JPH0632301B2 - Flexible distributed EL lamp manufacturing method - Google Patents

Description

BACKGROUND OF THE INVENTION 1. Field of the Invention The present invention relates to a method for manufacturing a flexible distributed EL lamp used as a light source for illumination, a display element, an auxiliary light source as a backlight of a liquid crystal display device, and the like.

2. Description of the Related Art An important item in manufacturing a flexible dispersion type EL lamp is how the light emitting layer film is adhered to the transparent electrode and the back electrode.

In other words, if the electrode surface of the transparent electrode and the light emitting layer coating are not completely adhered, if an AC voltage is applied to the transparent electrode and the back electrode, the contact impedance will become extremely large and the electric field will not be applied in the part that is not adhered. The electroluminescence, which is the principle of light emission of EL, is obstructed, resulting in a phenomenon that luminance is reduced or no light is emitted at all.

In particular, in the conventional manufacturing method, after forming a light emitting layer coating on either one of the transparent electrode or the back electrode, a method of adhering the remaining one electrode of the back electrode or the transparent electrode by some method is taken, Efforts are being made to ensure close contact between the light emitting layer coating and the electrodes.

As a concrete method, the surface of the coating formed by roller coding method, screen printing, etc. is subjected to surface smoothing by using a calender roll to smooth the coating. It is expensive.

Among the above-mentioned methods, the roller coating method can obtain a relatively smooth surface state, but it requires a large amount of equipment investment and has not yet completely eliminated the surface-adjusting step.

On the other hand, in the case of the screen printing method, it can be used as a small mass production facility and can be kept at a low cost compared to the roll coating method. Therefore, the film smoothness is worse than that of the roll coating method, and the surface conditioning process using a calendar roll is unavoidable, and capital investment is inevitable in the incidental process.

DISCLOSURE OF THE INVENTION Problems to be Solved by the Invention The present invention is a flexible dispersion type EL that can be mass-produced with inexpensive equipment without introducing an expensive calender roll device, can obtain a smooth coating surface, and can reduce the product price. It is intended to provide a method for manufacturing a lamp.

Means for Solving the Problems The present invention comprises a step of forming a light emitting layer coating and a back electrode layer on a smooth release substrate having a coating film releasability, and adhering a base material coated with an adhesive to the back electrode layer. It is a manufacturing method of a flexible dispersion type EL lamp, which comprises a step, a step of peeling the release substrate from the main surface of the light emitting layer, and a step of forming a transparent electrode on the main surface of the light emitting layer coating.

Function According to this method, the transparent electrode can be easily formed on the smooth surface of the light emitting layer film.

Example The manufacturing method of the example of the present invention is briefly described as follows. First, a light emitting layer coating is applied and baked on a release base material that allows easy film removal.

An adhesive is applied onto the light emitting layer coating, aluminum foil electrodes are superposed in a wet state, passed between rubber rolls to remove bubbles, and heated at 100 ° C to 180 ° C for 5 minutes to 60 minutes,
The adhesive is cured, and when the temperature has dropped to room temperature, the organic film is peeled off.

The light-emitting layer film is fixed to the aluminum foil electrode surface with an adhesive, and the surface of the side that is in close contact with the transparent electrode has a smooth surface that is almost equal to the surface roughness of the organic film.

After that, the outer shape is cut into an appropriate shape, the electrode lead-out terminal is applied to the aluminum foil, the collector electrode is applied and the transparent electrode film with the electrode lead-out terminal is laminated, and the wrapping film is applied from the outside and laminated. Make up a lamp.

Specific examples will be described below with reference to the drawings.

Figure 1 shows the outline of the process. Polyethylene terephthalate (PET) 188μ coated with a silicone release agent is used as a release organic film 12 on top of which has a high dielectric constant ZnS, Cu, Al, ZnS, Cu,
Mn-based, ZnS-, Cu-, and Br-based phosphor powders are dispersed in an organic binder to form a light-emitting layer coating 7 that is applied by screen printing, roll coating, etc., and baked, and then in an organic binder having a high dielectric constant. An insulating layer 6 in which a high dielectric constant pigment such as BaTiO ₃ is dispersed is applied and baked by screen printing, roll coating or the like, and a back electrode 13 is formed on the insulating layer 6 with an aluminum foil. Next, the adhesive 5 prepared by adding 5 to 15 parts of the curing agent to 100 parts of the thermosetting epoxy resin main agent was screen-printed on the substrate 15. (Above FIG. 1 (a)) Next, the adhesive 5 was superposed on the 0.1 t aluminum foil back electrode 13 in a wet state, and passed through a rubber roll for defoaming treatment.

The roll pressure at this time was 1 kg / cm ² or more. (First
(B)) Next, the sample is placed at 100 ° C-150 ° C for 10 minutes-60
The adhesive 5 was hardened by baking under the condition of minutes.

After curing and cooling, the peeling base material 12 was peeled off to complete the transfer.
(Fig. 1 (c)) Here, the surface roughness of the transfer surface is Rmax as shown in Fig. 2 (a).
Is 0.5μ, and the untreated product in FIG. 2 (b) (Rmax is 1
.mu.) and the calendered product of FIG. 2 (c) (Rmax is 0.8.mu.).

Then, it is cut into a predetermined shape, and as shown in FIG. 1 (d), the electrode lead-out terminal 10a made of brass is attached to the aluminum foil surface. On the other hand, as shown in Fig. 1 (e), PET of 100μ
A collector electrode is coated with a silver paste on the vapor deposition surface of the transparent electrode 9 in which In ₂ O ₃ 400 to 1000Å is vapor-deposited on the film, and an electrode lead terminal 10b made of brass is attached to the collector electrode.

The smooth surface of the light emitting layer coating and the transparent electrode vapor deposition surface are faced to each other, and the package films 11a and 11b with a thickness of about 200μ having extremely low moisture permeability are stacked on the outer side of the film.
It is passed through a roll laminator at 0 ° C. to 150 ° C., a roll pressure of 1 kg / cm ² , and a roll speed of 400 to 500 mm / min to complete the process as shown in FIGS. 3, 4, and 5.

The flexible dispersion type EL panel manufactured according to the method of the above embodiment uses ZnS, Cu, and Al-based fluorescent powder.
An initial luminance of 90 nt can be obtained under the conditions of 00 V and 500 Hz, and there is no unevenness in light emission, which is sufficiently practical.

Further, by forming the back electrode with a conductive ink or an etching metal foil, it is possible to easily manufacture a patterned light emitting panel typified by segment display.

Further, it is possible to manufacture by using a simple screen printing machine without introducing an expensive calender roll as the surface conditioning equipment, and a great effect can be obtained in reducing the product price.

EFFECTS OF THE INVENTION As described above, the method of manufacturing a flexible dispersion type EL lamp of the present invention can easily manufacture a high-performance EL lamp and has high industrial utility value.

[Brief description of drawings]

FIG. 1 is a diagram showing the steps involved in the manufacturing method of the present invention, FIG. 2 is a diagram showing the surface roughness of the light emitting layer coating, and FIGS. 3, 4 and 5 are each manufactured by the method of the present invention. FIG. 5 is a top view, a bottom view, and a sectional view taken along the line AA ′ of the flexible dispersion type EL lamp. 5 ... Adhesive, 6 ... Insulating layer, 7 ... Light emitting layer film, 9 ...
… Transparent electrode, 12 …… Peeling substrate, 13 …… Back electrode, 1
5 ... Insulating film.

Claims (12)

[Claims] 1. A step of forming a light emitting layer coating and a back electrode layer on a peeling substrate having a smooth coating film peeling property, a step of adhering a base material coated with an adhesive to the back electrode layer, and a peeling substrate. A method of manufacturing a flexible dispersion type EL lamp, which comprises a step of peeling from the main surface of the light emitting layer and a step of forming a transparent electrode on the main surface of the light emitting layer. 2. The method for manufacturing a flexible dispersed EL lamp according to claim 1, further comprising an insulating layer having a high dielectric constant between the light emitting layer coating and the back electrode. 3. A metal foil of 0.2 t or less such as aluminum, iron or copper is used as a peeling substrate.
Item 8. A method for manufacturing a flexible dispersed EL lamp according to the item. 4. A flexible dispersion type EL according to claim 1, wherein a paper of 0.5 t or less is used as a release substrate.
Lamp manufacturing method. 5. The method of manufacturing a flexible dispersion type EL lamp according to claim 1, wherein a plastic film of 0.5 t or less is used as the peeling substrate. 6. The method for producing a flexible dispersed EL lamp according to claim 1, wherein a laminate of a plastic film and a metal foil is used as the release substrate. 7. The method of manufacturing a flexible dispersion type EL lamp according to claim 1, wherein a substrate impregnated with or coated with a silicone-based or surfactant-based release agent is used as the release substrate. 8. The flexible dispersion type E according to claim 1, wherein the back electrode is formed by printing and applying a conductive ink in which a conductive powder such as silver, copper or carbon is dispersed in a resin.
L lamp manufacturing method. 9. The method of manufacturing a flexible distributed EL lamp according to claim 1, wherein a printed circuit board formed by etching an electrode pattern is used as the back electrode. 10. The method of manufacturing a flexible dispersed EL lamp according to claim 1, wherein an adhesive is applied between the transparent electrode and the light emitting layer film to improve the adhesion strength. 11. A dielectric constant of 3 between the transparent electrode and the light emitting layer film.
The method for manufacturing a flexible dispersion type EL lamp according to claim 1, wherein the adhesive layer is formed of a film made of a thermoplastic resin having a thickness of 20 μm or less. 12. The method for manufacturing a flexible dispersed EL lamp according to claim 1, wherein a metal foil is used as the back electrode.