JP2015076195A - Organic electroluminescent element, method of manufacturing the same, and lighting device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a highly reliable organic electroluminescent element.SOLUTION: The organic electroluminescent element includes: an organic light emitter 5 having a first electrode 6, a second electrode 8, and an organic layer 7 disposed between the first electrode 6 and the second electrode 8; a support substrate 1 for supporting the organic light emitter 5; and a sealing substrate 2 disposed facing the support substrate 1. In a gap between the support substrate 1 and the sealing substrate 2, a filling part 3 formed of a fluid filler is provided in contact with the organic layer 7. An inspection electrode 9 separated from the first electrode 6 and the second electrode 8 and being in contact with the filling part 3 is provided extending from the inside sealed by the support substrate 1 and the sealing substrate 2 to the outside.

Description

  The present invention relates to an organic electroluminescence element, a manufacturing method thereof, and a lighting device.

  As an organic electroluminescence element (hereinafter also referred to as “organic EL element”), an organic light-emitting body in which an organic layer including a light-emitting layer is disposed between an anode and a cathode is supported by a substrate. . The organic EL element is formed by a laminated structure of thin films, and a planar lighting device can be obtained. In the organic EL element, a sealing structure is provided to protect the organic layer from the outside.

  As an organic EL element sealing structure, an organic light emitter is disposed between a support substrate that supports an organic light emitter and a sealing substrate that is disposed to face the support substrate. There is known a structure (filling sealing structure) in which a gap is filled with a filler (for example, see Patent Document 1). In the case of this structure, sealing is possible without providing a recess for accommodating the organic light emitter in the sealing substrate, so that it is possible to save time and cost for processing the sealing substrate. Can do.

JP 2010-198980 A

  In the filling and sealing structure of the organic EL element, the organic layer and the filler are usually in direct contact with each other. Therefore, it is desired that the reaction hardly occurs between the filler and the organic layer. When a reaction occurs between the filler and the organic layer, the organic layer is deteriorated and the light emission efficiency may be reduced.

  Here, when what hardens | cures as a filler, since it becomes difficult to produce reaction between an organic layer and the hardened filler, deterioration of an organic EL element becomes difficult to occur. However, when the curing of the filler is not sufficient and poor curing occurs, the poorly cured filler and the organic layer are likely to react with each other, and deterioration of the organic EL element may proceed. Therefore, it is required to reduce the occurrence of poor curing of the filler and increase the reliability.

  This invention is made | formed in view of said situation, reduces generation | occurrence | production of the hardening defect of a filler, and provides a reliable organic EL element, its manufacturing method, and an illuminating device using the same. It is the purpose.

An organic electroluminescence device according to the present invention includes a first electrode, a second electrode, an organic light emitter having an organic layer disposed between the first electrode and the second electrode, and the organic light emitter. A supporting substrate to be supported and a sealing substrate disposed to face the supporting substrate are provided.
In the gap between the support substrate and the sealing substrate, a filling portion formed of a fluid filler is provided in contact with the organic layer. An inspection electrode that is spaced apart from the first electrode and the second electrode and is in contact with the filling portion extends from the inside sealed by the support substrate and the sealing substrate to the outside.

  In the organic electroluminescence element, preferably, the inspection electrode is provided without overlapping the first electrode and the second electrode in plan view.

  In the organic electroluminescence element, preferably, the flowable filler includes an ultraviolet curable resin, and the inspection electrode is supported by the support substrate.

  In the organic electroluminescence element, preferably, the filling portion contains a hygroscopic material.

  A method for producing an organic electroluminescent element according to the present invention is a method for producing the above organic electroluminescent element, wherein the support substrate on which the organic light-emitting body is formed and the sealing substrate are provided with fluidity therebetween. Inspecting electrical conductivity between the inspection electrode and a substrate placement step for placing the filler in opposition, a curing step for hardening the fluid filler, and at least one of the first electrode and the second electrode. An inspection process.

  In the method of manufacturing an organic electroluminescence element, preferably, when the degree of cure of the fluid filler is determined to be lower than a predetermined value in the inspection step, the fluid filler having a low degree of cure is added. Furthermore, it has a recuring process to harden.

  In the method of manufacturing an organic electroluminescence element, preferably, the support substrate is configured by a region of a mother support substrate in which a plurality of mother substrates are connected, and the sealing substrate is a mother sealing substrate in which a plurality of devices are connected. After the inspection step, the mother support substrate and the mother sealing substrate are divided to individualize the organic electroluminescence element.

  The illuminating device which concerns on this invention is an illuminating device provided with said organic electroluminescent element.

  According to the present invention, since the inspection electrode in contact with the filling portion is provided, occurrence of poor curing of the filler can be reduced. Therefore, a highly reliable organic EL element and lighting device can be obtained.

An example of an organic electroluminescent element is shown, (a) is a partially exploded plan view, (b) is a schematic sectional view of the whole, (c) is an enlarged sectional view in the vicinity of the second electrode lead portion, (d) is It is an expanded sectional view near a test electrode. It is a graph which shows the relationship between hardening of a filler, and the electric current value between electrodes. It is a top view which shows an example of the manufacturing method of an organic electroluminescent element.

  The organic electroluminescence element (organic EL element) according to the present invention includes an organic light emitter 5, a support substrate 1 that supports the organic light emitter 5, and a sealing substrate 2 that is disposed to face the support substrate 1. . The organic light emitter 5 includes a first electrode 6, a second electrode 8, and an organic layer 7 disposed between the first electrode 6 and the second electrode 8. In the gap between the support substrate 1 and the sealing substrate 2, a filling portion 3 formed of a fluid filler is provided in contact with the organic layer 7. An inspection electrode 9 that is separated from the first electrode 6 and the second electrode 8 and is in contact with the filling portion 3 is provided so as to extend from the inside sealed by the support substrate 1 and the sealing substrate 2 to the outside. In the organic EL element, since the inspection electrode 9 in contact with the filling portion 3 is provided, the occurrence of poor curing of the filler can be reduced. Therefore, a highly reliable organic EL element can be obtained.

  FIG. 1 shows an example of an organic EL element. The organic EL element includes an organic light emitter 5, a support substrate 1 that supports the organic light emitter 5, and a sealing substrate 2 that is disposed to face the support substrate 1. The organic light emitter 5 includes a first electrode 6, a second electrode 8, and an organic layer 7 disposed between the first electrode 6 and the second electrode 8. A gap between the support substrate 1 and the sealing substrate 2 is provided with a filling portion 3 formed of a fluid filler. The organic EL element is also called an organic electroluminescent element or an organic light emitting diode.

  In FIG. 1A, a state in which the sealing substrate 2, the filling portion 3, and the sealing wall 4 are removed and seen in a plan view is shown, and a region where the sealing wall 4 is provided is indicated by hatching. The plan view refers to a case when viewed from a direction perpendicular to the surface of the support substrate 1. In FIG. 1A, the hidden portion of the layer is indicated by a broken line so that the layered pattern can be easily understood. FIG. 1B shows a cross section at a position where the first electrode lead portion 11 formed by extending the first electrode 6 protrudes outside the sealing region. FIG. 1C shows a cross section at a portion where the second electrode lead portion 12 connected to the second electrode 8 protrudes outside the sealing region. FIG. 1D shows a cross section at a portion where the inspection electrode 9 is provided.

  The support substrate 1 is a substrate that supports the organic light emitter 5. The organic light emitter 5 is laminated on the support substrate 1. The support substrate 1 preferably has light transparency. The support substrate 1 may be transparent or translucent. The support substrate 1 may be colorless or colored. When the support substrate 1 is light transmissive, an organic EL element having a structure for extracting light from the support substrate 1 side (so-called bottom emission structure) can be obtained. In the case of a structure for extracting light from the sealing substrate 2 side (so-called top emission structure), the support substrate 1 may or may not have light transmittance.

  Although the support substrate 1 is not specifically limited, what was formed with glass or resin can be used. Examples of the glass include soda lime glass and non-alkali glass. Examples of the resin include polyester, polyolefin, polyamide resin, epoxy resin, and fluorine resin. It is also preferable to use a plastic substrate as the support substrate 1. The plastic may be composed of the resin described above. The support substrate 1 can be preferably made of glass. When the support substrate 1 is made of glass, the glass has low moisture permeability, so that moisture can be prevented from entering from the support substrate 1 side. In addition, the support substrate 1 may be comprised with the composite material of glass and resin. For example, when the support substrate 1 provided with a light extraction resin layer on the glass surface is used, the light extraction performance can be effectively improved. This resin layer may be provided on the surface of the support substrate 1 on the first electrode 6 side.

  The organic light emitter 5 is constituted by a stacked body of a first electrode 6, an organic layer 7 and a second electrode 8. The organic light emitter 5 can be defined as a structure in which the first electrode 6, the organic layer 7, and the second electrode 8 are stacked in the thickness direction. The first electrode 6, the organic layer 7, and the second electrode 8 are provided in this order from the support substrate 1 side. The region where the organic light emitter 5 is provided is a central region of the support substrate 1 in a plan view (when viewed from a direction perpendicular to the substrate surface). The organic light-emitting body 5 is covered and sealed by a sealing substrate 2 that is disposed so as to face the support substrate 1 and bonded thereto, and the organic light-emitting body 5 is disposed inside the sealing region. The first electrode 6 may be formed directly on the support substrate 1, or another layer (for example, the above-described resin layer) is provided between the first electrode 6 and the support substrate 1. The first electrode 6 may be formed on the layer.

  The first electrode 6 is an electrode formed on the support substrate 1 side. The second electrode 8 is a pair of electrodes with the first electrode 6. One of the first electrode 6 and the second electrode 8 constitutes an anode, and the other constitutes a cathode. In one aspect, the first electrode 6 may constitute an anode and the second electrode 8 may constitute a cathode. In another aspect, the first electrode 6 may constitute a cathode and the second electrode 8 may constitute an anode.

  Of the first electrode 6 and the second electrode 8, at least the electrode on the light extraction side preferably has light transmittance. Thereby, it becomes possible to take out the light emitted from the light emitting layer and emit it to the outside. For example, in the structure in which light is extracted from the support substrate 1 side, the first electrode 6 can be formed of a light transmissive electrode. In addition, for example, in a structure in which light is extracted from the sealing substrate 2 side, the second electrode 8 can be formed of a light transmissive electrode.

  Of the first electrode 6 and the second electrode 8, the electrode opposite to the light extraction side may have light reflectivity. In that case, the light from the light emitting layer can be reflected by the light reflective electrode and extracted to the outside. Thereby, light extraction property can be improved. Moreover, you may comprise the electrode on the opposite side to the light extraction side with a light transmissive electrode. In that case, an element having a double-sided light extraction structure can be formed. Alternatively, the electrode opposite to the light extraction side may be formed of a light transmissive electrode, and a light reflection layer may be provided on the surface of the electrode opposite to the organic layer 7. By providing the light reflecting layer, light can be reflected and extracted to the outside.

  In a preferred embodiment of the organic EL element, the first electrode 6 is a light transmissive electrode, and the second electrode 8 is a light reflective electrode. In that case, an organic EL element having a bottom emission structure can be obtained. In this structure, light generated in the light emitting layer in the organic layer 7 is extracted to the outside through the first electrode 6 and the support substrate 1. More preferably, the first electrode 6 is an anode and the second electrode 8 is a cathode. Thereby, an organic EL element with high light extraction efficiency can be obtained.

  The first electrode 6 can be formed using a transparent electrode material if it has optical transparency. Examples of the material of the first electrode 6 include an electrode material made of a metal, an alloy, an electrically conductive compound, or a mixture thereof. When the first electrode 6 constitutes an anode, it can be formed of a metal, an alloy, an electrically conductive compound, or a mixture thereof having a high work function. As a material of the first electrode 6, for example, a conductive metal oxide can be preferably used. Examples of the light-transmitting metal oxide include ITO, IZO, ZnO, and AZO. ITO stands for Indium Tin Oxide, and IZO stands for Indium Zinc Oxide. The first electrode 6 can be formed by sputtering, vapor deposition, coating, or the like. Although the thickness of the 1st electrode 6 is not specifically limited, For example, it can be set as the range of 10 nm-1000 nm.

  The second electrode 8 can be formed using an appropriate electrode material. Examples of the material of the second electrode 8 include an electrode material made of a metal, an alloy, an electrically conductive compound, and a mixture thereof. When the second electrode 8 forms a cathode, the second electrode 8 can be formed of a metal, an alloy, an electrically conductive compound, or a mixture thereof having a low work function. Examples of the material of the second electrode 8 include aluminum (Al), silver (Ag), sodium (Na), lithium (Li), and the like. The second electrode 8 can be formed by vapor deposition or sputtering. Although the thickness of the 2nd electrode 8 is not specifically limited, For example, it can be set as the range of 10 nm-1000 nm.

  The organic layer 7 is a layer having a function of causing light emission, and is usually appropriately selected from a hole injection layer, a hole transport layer, a light emitting layer (a layer containing a light emitting dopant), an electron transport layer, an electron injection layer, an intermediate layer, and the like. It is constituted by a plurality of layers. Of course, as long as light emission is possible, the organic layer 7 may have a single layer structure of the light emitting layer. Although the thickness of the organic layer 7 is not specifically limited, For example, it can be set to about 60-300 nm.

  For example, when the first electrode 6 is an anode and the second electrode 8 is a cathode, the stacked structure of the organic layer 7 is a hole injection layer, a hole transport layer, a light emitting layer, and an electron transport layer in order from the first electrode 6 side. The electron injection layer can be used. Note that the laminated structure is not limited to this, for example, a single layer of a light emitting layer, a laminated structure of a hole transport layer, a light emitting layer, and an electron transport layer, or a hole transport layer and a light emitting layer. A laminated structure or a laminated structure of a light emitting layer and an electron transport layer can be formed. Further, the light emitting layer may have a single layer structure or a multilayer structure. For example, when the emission color is white, the light emitting layer may be doped with three red, green, and blue dopant dyes, or red, green, and blue. A light emitting layer may be laminated. In addition, when a laminated structure that emits light when a voltage is applied between two electrodes sandwiched between two electrodes is used as one light emitting unit, a plurality of light emitting units have a light transmitting property and a conductive property. It may be a multi-unit structure laminated through layers. The multi-unit structure is a structure including a plurality of light emitting units that overlap in the thickness direction between a pair of electrodes (anode and cathode).

  The light emitting layer can be formed using a light emitting material that can be used for the organic EL element. The luminescent material is also called a dopant. The light emitting layer may be a layer in which a dopant is doped into a host material. Specific examples of the material for forming the light emitting layer include, but are not limited to, anthracene, naphthalene, pyrene, tetracene, coronene, perylene, phthaloperylene, naphthaloperylene, diphenylbutadiene, tetraphenylbutadiene, coumarin, oxadiazole, bis Benzoxazoline, bisstyryl, cyclopentadiene, quinoline metal complex, tris (8-hydroxyquinolinato) aluminum complex, tris (4-methyl-8-quinolinato) aluminum complex, tris (5-phenyl-8-quinolinato) aluminum complex Aminoquinoline metal complex, benzoquinoline metal complex, tri- (p-terphenyl-4-yl) amine, 1-aryl-2,5-di (2-thienyl) pyrrole derivative, pyran, quinacridone, rubrene, disty Rubenzen derivatives, distyryl arylene derivatives, distyrylamine derivatives, such as various fluorescent dyes may be mentioned. Two or more kinds of materials may be used in combination. Further, not only a material that generates fluorescence, but also a material that generates spin multiplet light emission such as phosphorescence emission, a compound that has a site that generates spin multiplet light emission in a part of the molecule, and the like may be used.

  The sealing substrate 2 is a substrate that seals the organic light emitter 5 by disposing the organic light emitter 5 between the support substrate 1 and the sealing substrate 2. The sealing substrate 2 is disposed to face the support substrate 1 on the surface on the organic light emitter 5 side. The sealing substrate 2 can be formed using a substrate material having low moisture permeability. The sealing substrate 2 can be made of glass, metal, resin, or the like. As the sealing substrate 2, a glass substrate etc. can be used, for example. Specific examples include soda lime glass and non-alkali glass. Since these are relatively inexpensive glass materials, the manufacturing cost of the element can be suppressed. Further, as the sealing substrate 2, a metal material such as aluminum or stainless steel may be used. Intrusion of moisture by the metal material can be suppressed. Further, a resin material may be used as the material of the sealing substrate 2. Examples of the resin material include polyethylene terephthalate (PET) and polyethylene naphthalate (PEN). However, when using a resin material for the sealing substrate 2, it is preferable to use the sealing substrate 2 having a moisture-proof film formed on the surface of the resin material. Thereby, infiltration of moisture can be suppressed. Examples of the moisture-proof film include a SiON film and a SiN film. The moisture-proof film may be provided on the surface of the resin material on the organic light emitter 5 side.

  The sealing substrate 2 may or may not have optical transparency. When taking out light from the sealing substrate 2 side, it is preferable that the sealing substrate 2 has a light transmittance.

  The surface of the sealing substrate 2 on the organic light emitter 5 side may be a flat surface. As a result, it is possible to seal the flat surface of the sealing substrate 2 so as to face the support substrate 1, and the plate-shaped sealing substrate 2 can be used as it is. It can be carried out. The sealing substrate 2 may have a recess for accommodating the organic light-emitting body 5. However, when the sealing substrate 2 has a recess, processing of the sealing substrate 2 is required. In the organic EL element of this embodiment, since the sealing wall 4 is provided, the sealing wall 4 can function as a spacer. Therefore, even if the sealing substrate 2 does not have a recess, the sealing wall 4 can secure a space corresponding to the thickness of the organic light emitter 5.

  In the organic EL element, a voltage is applied to the first electrode 6 and the second electrode 8, and holes and electrons are combined in the organic layer 7 to cause light emission. For this reason, it is required to provide a lead-out portion of the electrode that is electrically connected to each of the first electrode 6 and the second electrode 8 so as to be drawn outside the sealing region. The lead portion of the electrode functions as a terminal for electrical connection with the external electrode. In the form of FIG. 1, the lead-out portion of the electrode is formed by pulling out the conductive layer constituting the first electrode 6 to the end portion of the support substrate 1. An electrode pad for connection to an external power source may be provided on the surface of the electrode lead-out portion.

  The electrode lead-out portion is provided on the end surface of the support substrate 1. The electrode lead portion is divided into a first electrode lead portion 11 that is electrically connected to the first electrode 6 and a second electrode lead portion 12 that is electrically connected to the second electrode 8. The first electrode lead portion 11 can be defined as a portion where the first electrode 6 extends and protrudes to the outside of the organic layer 7. The second electrode lead portion 12 can be defined as a portion where the conductive layer constituting the first electrode 6 is divided by patterning at the end portion of the support substrate 1. Note that the second electrode lead portion 12 may be formed by drawing the material of the second electrode 8, and in this case, the second electrode lead portion 12 protrudes to the outside of the organic layer 7. Can be defined as an extension of

  The first electrode lead portion 11 and the second electrode lead portion 12 are formed across the sealing wall 4. Specifically, the first electrode lead portion 11 is formed by the conductive layer constituting the first electrode 6 being drawn to the end side of the support substrate 1 and extending outside the sealing wall 4. Yes. That is, the conductive layer constituting the first electrode 6 is formed on the surface of the support substrate 1 so as to protrude from the sealing region by extending the conductive layer at the end where the first electrode lead-out portion 11 is provided. . The first electrode lead portion 11 is constituted by an extended portion of the first electrode 6. Further, the conductive layer constituting the first electrode 6 protrudes from the sealing region at the end where the second electrode lead-out portion 12 is provided by dividing the conductive layer and extending the divided conductive layer. It is formed on the surface of the support substrate 1. The second electrode lead portion 12 is constituted by an extended portion of the conductive layer separated from the first electrode 6. The second electrode lead-out portion 12 is in contact with the stacked second electrodes 8 inside the sealing region, whereby the second electrode lead-out portion 12 and the second electrode 8 are electrically connected. .

  The structure for pulling out the electrodes to the outside from the sealing region is not limited to the structure in the form of FIG. 1. For example, one or both of the first electrode lead portion 11 and the second electrode lead portion 12 may be You may form using the conductive layer different from the conductive layer which comprises the 1 electrode 6. FIG.

  The filling portion 3 is formed so as to fill a gap between the support substrate 1 and the sealing substrate 2. By providing the filling portion 3, the organic light emitter 5 can be easily sealed by surrounding the organic light emitter 5 with the filling portion 3. Moreover, the reliability of an organic EL element can be improved by forming the filling part 3. When the filling portion 3 is not provided and a hollow structure is formed, the sealing substrate 2 is bent and recessed toward the inside so that the organic light emitting body 5 can be easily contacted, and the organic light emitting body 5 may be deteriorated. By providing the portion 3, the bending of the sealing substrate 2 can be suppressed. Further, when the filling portion 3 is provided, if the filling portion 3 has adhesiveness, the surface of the sealing substrate 2 can be adhered by the filling portion 3. Can improve the adhesion.

  The filling part 3 may be formed by being filled with a fluid filler. The fluid filler is a filler having fluidity. The flowable filler preferably has curability. The filling part 3 may be one in which the fluid filler is cured and becomes solid. The filling portion 3 may be sealed in a liquid state, but in that case, the filling portion 3 tends to flow, so that the reliability of the element may be lowered. Therefore, it is preferable that the filling portion 3 is formed by curing the fluid filler.

  The flowable filler preferably contains at least one of a thermosetting resin and an ultraviolet curable resin. Thereby, sclerosis | hardenability becomes favorable and the stable filling part 3 can be formed more. As the fluid filler, for example, a resin composition or a monomer that is cured by a polymerizable reaction can be used. The fluid filler may be a thermosetting resin, an ultraviolet curable resin, or a mixture of a thermosetting resin and an ultraviolet curable resin. Specifically, as the resin, for example, silicone resin, urea resin, melamine resin, phenol resin, resorcinol resin, epoxy resin, acrylic resin, polyester resin, polyamide resin, polybenzimidazole resin, diallyl phthalate resin, xylene resin, Examples thereof include curable resins such as alkyl-benzene resins, epoxy acrylate resins, silicon resins, and urethane resins. It may be a liquid material containing silicone oil or the like. As the resin of the fluid filler, one containing at least one of an epoxy resin and an acrylic resin is preferable. As the fluid filler, an epoxy resin is particularly preferable because it is excellent in the reliability of electronic components. The resin constituting the fluid filler may be a resin composition including a resin component that is a main component of polymerization and an auxiliary component that assists the polymerization. Examples of auxiliary components include a curing agent, a curing accelerator, a polymerization initiator, and a polymerization inhibitor.

  The filling part 3 may contain a filler. That is, the fluid filler may contain a filler. As the filler, for example, one or more materials selected from the group consisting of alumina, calcium oxide, strontium oxide, barium oxide, zeolite, and silica can be used. When the filler is contained, the thermal expansibility can be reduced.

  It is preferable that the filling part 3 contains a hygroscopic material. In this case, even if moisture enters the element, the moisture can be absorbed by the hygroscopic material, so that deterioration of the element due to moisture can be suppressed. Thereby, it is possible to suppress the occurrence of defects such as dark spots. The hygroscopic material is preferably composed of a hygroscopic filler. As the hygroscopic filler, for example, one or more materials selected from the group consisting of calcium oxide, strontium oxide, barium oxide, zeolite, and silica can be used.

  The filler content in the filling portion 3 is not particularly limited, but is preferably in the range of 0.01 to 30% by mass with respect to the total amount of the filling portion 3. Thereby, the more stable filling part 3 can be formed.

  The flowable filler preferably has adhesiveness. Since the fluidity filler has adhesiveness, the substrate can be bonded in a planar shape, so that the support substrate 1 and the sealing substrate 2 can be bonded with higher adhesion.

  The filling part 3 may or may not have light transmittance. It is a preferable aspect that the filling portion 3 has light transmittance. It is a more preferable aspect that the filling portion 3 is transparent. When taking out light from the sealing substrate 2 side, it is preferable that the filling part 3 has a light transmittance.

  In this embodiment, the filling part 3 is in contact with the organic layer 7. In the organic light emitter 5, the second electrode 8 is disposed on the sealing substrate 2 side. However, in the portion where the side portion of the organic light emitter 5 and the second electrode 8 are not stacked, the organic layer 7 is organic. It is exposed as the surface of the light emitter 5. Therefore, the filler 3 and the organic layer 7 are in contact with each other in the exposed portion of the organic layer 7. In the drawing, the contact portion with the filling portion 3 in the organic layer 7 is shown as a contact portion 7 a with the filling portion 3. When the organic layer 7 is in contact with the filling portion 3, the organic layer 7 is easily deteriorated by being damaged by the filling portion 3. However, in this embodiment, even if the filling portion 3 is in contact with the organic layer 7, the element It can suppress that it becomes easy to deteriorate.

  In the organic EL element of this embodiment, the sealing wall 4 is formed on the outer peripheral side portion of the filling portion 3. The sealing wall 4 is provided between the support substrate 1 and the sealing substrate 2. The sealing wall 4 is provided so as to surround the outer periphery of the organic light-emitting body 5. The sealing wall 4 has a function as a spacer for accommodating the organic light-emitting body 5. The height (thickness) of the sealing wall 4 is larger than the thickness of the organic light emitter 5. Therefore, the organic light emitter 5 is accommodated in the gap between the support substrate 1 and the sealing substrate 2. The sealing wall 4 has a function as a weir for filling the fluid filler. By providing the sealing wall 4, the fluid filler can be dammed and the filling portion 3 can be formed. When manufacturing an organic EL element, the sealing wall 4 can be provided in a frame shape around the organic light emitter 5 in a plan view, and a region surrounded by the sealing wall 4 can be filled with a fluid filler. . The sealing wall 4 functions as a dam material. The fluid filler (filling part 3) functions as a filler material. This structure is also called a dam-fill structure.

  It is preferable that the sealing wall 4 has moisture resistance. Thereby, it is possible to suppress moisture from entering the sealing region.

  The sealing wall 4 is preferably formed of a fluid sealing material. By using a fluid sealing material, the sealing wall 4 can be easily formed. The fluid sealing material is a sealing material having fluidity. The fluid sealing material may be curable. The sealing wall 4 may be a solid which is obtained by curing the fluid sealing material. In addition, when the fluid filler is filled, the sealing wall 4 may be cured, but may not be completely cured. For example, using a fluid sealing material that has viscosity, such as having viscosity, so that the fluid filler is functioned as a weir to dam the fluid filler, and at the same time the fluid filler is cured The material may be cured. Thereby, it can harden efficiently. The fluid sealing material functions as a weir member. Further, the fluid sealing material may be semi-cured to such an extent that the form retainability is exhibited. In short, the sealing wall 4 should just function as a weir of a fluid filler. In order to improve the filling property, the viscosity of the fluid filler may be lower than the viscosity of the fluid sealing material. Of course, the sealing wall 4 may be formed of an uncured sealing material having no fluidity.

  The fluid sealing material preferably includes at least one of a thermosetting resin and an ultraviolet curable resin. Thereby, sclerosis | hardenability becomes favorable and the stable sealing wall 4 can be formed more. As the fluid sealing material, for example, a resin composition or a monomer that cures by a polymerizable reaction can be used. The fluid sealing material may be a thermosetting resin, an ultraviolet curable resin, or a mixture of a thermosetting resin and an ultraviolet curable resin. Specifically, as the resin, for example, silicone resin, urea resin, melamine resin, phenol resin, resorcinol resin, epoxy resin, acrylic resin, polyester resin, polyamide resin, polybenzimidazole resin, diallyl phthalate resin, xylene resin, Examples thereof include curable resins such as alkyl-benzene resins, epoxy acrylate resins, silicon resins, and urethane resins. It may be a liquid material containing silicone oil or the like. As the resin for the fluid sealing material, one containing at least one of an epoxy resin and an acrylic resin is preferable. As the fluid sealing material, an epoxy resin is particularly preferable because of excellent reliability of electronic components. In addition, resin which comprises a fluid sealing material may be a resin composition containing the resin component used as the main body of superposition | polymerization, and the auxiliary component which assists superposition | polymerization. Examples of auxiliary components include a curing agent, a curing accelerator, a polymerization initiator, and a polymerization inhibitor.

  The sealing wall 4 may contain a filler. That is, the fluid sealing material may contain a filler. As the filler, for example, one or more materials selected from the group consisting of alumina, calcium oxide, strontium oxide, barium oxide, zeolite, and silica can be used. When the filler is contained, the thermal expansibility can be reduced.

  It is preferable that the sealing wall 4 contains a hygroscopic material. In this case, moisture that is about to pass through the sealing wall 4 can be absorbed by the hygroscopic material, and moisture can be prevented from entering the element, so that deterioration of the element due to moisture can be suppressed. Thereby, it is possible to suppress the occurrence of defects such as dark spots. The hygroscopic material is preferably composed of a hygroscopic filler. As the hygroscopic filler, for example, one or more materials selected from the group consisting of calcium oxide, strontium oxide, barium oxide, zeolite, and silica can be used.

  Although content of the filler in the sealing wall 4 is not specifically limited, It is preferable to exist in the range of 0.01-30 mass% with respect to the whole quantity of the sealing wall 4. FIG. Thereby, a more stable sealing wall 4 can be formed.

  The fluid sealing material preferably has adhesiveness. When the fluid sealing material has adhesiveness, the support substrate 1 and the sealing substrate 2 can be bonded with high adhesion, and the sealing performance can be improved.

  And in the organic EL element of this embodiment, the test | inspection electrode 9 spaced apart from the 1st electrode 6 and the 2nd electrode 8 and contacting the filling part 3 is provided. The inspection electrode 9 extends from the inside sealed by the support substrate 1 and the sealing substrate 2 to the outside. By having the inspection electrode 9, it is possible to inspect the electrical continuity between the inspection electrode 9 and the first electrode 6 and at least one of the inspection electrode 9 and the second electrode 8. The cured state of the filler can be determined.

  As shown in FIGS. 1A and 1D, the inspection electrode 9 has a portion 9a disposed inside the sealing region and a portion 9b disposed outside the sealing region. The inspection electrode 9 is electrically insulated from the first electrode 6 and the second electrode 8. The inspection electrode 9 is in contact with the filling portion 3 in a portion 9a disposed inside the sealing region. In the inspection electrode 9, a portion 9b arranged outside the sealing region is arranged outside the sealing wall 4 and exposed to the outside. The inspection electrode 9 is separated from the first electrode lead portion 11 and the second electrode lead portion 12.

  The inspection electrode 9 is preferably provided without overlapping the first electrode 6 and the second electrode 8 in plan view. As shown in FIG. 1 (a), in this embodiment, the inspection electrode 9 includes the first electrode 6 and the second electrode 8 in which the regions where the first electrode 6 and the second electrode 8 are formed do not overlap in plan view. The two electrodes 8 are disposed in a gap between the electrodes where the two electrodes 8 are not disposed. Thereby, it is possible to easily determine the curing failure of the filler by the inspection electrode 9. In addition, since the arrangement of the inspection electrode 9 is an arrangement that does not easily hinder the hardening of the fluid filler, the fluid filler can be cured well. The inspection electrode 9 is preferably provided so as not to overlap the first electrode lead portion 11 and the second electrode lead portion 12 in plan view.

  In this embodiment, the inspection electrode 9 is provided on the end surface of the support substrate 1. The inspection electrode 9 is supported on the support substrate 1. Thus, in the organic EL element, the inspection electrode 9 is preferably supported by the support substrate 1. Thereby, the inspection electrode 9 can be easily formed. In addition, since the arrangement of the inspection electrode 9 is an arrangement that does not easily hinder the hardening of the fluid filler, the fluid filler can be cured well. Further, when the inspection electrode 9 is provided on the surface of the support substrate 1, the plurality of electrodes for conducting the conductivity inspection are arranged on the same side surface of the substrate, so that the inspection can be easily performed. For example, the inspection electrode 9 may be provided on the surface of the sealing substrate 2 or may be provided through the sealing wall 4. However, when the inspection electrode 9 is not provided on the surface of the support substrate 1, the formation of the inspection electrode 9 becomes difficult, the conductivity inspection by the inspection electrode 9 becomes difficult, or the hardening of the fluid filler is prevented. There is a risk. In particular, when an ultraviolet curable resin is used, if the resin is present on the opposite side of the inspection electrode 9 from the ultraviolet irradiation side, the ultraviolet ray will be shaded by the inspection electrode 9 and will not be irradiated to the resin, and the resin will be cured. May not be sufficient. Therefore, preferably, the inspection electrode 9 is formed on the support substrate 1. Then, when the ultraviolet irradiation is performed from the sealing substrate 2 side, it is possible to prevent the resin from being present behind the inspection electrode 9 (on the opposite side to the ultraviolet irradiation side), so that the curing becomes insufficient. Can be suppressed. Of course, if there is no problem in the reliability of the element, for example, the inspection electrode 9 may be provided on the surface of the sealing substrate 2.

  The inspection electrode 9 can be formed of an appropriate electrode material having conductivity. Examples of the material of the inspection electrode 9 include an electrode material made of a metal, an alloy, an electrically conductive compound, or a mixture thereof. As a material of the inspection electrode 9, a conductive metal oxide or the like can be preferably used. Examples of the metal oxide include ITO, IZO, ZnO, AZO and the like. The inspection electrode 9 may be made of metal, and examples of the metal include aluminum (Al), silver (Ag), sodium (Na), and lithium (Li). The inspection electrode 9 can be formed by a sputtering method, a vapor deposition method, a coating method, or the like. The inspection electrode 9 may be formed of a metal, an alloy, an electrically conductive compound, or a mixture thereof having a high work function. The thickness of the inspection electrode 9 is not particularly limited, but can be, for example, in the range of 10 nm to 1000 nm.

  In one preferred embodiment, the inspection electrode 9 is formed by patterning the conductive layer constituting the first electrode 6. Thereby, the inspection electrode 9 can be formed easily. In the form of FIG. 1, the inspection electrode 9 is formed by patterning the conductive layer of the first electrode 6. That is, the conductive layer constituting the first electrode 6 protrudes from the sealing region by dividing the conductive layer and extending the divided conductive layer at the end where the inspection electrode 9 is provided. Is formed on the surface. The inspection electrode 9 is constituted by an extended portion of the conductive layer separated from the first electrode 6. The inspection electrode 9 is formed across the sealing wall 4. The inspection electrode 9 is separated from both the first electrode 6 and the second electrode 8 inside the sealing region, and is not in contact with them. Thereby, it has the structure which can test | inspect the hardening state of the filling part 3. FIG. Of course, the inspection electrode 9 is not limited to the one formed by the conductive layer constituting the first electrode 6. For example, it may be formed by patterning a conductive layer constituting the second electrode 8. Alternatively, for example, an electrode material different from the first electrode 6 and the second electrode 8 may be laminated.

  The inspection electrode 9 preferably has light transmittance. When the inspection electrode 9 has light transmittance, the curability of the fluid filler can be increased. Further, when the first electrode 6 has light transmittance and the inspection electrode 9 is formed of a conductive layer constituting the first electrode 6, the light transmittance of the first electrode 6 and the inspection electrode 9 is equal. Therefore, the amount of ultraviolet irradiation can be made more uniform in the plane.

  The inspection electrode 9 may be a linear pattern in plan view. The inspection electrode 9 is formed so as to intersect the sealing wall 4. Thereby, the inspection electrode 9 can be formed so as to protrude from both sides of the sealing wall 4. The inspection electrode 9 and the sealing wall 4 may be orthogonal to each other. The inspection electrode 9 may be a linear pattern in plan view. Thereby, the inspection electrode 9 can be efficiently provided with a simple configuration.

  The inspection electrode 9 is provided outside the organic light-emitting body 5 in a region where the first electrode lead portion 11 and the second electrode lead portion 12 are not formed. The inspection electrode 9 is not in contact with the organic light emitter 5 and is separated. The inspection electrode 9 is preferably provided in a place where the fluid filler is difficult to cure. Thereby, since the whole hardening state can be judged by inspecting the hardening state in the place where a fluid filler is hard to harden, the reliability by inspection can be improved. In FIG. 1A, the organic EL element has a rectangular shape, the region surrounded by the sealing wall 4 is formed in a rectangular shape, and the inspection electrodes 9 are formed at the corners of the sealing region. ing. Thereby, since the corner is a place where the fluid filler is hard to be hardened, the hardened state can be determined with higher accuracy. Of course, in the electrode pattern in which the first electrode lead portion 11 and the second electrode lead portion 12 are arranged side by side at the end portion on the same side of the organic EL element, the first electrode lead portion 11 and the second electrode lead portion are arranged. The inspection electrode 9 may be provided between the part 12. In that case, the test | inspection electrode 9 does not need to be arrange | positioned at the corner | angular corner part of a sealing area | region. Even in that case, it is possible to accurately check the cured state by arranging the inspection electrode 9 at the end portion (in the vicinity of the sealing wall 4) of the support substrate 1 where the fluid filler is hard to be cured. it can.

  The inspection electrode 9 is preferably provided in the vicinity of at least one of the first electrode 6 and the first electrode lead portion 11. Thereby, the accuracy of the inspection can be increased. In FIG. 1A, the inspection electrode 9 extends along the direction in which the first electrode lead portion 11 extends from the inside of the sealing region to the outside, and the inspection electrode 9 extends to the extended portion of the first electrode 6. They are formed next to each other. Thereby, since the distance between the first electrode 6 and the inspection electrode 9 is reduced, the accuracy of the inspection can be increased. Such an arrangement is advantageous when inspecting continuity between the first electrode 6 and the inspection electrode 9. Of course, the inspection electrode 9 may be formed along the extending direction of the second electrode lead portion 12. In that case, it is advantageous when the conductivity is inspected between the second electrode 8 and the inspection electrode 9.

  In the organic EL element, the first electrode 6 and the first electrode lead portion 11 continuous with the first electrode 6 are in contact with the filling portion 3. It can be said that the first electrode 6 and the first electrode lead portion 11 collectively constitute the first electrode 6. The second electrode 8 and the second electrode lead portion 12 connected to the second electrode 8 are in contact with the filling portion 3. It can be said that the second electrode 8 and the second electrode lead portion 12 collectively constitute the second electrode 8. At this time, the first electrode 6 and the second electrode 8 are defined as element electrodes for driving the organic EL element. The inspection electrode 9 is in contact with the filling portion 3. Therefore, it can be said that the space between the inspection electrode 9 and the element electrode (the first electrode 6 or the second electrode 8) is filled with the filling portion 3. That is, when a voltage is applied between the inspection electrode 9 and the element electrode (the first electrode 6 or the second electrode 8), the current value and electrical resistance value of the filling portion 3 are measured, and these values are measured. From the above, the cured state of the filling part 3 can be confirmed. Usually, if it is not cured or is not sufficiently cured, the flowable filler tends to move internal components due to its fluidity, so that electricity easily flows and electrical resistance is lowered.

  FIG. 2 is a schematic graph showing the amount of current flowing between the electrodes when a voltage is applied between the inspection electrode 9 and the element electrode (the first electrode 6 or the second electrode 8). In this graph, the horizontal axis is time, the vertical axis is the current amount, and the change in current amount over time is measured before and after ultraviolet irradiation (arrows in the figure) before and after ultraviolet irradiation. Is shown. As can be seen from this graph, since the fluid filler is not cured before the ultraviolet irradiation, the current easily flows and the amount of current increases. On the other hand, when ultraviolet rays are irradiated, the amount of current gradually decreases as the resin hardens. When the curing is completed, the filler 3 loses its fluidity to form a solidified filling portion 3. When the curing is good, the amount of current flowing between the electrodes is zero as long as it is zero. Get closer. However, if the curing is poor, the fluidity of the flowable filler will partially remain and current will flow easily between the electrodes, and the amount of current flowing between the electrodes will be Compared to larger. Therefore, the cured state can be determined by the amount of current flowing between the electrodes. Of course, you may judge by an electrical resistance value. With respect to the electrical resistance value, the resistance becomes small when curing is poor, and the resistance becomes large when curing is good.

  If there is a poorly cured portion in the filling portion 3, the filler that is not completely cured penetrates into the organic layer 7, or the components of the organic layer 7 move to the filler, thereby damaging the organic layer 7. It becomes easy to give. When the organic layer 7 is damaged, there is a possibility that light emission does not occur in the damaged part or the light emission becomes weak. Further, when the organic layer 7 is damaged, the deterioration may be accelerated. Further, in the uncured filling portion 3, since it becomes easy for electricity to flow, when an organic EL element is actually driven by applying a voltage between the first electrode 6 and the second electrode 8, the organic layer A current passing through the filling portion 3 without passing through 7 can be generated. Therefore, there is a possibility that the light emission efficiency may be reduced or the reliability of the element may be reduced. However, by providing the inspection electrode 9, it is possible to determine whether the curing is good or not by the inspection using the inspection electrode 9, and the filling portion 3 can be cured well. When the filling part 3 is cured well, it is possible to prevent the organic layer 7 from being damaged. Moreover, if the filling part 3 is hardened | cured favorably, it can suppress that an electric current flows through the filling part 3. FIG. Therefore, the luminous efficiency and reliability of the organic EL element can be improved. Therefore, an element with poor curing can be removed by inspection and an element with good curing can be handled as a non-defective organic EL element, so that a highly reliable organic EL element can be obtained.

  The continuity test of the filling portion 3 may be performed between the test electrode 9 and the first electrode 6, or may be performed between the test electrode 9 and the second electrode 8, or both. May be. The continuity test of the filling portion 3 is preferably performed between the test electrode 9 and the first electrode 6. Thereby, the accuracy of the inspection can be increased.

  The inspection of the continuity of the filling unit 3 can be performed by, for example, an inspection apparatus including a plurality (at least two) of probes. At this time, one probe of the inspection apparatus is brought into contact with the inspection electrode 9 and another probe is brought into contact with the element electrode (the first electrode 6 or the second electrode 8), a voltage is applied between the probes, and the current amount Inspection can be carried out by measuring. In the inspection, an electric resistance value may be measured. The probe may be needle-shaped formed of a material having high electrical conductivity. Although the inspection can be performed manually, it can be efficiently inspected by using an inspection apparatus.

  A plurality of inspection electrodes 9 may be provided in the organic EL element, or one inspection electrode 9 may be provided. When the organic EL element has a plurality of inspection electrodes 9, the cured state can be inspected at a plurality of locations, so that the reliability of the organic EL element can be further improved. In addition, when a plurality of inspection electrodes 9 are provided, for example, the conductivity between the inspection electrode 9 and the first electrode 6 and the conductivity between the inspection electrode 9 and the second electrode 8 are measured at a time. Is possible. Of course, the inspection electrode 9 may be single. In that case, the formation of the inspection electrode 9 is simplified. The inspection electrode 9 may be covered with an insulator after the inspection. If the test electrode 9 is covered with an insulator, the current can be prevented from inadvertently flowing through the electrode, so that the reliability can be improved.

  Hereinafter, the manufacturing method of an organic EL element is demonstrated.

  In manufacture of an organic EL element, it preferably includes a substrate placement process, a curing process, and an inspection process. The substrate disposing step is a step of disposing the support substrate 1 on which the organic light-emitting body 5 is formed and the sealing substrate 2 to face each other with a fluid filler interposed therebetween. The curing step is a step of curing the flowable filler. The inspection step is a step of inspecting conductivity between at least one of the first electrode 6 and the second electrode 8 and the inspection electrode 9. In this method of manufacturing an organic EL element, the fluid filler is cured in order to inspect the electrical continuity between the inspection electrode 9 and the element electrode (at least one of the first electrode 6 and the second electrode 8). The hardening state of the filling part 3 can be confirmed, and the hardening failure of the filling part 3 can be detected. Therefore, it can suppress that manufacture of an organic EL element is completed with a filler being hardened | cured poorly, and the reliability of an organic EL element can be improved.

  In the manufacture of the organic EL element, first, the organic light emitter 5 is formed on the support substrate 1. The organic light emitter 5 can be formed by sequentially stacking the layers constituting the organic light emitter 5. The step of forming the organic light emitter 5 can be referred to as an organic light emitter formation step. In the organic light emitter formation step, for example, first the first electrode 6 is laminated on the surface of the support substrate 1, then the organic layer 7 is laminated, and then the second electrode 8 is laminated. Lamination can be performed by selecting an appropriate method of sputtering, vapor deposition, and coating for each layer. When the organic layer 7 has a multilayer structure, each layer of the organic layer 7 can be sequentially stacked. The first electrode 6, the organic layer 7, and the second electrode 8 may be formed by patterning so that the organic EL element can be driven. A layer that enhances light extraction properties may be disposed between the support substrate 1 and the first electrode 6. In that case, for example, a layer (for example, a resin layer) that enhances light extraction properties can be formed on the surface of the support substrate 1, and the first electrode 6 can be laminated on the surface of the resin layer.

  When forming the first electrode 6, preferably, the conductive layer constituting the first electrode 6 is extended to form the first electrode lead portion 11, and the conductive layer constituting the first electrode 6 is divided by patterning. Thus, the second electrode lead portion 12 is formed. At this time, the inspection electrode 9 is preferably formed by dividing the conductive layer constituting the first electrode 6 by patterning. The inspection electrode 9 is formed so as not to contact with the electrodes (first electrode 6, second electrode 8, first electrode lead portion 11 and second electrode lead portion 12) to be element electrodes. When the inspection electrode 9 is formed by patterning the conductive layer of the first electrode 6, the inspection electrode 9 can be easily formed. Further, the inspection electrode 9 may be formed by patterning the second electrode 8. In short, the inspection electrode 9 is preferably formed in the organic light emitter forming step. The organic light emitter 5 is formed by stacking the first electrode 6, the organic layer 7, and the second electrode 8.

  In sealing the organic light-emitting body 5, first, as a substrate arranging step, the support substrate 1 on which the organic light-emitting body 5 is formed and the sealing substrate 2 are disposed to face each other with a fluid filler interposed therebetween. The organic light emitter 5 is disposed between the support substrate 1 and the sealing substrate 2. In this step, preferably, the fluid sealing material is formed in a frame shape on the support substrate 1 so as to surround the outer periphery of the organic light-emitting body 5, and the portion surrounded by the fluid sealing material is fluid-filled. Fill the material. The fluid sealing material preferably has a form retaining property although it has a certain degree of fluidity, and is configured to function as a frame for damming the fluid filler. The flowable filler is preferably configured to have a fluidity that slightly spreads from the applied position when applied in the form of dots. Of course, a fluid sealing material and a fluid filler may be disposed on the sealing substrate 2 side, but in that case, it may be difficult to seal the organic light-emitting body 5 with high sealing performance. It is preferable to dispose a fluid sealing material and a fluid filler on the support substrate 1 side. In short, a fluid filler and a fluid sealing material may be disposed between the support substrate 1 and the sealing substrate 2. Note that the fluidity sealing material may not be used as long as the fluidity filler can provide adhesiveness, sealing performance, and strength without using the fluidity sealing material. In that case, the organic EL element which does not have the sealing wall 4 and the side part of the filling part 3 is exposed to the outside can be formed.

  The opposing arrangement of the support substrate 1 and the sealing substrate 2 can be performed by bringing the sealing substrate 2 close to the support substrate 1 provided with the fluid sealing material and the fluid filler. In the opposed arrangement, it is preferable that the sealing substrate 2 is held in contact with the fluid sealing material and the fluid filler. This holding may be temporary. At the time of opposing arrangement, the fluidity filler is provided so as to rise slightly from the fluidity sealing material in the thickness direction, and the sealing substrate 2 is made into the fluidity sealing material while spreading the fluidity filler on the sealing substrate 2. You may make it contact. In that case, the filling property of the fluid filler can be improved.

  After opposing arrangement | positioning of the support substrate 1 and the sealing substrate 2, a fluid filler is hardened as a hardening process. When an ultraviolet curable resin is used, it can be cured by irradiating with ultraviolet rays. For example, when ultraviolet rays are irradiated from the sealing substrate 2 side, the resin can be efficiently cured. At this time, the sealing substrate 2 preferably has a property of transmitting ultraviolet rays. In addition, when a thermosetting resin is used, the resin can be cured by heating to a thermosetting temperature. When the heating step is included, the organic EL element may be deteriorated depending on the temperature. Therefore, the case where an ultraviolet curable resin is used is more advantageous. By the curing of the resin, the fluid filler is solidified to form the filling portion 3. In addition, due to the curing of the resin, the fluid sealing material is solidified and the sealing wall 4 is formed.

  In the inspection process, the electrical continuity between at least one of the first electrode 6 and the second electrode 8 and the inspection electrode 9 is inspected. As described above, the inspection process can be performed using an inspection apparatus or the like. For example, when a voltage is applied between the element electrode (the first electrode 6 or the second electrode 8) and the inspection electrode 9, and the amount of flowing current is smaller than a predetermined value, it is determined that the curing is good, and is equal to or higher than the predetermined value. In this case, it can be determined that the curing is poor. When the electrical resistance value is used, it can be determined that curing is good when the electrical resistance value is greater than a predetermined value, and poor curing can be determined when the electrical resistance value is equal to or less than the predetermined value.

  After the inspection process, for example, the one determined to be poorly cured can be removed from the production line, and the one determined to be good cured can be sent to the next process along the production line. As a result, it is possible to suppress the production of an organic EL element whose filling material is poorly cured and has low reliability.

  The method for manufacturing an organic EL device has a re-curing step of further curing the fluid filler having a low degree of cure when it is determined in the inspection step that the degree of cure of the fluid filler is lower than a predetermined value. Is preferred. As described above, when a curing failure occurs, the organic EL element can be removed from the production line. However, if the defective organic EL element is discarded, the productivity may be deteriorated. Such an organic EL element is manufactured in the same manner as a normal organic EL element except that the curing is poor. If the curing is sufficient, the organic EL element can be a good product. Therefore, in the poorly cured organic EL element, the process of curing the fluid filler is performed again. Then, curing of the fluid filler that is not sufficiently cured proceeds, and an organic EL element with good curing in which the fluid filler is sufficiently cured can be obtained. Therefore, waste of materials can be eliminated, and a highly reliable organic EL element can be manufactured with high yield.

  The curing method in the re-curing step may be the same as the curing method for curing the fluid filler. When an ultraviolet curable resin is used, ultraviolet rays are irradiated. When a thermosetting resin is used, it is heated. After the re-curing process, the inspection process may be performed again. As a result, it is possible to further suppress the occurrence of poor curing, thereby further improving the reliability.

  FIG. 3 shows an example of a method for manufacturing an organic EL element. As shown in FIG. 3, in the manufacture of an organic EL element, preferably, an organic EL element connection body in which a plurality of organic EL elements are connected by a substrate is manufactured, and the organic EL element connection body is individualized to produce an organic EL element It is preferable to manufacture. This method is called so-called multi-cavity. In this method, since a plurality of organic EL elements can be simultaneously formed using a large substrate, the organic EL elements can be efficiently manufactured. In FIG. 3, positions where the support substrate 1 and the sealing substrate 2 are cut are indicated by broken lines as cutting lines 23. In FIG. 3, the outer edge of the organic light emitter 5 provided in the back of the sealing substrate 2 is indicated by a two-dot chain line.

  In the combined organic EL element, each organic EL element before individualization is represented by a single element 10. In the manufacture of the organic EL element assembly, a large mother support substrate 21 having a size in which a plurality of single elements 10 are gathered and a large mother sealing substrate 22 having a size in which a plurality of single elements 10 are gathered are used. The support substrate 1 is configured by a region of the mother support substrate 21 in which a plurality of support substrates 1 are connected. The sealing substrate 2 is configured by a region of the mother sealing substrate 22 in which a plurality of sealing substrates 2 are connected.

  Manufacture of an organic EL element coupling body can be performed similarly to manufacture of the organic EL element mentioned above. At this time, the organic light emitter 5 may be formed and sealed for each region of the single element 10 of the mother support substrate 21. By stacking a plurality of organic light emitters 5 at a time, it can be efficiently manufactured.

  When manufacturing an organic EL element coupling body and manufacturing an organic EL element, it is preferable that an inspection process is performed in the state of the organic EL element coupling body before individualization. By inspecting the organic EL element before individualization, it is possible to suppress an increase in the number of test specimens, so that it is possible to suppress complication of work and to inspect efficiently. In addition, when a curing failure is found, the entire organic EL element assembly can be sent to the re-curing step, so that productivity can be improved.

  In the organic EL element assembly, the test electrode 9 and at least one of the first electrode lead portion 11 and the second electrode lead portion 12 are connected to the sealing substrate 2 in a plan view so that the conductivity can be inspected. It is preferable that a part protrudes from. In FIG. 3, the mother sealing substrate 22 is formed slightly smaller than the mother support substrate 21, so that the inspection electrode 9, the first electrode lead portion 11, and the second electrode lead portion 12 protrude from the mother sealing substrate 22. Yes. Therefore, when performing inspection, an inspection instrument such as a probe can be brought close to and brought into contact with the inspection electrode 9 and the element electrode from the mother sealing substrate 22 side, and the inspection can be easily performed.

  In FIG. 3, an organic EL element coupling body in which the number of single elements 10 is six in two rows and three columns is shown, but the number of single elements 10 is not limited to this. When the horizontal or vertical positions are arranged in two rows, the electrodes can be easily protruded by arranging the electrodes (inspection electrodes 9 and element electrodes) on both outer sides of the single elements 10 in two rows. Of course, the electrode arrangement in the organic EL element assembly is not limited to this. In short, it is only necessary that the electrode for inspection is exposed so that inspection can be performed in the inspection process. For example, a part of the mother sealing substrate 22 may be divided to expose the electrodes in advance before individualizing the organic EL elements, and the inspection may be performed using the exposed electrodes. Specifically, for example, when the single elements 10 are arranged in three or more rows in one direction, the electrodes can be arranged inside the organic EL element coupling body, but a part of the mother sealing substrate 22 (adjacent to each other). The electrode can be exposed by cutting and removing the portion between the single elements 10.

  After the inspection process, the mother support substrate 21 and the mother sealing substrate 22 are divided to individualize the organic EL elements. The division can be performed by cutting along the cutting line 23 with an appropriate cutting device. The cutting line 23 is provided at the boundary portion of the single element 10. As the cutting device, for example, a cutting device such as a scriber or a laser can be used.

  As shown in FIG. 3, the cutting line 23 of the support substrate 1 and the cutting line 23 of the sealing substrate 2 may be provided with their positions shifted. In that case, the support substrate 1 and the sealing substrate 2 are cut in steps. Thereby, the lead-out portion of the electrode provided on the surface of the support substrate 1 can be exposed on the surface on the sealing substrate 2 side. In order to expose the electrode, the cutting line 23 of the sealing substrate 2 is usually provided inside the single element 10 with respect to the cutting line of the support substrate 1. By exposing the electrodes, connection to an external power source can be easily performed.

  An organic EL element is manufactured by individualizing the single element 10 from a combined organic EL element.

  A lighting device can be obtained by the organic EL element. The lighting device includes the organic EL element described above. Thereby, a highly reliable lighting device can be obtained. The illuminating device may arrange a plurality of organic EL elements in a planar shape. The illumination device may be a planar illumination body composed of one organic EL element. The illumination device may include a wiring structure for supplying power to the organic EL element. The illumination device may include a housing that supports the organic EL element. The illumination device may include a plug that electrically connects the organic EL element and the power source. The lighting device can be configured in a panel shape. Since the lighting device can be made thin, it is possible to provide a space-saving lighting fixture.

(Example 1)
As a support substrate, a non-alkali glass substrate having a square shape in a plan view and having a side length of 50 mm and a thickness of 0.7 mm was prepared. On this support substrate, an organic light-emitting body having a square shape in a plan view and having a dimension of a side length of 40 mm was formed. At this time, the inspection electrode was formed on the support substrate with the material of the first electrode. The formation pattern and arrangement of the organic light emitter and the inspection electrode were the same as in FIG. The organic EL element has a bottom emission structure.

  Next, a rectangular frame-shaped weir member was formed on the support substrate with a fluid sealing material for forming a sealing wall so as to surround the organic light-emitting body. As the fluid sealing material, one containing an ultraviolet curable resin was used. The height of the weir member was 50 μm, the width was 2 mm, and the length of one side of the region surrounded by the weir member in plan view was 45 mm. And the area | region enclosed by the frame of the weir member was filled and arrange | positioned with the fluid filler. As the fluid filler, an ultraviolet curable epoxy resin was used.

  Next, as a sealing substrate, a soda-lime glass substrate having a square shape in a plan view and having a length of one side of 50 mm and a thickness of 0.7 mm was prepared. And this sealing substrate was arrange | positioned facing the support substrate, the sealing substrate was made to contact a dam member, and the dam member was further pressed with the sealing member. As a result, the fluid filler was spread to fill the region surrounded by the weir member in the gap between the support substrate and the sealing substrate. At this time, the support substrate and the sealing substrate were temporarily bonded by the viscosity of the weir member and the fluid filler.

  Subsequently, the filling substrate and the sealing wall were formed by irradiating ultraviolet rays from the sealing substrate side to cure the fluid filler and the fluid sealing material.

  Thus, the organic EL element of Example 1 was obtained.

(Example 2)
Instead of the fluid filler used in Example 1, a mixture of 10% by mass of a hygroscopic material and 90% by mass of an ultraviolet curable epoxy resin was used as the fluid filler. As the hygroscopic material, zeolite F-9 (100 # or less) manufactured by Tosoh Corporation, which is a water-absorbing zeolite, was used. This water-absorbing zeolite is a particulate material. Other than that produced the organic EL element by the same method and conditions as Example 1, and obtained the organic EL element of Example 2. FIG.

(Comparative Example 1)
An organic EL element was produced by the same method and conditions as in Example 1 except that no inspection electrode was formed, and an organic EL element of Comparative Example 1 was obtained.

(Comparative Example 2)
An organic EL element was produced by the same method and conditions as in Example 2 except that the inspection electrode was not formed, and an organic EL element of Comparative Example 2 was obtained.

(Quality assessment rate evaluation)
In each example and comparative example, 100 or more organic EL elements were produced. About each of the obtained organic EL element, the electric current value between electrodes was measured with the source meter 2400 by a Keithley company. In Examples 1 and 2, the current value when 7 V was applied was measured between the first electrode and the inspection electrode or between the second electrode and the inspection electrode. In Comparative Examples 1 and 2, the current value when -7 V was applied between the first electrode and the second electrode was measured. In Comparative Examples 1 and 2, since the voltage is applied so that the current flows in the direction opposite to the direction in which the light emitting layer emits light (forward direction), the sign of the voltage is negative. That is, the reverse bias current is examined. Here, when the fluid filler is not cured, the electrodes easily flow between the electrodes. The comparative example is a method of confirming the cured state by examining whether the reverse bias current flows and the amount of the current by applying a voltage in the reverse direction.

  In determining the quality of the cured state, the relationship between the degree of UV curing and the amount of current is examined in advance, and when the amount of current is the lowest, the state is completely cured. A cured state was assumed. A current amount smaller than a predetermined value was judged good, and a current amount smaller than a predetermined value was judged bad. The amount of current correlates with the amount of residual epoxy groups in FI-IR, and the curability can be determined from the value of the amount of current.

  Furthermore, as a reliability evaluation, all the organic EL elements were evaluated for luminous efficiency after 1000 hours at a temperature of 85 ° C. and a humidity of 85%, and a non-defective product or a defective product was determined in comparison with the specified efficiency. . In the evaluation of the luminous efficiency, those having the same or higher luminous efficiency than the prescribed efficiency are good, and those having the luminous efficiency lower than the prescribed efficiency are bad.

  As described above, two kinds of determinations were performed, namely, the determination of the quality of the cured state based on the current value between the electrodes, and the determination of the quality of the luminous efficiency after being left under a predetermined condition. The determination of whether or not the luminous efficiency is good is a method by which the reliability of the organic EL element can be evaluated after the completion of manufacturing.

  Table 1 shows the result of the defective product detection rate. In this table, the ratio of what is determined to be defective from the current value between the electrodes to what is determined to be defective in the evaluation of luminous efficiency (reliability evaluation) is expressed in%. It is considered that 100% failure is detected in the light emission efficiency determination.

  In Comparative Examples 1 and 2, the defective product detection rate is low. That is, the ratio of what is determined to be good in the quality determination of the cured state to high in the quality determination of the light emission efficiency is high. On the other hand, in Examples 1 and 2, the defective product detection rate is higher than in the comparative example. That is, what is determined to be defective in the light emission efficiency determination is also defective in the cured state determination, and the defect detection rate is higher than in the comparative example.

  When a test electrode is provided, it is possible to detect a defect by conducting a continuity test using the test electrode before making a light emission efficiency determination (reliability evaluation). It can be carried out. Also, the defect detection rate is higher than when judged by the reverse bias current. Therefore, the quality determination can be performed efficiently, the organic EL element can be manufactured with a high yield, and the manufacturing efficiency can be increased.

  By the way, when a zeolite is contained as a hygroscopic material, the fluid filler is reduced in transparency and becomes difficult to transmit ultraviolet rays, and unevenness in ultraviolet irradiation is likely to occur. The reason why the detection rate in Comparative Example 2 is lower than that in Comparative Example 1 is considered to be due to unevenness of the reverse bias current distribution caused by unevenness of ultraviolet irradiation. However, in the second embodiment, the inspection is performed using the inspection electrode, and the inspection does not need to be performed with the reverse bias current. Therefore, the determination accuracy can be improved. Therefore, when the inspection electrode is provided, the reliability can be further improved when the filling portion contains a hygroscopic material.

DESCRIPTION OF SYMBOLS 1 Support substrate 2 Sealing substrate 3 Filling part 4 Sealing wall 5 Organic light-emitting body 6 1st electrode 7 Organic layer 8 2nd electrode 9 Inspection electrode 10 Single element 11 1st electrode extraction part 12 2nd electrode extraction part 21 Mother support Substrate 22 Mother sealing substrate 23 Cutting line

Claims (8)

A first electrode, a second electrode, an organic light emitter having an organic layer disposed between the first electrode and the second electrode, a support substrate for supporting the organic light emitter, and the support substrate; An organic electroluminescence device comprising a sealing substrate disposed opposite to the substrate,
The gap between the support substrate and the sealing substrate is provided with a filling portion formed of a fluid filler in contact with the organic layer,
An inspection electrode that is separated from the first electrode and the second electrode and is in contact with the filling portion is provided to extend from the inside sealed by the support substrate and the sealing substrate to the outside. An organic electroluminescence element.   The organic electroluminescence element according to claim 1, wherein the inspection electrode is provided without overlapping the first electrode and the second electrode in a plan view. The flowable filler includes an ultraviolet curable resin,
The organic electroluminescence element according to claim 1, wherein the inspection electrode is supported by the support substrate.   The organic electroluminescence element according to claim 1, wherein the filling portion contains a hygroscopic material. It is a manufacturing method of the organic electroluminescent element of any one of Claims 1 thru | or 4, Comprising:
A substrate placement step of placing the support substrate on which the organic light-emitting body is formed and the sealing substrate so as to face each other with a fluid filler interposed therebetween;
A curing step of curing the flowable filler;
An inspection step of inspecting conductivity between at least one of the first electrode and the second electrode and the inspection electrode;
A method for producing an organic electroluminescence element, comprising:   When the degree of cure of the fluid filler is determined to be lower than a predetermined value in the inspection step, the method further comprises a re-curing step of further curing the fluid filler having a low degree of cure. Item 6. A method for producing an organic electroluminescent element according to Item 5. The support substrate is composed of one region of a mother support substrate in which a plurality are connected,
The sealing substrate is composed of one region of a mother sealing substrate in which a plurality are connected,
The organic electroluminescence element according to claim 5 or 6, wherein after the inspection step, the mother support substrate and the mother sealing substrate are divided to individualize the organic electroluminescence element. Method.   The illuminating device provided with the organic electroluminescent element of any one of Claims 1 thru | or 4.

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