KR20100125010A - Method for manufacturing display device - Google Patents

Abstract

PURPOSE: A method for manufacturing a display device is provided to accurately form a pattern and a uniform thin film layer without the non-uniformity of the interface of a thin film layer. CONSTITUTION: A scriber(117) is installed on one side of a pattern forming roller(113) to rack out resins on the outer side of the pattern forming roller except a pattern groove(114). A UV curing device(118) is installed on one side of a blanket roller(115) to cure the resin of an organic thin film layer by irradiating UV to the outer surface of the blanket roller. The outer surface of the resin supply roller is stained with the resin of the organic thin film layer of a resin supply unit(111) while a resin supply roller(112) is rotated. The pattern forming roller receives the resin of the organic thin film layer resin from the resin supply roller while rotating in a reverse direction to the resin supply roller.

Description

Method for Manufacturing Display Device

The present invention relates to a method for manufacturing a display device such as OLED (Organic Light Emitting Diodes) or PLED (Polymer Light Emitting Diode), and more particularly, to easily form a plurality of layers on a substrate of the display device using a release film. The present invention relates to a manufacturing method of a display apparatus capable of realizing a high quality display apparatus by minimizing the breakage of the interface between the stacked and stacked layers.

Organic Light Emitting Diodes (OLEDs) recombine electrons and holes injected through an anode and a cathode to an organic thin film to form excitons, and light of a specific wavelength is generated by energy from the excitons formed. Self-luminous display device using the phenomenon.

The organic light emitting diode (OLED) is an anode electrode to which positive power is applied to a screen display area, which is a part where a screen is displayed by depositing an ITO metal on a glass substrate and patterning the electrode into a desired shape through a photoresist process. And an organic material having a predetermined chromophore is deposited to form an organic electroluminescent unit that emits light by the flow of current, and a cathode is formed on the upper surface of the organic electroluminescent unit, that is, aluminum (Al) And depositing an electrode material such as magnesium (Mg) to form a cathode electrode.

In general, organic light emitting diodes (OLEDs) may be classified into small molecular LEDs (OLEDs) and polymer light emitting diodes (PLEDs) according to molecular weight of materials.

Bi-polymer LEDs have a mono-layer or bi-layer structure, and because the device is manufactured and polymerized in a precursor state, the lifespan is longer than that of low-molecular OLED, while the choice of materials It is not easy, and there is a disadvantage in that the efficiency is relatively low because the injection layers of holes and electrons are not manufactured separately.

In addition, the polymer LED is manufactured through a solution process in which a polymer is dissolved in a solvent to form a thin film layer, and a spin coating method, a blade coating method, a roller printing method, an ink jet (ink jet) is manufactured using a printing method, etc., due to the solvent property of the solvent, when forming a multilayered thin film, the interface is formed unevenly, which causes a problem that the electrode characteristics of the device worsen and cause defects.

In addition, the method of forming a thin film using spin coating is a laboratory-level manufacturing method, and there are various problems depending on productivity and the size of the product, and the blade coating method has a limitation in controlling the size of the pattern and the spacing between pixels, and printability. As the failure rate due to failure increases, it is rarely applied at present.

The roller printing method is a technique using a gravure roller, the printing of the pattern and the control of the shape is simple, but there is a disadvantage in printability due to the adhesive surface of the substrate and the roller point.

The inkjet printing method is the best technology of printing and quality of the pattern developed so far, but the equipment is expensive, the clogging of the nozzle frequently occurs, the low-viscosity material to solve this problem has the disadvantage of causing a shrinkage problem.

The present invention is to solve the above problems, the object of the present invention is to form a display device with excellent reliability by forming a pattern with the interface of the thin film layer uniformly, manufacturing process is simple and manufacturing The present invention provides a method of manufacturing a display device having low cost and high productivity.

In the present invention for achieving the above object, in the manufacturing method of a display device comprising a substrate and a plurality of thin film layers laminated on the surface of the substrate, a thin film layer is applied to each surface on which the adhesive of the plurality of release films is applied A first step of doing; And a second step of laminating a plurality of thin film layers on the surface of the substrate or the base film by continuously performing a process of peeling the release film after adhering the thin film layers of the respective release films to the surface of the substrate or the surface of the base film. It provides a method for manufacturing a display device, characterized in that configured.

According to the present invention, a plurality of thin film layers can be easily formed by forming a desired thin film layer on the release film and then transferring the thin film layer of the release film onto a substrate or another thin film layer on the substrate. Therefore, a uniform thin film layer can be formed without the phenomenon that the interface of a thin film layer becomes nonuniform, and an accurate pattern can be formed.

In addition, since a thin film layer is formed on a release film and the thin film layer formed on the release film is transferred onto a substrate or another thin film layer on the substrate, a display device having a multi-layer structure can be manufactured, thereby improving productivity and manufacturing at low cost. It is possible, and there is an advantage to manufacture a display device of excellent quality.

Hereinafter, with reference to the accompanying drawings will be described in detail a preferred embodiment of the manufacturing method of the display device according to the present invention.

Referring to FIG. 1, the method of manufacturing a display apparatus according to the present invention includes forming a predetermined thin film layer on each of a plurality of release films, and forming a thin film layer of each release film on a surface of a substrate or a base film. Laminating a plurality of thin films on the surface of the substrate or the base film by performing a process of peeling the release film after adhering to the surface (S2), laminating the thin film layer on the substrate or the base film or the substrate After the thin film layer is laminated on the substrate or the substrate film is composed of a step (S3) of heat treatment or UV curing.

Referring to Figures 2 to 4 as an embodiment of the manufacturing method of the display device according to the present invention will be described a method of manufacturing a polymer light emitting diode (PLED) as follows.

First, as shown in FIG. 2, a polymer light emitting diode (PLED) is formed of an anode ITO electrode layer 2, an organic thin film layer 3, and a cathode electrode layer 8 which are sequentially stacked on a glass substrate 1. )

The organic thin film layer 3 may include a hole injection layer (HIL) 4, a hole transport layer (HTL) 5, an organic light emitting layer (EML) 5, and an electron. ETL (electron transport layer) (7) or the like.

3 and 4 illustrate an embodiment of an apparatus for manufacturing a polymer light emitting diode (PLED) having the above configuration by applying the display device manufacturing method of the present invention.

First, an anode ITO electrode layer is deposited on a base film made of PAT or the like to produce an electrode film 2a, while an offset and roller scribing technique as shown in FIG. A hole injection layer (HIL) (4), a hole transport layer (HTL) (5), and an organic light emitting layer (EML) are applied to a plurality of release films 4a, 5a, 6a, and 7a using a mixed organic thin film manufacturing apparatus. 6) The electron transport layer (ETL) 7 is applied in a predetermined pattern, respectively.

The organic thin film layer manufacturing apparatus shown in FIG. 3 includes a resin supply part 111 containing a polymer resin R for forming an organic thin film layer (for example, a hole injection layer) and rotatably installed on an upper side of the resin supply part 111. The outer peripheral surface of the lower end portion of the resin supply roller 112 immersed in the organic thin film resin (R) contained in the resin supply unit 111, and is installed in contact with the upper side of the resin supply roller 112, the pattern corresponding to the organic thin film layer on the outer peripheral surface Pattern grooves 114 are formed to be connected to the pattern forming roller 113 and the upper side of the pattern forming roller 113 to receive the resin from the outer circumferential surface of the resin supply roller 112 into the pattern groove 114. Blanket roller 115 (blanket roller) is installed to receive the resin from the pattern groove 114 of the pattern forming roller 113 and the outer peripheral surface of the blanket roller 115 is installed in contact with the upper side of the blanket roller 115 Release film passing through the film (4a, 5a, 6a, 7a) ) Is pressed against the blanket roller 115, and the pressure roller 116 to bond the organic thin film resin to the release film (4a, 5a, 6a, 7a).

One side of the pattern forming roller 113 is provided with a scriber 117 is scraped so that the resin crushed on the outer surface of the pattern forming roller 113 is not stuck to the portion other than the pattern groove 114. In addition, one side of the blanket roller 115 is provided with a UV curing apparatus 118 for curing the organic thin film resin (R) by irradiating ultraviolet (UV) to the outer peripheral surface of the blanket roller 115.

The process of forming the organic thin film layers 4, 5, 6, and 7 on the release films 4a, 5a, 6a, and 7a by the organic thin film layer manufacturing apparatus 10 configured as described above is as follows.

When the resin feed roller 112 rotates, the organic thin film resin R of the resin feed part 111 is bound to the outer circumferential surface of the resin feed roller 112. At this time, the pattern forming roller 113 is rotated in the opposite direction to the resin supply roller 112 receives the thin organic layer layer resin (R) thinned to the resin supply roller (112).

The organic thin film resin R transferred to the pattern forming roller 113 passes through the scriber 117, and those remaining on the outside of the pattern groove 114 are removed and only those contained in the pattern groove 114 remain.

The organic thin film layer resin R accommodated inside the pattern groove 114 of the pattern forming roller 113 has a relatively high surface energy compared to the pattern forming roller 113 at a portion in contact with the blanket roller 115. The outer peripheral surface of the roller 115 is moved.

The organic thin film resin (R) transferred to the blanket roller 115 is cured by the UV curing apparatus 118 to have a certain viscosity, and then releases passing between the pressure roller 116 and the blanket roller 115. It is bonded to one surface of the films 4a, 5a, 6a, and 7a.

Of course, the organic thin film layer may be formed on the release film by a printing method or an inkjet method different from this embodiment.

Meanwhile, as described above, when the hole injection layer 4 or the hole transport layer 5, the organic light emitting layer 6, and the electron transport layer 7 are applied to each of the release films 4a, 5a, 6a, and 7a, the same is illustrated in FIG. The organic thin film layers of each of the release films 4a, 5a, 6a, and 7a are sequentially stacked on the electrode film 2a using an apparatus as shown.

In more detail, the electrode film 2a on which the ITO electrode layer is deposited is mounted on the feeding spool 10, and one end of the electrode film 2a is wound by passing the first to fifth pressure rollers 41 to 45. It is installed to be wound around the spool (20). In addition, the spools 31 to 35 of the functional film 9 which serve to protect one surface of the release films 4a, 5a, 6a, and 7a coated with the organic thin film layer and the electrode film 2a. Mount on. For better understanding, the spool on which the release film 4a to which the hole injection layer (HIL) 4 is applied is mounted is referred to as a first spool 31, and the spool on which the functional film 9 is mounted is referred to as a second spool ( 32) a spool equipped with a release film 5a coated with a hole transport layer (HTL) 5, a third spool 33, and a release film 6a coated with an organic light emitting layer (EML) 6; A spool on which the release film 7a to which the fourth spool 34 and the electron transport layer (ETL) 7 is applied is mounted will be described as a fifth spool 35.

The release films 4a, 9, 5a, 6a, and 7a mounted on the first to fifth spools 31 to 35 respectively include the first to fifth pressure rollers 41 to 45 together with the electrode film 2a. After passing through and adhered to the surface of the electrode film 2a, it is wound on a recovery spool not shown.

The electrode film 2a and the release film are rotated by rotating the winding spool 20 and the recovery spool (not shown) while the electrode film 2a and the release films 4a, 5a, 6a, and 7a configured as described above are mounted. When winding the 4a, 5a, 6a, and 7a, the electrode film 2a and the release films 4a, 5a, 6a, and 7a pass between the first to fifth pressure rollers 41 to 45, and the release film 4a. , 5a, 6a, and 7a of the thin film layers 4, 5, 6, and 7 are sequentially transferred onto the electrode film 2a.

That is, the release film 4a coated with the hole injection layer HIL 4 is transferred to the outer surface of the ITO electrode layer of the electrode film 2a while passing through the first pressing roller 41 together with the electrode film 2a. Are bonded. Since the hole injection layer 4 is made of a polymer material, the hole injection layer 4 is adhered to the electrode film 2a without an adhesive.

Subsequently, while the electrode film 2a and the functional film 9 pass between the second press rollers 42, the functional film 9 is formed on the other side of the electrode film 2a, that is, the surface opposite to the surface on which the ITO electrode layer is formed. ) Is joined.

Thereafter, the electrode film 2a passes through the third pressure roller 43, the fourth pressure roller 44, and the fifth pressure roller 45 in sequence, and the hole injection layer 4 laminated on the electrode film 2a. ), The hole transport layer 5, the organic light emitting layer 6, and the electron transport layer 7 are sequentially transferred and stacked. The release films 4a, 5a, 6a, 7a and the functional film 9 passing through the first to fifth pressure rollers 41 to 45 are wound on a recovery spool (not shown).

As described above, the hole injection layer 4, the hole transport layer 5, the organic light emitting layer 6, and the electron transport layer 7 are sequentially stacked on one surface while passing through the first to fifth pressure rollers 41 to 45. The electrode film 2a having the functional film 9 bonded to the other surface is wound on the winding roller 20.

Meanwhile, as described above, the electrode films 2a and the release films 4a, 5a, 6a, and 7a are passed between the pressure rollers 41 to 45 to transfer and laminate the thin film layers on the electrode films 2a, and then heat treated or It is preferable to perform an ultraviolet (UV) curing treatment to increase the interfacial adhesion of each thin film layer. Of course, such heat treatment or ultraviolet (UV) curing may be performed in the process of laminating a plurality of thin film layers.

In addition, it is preferable to add a conductive polymer material to the organic thin film layer for adhesion between the electrode film 2a and the organic thin film layer.

The electrode film 2a wound on the winding roller 20 is then conveyed to another process position so that the functional film 9 is separated from the electrode film 2a and then on the glass substrate 1 (see FIG. 1). A cathode electrode 8 (see FIG. 1) is deposited on the bonded and stacked organic thin film layers 3 to form a display device.

The display device manufacturing method of the above-described embodiment relates to a method of manufacturing a polymer light emitting diode (PLED), but the present invention can be applied to the display device such as an organic light emitting diode (OLED) or the like.

1 is a flow chart showing an embodiment of a display device manufacturing method according to the present invention

2 is a cross-sectional view showing the configuration of a polymer light emitting diode (PLED)

3 is a configuration diagram showing an embodiment of an apparatus for manufacturing an organic thin film layer on a release film as an embodiment of a method of manufacturing a polymer light emitting diode (PLED) according to the present invention;

Figure 4 is a configuration diagram showing an embodiment of a device for transferring the organic thin film layers applied to the release film to the electrode film as an embodiment of the manufacturing method of the polymer light emitting diode (PLED) according to the present invention

Explanation of symbols on the main parts of the drawings

1: glass substrate 2: anode ITO electrode layer

3: organic thin film layer 4: hole injection layer (HIL)

5: hole transport layer (HTL) 6: organic light emitting layer (EML)

7: electron transport layer (ETL) 8: cathode electrode

9: functional film 2a: electrode film

4a ~ 7a: Release film 10: Feeding Spool

20: winding spool 31 to 35: first to fifth spool

41 ~ 45: 1st ~ 5th pressure roller 111: Resin supply part

112: resin supply roller 113: pattern forming roller

114: pattern groove 115: blanket roller

116: pressure roller

Claims (7)

In the manufacturing method of a display device comprising a substrate and a plurality of thin film layers laminated on the surface of the substrate, A first step of applying a thin film layer to each of the surfaces on which the adhesive of the plurality of release films is applied; Attaching the thin film layers of the respective release films to the surface of the substrate or the surface of the base film, and then performing the process of transferring the thin film layer by peeling the release film, thereby laminating a plurality of thin film layers on the surface of the substrate or the base film. A manufacturing method of a display apparatus, comprising the second step. The method of claim 1, wherein the step of depositing an ITO electrode layer on the surface of the substrate or the surface of the base film prior to performing the second step, to transfer the thin film layer of the release film on the ITO electrode layer in the second step Method of manufacturing a display device, characterized in that. The method of claim 1, wherein the thin film layer formed on the substrate or the base film is an organic thin film layer forming an organic light emitting diode (OLED) or a polymer light emitting diode (PLED). The method of claim 1, further comprising a third step of increasing the interfacial adhesion between the thin film layers by performing heat treatment or ultraviolet (UV) curing after performing the second step or after performing the second step. Method of manufacturing a display device characterized in that. The method of claim 1, wherein in the first step, a thin film layer is formed on one surface of the release film by a printing method. The display apparatus of claim 1, wherein the second step sequentially transfers and laminates a thin film layer on the base film while sequentially passing a plurality of pairs of pressure rollers rotating at a predetermined distance from the base film and the release film. Method of manufacturing the device. The method of claim 1, wherein the conductive polymer is added to the thin film layer to apply the thin film layer to the release film.

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