluminescent illuminating device according to claim 1 or 2, wherein in the third film forming step, the surfaces of the plurality of organic light emitting films are individually covered with a plurality of cathode films.

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