JPH10208878A - Manufacture of el panel and el panel manufacturing device - Google Patents

Abstract

PROBLEM TO BE SOLVED: To restrain generation of bubble and wrinkles or the like being a reducing cause of light emitting efficiency or the like by restraining partial adhesion of a laminated material before thermocompression bonding when an EL element part and an EL panel by sealing it by packaging films are manufactured by thermocompression roller bonding. SOLUTION: In the case of thermally compressing a laminated material to constitute an EL element part or a laminated material 23 where packaging films are respectively arranged on both sides of the EL element part by passing it between heat rollers 11 and 12 by sandwiching it by a pair of upper and lower carrier films 13 and 14, the laminated material 23 is cooled so that a temperature of the laminated material 23 before reaching between the heat rollers 11 and 12 holds a temperature lower than its adhesive temperature. For example, a carrier table 21 to carry the carrier film 4 is arranged in the front stage of the heat rollers 11 and 12, and the carrier table 21 is cooled by blowing cooling air from an air supply nozzle 24 against the under surface side of this carrier table 21, and the laminated material 23 is indirectly cooled thereby.

Description

DETAILED DESCRIPTION OF THE INVENTION

[0001]

The present invention relates to a method and an apparatus for manufacturing an EL (electroluminescence) panel.

[0002]

2. Description of the Related Art In recent years, for example, an organic dispersion-type EL panel has begun to be frequently used as a light-weight and thin-type surface light-emitting body having excellent flexibility in shape. Such an organic dispersion type EL panel is widely used for various uses including a liquid crystal display device and a backlight of various display panels.

In the conventional manufacturing process of an organic dispersion type EL panel, first, phosphor particles such as ZnS are dispersed and contained in an organic polymer on a back electrode made of Al foil or the like via a reflective insulating layer. A transparent electrode layer (transparent electrode sheet) in which a luminous body layer is formed by lamination, and a transparent insulating film is provided on the luminous body layer with a transparent electrode made of an ITO vapor-deposited film or the like;
An EL element is manufactured by thermocompression bonding of a laminate in which hygroscopic films such as a 6-nylon film are sequentially laminated.

A thermo roll laminator is used for thermocompression bonding of a laminate in which the above-described back electrode, reflective insulating layer, luminescent layer, transparent electrode sheet, and hygroscopic film are laminated in this order. Specifically, as shown in FIG. 4, the laminate 1 is sandwiched between carrier films 2 and 3 such as an Al film and passed between a pair of heat rolls 4 and 5 to perform thermocompression bonding of the laminate 1. ing.

[0005] At this time, it is necessary to apply heat evenly to the laminate 1 when passing it between the heat rolls 4 and 5, and to press the laminate 1 together. Alternatively, in a state where one end is sandwiched between the heat rolls 4 and 5, the radiant heat from the heat rolls 4 and 5 and the carrier films 2 and 3 heated thereby make the laminate 1 partially uneven before the thermocompression bonding. There was a problem of adhesion.

The above-described partial bonding of the laminate 1 causes bubbles and wrinkles to be generated during the subsequent thermocompression bonding by the heat rolls 4 and 5, and causes the generation of the bubbles and wrinkles in the thermocompression bonded product, that is, the EL element portion. It has become. For example, bubbles generated between the luminous body layer and the transparent electrode sheet or between the back electrode and the luminous body layer generate a non-light-emitting portion, and bubbles and wrinkles generated between other layers lower the luminous efficiency. Will be brought. Further, the portion where bubbles, wrinkles, and the like are generated has a low light transmission amount, and thus causes light emission unevenness (luminance unevenness).

In addition, the EL element portion made of the above-mentioned thermocompression-bonded product is further laminated with a packaging film on both sides thereof, and the outer periphery of the packaging film is thermocompression-bonded to produce an organic dispersion type EL panel. I have.

[0008] A similar hot roll compression type laminator is used for the thermocompression bonding of the packaging film. However, similar to the thermocompression bonding of the laminate constituting the EL element portion, the lamination is performed before the thermocompression bonding. There is a problem that the packaging film partially adheres unevenly. Bubbles, wrinkles, and the like also occur due to the partial adhesion of the packaging film, which causes a reduction in the luminous efficiency and uniformity of the organic dispersion type EL panel.

[0009]

As described above, in the conventional manufacturing process of an EL panel, a hot roll is used for thermocompression bonding of a laminate constituting an EL element portion and a laminate having a packaging film disposed on both sides thereof. There is a problem that the laminate is partially and non-uniformly adhered before the thermocompression bonding due to the radiant heat from the carrier and the carrier film heated thereby. The adhesion of the laminate before the thermocompression bonding causes bubbles, wrinkles, and the like.

The air bubbles and wrinkles generated in the EL element portion and the panel in which the EL element portion is sealed with a packaging film cause a reduction in the luminous efficiency and uniformity of the EL panel. It is required to suppress partial adhesion of objects.

SUMMARY OF THE INVENTION The present invention has been made to address such a problem. When an EL element portion and an EL panel in which the EL element portion is sealed with a packaging film are manufactured by hot roll pressing, the EL device portion before the thermocompression bonding is used. By suppressing the partial adhesion of the laminate, the luminous efficiency and the uniformity thereof are excellent.
It is an object of the present invention to provide an EL panel manufacturing method and an EL panel manufacturing apparatus that enable an L panel to be manufactured with high reproducibility.

[0012]

The first E in the present invention is described.
The method for manufacturing an L panel includes, as described in claim 1, a laminate forming an EL element portion in which at least a back electrode layer, a reflective insulating layer, a luminous body layer, and a transparent electrode layer are sequentially laminated.
In a method for manufacturing an EL panel, comprising a step of passing between hot rolls and sandwiching between a pair of upper and lower carrier films and performing thermocompression bonding, a temperature of the laminate before reaching between the hot rolls is lower than the bonding temperature. The method is characterized in that the laminate is cooled so as to be held.

The above-described first EL panel manufacturing method includes:
Further, as described in claim 2, a transport table for transporting one carrier film is provided at a stage preceding the hot roll, and the EL device part is formed on the carrier film located on the transport table. And cooling the transfer table so that the temperature of the laminate is lower than the bonding temperature.

According to a second aspect of the invention, there is provided a method of manufacturing an EL panel, comprising laminating at least a back electrode layer, a reflective insulating layer, a luminous body layer and a transparent electrode layer in this order, and performing thermocompression bonding. Manufacturing of an EL panel including a step of passing a laminate in which a packaging film is arranged on both sides of an element portion between a pair of upper and lower carrier films and passing between hot rolls, and thermocompression bonding an outer peripheral portion of the packaging film. The method is characterized in that the laminate is cooled such that the temperature of the laminate before reaching between the hot rolls remains below its bonding temperature.

Further, the first EL panel manufacturing apparatus according to the present invention, as described in claim 4, comprises an EL element portion in which at least a back electrode layer, a reflective insulating layer, a luminous layer and a transparent electrode layer are sequentially laminated. The constituent laminate or the EL
A laminate in which the packaging films are arranged on both sides of the element portion is passed while being sandwiched between a pair of upper and lower carrier films, and a pair of heat rolls for thermocompression bonding the laminate, and before reaching between the heat rolls. And a cooling means for maintaining the temperature of the laminate at a temperature lower than the bonding temperature.

The second EL panel manufacturing apparatus according to the present invention constitutes an EL element section in which at least a back electrode layer, a reflective insulating layer, a luminous layer and a transparent electrode layer are sequentially laminated. A laminate, or a laminate in which packaging films are arranged on both sides of the EL element portion, respectively, are passed through in a state sandwiched between a pair of upper and lower carrier films, and a pair of heat rolls for thermocompression bonding the laminate,
A transport table that is provided in a preceding stage of the heat roll and transports one of the carrier films of the pair of upper and lower carrier films, and a temperature of the laminate placed on the carrier film located on the transport table. And cooling means for cooling the transfer table so as to keep the temperature lower than the bonding temperature.

In the method and apparatus for manufacturing an EL panel according to the present invention, the laminate is cooled so that the temperature of the laminate before reaching between the hot rolls is kept lower than the bonding temperature. In addition, partial adhesion of the laminate before thermocompression bonding can be suppressed. Therefore, since it is possible to significantly suppress air bubbles and wrinkles between the layers of the EL element portion and the EL panel in which the EL element portion is sealed with a packaging film, an EL panel having excellent luminous efficiency and uniformity can be obtained. Can be manufactured well.

A transport table for transporting one of the carrier films is provided before the heat roll, and the temperature of the laminate is easily and reliably maintained at a temperature lower than the bonding temperature by cooling the transport table. be able to. Furthermore, by placing the laminate on the carrier film located on such a transport table, the laminate can be automatically transported, and the manufacturing efficiency of the EL panel can be increased.

[0019]

Embodiments of the present invention will be described below with reference to the drawings.

FIG. 1 is a diagram schematically showing the configuration of an embodiment of an EL panel manufacturing apparatus according to the present invention. EL shown in FIG.
The panel manufacturing apparatus, that is, the hot roll press-type laminator is used to move a pair of upper and lower heat rolls 11 and 12 between a pair of upper and lower carrier films 13 and 14 made of, for example, an Al film.
Are configured to pass through.

A pair of carrier films 13 and 14 are supplied from film supply rolls 15 and 16, respectively, and are wound up by roll-up rolls 1 arranged at the subsequent stage of heat rolls 11 and 12.
It is wound up by 7 and 18. In the drawings, 19 and 20 are guide rollers. Such a carrier film 1
The upper carrier film 13 is directly supplied between the pair of heating rolls 11 and 12 from the supply roll 15.

On the other hand, the lower carrier film 14 is supplied between a pair of heat rolls 11 and 12 from a supply roll 16 via a transfer table 21. That is, the lower carrier film 1 is provided in front of the pair of heat rolls 11 and 12.
The transport table 21 for transporting the heat rolls 4 is provided along the traveling direction between the heat rolls 11 and 12. The lower carrier film 14 supplied from the supply roll 16 is sent to the above-described transport table 21 via the guide roller 22 and further sent between the heat rolls 11 and 12.

A laminate (thermocompression laminate) 23 thermocompression-bonded by a pair of heat rolls 11 and 12, ie, an EL element in which a back electrode layer, a reflective insulating layer, a luminous body layer, a transparent electrode layer and the like are laminated in this order. And a laminate in which packaging films are arranged on both sides of an EL element portion obtained by thermocompression-bonding the laminate, are placed on the lower carrier film 14 located on the transport table 21. Is placed.

The heat-pressed laminate 23 placed on the lower carrier film 14 is
Is transported between the heat rolls 11 and 12 as the paper moves.
Here, an air supply nozzle 24 is provided below the transfer table 21 as cooling means. Transport table 2
1 and lower carrier film 1 located on the upper side
4 is cooled by the cooling air supplied from the air supply nozzle 24. With the cooling of the transport table 21 and the lower carrier film 14, the thermocompression-bonded laminate 23 on the lower carrier film 14 is indirectly cooled to a temperature before reaching the space between the hot rolls 11 and 12. Is kept below its bonding temperature.

As described above, by keeping the temperature of the heat-compressed laminate 23 before reaching between the hot rolls 11 and 12 at a temperature lower than the bonding temperature, the heat-pressed laminate 23 is partially heated before the thermocompression bonding. Nonuniform adhesion can be prevented. That is, the thermocompression-bonded laminate 23 is adhered for the first time when it passes between the hot rolls 11 and 12, so that the thermocompression-bonded laminate 23 can be thermocompressed uniformly.

The amount of cooling air supplied from the air supply nozzle 24 serving as a cooling means is controlled by the transfer table 21.
The temperature is set in accordance with the ambient temperature of the thermocompression-bonded laminate 23 and the bonding temperature of the thermocompression-bonded laminate 23. For example, it is preferable to set the amount of air so that the temperature of the thermocompression-bonded laminate 23 is about 293 to 313K. . The cooling means is an air supply nozzle 24.
Not limited to this, various cooling means can be used. For example, a cooling jacket is installed in the transfer table 21,
Similar effects can be obtained by circulating cooling water through the cooling jacket.

Further, the thermocompression-bonded laminate 23 before thermocompression bonding may be directly cooled without using the transport table 21.
The use of the transport table 21 allows the thermocompression-bonded laminate 23 before thermocompression bonding to be efficiently cooled.
Further, the thermocompression-bonded laminate 23 is placed on the lower carrier film 14 located on the transport table 21, and the thermocompression-bonded laminate 23 is fed between the heat rolls 11 and 12, so as to be heated. The automatic transfer of the crimped laminate 23 becomes possible. Thereby, the production efficiency of the organic dispersion type EL panel can be improved. As described above, the transfer table 21 exerts effects on both cooling and automatic transfer of the thermocompression-bonded laminate 23 before thermocompression bonding.

The thermocompression-bonded laminate 23 is made up of hot rolls 11 and 12.
Immediately before, the sheet is sandwiched between the upper carrier film 13 and the lower carrier film 14, passes between the heat rolls 11 and 12, and is thermocompression-bonded (laminated). The laminate after the thermocompression bonding, that is, the thermocompression bonding material 25 is discharged when the carrier films 13 and 14 are separated by the guide rollers 19 and 20 arranged at the subsequent stage of the heat rolls 11 and 12.

Next, a process of manufacturing an organic dispersion type EL panel using the above-described EL panel manufacturing apparatus will be described.

First, the fabrication of the EL element will be described.
As shown in FIG. 2, a paste for forming the reflective insulating layer 32 and a paste for forming the light emitting layer 33 are sequentially applied on, for example, an Al foil to be the back electrode layer 31, and then dried. As the paste for forming the reflective insulating layer, for example, T
A material in which a highly reflective inorganic oxide powder such as TiO ₂ or BaTiO ₃ is dispersed and contained in an organic polymer having a high dielectric constant such as cyanoethylcellulose is used. As a paste for forming a light emitting layer, ZnS or the like is used. The phosphor particles are dispersed and contained in an organic polymer having a high dielectric constant such as cyanoethyl cellulose.

On the other hand, a transparent electrode sheet (transparent electrode layer) 34 is formed by depositing an ITO vapor-deposited film or the like on a transparent insulating film such as a polyester film. Next, a conductive paste such as an Ag paste is printed on the transparent electrode sheet 34 to form a power supply unit (not shown). Such a transparent electrode sheet 14 is formed by laminating a reflective insulating layer 32 and a luminous layer 33 on the above-mentioned back electrode layer 31 in this order.
3 and a hygroscopic film such as a 6-nylon film as a hygroscopic layer 35 as a hygroscopic layer 35 to form an EL element portion. Is prepared.

At this time, although not shown, the back electrode layer 3
In FIG. 1, a back electrode lead is temporarily fixed on the back surface side. In addition, a transparent electrode lead is temporarily fixed to a power supply unit where the transparent electrode layer 34 is not shown.

Then, the laminate 36 (the laminate 23 to be thermally compressed) constituting the above-mentioned EL element portion is thermocompression-bonded by the hot roll compression laminator shown in FIG. Specifically, the laminate 36 (the thermocompression-bonded laminate 23) is placed on the lower carrier film 14 located on the transport table 21. The thermocompression-bonded laminate 23 placed on the lower carrier film 14 is automatically sent between the heat rolls 11 and 12 as the lower carrier film 14 moves, and Immediately before the upper carrier film 13
And between the hot rolls 11 and 12 and thermocompression-bonded (laminated).

During the thermocompression bonding of the laminate 36 constituting the EL element portion, the temperature of the heat rolls 11 and 12 is usually 43
It is set to about 3K. Here, when the cooling of the transfer table 21 is not performed, the temperature of the transfer table 21 immediately before the hot rolls 11 and 12 rises to about 403K due to radiant heat from the hot rolls 11 and 12, and the like before the thermocompression bonding. Partial adhesion of the laminate 36 occurs. On the contrary,
In the heat roll pressure bonding type laminator of the above embodiment, the temperature of the transfer table 21 is cooled to about room temperature by supplying cooling air from the air supply nozzle 24 to the lower surface side of the transfer table 21. The laminate 36 indirectly cooled by 21 does not partially adhere before thermocompression bonding.

Accordingly, the laminate 36 constituting the EL element portion is formed.
Are bonded and thermocompressed for the first time when passing between the heat rolls 11 and 12. In this way, when passing between the heat rolls 11 and 12, the layers are first adhered to each other so that the laminate 36 has the heat rolls 11 and 1.
2, heat can be applied evenly and pressure can be applied, so that generation of bubbles and wrinkles can be greatly suppressed. As described above, such bubbles and wrinkles cause a reduction in the luminous efficiency and the uniformity of the organic dispersion type EL panel, and therefore, as described above, the layers between the layers 36 of the EL element portion are uniformly formed. By bonding and thermocompression bonding to greatly suppress the generation of bubbles and wrinkles, it is possible to produce an organic dispersion-type EL panel having excellent luminous efficiency and uniformity in the plane with good reproducibility. In addition, by automatically transporting the laminate 36 using the transport table 21, the organic dispersion EL
Panel manufacturing efficiency can be increased.

As shown in FIG. 3, the above-mentioned EL element portion is formed of a packaging made of a transparent film having a low water-moisture permeability, such as a polychlorotrifluoroethylene film, on both sides of a thermocompression bonding member 36 '. Film 3
7 and 38 are arranged, and the laminate 39 is thermocompressed and sealed with the hot roll crimping laminator shown in FIG. 1 in the same manner as the laminate 36, whereby an organic dispersion type EL panel is manufactured.

Specifically, the thermocompression bonding material 3 serving as the EL element portion
A laminate 39 (package 23 to be thermally compressed) in which packaging films 37 and 38 are arranged on both sides of 6 ′ is placed on the lower carrier film 14 located on the transport table 21, and the upper carrier film The sheet is passed between the hot rolls 11 and 12 by being sandwiched between the lower roll 13 and the lower carrier film 14. The outer peripheral portions of the packaging films 37 and 38 are thermocompression-bonded, thereby sealing the EL element portion composed of the thermocompression bonded product 36 '.

During the thermocompression bonding of the laminate 39 constituting the EL panel, the temperature of the heat rolls 11 and 12 is usually
It is set at around 433K. Even in such a situation, by supplying cooling air from the air supply nozzle 24 to the lower surface side of the transfer table 21 and cooling the temperature of the transfer table 21 to about room temperature, the outer peripheral portions of the packaging films 37 and 38 are cooled. Thermocompression bonding material 3 which becomes non-uniform adhesion and EL element portions of packaging films 37 and 38
Non-uniform adhesion to 6 'can be suppressed. Therefore, the generation of bubbles and wrinkles can be significantly suppressed, and the thermocompression bonding material 36 ′ serving as the EL element portion can be uniformly sealed with the packaging films 37 and 38. The luminous efficiency of the panel and its in-plane uniformity can be improved.

As described above, by using the apparatus for manufacturing an EL panel of the present invention, an organic dispersion type EL panel having excellent luminous efficiency and in-plane uniformity can be manufactured with good reproducibility. In the above-described manufacturing process of the organic dispersion type EL panel, both the thermocompression bonding of the laminate 36 constituting the EL element portion and the thermocompression bonding of the panel laminate 39 sealed with a packaging film are performed. EL of the invention
Although the case where the panel manufacturing apparatus is applied has been described, the present invention can be applied to only one step.

[0040]

As described above, according to the EL panel manufacturing method and the EL panel manufacturing apparatus of the present invention, the EL panel
EL element and its sealed with packaging film
When producing a panel by hot roll compression, partial adhesion of the laminate before thermocompression can be suppressed. This makes it possible to significantly suppress the occurrence of bubbles, wrinkles, and the like, so that an EL panel having excellent luminous efficiency and uniformity can be manufactured with good reproducibility.

[Brief description of the drawings]

FIG. 1 is a diagram schematically showing a configuration of an embodiment of an EL panel manufacturing apparatus of the present invention.

FIG. 2 is a diagram illustrating an E supplied to the EL panel manufacturing apparatus shown in FIG.
It is sectional drawing which shows an example of the laminated body which comprises an L element part.

FIG. 3 is a cross-sectional view showing an example of a panel laminate supplied to the EL panel manufacturing apparatus shown in FIG.

FIG. 4 is a diagram schematically illustrating an example of a configuration of a conventional EL panel manufacturing apparatus (a hot roll compression laminator).

[Explanation of symbols]

 11, 12 Heat rolls 13, 14 Carrier film 21 Carrier table 23, 36, 39 Heat-pressed laminate 24 Air supply nozzle 31 Back electrode layer 32 Reflective insulating layer 33 … Luminescent layer 34… Transparent electrode sheet (transparent electrode layer) 37, 38… Packaging film

Claims (5)

[Claims] 1. A laminate constituting an EL element portion in which at least a back electrode layer, a reflective insulating layer, a luminous body layer, and a transparent electrode layer are sequentially laminated is passed between hot rolls with a pair of upper and lower carrier films interposed therebetween. In a method for manufacturing an EL panel having a step of thermocompression bonding, the laminate is cooled so that the temperature of the laminate before reaching the space between the hot rolls is maintained at a temperature lower than its bonding temperature. EL panel manufacturing method. 2. The method for manufacturing an EL panel according to claim 1, further comprising: a transport table for transporting one of the carrier films in front of the hot roll, and the EL table on a carrier film located on the transport table. A method for manufacturing an EL panel, comprising mounting a laminate constituting an element portion and cooling the transport table so that the temperature of the laminate is lower than the bonding temperature. 3. A laminate in which at least a back electrode layer, a reflective insulating layer, a luminous body layer, and a transparent electrode layer are sequentially laminated and a packaging film is disposed on both sides of a thermocompression-bonded EL element portion. In a method for manufacturing an EL panel, comprising a step of sandwiching a carrier film between heat rolls and thermocompression bonding an outer peripheral portion of the packaging film, the temperature of the laminate before reaching the space between the heat rolls is determined by bonding A method for manufacturing an EL panel, comprising cooling the laminate so as to maintain a temperature lower than the temperature. 4. A laminate constituting an EL element portion in which at least a back electrode layer, a reflective insulating layer, a light emitting layer and a transparent electrode layer are sequentially laminated, or a laminate in which a packaging film is disposed on both sides of the EL element portion, respectively. The article is passed in a state sandwiched by a pair of upper and lower carrier films, and a pair of heat rolls for thermocompression bonding the laminate, and the temperature of the laminate before reaching the heat roll,
An EL panel manufacturing apparatus, comprising: a cooling means for maintaining a temperature lower than the bonding temperature. 5. A laminate constituting an EL element portion in which at least a back electrode layer, a reflective insulating layer, a light emitting layer and a transparent electrode layer are sequentially laminated, or a laminate in which a packaging film is disposed on both sides of the EL element portion, respectively. A pair of heat rolls for passing an object in a state sandwiched by a pair of upper and lower carrier films and thermocompression-bonding the laminate, provided at a stage preceding the heat roll, and one of the carrier films of the pair of upper and lower carrier films And a cooling table that cools the transport table so as to maintain the temperature of the laminate placed on the carrier film positioned on the transport table at a temperature lower than the bonding temperature. Means for manufacturing an EL panel.