TWI692896B - Method of manufacturing organic light-emitting diode and organic light-emitting diode - Google Patents

Method of manufacturing organic light-emitting diode and organic light-emitting diode Download PDF

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TWI692896B
TWI692896B TW105126135A TW105126135A TWI692896B TW I692896 B TWI692896 B TW I692896B TW 105126135 A TW105126135 A TW 105126135A TW 105126135 A TW105126135 A TW 105126135A TW I692896 B TWI692896 B TW I692896B
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point
convex portions
mold
layer
emitting diode
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TW105126135A
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TW201714334A (en
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本鄉弘毅
篠塚啓
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日商王子控股股份有限公司
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    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K50/00Organic light-emitting devices
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C33/00Moulds or cores; Details thereof or accessories therefor
    • B29C33/42Moulds or cores; Details thereof or accessories therefor characterised by the shape of the moulding surface, e.g. ribs or grooves
    • BPERFORMING OPERATIONS; TRANSPORTING
    • B29WORKING OF PLASTICS; WORKING OF SUBSTANCES IN A PLASTIC STATE IN GENERAL
    • B29CSHAPING OR JOINING OF PLASTICS; SHAPING OF MATERIAL IN A PLASTIC STATE, NOT OTHERWISE PROVIDED FOR; AFTER-TREATMENT OF THE SHAPED PRODUCTS, e.g. REPAIRING
    • B29C59/00Surface shaping of articles, e.g. embossing; Apparatus therefor
    • B29C59/02Surface shaping of articles, e.g. embossing; Apparatus therefor by mechanical means, e.g. pressing
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00Electroluminescent light sources
    • H05B33/02Details
    • HELECTRICITY
    • H05ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
    • H05BELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
    • H05B33/00Electroluminescent light sources
    • H05B33/10Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
    • HELECTRICITY
    • H10SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
    • H10KORGANIC ELECTRIC SOLID-STATE DEVICES
    • H10K71/00Manufacture or treatment specially adapted for the organic devices covered by this subclass

Abstract

The present invention relates to a metallic mold including a flat surface and a plurality of protrusions on a main surface, wherein the average pitch between the plurality of protrusions is 50nm to 5μm, the average aspect ratio of the plurality of the protrusions is 0.01 to 1, 80% or more of the plurality of protrusions have a predetermined curved surface, and in the predetermined curved surface, when a first point is arbitrarily set and a second point is set at a position equal to a distance 1/10 of the average pitch away from the first point, the inclined angle of a second tangential plane which contacts the second point with respect to the first tangential plane which contacts the first position is 60° or less.

Description

有機發光二極體之製造方法及有機發光二極體 Manufacturing method of organic light-emitting diode and organic light-emitting diode

本發明係關於一種模具、有機發光二極體之製造方法及有機發光二極體。本案係基於2015年9月10日於日本申請之日本專利特願2015-178324號而主張優先權,並將其內容引用於此。 The invention relates to a mold, a method for manufacturing an organic light-emitting diode, and an organic light-emitting diode. This case claims priority based on Japanese Patent Application No. 2015-178324 filed in Japan on September 10, 2015, and the contents are cited here.

有機發光二極體係利用有機電致發光之發光元件。有機發光二極體一般而言具有於包含含有有機發光材料之發光層之有機半導體層之兩表面分別設置有陽極、陰極之構成。有機半導體層除了發光層以外,視需要具有電子注入層、電子傳輸層、電洞傳輸層、電洞注入層等。有機發光二極體具有視角依存性較少、消耗電力較少、可形成極薄者等之優點。 The organic light-emitting diode system uses organic electroluminescent light-emitting elements. Organic light-emitting diodes generally have a structure in which an anode and a cathode are provided on both surfaces of an organic semiconductor layer including a light-emitting layer containing an organic light-emitting material. In addition to the light-emitting layer, the organic semiconductor layer has an electron injection layer, an electron transport layer, a hole transport layer, a hole injection layer, etc. as needed. Organic light emitting diodes have the advantages of less viewing angle dependence, less power consumption, and extremely thin ones.

另一方面,有機發光二極體之光取出效率未必充分。光取出效率係自光之取出面(例如底部發光型之情形時為基體面)放出至大氣中之光能相對於在發光層產生的光能之比例。 On the other hand, the light extraction efficiency of the organic light emitting diode is not necessarily sufficient. The light extraction efficiency is the ratio of the light energy released into the atmosphere from the light extraction surface (for example, the base surface in the case of a bottom-emission type) relative to the light energy generated in the light-emitting layer.

作為使光取出效率降低之主要原因之一,存在表面電漿子之影響。於有機發光二極體中,發光層與作為金屬之陰極之間之距離較近。因此,於發光層產生之近場光之一部分於陰極之表面轉換為表面電漿子而消失,有機發光二極體之光取出效率降低。光取出效率係影響具備有機發光二極體之顯示器、照明等之亮度之指標,正在研究用以改善之各種方法。 為了提高光取出效率,於專利文獻1中,揭示了將凸部或凹部之二維晶格構造設置於金屬層(陰極)之表面之構造。金屬層表面之二維晶格構造將表面電漿子之能量轉換為光,並將所轉換之光向元件外部取出。於專利文獻1中,可反映設置於基體之二維晶格構造而獲得金屬層表面之二維晶格構造。具體而言,藉由於設置有二維晶格構造之基體上積層第1電極、包含發光層之有機半導體層、第2電極,而於第2電極之發光層側之面反映與基體同等之二維晶格構造。 一般而言,有機半導體層及第1、第2電極係藉由使用濺鍍或蒸鍍法之真空成膜法而形成。相對於此,於專利文獻2中,揭示了藉由旋轉塗佈法、噴墨法、狹縫式塗佈法等塗佈法而形成有機薄膜太陽電池中之有機半導體層。有機薄膜太陽電池具有與有機發光二極體相同之構成,有機發光二極體之有機半導體層亦可藉由塗佈法而形成。 [先前技術文獻] [專利文獻] [專利文獻1]國際公開第2012/60404號 [專利文獻2]國際公開第2014/208713號As one of the main reasons for lowering the light extraction efficiency, there is the effect of surface plasmons. In organic light-emitting diodes, the distance between the light-emitting layer and the metal cathode is relatively short. Therefore, part of the near-field light generated in the light-emitting layer is converted into surface plasmon on the surface of the cathode and disappears, and the light extraction efficiency of the organic light-emitting diode is reduced. Light extraction efficiency is an index that affects the brightness of displays, lighting, etc. equipped with organic light-emitting diodes, and various methods for improvement are being studied. In order to improve light extraction efficiency, Patent Document 1 discloses a structure in which a two-dimensional lattice structure of convex portions or concave portions is provided on the surface of a metal layer (cathode). The two-dimensional lattice structure on the surface of the metal layer converts the energy of the surface plasmons into light, and takes the converted light out of the device. In Patent Document 1, the two-dimensional lattice structure on the surface of the metal layer can be obtained by reflecting the two-dimensional lattice structure provided on the substrate. Specifically, since the first electrode on the base provided with the two-dimensional lattice structure, the organic semiconductor layer including the light-emitting layer, and the second electrode are reflected on the surface of the second electrode on the light-emitting layer side, the second equivalent to the base Dimensional lattice structure. Generally, the organic semiconductor layer and the first and second electrodes are formed by a vacuum film formation method using sputtering or vapor deposition. On the other hand, Patent Document 2 discloses that an organic semiconductor layer in an organic thin-film solar cell is formed by a coating method such as a spin coating method, an inkjet method, and a slit coating method. The organic thin-film solar cell has the same structure as the organic light-emitting diode, and the organic semiconductor layer of the organic light-emitting diode can also be formed by a coating method. [Prior Art Literature] [Patent Literature] [Patent Literature 1] International Publication No. 2012/60404 [Patent Literature 2] International Publication No. 2014/208713

[發明所欲解決之問題] 然而,例如,如專利文獻1中記載之方法般之於基體加工二維晶格構造之方法,存在基體之加工成本變高之問題。又,存在如下問題:於加工基體而製作二維晶格構造之情形時,形成於基體上之有機半導體層無法利用專利文獻2中記載之塗佈法來形成。塗佈法由於在塗佈時使用液相之材料,故而容易填埋凹凸形狀(二維晶格構造)。因此,與真空成膜法比較,基體表面之凹凸形狀之反映性於金屬層表面變低。若形狀之反映性較低,則難以於第2電極設置用以取出表面電漿子所需要之所期望之形狀。 另一方面,利用塗佈形成有機半導體層等具有伴隨製造設備之簡單化之製造成本之降低、由縮短抽真空等之時間所致之產出量之提高等優點。因此,具有欲使用塗佈法來形成有機半導體層之強烈之要求。 因此,本發明者等人採用依序進行塗佈步驟、製作凹凸形狀之壓模步驟、真空成膜步驟來製作有機發光二極體之方法。於該方法中,首先,於塗佈步驟中,藉由塗佈法而形成有機半導體層之至少一部分。繼而,將與所期望之凹凸為相反形狀之模具壓抵於塗佈步驟中所獲得之塗佈層之最外表面,而於塗佈層之最外層形成所期望之凹凸。最後,藉由真空成膜法而形成未於塗佈步驟中形成之剩餘之層。該方法由於無需加工基體,故而具有基體之加工成本降低之優點,由於可減少藉由真空成膜而製作之層數,故而具有製造之產出量提高之優點,由於在形成凹凸形狀之後使用真空成膜法,故而具有可使所期望之凹凸形狀反映於第2電極之優點。 然而,發明者等人進一步研究之結果發現如下問題:將塗佈步驟、壓模步驟及真空成膜步驟加以組合而製作之有機發光二極體與設想之發光強度相比無法獲得充分之發光強度。 本發明係鑒於上述情況而完成者。本發明之課題在於提供一種用以即便於使用將塗佈步驟、壓模步驟及真空成膜步驟加以組合之方法之情形時亦可製作顯示充分的發光特性之有機發光二極體之模具。 [解決問題之技術手段] 本發明者等為了解決上述課題而進行了銳意研究。 其結果發現,藉由使模具之形狀為特定之形狀,即便於將塗佈步驟、壓模步驟及真空成膜步驟加以組合而製作有機發光二極體之情形時,有機發光二極體亦可顯示充分之發光特性。 本發明包含以下之發明。 (1)本發明之一態樣之模具係於主面具有平坦面及複數個凸部,上述複數個凸部之平均間距為50 nm~5 μm,上述複數個凸部之平均縱橫比為0.01~1,上述複數個凸部中80%以上具有特定之彎曲面,上述特定之彎曲面於將上述特定之彎曲面之任意之點設為第1點,且將自上述第1點僅偏離上述平均間距之1/10之點設為第2點時,與上述第2點相接之第2切平面相對於與上述第1點相接之第1切平面的傾斜角為60°以內。 (2)於上述(1)記載之模具中,亦可為上述主面中之上述平坦面所占之面積率為5~50%。 (3)於上述(1)或(2)中任一項記載之模具中,亦可為上述平坦面與具有上述特定之彎曲面之凸部,以滿足上述特定之彎曲面之條件之方式連結。 (4)於上述(1)~(3)中任一項記載之模具中,亦可為構成上述複數個凸部之上述特定之彎曲面具有至少1個以上之反曲部,上述反曲部中自最接近上述平坦面之第1反曲部至上述平坦面為止之最接近距離為上述複數個凸部的平均間距之1/10以上。 (5)於上述(1)~(4)中任一項記載之模具中,亦可為上述複數個凸部形成蜂巢晶格,於自相對於上述平坦面垂直之方向之俯視下,上述複數個凸部之頂部位於構成上述蜂巢晶格之六邊形之頂點之構成。 (6)於上述(5)記載之模具中,亦可為位於上述六邊形之頂點之凸部於與位於上述六邊形之鄰接之頂點之凸部之間具有稜線部,上述稜線部之至少一部分存在於較將上述稜線部連接之凸部靠上述平坦面側。 (7)於上述(6)記載之模具中,亦可為上述稜線部之最接近上述平坦面之部分距上述平坦面之高度,相對於將上述稜線部連接之凸部距上述平坦面之高度為50%~90%。 (8)本發明之一態樣之有機發光二極體之製造方法係藉由塗佈步驟與其後之真空成膜步驟,而於在基體上具有透明之第1電極之帶電極之基體的形成有上述第1電極之面形成包含發光層之有機半導體層及第2電極者,且於上述塗佈步驟與上述真空成膜步驟之間,具有將如上述(1)~(7)中任一項記載之模具壓抵於上述塗佈步驟中所形成之塗佈層之最外表面,而將上述模具之主面之形狀之反轉形狀形成於上述塗佈層之最外表面之壓模步驟。 (9)本發明之一態樣之有機發光二極體依序具有基體、透明之第1電極、包含發光層之有機半導體層、及第2電極,上述第2電極之上述有機半導體層側之面具有平坦面、及自上述平坦面朝向上述基體突出之複數個凸部,上述複數個凸部之平均間距為50 nm~5 μm,上述複數個凸部之平均縱橫比為0.01~1,上述複數個凸部中80%以上具有特定之彎曲面,上述特定之彎曲面於將上述特定之彎曲面之任意之點設為第1點,且將自上述第1點朝向上述凸部之中心點僅偏離上述平均間距之1/10之點設為第2點時,與上述第2點相接之第2切平面相對於與上述第1點相接之第1切平面的傾斜角為60°以內。 (10)於上述(9)記載之有機發光二極體中,亦可為上述第2電極之上述有機半導體層側之面中之上述平坦面所占的面積率為5~50%。 [發明之效果] 本發明之一態樣之模具即便於將塗佈步驟、壓模步驟及真空成膜步驟組合而製作有機發光二極體之情形時,有機發光二極體亦可顯示充分之發光特性。 本發明之一態樣之有機發光二極體具有所期望之發光特性,並且可高效率地取出所產生之表面電漿子。 本發明之一態樣之有機發光二極體之製造方法可以低成本製作可高效率地取出表面電漿子之有機發光二極體。[Problems to be Solved by the Invention] However, for example, the method of processing a two-dimensional lattice structure on a substrate like the method described in Patent Document 1 has a problem that the processing cost of the substrate becomes high. In addition, there is a problem that when a substrate is processed to produce a two-dimensional lattice structure, the organic semiconductor layer formed on the substrate cannot be formed by the coating method described in Patent Document 2. Since the coating method uses liquid phase materials during coating, it is easy to fill the uneven shape (two-dimensional lattice structure). Therefore, compared with the vacuum film forming method, the reflectivity of the uneven shape on the surface of the substrate becomes lower on the surface of the metal layer. If the reflectivity of the shape is low, it is difficult to provide the second electrode with the desired shape required for taking out surface plasmons. On the other hand, forming an organic semiconductor layer by coating has advantages such as a reduction in manufacturing cost due to the simplification of manufacturing equipment and an increase in output due to shortening the time for vacuuming and the like. Therefore, there is a strong demand to form an organic semiconductor layer using a coating method. Therefore, the inventors of the present invention have adopted a method of manufacturing an organic light-emitting diode by sequentially performing a coating step, a stamper step for forming an uneven shape, and a vacuum film-forming step. In this method, first, in the coating step, at least a part of the organic semiconductor layer is formed by the coating method. Then, the mold having the opposite shape to the desired unevenness is pressed against the outermost surface of the coating layer obtained in the coating step, and the desired unevenness is formed on the outermost layer of the coating layer. Finally, the remaining layer not formed in the coating step is formed by the vacuum film forming method. This method does not need to process the substrate, so it has the advantage of reducing the processing cost of the substrate. Since it can reduce the number of layers produced by vacuum film formation, it has the advantage of increasing the production output. Because the vacuum is used after the formation of the uneven shape The film forming method has the advantage that the desired uneven shape can be reflected in the second electrode. However, as a result of further research by the inventors and others, the following problem was found: the organic light-emitting diode produced by combining the coating step, the compression molding step, and the vacuum film-forming step cannot obtain sufficient luminous intensity compared with the luminous intensity assumed . The present invention has been completed in view of the above circumstances. An object of the present invention is to provide a mold for producing an organic light-emitting diode that exhibits sufficient light-emitting characteristics even when a method combining a coating step, a stamping step, and a vacuum film-forming step is used. [Technical Means for Solving the Problems] The inventors of the present invention have made intensive studies to solve the above-mentioned problems. As a result, it was found that by making the shape of the mold a specific shape, even in the case of combining the coating step, the stamping step, and the vacuum film-forming step to produce an organic light-emitting diode, the organic light-emitting diode can Show sufficient luminous properties. The present invention includes the following inventions. (1) The mold of one aspect of the present invention has a flat surface and a plurality of convex portions on the main surface. The average pitch of the plurality of convex portions is 50 nm to 5 μm, and the average aspect ratio of the plurality of convex portions is 0.01 ~1, 80% or more of the plurality of convex portions have a specific curved surface, the specific curved surface is set at any point of the specific curved surface as the first point, and will deviate from the first point only by the above When the point of 1/10 of the average pitch is set as the second point, the inclination angle of the second tangent plane in contact with the second point with respect to the first tangent plane in contact with the first point is within 60°. (2) In the mold described in (1) above, the area ratio of the flat surface of the main surface may be 5 to 50%. (3) In the mold described in any one of (1) or (2) above, the flat surface and the convex portion having the specific curved surface may be connected in such a manner as to satisfy the conditions of the specific curved surface . (4) In the mold described in any one of (1) to (3) above, the specific curved surface constituting the plurality of convex portions may have at least one recurved portion, and the recurved portion The closest distance from the first curved portion closest to the flat surface to the flat surface is 1/10 or more of the average pitch of the plurality of convex portions. (5) In the mold described in any one of (1) to (4) above, a honeycomb lattice may be formed for the plurality of convex portions, and in a plan view from a direction perpendicular to the flat surface, the plurality of The top of each convex portion is located at the vertex of the hexagon that constitutes the honeycomb lattice. (6) In the mold described in (5) above, the convex portion located at the vertex of the hexagon may have a ridge portion between the convex portion located at the vertex adjacent to the hexagon, and the ridge portion At least a portion exists on the flat surface side of the convex portion connecting the ridge portion. (7) In the mold described in (6) above, the height of the portion of the ridge portion closest to the flat surface from the flat surface may be the height of the convex portion connecting the ridge portion from the flat surface It is 50%~90%. (8) The method for manufacturing an organic light-emitting diode according to one aspect of the present invention is to form a substrate with an electrode having a transparent first electrode on the substrate through a coating step and a subsequent vacuum film-forming step An organic semiconductor layer including a light-emitting layer and a second electrode are formed on the surface with the first electrode, and between the coating step and the vacuum film-forming step, any of the above (1) to (7) The die described in the item is pressed against the outermost surface of the coating layer formed in the above coating step, and the step of forming the inverted shape of the main surface of the mold on the outermost surface of the coating layer . (9) An organic light-emitting diode according to an aspect of the present invention has a substrate, a transparent first electrode, an organic semiconductor layer including a light-emitting layer, and a second electrode, the second electrode on the side of the organic semiconductor layer The surface has a flat surface, and a plurality of convex portions protruding from the flat surface toward the substrate, the average pitch of the plurality of convex portions is 50 nm to 5 μm, and the average aspect ratio of the plurality of convex portions is 0.01 to 1. More than 80% of the plurality of convex portions have a specific curved surface, the specific curved surface is set at any point of the specific curved surface as the first point, and will be from the first point toward the center point of the convex portion When only a point deviating from 1/10 of the average pitch is set as the second point, the inclination angle of the second tangent plane that is in contact with the second point with respect to the first tangent plane that is in contact with the first point is 60° Within. (10) In the organic light-emitting diode described in (9) above, the area ratio of the flat surface of the surface of the second electrode on the side of the organic semiconductor layer may be 5 to 50%. [Effects of the invention] Even if the mold of one aspect of the present invention is combined with a coating step, a compression molding step, and a vacuum film-forming step to produce an organic light-emitting diode, the organic light-emitting diode can exhibit sufficient Luminous properties. The organic light-emitting diode according to one aspect of the present invention has the desired light-emitting characteristics, and the generated surface plasmons can be efficiently taken out. The method for manufacturing an organic light-emitting diode according to one aspect of the present invention can produce an organic light-emitting diode that can efficiently extract surface plasmons at low cost.

以下,使用圖式對各構成進行說明。以下之說明所使用之圖式存在為了易於理解特徵而方便起見將成為特徵之部分放大而表示之情形,各構成要素之尺寸比率等未必與實際情況相同。於以下之說明中例示之材料、尺寸等為一例,本發明並非限定於其等者,能夠於不變更其主旨之範圍內適當變更而實施。 「模具」 圖1係模式性地表示本發明之一態樣之模具之立體圖。於本發明之一態樣之模具10,於主面10A設置有複數個平坦面1a~1n、及複數個凸部2a~2n。複數個平坦面1a~1n配設於由複數個凸部2a~2n中最鄰接之凸部而包圍之區域內。於圖1中,若將最鄰接之凸部之中心點連接則描繪出俯視六邊形,於其中央之區域配設有平坦面。複數個凸部2a~2n係於一部分連結。 圖2係於將本發明之一態樣之模具之凸部之中心點與平坦面之中心點連接之面切斷的剖視圖。如圖2所示之剖面係以AFM(Atomic Force Microscopy,原子力顯微鏡)影像或用電子顯微鏡觀察切斷樣品所得之顯微鏡圖像之形式獲得。 利用AFM影像之剖面係自對凸部2a~2n之平均間距P之30~40倍之正方形之區域進行攝影所得的AFM影像,取出通過凸部2n之中心點2An與平坦面1n之中心點1An之切斷面之剖面資訊而獲得。 剖面係將模具10以FIB(Focused Ion Beam,聚焦離子束)等切開通過凸部2n之中心點2An之剖面而獲得。剖面之顯微鏡圖像係以光學顯微鏡觀察該剖面而獲得。於存在模具之剖面形狀因切斷而變形之可能性之情形時,較佳為以可承受切斷之材料覆蓋凸部表面或以樹脂等包埋凸部而切斷。 於以AFM影像測定之剖面與以顯微鏡圖像觀察之剖面之任一者均可獲得之情形時,優先以AFM影像測定之剖面。其原因在於,以AFM影像測定之剖面容易獲得特定之切斷面之測定面,且容易確認剖面形狀。於凸部2a~2n規則地排列之情形時,較佳為將用以獲得剖面之切斷方向設為沿著凸部2a~2n之排列方向之方向。 凸部2a~2n之中心點2Aa~2An係基於AFM之測定結果來設定。具體而言,與基準面平行地針對各凸部2a~2n以每個隔20 nm地畫複數個等高線,且求出各等高線之重心點(由x座標與y座標決定之點)。將該等各重心點之平均位置(由各x座標之平均值與y座標之平均值決定之位值)設為各凸部2a~2n之中心點2Aa~2An。基準面係自具有以AFM測定之斜率之圖像資訊進行斜率修正後之測定面。 平坦面1a~1n之中心點1Aa~1An係基於AFM之測定結果來設定。具體而言,於複數個平坦面1a~1n之各者設置俯視內切之內切圓。將該內切圓之中心設為平坦面1a~1n之中心點1Aa~1An。 凸部2a~2n係相對於平坦面1a~1n突出之部分。所謂平坦面1a~1n係指相對於通過將最鄰接之凸部連接之區域之重心點且與AFM之基準面平行的面而斜率為±5゜以內之區域。 凸部2a~2n係二維地配置於模具10之一面。所謂「二維地配置」係指複數個凸部配置於同一平面上之狀態。複數個凸部二維地配置之二維構造既可為週期性亦可為非週期性。 模具10可於在有機發光二極體之包含金屬之電極製作凹凸形狀時較佳地使用。凹凸形狀有助於取出於電極表面產生之表面電漿子。於使用模具10製作之有機發光二極體發出較窄頻帶之光之情形時,複數個凸部之二維性之配置較佳為週期性。 作為週期性之二維構造之較佳之具體例,可列舉將鄰接之凸部連接之直線之配向方向為2個方向且其交叉角度為90°者(正方晶格)、及將鄰接之凸部連接之直線之配向方向為3個方向且其交叉角度為120°者(六方晶格、蜂巢晶格)等。 所謂「交叉角度為120°之位置關係」,具體而言係指滿足以下之條件之關係。首先,自1個中心點2Aa向鄰接之中心點2Ab之方向畫長度與平均間距P相等之長度之線段L1。繼而,自中心點2Aa相對於線段L1而向120°之方向,畫與平均間距P相等之長度之線段L2。若與中心點2Aa鄰接之中心點自與中心點2Aa為相反側之各線段L1之終點分別處於平均間距P之15%以內之範圍,則交叉角度處於120°之位置關係。所謂交叉角度為90度之位置關係係藉由將上述之「120°」之記載替換為「90°」而定義。 若凸部2a~2n以滿足上述關係之方式週期性地配置,則凸部2a~2n之配置之週期與表面電漿子之週期共振,特定之頻帶之光之取出效率提高。又,於凸部2a~2n排列為蜂巢晶格狀之情形時,模具10強度增加,反覆利用時之耐久性尤其提高。蜂巢晶格狀亦可換句話說為自相對於平坦面1a~1n垂直之方向觀察之俯視下,複數個凸部2a~2n之頂部位於六邊形之頂點之關係。 相對於此,於使用模具10製作之有機發光二極體發出較寬頻帶之光或互不相同之複數個頻帶之光的情形時,較佳為複數個凸部2a~2n之二維性之配置為非週期性。所謂「非週期之配置」係指凸部2a~2n之中心間之間隔及配置方向不固定之狀態。 此處,平均間距P為鄰接之凸部間之距離,具體而言,能以如下之方式求出。此處,所謂鄰接之凸部係指於圖1中不隔著平坦面而鄰接之凸部之情況。 首先,於模具10之主面10A中之無規地選擇之區域,針對一邊為平均間距P之30~40倍之正方形之區域獲得AFM影像。例如,於設計上之間距為300 nm左右之情形時,獲得9 μm×9 μm~12 μm×12 μm之區域之影像。而且,測量所獲得之區域內之各凸部之鄰接間距離,將所測量之鄰接間距離求平均值,藉此求出區域內之平均間距P1 。對於無規地選擇之合計25處以上之相同面積之區域同樣地進行此種處理,求出各區域中之平均間距P1 ~P25 。如此獲得之25處以上之區域中之平均間距P1 ~P25 之平均值為平均間距P。此時,各區域彼此較佳為相隔至少1 mm進行選擇,更佳為相隔5 mm~1 cm進行選擇。 凸部2a~2n之平均間距P為50 nm~5 μm,較佳為50 nm~500 nm。若凸部2a~2n之平均間距為該範圍內,則於使用模具10製作之有機發光二極體中,可高效率地自金屬電極取出表面電漿子。 凸部2a~2n係將週期性之構造於每一區域以Ca~Cn形成。作為宏觀之整體,各區域Ca~Cn亦可成為非週期性之構造。圖3所示之各區域Ca~Cn係以各凸部之中心點相對於平坦面之中心點的交叉角度為120°之位置關係排列之區域。於圖3中,為方便起見,將各凸部2a~2n之中心點之位置以設其中心點為中心之圓u表示。 各區域Ca~Cn之最頻面積Q(各區域面積之最頻值)較佳為以下之範圍。 於平均間距P未達500 nm時,10 μm×10 μm之AFM影像測定範圍內之最頻面積Q較佳為0.026 μm2 ~6.5 μm2 。 於平均間距P為500 nm以上且未達1 μm時,10 μm×10 μm之AFM影像測定範圍內之最頻面積Q較佳為0.65 μm2 ~26 μm2 。 於平均間距P為1 μm以上時,50 μm×50 μm之AFM影像測定範圍內之最頻面積Q較佳為2.6 μm2 ~650 μm2 。 若最頻面積Q為較佳之範圍內,則週期性之構造宏觀而言成為晶格方位無規之多晶體,故而於在金屬表面將表面電漿子轉換為傳播光而輻射時,可抑制於平面方向輻射光之放出角度成為無規而使自元件取出之發光光具有各向異性。 各區域Ca~Cn如圖3所示,面積、形狀及晶格方位為無規。 面積之無規性之程度具體而言較佳為滿足以下之條件。 首先,描畫一個區域之交界線所外切之最大面積之橢圓,以下述式(1)表示該橢圓。 X2 /a2 +Y2 /b2 =1・・・(1) 於平均間距P未達500 nm時,10 μm×10 μm之AFM影像測定範圍內之πab之標準偏差較佳為0.08 μm2 以上。 於平均間距P為500 nm以上且未達1 μm時,10 μm×10 μm之AFM影像測定範圍內之πab之標準偏差較佳為1.95 μm2 以上。 於平均間距P為1 μm以上時,50 μm×50 μm之AFM影像測定範圍內之πab之標準偏差較佳為8.58 μm2 以上。 若πab之標準偏差為較佳之範圍內,則使自金屬表面向特定角度輻射之表面電漿子之向元件外部之於平面方向的放出角度平均化之效果優異,從而可抑制發光光具有各向異性。 各區域Ca~Cn之形狀之無規性之程度具體而言,式(1)中之a與b之比、a/b之標準偏差較佳為0.1以上。各區域Ca~Cn之晶格方位之無規性具體而言,較佳為滿足以下之條件。 首先,畫出將任意之區域(I)中之任意之鄰接之2個凸部之中心點連接的直線K0。其次,選擇鄰接於該區域(I)之1個區域(II),畫出將該區域(II)中之任意之凸部與鄰接於該凸部之3個凸部之中心點連接的3條直線K1~K3。於直線K1~K3相對於以直線K0為基準每次旋轉60°之6條直線均具有相差3度以上之角度之情形時,定義為區域(I)與區域(II)之晶格方位不同。 於鄰接於區域(I)之區域中,晶格方位與區域(I)之晶格方位不同之區域較佳為存在2個以上,較佳為存在3個以上,進而較佳為存在5個以上。 此時,凸部係晶格方位於各區域Ca~Cn內一致,但宏觀而言為不一致之多晶構造體。宏觀之晶格方位之無規性可利用FFT(Fast Fourier Transform,高速傅立葉轉換)基波之最大值與最小值之比進行評估。FFT基波之最大值與最小值之比係獲取AFM像,求出其2維傅立葉轉換像,繪製自原點離開基波之波數之圓周,選出該圓周上之振幅最大之點與振幅最小之點,以其振幅之比之形式求出。 可認為FFT基波之最大值與最小值之比較大之情形時,凸部之晶格方位一致,且於將凸部視為2維結晶之情形時單晶性較高之構造。相反,可認為FFT基波之最大值與最小值之比較小之情形時,凸部之晶格方位不一致,且於將凸部視為2維結晶之情形時為多晶構造。 複數個凸部2a~2n之平均縱橫比為0.01~1,較佳為0.05~0.5。所謂平均縱橫比係指凸部2a~2n之平均高度H相對於凸部2a~2n之平均寬度D。若模具10之平均縱橫比為0.01以下,則於使用模具10製作之有機發光二極體中,無法充分獲得將表面電漿子作為輻射光取出之效果。相對於此,若平均縱橫比為1以上,則難以以下述之特定之彎曲面構成凸部。又,於製造有機發光二極體時難以進行使用模具10之形狀之轉印。 凸部2a~2n之平均縱橫比係藉由AFM而測定。 首先,針對模具10之主面10A之無規地選擇之25 μm2 (5 μm×5 μm)之1處區域獲得AFM像。繼而,於所獲得之AFM像之對角線方向畫線,測定與該線相交之複數個凸部2a~2n之各者之高度與寬度。凸部之高度係指自平坦面1a~1n至凸部之頂部為止之距離,凸部之寬度係指俯視時將凸部之中心點作為中心之內切圓之直徑。然後,求出該區域中之凸部之高度與寬度之平均值。對於無規地選擇之合計25處區域進行同樣之處理。然後,將所獲得之25處之每個區域之凸部之高度與寬度之平均值進而平均所得之值為平均高度與平均寬度。然後,將平均高度除以平均寬度所得之值為平均縱橫比。 凸部2a~2n之80%以上由特定之彎曲面而構成。複數個凸部中具有特定之彎曲面之凸部之比例更佳為90%以上,進而較佳為95%以上。特定之彎曲面係以如下之方式定義。 圖4係將模具於通過凸部之中心點之任意之剖面切斷,並將其中之一凸部放大之剖視模式圖。首先,自構成凸部2n之彎曲面2B選擇任意之1點作為第1點p1。將相對於該第1點p1之切平面設為第1切平面t1。又,將自第1點p1朝向凸部2n之中心點2An僅偏離平均間距之1/10之點設為第2點p2。此處,所謂僅偏離平均間距之1/10,係指自第1點p1朝向中心點2An與平坦面1平行地移動之距離L。將相對於該第2點p2之切平面設為第2切平面t2。此時,將第2切平面t2相對於第1切平面t1之傾斜角設為θ。 即便於凸部2n之彎曲面2B之任一部分,於滿足第2切平面t2相對於第1切平面t1之傾斜角θ為60°以內之關係之情形時,均可認為凸部2n為特定之彎曲面。傾斜角θ較佳為45°以內,進而較佳為30°以內。 圖5係將本發明之一態樣之模具壓抵於藉由塗佈而形成之積層體表面時之剖視模式圖。積層體20包括第1層21、第2層22、及第3層23。若將模具10壓抵於積層體20之第3層23,則模具10之凸部2a~2n最初壓抵於積層體20。因此,對構成積層體20之各層自凸部2a~2n之頂部朝向外周部施加力F1。藉由該力F1而亦對模具10之複數個凸部2a~2n之間之空間供給構成各層之材料。其結果,構成積層體20之各層變形,成為與模具10對應之形狀。 施加至積層體20之各層之力F1不會應力集中而自被壓抵之凸部2a~2n之頂部朝向外周部擴散。其原因在於,模具10之凸部2a~2n包括特定之彎曲面,呈平緩之形狀。若力F1不應力集中,則第1層21、第2層22、第3層23之各者於面內方向均勻地擴散。因此,可避免各者之厚度變得極薄。 又,一般而言,亦對作為容易產生空隙之部分之模具10之複數個凸部2a~2n與平坦面之交界部3沿著特定之彎曲面2B充分供給各層之材料。即,亦可防止於交界部3產生空隙。 相對於此,圖6係將不具有特定之彎曲面之模具壓抵於藉由塗佈而形成之積層體表面時之剖視模式圖。圖6所示之模具15之凸部152n具有形狀急遽變化之角部155。該角部155係隔著角部155之2點之切平面不滿足特定之彎曲面之關係性。因此,施加至構成積層體20之各層之力F2不沿著凸部152n之形狀均勻地分散,而於角部155附近應力集中。其結果,第1層21、第2層22、第3層23之各者無法於面內方向均勻地擴散。因此,存在各層於角部155附近被切斷,或層厚變得極薄之情形。 又,無法對凸部152n與平坦面之交界部153供給充分量之材料,從而容易產生空隙。 構成積層體20之層與構成有機發光二極體之任一層對應。若構成有機發光二極體之各層之一部分被切斷,則產生於被切斷之部分有機發光二極體不發光,或不顯示充分之發光特性之問題。即,藉由使用本實施形態之模具10,可避免有機發光二極體不發光,或不顯示充分之發光特性之問題。 返回至圖5,為了避免於模具10與積層體20之間產生空隙,較佳為交界部3亦平緩。即,於凸部2a~2n與平坦面之連接部分之任一者中,均較佳為滿足自任意1點偏離平均間距之1/10之點中之切平面相對於任意1點中之切平面的傾斜角為60°以內之關係。 圖7係將本發明之另一態樣之模具壓抵於藉由塗佈而形成之積層體表面時之剖視模式圖。圖7所示之模具30具有複數個凸部與平坦面31,且複數個凸部與平坦面31之交界部33藉由特定之彎曲面而連結。即,於平坦面31與凸部32n之連接部分中,亦滿足自任意1點偏離平均間距之1/10之點中之切平面相對於任意1點中之切平面的傾斜角為60°以內之關係。即,交界部33變得平緩。 若將圖7所示之模具30壓抵於積層體20,則自凸部32n之頂部朝向外周部施加之力F1與施加至交界部33附近之力F3之任一者均不應力集中。因此,構成各層之材料沿著模具30之主面順利地擴散。其結果,可避免於模具10與積層體20之間產生空隙,並且可使積層體20之各層之厚度於面內方向均勻。 於模具30中,使平坦面31與複數個凸部之交界部33平緩,可藉由同時滿足構成凸部之特定之彎曲部具有至少1個以上之反曲部pin 、及將反曲部pin 中最靠平坦面31側之第1反曲部p1in 與平坦面31連接之曲面向下凸而實現。反曲部pin 為凸部之剖面中之反曲點之集合體,為自向上凸之曲面變更為向下凸之曲面之部分,或自向下凸之曲面變更為向上凸之曲面之部分。若俯視反曲部pin ,則形成為沿著凸部32n之線狀。 自第1反曲部p1in 至平坦面31為止之最接近距離較佳為複數個凸部之平均間距P之1/10以上,更佳為1/5以上。所謂最接近距離係指俯視凸部32n時之第1反曲部p11n 與平坦面31間之寬度中寬度最窄之部分之距離。若自第1反曲部p1in 至平坦面31為止之最接近距離為複數個凸部之平均間距P之1/10以上,則可使交界部33之傾斜更平緩。 又,若使模具30之交界部33平緩,則於使用模具30製作之被轉印物上以真空成膜法形成層時,以真空成膜法形成之層反映被轉印物之形狀之反映性提高。 圖8係於圖7所示之轉印物上以真空成膜法形成層之情形時之剖視模式圖。圖7所示之模具30中,平坦面31與凸部32n之交界部33平緩。因此,使用模具30而形成於積層體20之最表面之彎曲面20A之交界部23A亦平緩。形狀急遽變化之部分一般而言多為真空成膜時之成膜粒子的分散大幅變化。相對於此,若包含交界部23A之彎曲面20A之形狀平緩,則成膜粒子之分散不大幅變化,可形成均勻之層。圖8所示之轉印物係積層體20之主面(最表面)20A較為平緩。因此,所真空成膜之層26之外表面26B可充分地反映主面20A之形狀。此處,所謂「充分地反映」係指不需要完全反映壓模步驟中所形成之形狀。若構成所真空成膜之層26之外表面26B之凸部的平均間距與構成主面20A之凸部之平均間距相比為±10%以內,且構成所真空成膜之層26之外表面26B之凸部的平均高度與構成主面20A之凸部之平均高度相比為±10%以內,則可謂所真空成膜之層26之外表面26B充分地反映主面20A之形狀。此處言及之平均間距之測定可應用上述平均間距P之測定方法。又,平均高度之測定可應用上述平均高度H之測定方法。 於所真空成膜之層26為電極之情形時,無須成為外表面26B充分地反映主面20A之形狀之形狀。於該情形時,亦由於主面20A平緩,故而層26之膜厚不會變薄或被切斷。 作為確認彎曲面22B或外表面26B之形狀之方法,可列舉利用掃描式電子顯微鏡(SEM)或穿透式電子顯微鏡(TEM)之剖面觀察,或於將被覆觀察面之層去除之後藉由三維電子顯微鏡或AFM而觀察之方法。 返回至圖1,主面10A中之平坦面1a~1n所占之面積率較佳為5~50%,更佳為5%~30%。若主面10A中之平坦面1a~1n之面積率為5%以上,則於使用該模具製作之有機發光二極體中,可使用以取出表面電漿子之凹凸之縱橫比變小。另一方面,若主面10A中之平坦面1a~1n之面積率為50%以下,則於使用該模具製作之有機發光二極體中,可抑制表面電漿子被平坦面捕獲。 圖9係將本發明之一態樣之模具藉由連接鄰接之凸部之中心間之面而切斷之剖視模式圖。更具體而言,係於將圖1中之鄰接之凸部之中心點連接之平面切斷之剖視圖。圖9中之虛線為凸部2a~2n之近似曲線。近似曲線可藉由將凸部2a~2n之中心點2Aa~2An設為頂點以正態分佈近似而獲得。凸部2a~2n與稜線部4之交界為近似曲線。鄰接之凸部藉由稜線部4而連結。較近似曲線靠中心點2Aa~2An側為凸部2a~2n,其相反側為稜線部4。 較佳為,稜線部4與凸部2a~2n之連接部、及稜線部4與平坦面1a~1n之連接部,以滿足特定之彎曲面之條件之方式連結。藉由將該等連接部以滿足特定之彎曲面之條件之方式連結,可使將模具10壓抵於積層體時所產生之力更均勻地分散。即,可抑制構成模具10壓抵之積層體之層被切斷。 又,如圖9所示,較佳為,稜線部4之至少一部分存在於較將稜線部4連接之凸部2n靠平坦面1n側。即,較佳為,稜線部4之最接近平坦面1n之部分的距平坦面1n之高度h,低於將稜線部4連接之凸部2n之距平坦面1n之高度H。 圖13係自相對於平坦面垂直之方向俯視本實施形態之模具之主要部分之圖。若稜線部4之高度h低於凸部2n之高度H,則於將模具壓抵於被轉印物時,經由該部分而將介置於模具與被轉印物之間之空氣去除(圖13之箭頭)。即,可避免空氣混入至被轉印物,從而進行均勻之轉印。 又,如圖13所示,於在自相對於平坦面1n垂直之方向之俯視下,複數個凸部2a~2n之頂部位於構成蜂巢晶格(六方晶格)之六邊形之頂點之情形時,將模具壓抵於被轉印物時之樹脂等之擴散變得均等,可對被轉印物均等地施加壓力。若可均勻地施加壓力,則例如即便於被轉印物為薄層之情形時亦可避免層被切斷,或層厚變得極薄。 又,圖9所示之稜線部4之最接近平坦面1n之部分的距平坦面1n之高度h,相對於將稜線部4連接之凸部2n之距平坦面1n之高度H而較佳為50%~90%,更佳為60~85%。若稜線部4之高度h過低則模具之強度降低,若稜線部4之高度h過高則空氣之逃逸路徑變少。 至此為止,以圖1之模具10為例對本發明之一實施形態進行了說明,但模具之形狀並不限定於該構成。 圖10係本發明之另一態樣之模具之立體模式圖。圖10所示之模具40係凸部42a~42n彼此相互隔開配置,且包含1個平坦面41之方面與上述模具10等不同。 此外,例如,亦可為如圖11之構成。圖11係本發明之另一態樣之模具之立體模式圖。如圖11所示,模具50具有複數個凸部52a~52n、及複數個平坦面51a~51n。圖1所示之模具10與圖11所示之模具50係凸部與平坦面之位置關係反轉。即,於模具50中,複數個凸部52a~52n配設於由複數個平坦面51a~51n中最鄰接之平坦面包圍之區域內。於圖11中,若將最鄰接之平坦面之中心點連接則描畫俯視六邊形,於其中央之區域配設有凸部。即便於如模具50般複數個凸部52a~52n與平坦面51a~51n之位置關係反轉之情形時,各凸部52a~52n亦由特定之彎曲面而形成,故而於壓抵模具50之壓模步驟中可抑制構成積層體之層被切斷。 本發明之一態樣之模具具有凸部,該凸部具有特定之彎曲面。因此,使用模具10製作之有機發光二極體不具有層厚較薄之部分或未形成層之部分,可有效率地取出表面電漿子。 「模具之製造方法」 模具可使用電子束微影、機械式切削加工、雷射微影、雷射熱微影、干涉曝光、縮小曝光、鋁之陽極氧化法及利用粒子遮罩之方法等來形成。其中,較佳為使用利用粒子遮罩之方法來製作模具。利用粒子遮罩之方法係指於模具之母材之平坦面上形成粒子單層膜作為蝕刻遮罩之後,進行蝕刻處理之方法。於利用粒子遮罩之方法中,粒子正下方之母材未被蝕刻而成為凸部。 以下,對利用粒子遮罩之方法之具體例進行說明。圖14係模式性地表示模具之製造方法之圖。 首先,於基體61上形成包含多個粒子M之單粒子膜蝕刻遮罩62(圖14(a))。於基體61上形成單粒子膜蝕刻遮罩62之方法,例如可使用利用所謂LB法(Langmuir-Blodgett法)之方案之方法。具體而言,形成單粒子膜蝕刻遮罩62之方法具有:滴加步驟,其將於溶劑中分散有粒子而成之分散液滴加至水槽內之液面;單粒子膜形成步驟,其藉由使溶劑揮發而形成包含粒子之單粒子膜F;及移行步驟,其將單粒子膜F移取至基板上。以下對各步驟具體地進行說明。 (滴加步驟及單粒子膜形成步驟) 首先,於包含氯仿、甲醇、乙醇、甲基乙基酮等揮發性較高之溶劑中之1種以上之疏水性之有機溶劑中,添加表面為疏水性之粒子而製備分散液。又,如圖15所示準備水槽(槽)V,加入水W來作為用以使粒子於其液面上展開之液體(以下,亦有時稱為下層水)。 然後,將分散液滴加至下層水之液面(滴加步驟)。於是,作為分散介質之溶劑揮發,並且粒子於下層水之液面上以單層展開,而形成二維地最密填充之單粒子膜F(單粒子膜形成步驟)。 如此,於作為粒子而選擇疏水性者之情形時,作為溶劑亦必須選擇疏水性者。另一方面,於該情形時,下層水必須為親水性,通常,如上所述使用水。藉由如此組合而如下述般推進粒子之自組裝,形成二維地最密填充之單粒子膜F。但是,作為粒子及溶劑亦可選擇親水性者,於該情形時,作為下層水,選擇疏水性之液體。 (移行步驟) 如圖15所示,將藉由單粒子膜形成步驟而形成於液面上之單粒子膜F繼而保持單層狀態移取至作為蝕刻對象物之基體61上(移行步驟)。基體61既可為平面狀,亦可於一部分或全部包含曲面、傾斜、階差等非平面形狀。 單粒子膜F即便基體61不為平面亦可一面維持二維之最密填充狀態一面被覆基體表面。將單粒子膜F移取至基體61上之具體性之方法並不特別限制。例如,作為第1方法,亦可使疎水性之基體61一面保持相對於單粒子膜F而大致平行之狀態,一面自上方下降而接觸於單粒子膜F,藉由均為疎水性之單粒子膜F與基體61之親和力而使單粒子膜F移行而移取至基體61。又,作為第2方法,亦可於形成單粒子膜F之前預先於水槽之下層水內於大致水平方向配置基體61,於液面上形成單粒子膜F之後使液面逐漸下降,藉此將單粒子膜F移取至基體61上。根據該等方法,不使用特別之裝置即可將單粒子膜F移取至基體61上。即便為更大面積之單粒子膜F,亦可容易地維持其二次之最密填充狀態而移取至基體1上,就該方面而言較佳為採用所謂LB槽法。 藉由該移行步驟,而於基體61之一面即平坦面61a以大致單一層排列複數個粒子M。即,粒子M之單粒子膜F形成於平坦面61a上。 (蝕刻步驟) 如此形成之單粒子膜F係作為單粒子蝕刻遮罩62而發揮功能。對將單粒子蝕刻遮罩62設置於單面之基體61進行氣相蝕刻而進行表面加工(蝕刻步驟)。 具體而言,若開始氣相蝕刻,則首先如圖14(b)所示,蝕刻氣體穿過構成蝕刻遮罩62之粒子M之間隙而到達至基體61之表面,於該部分形成槽。然後,於與各粒子M對應之位置分別出現圓柱63。於圓柱63之間形成槽部61m。槽部61m形成於藉由最密填充而配置於正三角形上之3個粒子M之中央。因此,槽部61m以圓柱63為中心而位於正六邊形之頂點。 構成單粒子膜蝕刻遮罩62之粒子M並無特別限定,例如可使用金粒子、膠體氧化矽粒子等。又,蝕刻氣體可使用一般所使用之氣體。例如,可使用Ar、SF6 、F2 、CF4 、C4 F8 、C5 F8 、C2 F6 、C3 F6 、C4 F6 、CHF3 、CH2 F2 、CH3 F、C3 F8 、Cl2 、CCl4 、SiCl4 、BCl2 、BCl3 、BC2 、Br2 、Br3 、HBr、CBrF3 、HCl、CH4 、NH3 、O2 、H2 、N2 、CO、CO2 等。 該等粒子M及蝕刻氣體可配合所蝕刻之基體61而變更。例如,於作為構成單粒子膜蝕刻遮罩62之粒子M而選擇金粒子,且作為基體61而選擇玻璃基板並將該等組合之情形時,若蝕刻氣體使用CF4 、CHF3 等與玻璃具有反應性者,則金粒子之蝕刻速度相對性地變慢,玻璃基板被選擇性地蝕刻。 如圖1、圖10及圖11所示之各種形狀之模具藉由使乾式蝕刻條件變化,可獲得所期望之形狀。又,為了使凸部之表面形狀更平緩,亦可一併使用濕式蝕刻。 作為乾式蝕刻之各條件,可列舉構成粒子遮罩之粒子之材質、原板之材質、蝕刻氣體之種類、偏壓功率、電源功率、氣體之流量及壓力、蝕刻時間等。平坦面可藉由提高初始之蝕刻氣體之流量並逐漸降低流量而獲得。又,於如圖1所示之模具10般殘留稜線部之情形時,可藉由提高使用於粒子遮罩之粒子之硬度而獲得。 凸部之平均間距等可藉由變更所使用之粒子之粒徑而自由地變更。又,於利用粒子單層膜形成非週期構造之情形時,可藉由使用粒徑不同之複數個粒子而製作。 (奇數次轉印步驟) 繼而,將圖14(b)所示之基體61進行奇數次轉印。藉由奇數次轉印而獲得圖14(c)所示之轉印體71。具體而言,首先,將所製作之基體61利用樹脂轉印。於所獲得之樹脂轉印品之表面,藉由電鑄等而被覆Ni等金屬鍍敷。藉由被覆金屬鍍敷而提高轉印體71之硬度,從而可進行下述之形狀調整等。 基體61之圓柱63之頂部由於被粒子M被覆故而為平坦面。因此,於轉印體71中於與基體61之圓柱63對應之位置形成有平坦面71n。又,於轉印體71中於與基體61之槽部61m對應之位置形成有凸部72n。因此,凸部72以平坦面71n為中央而位於正六邊形之頂點。即,獲得與圖1對應之形狀。 (形狀調整步驟) 然而,有未於轉印體71之表面形成特定之彎曲面之情形。例如,有於凸部72n之頂部形成角部72a之情形。角部72a係不滿足特定之彎曲面之部分。因此,將角部72a去除而使凸部72n之外表面為特定之彎曲面。進一步之蝕刻既可利用濕式蝕刻進行,亦可利用乾式蝕刻進行。以下,對乾式蝕刻之情形具體地進行說明。 為了將角部72a去除,如圖14(d)所示,對轉印體71照射藉由電漿蝕刻裝置而產生之電漿P來進行物理蝕刻。 物理蝕刻與蝕刻步驟中所使用之反應性蝕刻不同。反應性蝕刻係藉由電漿化之化學種與轉印體71反應而推進蝕刻。相對於此,物理蝕刻係藉由電漿化之化學種與轉印體71衝突之物理力而蝕刻。因此,物理蝕刻係於電漿化之化學種衝突之機率較高之部分與機率較低之部分蝕刻速度存在不均,與反應性蝕刻相比具有蝕刻之各向異性。物理蝕刻係與灰化處理類似之處理。 於電漿蝕刻裝置中,於上部電極與下部電極之間利用電漿化之化學種。具體而言,將低電位之下部電極與轉印體71電性地連接而使轉印體71帶電。於上部電極與下部電極之間電漿化之化學種被低電位之轉印體71吸引而朝向轉印體71以高速衝突。 此時,具有如下性質,即,若於帶電之轉印體71存在如角部72a般之尖銳之部分,則電荷集中於該部分。因此,電漿化之化學種大多被尖銳之部分吸引。即,尖銳之部分較其他部分與電漿化之化學種衝突之機率提高。若與電漿化之化學種之衝突機率提高,則該部分較其他部分更快地被蝕刻。即,凸部72之角部72a慢慢被削除,而形成具有特定之彎曲面之凸部2n(圖14(e))。 作為用於物理蝕刻之蝕刻氣體,例如,可使用氬等稀有氣體、氧等。該等氣體缺乏反應性而推進物理蝕刻。 又,作為用於物理蝕刻之蝕刻氣體,亦可使用具有反應性之蝕刻氣體。例如,可使用CF4 、CHF3 等具有反應性之氣體。於該情形時,以較離子種之化學反應性而利用物理衝突之蝕刻變得更顯著之方式調整蝕刻條件。例如,以上部電極與下部電極間之電位差變大之方式調整蝕刻條件。若上部電極與下部電極間之電位差變大,則電漿化之化學種之衝突速度提高,物理蝕刻之效果較反應性蝕刻之效果變得更顯著。 較佳為,物理蝕刻使用氬或氧於低壓高偏壓下進行。具體性之條件根據裝置而不同,故而無法一概決定,例如,於使用感應耦合型電漿(ICP)進行乾式蝕刻之情形時,較佳為以0.5~1.0 Pa之壓力施加0.5~1.5 W/cm2 之偏壓。即便於使用其他乾式蝕刻氣體之情形時,亦不會較大地脫離上述範圍,但較佳為縮短處理時間。其原因在於,存在蝕刻之速度較快,而角部62a以設想以上被蝕刻之情形。 至此為止,僅言及了角部72a,例如,亦存在亦於鄰接之凸部72n間之稜線部(參照圖1、圖9)形成有尖銳之部分之情形。即便於該情形時,藉由物理蝕刻亦可而與角部72a同時地將稜線部之尖銳之部分去除。 (複製步驟) 利用上述之方法製作之模具既可直接作為模具使用,亦可將以所製作之模具作為原版而製作之複製品作為實時使用之模具而使用。複製可藉由將所製作之模具轉印偶數次而製作。具體而言,首先,將所製作之模具利用樹脂轉印。於所獲得之奇數次轉印體之表面,藉由電鑄等而被覆Ni等之金屬鍍敷。藉由被覆金屬鍍敷而提高奇數次轉印體之硬度,可進行進一步之轉印。然後,將奇數次轉印體進而轉印而製作偶數次轉印體。偶數次轉印體成為與所製作之模具相同之形狀。最後,於偶數次轉印體之表面,藉由電鑄等而鍍敷Ni等金屬,藉此完成模具之複製。 又,圖7所示之複數個凸部32n與平坦面31之交界部33亦藉由特定之彎曲面而連結之模具30可利用以下之方法製作。 例如,作為第一個方法,具有於上述之蝕刻步驟與奇數次轉印步驟之間實施物理蝕刻之方法。藉由於蝕刻步驟與奇數次轉印步驟之間實施物理蝕刻,而圓柱63之頂部變得平緩,轉印體71n之凹部之形狀變得平緩。 又,作為其他方法,具有於複製步驟中之轉印過程中實施物理蝕刻之方法。藉由進行物理蝕刻,可使於轉印之後成為凸部之部分之形狀平緩。 「有機發光二極體」 圖12係本發明之一態樣之有機發光二極體元件100之剖視模式圖。有機發光二極體元件100依序具備基體110、第1電極120、包含發光層133之有機半導體層130、及第2電極140。 圖12所示之有機半導體層130除了發光層133以外,還於第1電極120與發光層133之間具有電洞注入層131、電洞傳輸層132,且於發光層133與第2電極140之間具備電子傳輸層134、電子注入層135。電洞注入層131、電洞傳輸層132、電子傳輸層134、電子注入層135之各者並非必須具備,亦可不具備。本發明之有機發光二極體元件100於不損及本發明之效果之範圍內,亦可進而具備其他層。 有機發光二極體之第1電極120與第2電極140對有機半導體層130施加電壓。當對第1電極120與第2電極140之間施加電壓時,對發光層133注入電子與電洞,該等耦合而產生光。所產生之光直接透過第1電極120而取出至元件外部,或者於第2電極140反射一次後取出至元件外部。 第2電極140具有於發光層133側之表面140A二維地配置有複數個凸部142a~142n之二維構造。二維構造與上述之模具相同,既可為週期性,亦可為非週期性。 複數個凸部142a~142n之平均間距為50 nm~5 μm,較佳為50 nm~500 nm。平均間距可利用與模具中之平均間距相同之方法求出。若凸部142a~142n之平均間距為該範圍內,則可將於作為金屬電極之第2電極之表面140A以表面電漿子之形式被捕獲之能量有效率地輻射,從而可作為光取出。 複數個凸部142a~142n之平均縱橫比為0.01~1,較佳為0.05~0.5。平均縱橫比可利用與模具中之平均縱橫比相同之方法求出。若第2電極140之發光層側之表面中之凸部142a~142n之平均縱橫比為該範圍內,則可將於作為金屬電極之第2電極之表面140A以表面電漿子之方式被捕獲之能量有效率地輻射,從而可作為光取出。 表面電漿子之捕獲於如以下之過程中產生。於在發光層133自發光分子發光時,於發光點之極其附近產生近場光。由於發光層133與第2電極140之距離非常近,故而近場光於第2電極140之表面轉換為傳播型之表面電漿子之能量。 金屬表面之傳播型表面電漿子係藉由入射之電磁波(近場光等)而產生之自由電子之疏密波伴隨表面電磁場者。於存在於平坦之金屬表面之表面電漿子之情形時,表面電漿子之分散曲線與光(空間傳播光)之分散直線不交叉。因此,無法將表面電漿子之能量作為光取出。相對於此,若於金屬表面具有二維週期構造,則藉由二維週期構造而繞射之表面電漿子之分散曲線與空間傳播光之分散曲線交叉。其結果,可將表面電漿子之能量作為輻射光取出至元件之外部。 如此,若設置有二維週期構造,則取出以表面電漿子之形式失去之光之能量。所取出之能量作為空間傳播光自第2電極140之表面輻射。此時,自第2電極140輻射之光之指向性較高,其大部分朝向取出面。因此,自取出面出射高強度之光,從而取出效率提高。 複數個凸部142a~142n中80%以上具備特定之彎曲面。特定之彎曲面與模具中之特定之彎曲面相同地定義。 於第2電極之表面140A,於複數個凸部142a~142n之間形成有平坦面141。平坦面141所占之面積率較佳為5~50%,更佳為5%~30%。若第2電極之表面140A中之平坦面141之面積率為5%以上,則可減小用以取出表面電漿子之凹凸之縱橫比。另一方面,若第2電極之表面140A中之平坦面141之面積率為50%以下,則可將被第2電極之表面140A捕獲之表面電漿子有效率地轉換為光。 第2電極140較佳為如具有複介電常數之實部之絕對值較大之負之值的材料,且較佳為選擇對表面電漿子之取出有利之電漿頻率較高之金屬材料。作為該材料,例如可列舉金、銀、銅、鋁、鎂等單體,或金與銀之合金、銀與銅之合金。若考慮有機發光二極體之光取出,則較佳為於可見光區域全體具有共振頻率之金屬材料,尤佳為使用銀或鋁。第2電極140亦可為2層以上之積層構造。 第2電極140之厚度並不特別限定。例如為20~2000 nm,較佳為50~500 nm。若較20 nm薄,則反射率變低而正面亮度降低,若較500 nm厚,則成膜時之熱或由放射線所致之損傷、由膜應力所致之機械性損傷蓄積於有機發光層133等包括有機物之層。 有機半導體層130包含有機材料。於圖12中,於有機半導體層130之發光層133與電子傳輸層134之界面、及電子傳輸層134與電子注入層135之界面形成有凹凸形狀。該凹凸形狀成為模具10之主面10A之相反形狀。該凹凸形狀未必需要形成於有機半導體層130之發光層133與電子傳輸層134之界面、及電子傳輸層134與電子注入層135之界面。將於下文於製造有機發光二極體之方法中敍述詳細情況,凹凸形狀只要形成於構成有機半導體層之任一層之第2電極140側之面即可。較形成有凹凸形狀之層,而第2電極140側之層具有全部反映凹凸形狀之形狀。 發光層133包括有機發光材料。作為有機發光材料,例如可列舉三[1-苯基異喹啉-C2,N]銥(III)(Ir(piq)3)、1,4-雙[4-(N,N-二苯氨基苯乙烯基苯)](DPAVB)、雙[2-(2-苯并噁唑基)苯酚]鋅(II)(ZnPBO)等色素化合物。又,亦可使用將螢光性色素化合物或磷光發光性材料摻雜至其他物質(主體材料)而成者。於該情形時,作為主體材料,可列舉電洞傳輸材料、電子傳輸材料等。 作為構成電洞注入層131、電洞傳輸層132、電子傳輸層134及電子注入層135之材質,分別通常使用有機材料。 例如,作為構成電洞注入層131之材質(電洞注入材料),例如可列舉4,4',4''-三[2-萘基苯基氨基]三苯基胺(2-TNATA)等化合物等。 作為構成電洞傳輸層132之材質(電洞傳輸材料),例如可列舉N,N'-二苯基-N,N'-雙(1-萘基)-(1,1'-聯苯)-4,4'-二胺(NPD)、酞菁銅(CuPc)、N,N'-二苯-N,N'-雙(間-甲基苯基)氨基聯苯(TPD)等芳香族胺化合物等。 作為構成電子傳輸層134之材質(電子傳輸材料)及構成電子注入層135之材質(電子注入材料),例如可列舉2,5-雙(1-萘基)-1,3,4-

Figure 105126135-A0304-12-0015-1
二唑(BND)、2-(4-第三丁基苯基)-5-(4-聯苯)-1,3,4-
Figure 105126135-A0304-12-0015-1
二唑(PBD)等
Figure 105126135-A0304-12-0015-1
二唑系化合物、三(8-喹啉根基)鋁(Alq)等金屬錯合物系化合物等。 包含發光層133之有機半導體層之整體之厚度通常為30~500 nm。 第1電極120使用透過可見光之透明導電體。 構成第1電極120之透明導電體並不特別限定,作為透明導電材料可使用公知者。例如,可列舉氧化銦錫(Indium Tin Oxide(ITO))、氧化銦鋅(Indium Zinc Oxide(IZO))、氧化鋅(Zinc Oxide(ZnO))、氧化鋅錫(Zinc Tin Oxide(ZTO))等。第1電極120之厚度通常為50~500 nm。 基體110使用透過可見光之透明體。作為構成基體110之材質,既可為無機材料亦可為有機材料,亦可為其等之組合。作為無機材料,例如可列舉石英玻璃、無鹼玻璃、白板玻璃等各種玻璃、雲母等透明無機礦物等。作為有機材料,可列舉環烯系膜、聚酯系膜等樹脂膜、於該樹脂膜中混入有纖維素奈米纖維等微細纖維而成之纖維強化塑膠素材等。 雖亦根據用途,但一般而言基體110使用可見光透過率較高者。使用如下者,即,透過率於可見光之範圍(波長380 nm~800 nm)未於光譜賦予偏倚而為透過率70%以上,較佳為80%以上,更佳為90%以上。 構成有機發光二極體100之各層之厚度可藉由光譜式橢圓儀、接觸式階差計、AFM等而測定。 「有機發光二極體之製造方法」 本發明之一態樣之有機發光二極體之製造方法係於在基體上具有透明之第1電極之帶電極之基體的形成有第1電極之面,藉由塗佈步驟與其後之真空成膜步驟而形成包含發光層之有機半導體層與第2電極的有機發光二極體之製造方法。於塗佈步驟與真空成膜步驟之間,具有將上述模具壓抵於塗佈步驟所形成之塗佈層之最外表面,而於塗佈層之最外表面形成模具之主面之形狀之反轉形狀的壓模步驟。 <帶電極之基體的準備步驟> 帶電極之基體係於透明之基體上形成透明之第1電極。基體及第1電極可使用上述者。 於基體上形成第1電極之方法可使用公知之方法。例如,可將ITO等透明電極用材料藉由濺鍍而形成於基體上。又,亦可購入市售之帶電極之基體。 <塗佈步驟> 於塗佈步驟中,藉由塗佈而形成構成有機半導體層之層中之一部分層、或所有層。一般而言,於塗佈步驟中必須以不侵入至前步驟為止已經成膜之各層之方式選擇塗佈液之溶劑,故而藉由塗佈而成膜之層之數量越增加越難以選擇適當之溶劑。因此,於塗佈步驟中,較佳為形成至構成有機半導體層之層中之發光層為止。 塗佈法可使用公知之方法,例如可使用旋轉塗佈、棒式塗佈、狹縫式塗佈、模嘴塗佈、噴塗、噴墨法等。塗佈法無須使積層時之環境為真空,不需要大規模之設備。又,由於不需要抽真空等時間,故而可使製造有機發光二極體之產出量提高。 <壓模步驟> 壓模步驟係藉由所謂壓印法而形成凹凸形狀之方法。若將模具壓抵於塗佈步驟中所形成之塗佈層,則構成塗佈層之塗佈液沿著模具之形狀而追隨。塗佈液由於具有可維持形狀之程度之黏度,故而於將模具卸除之後亦維持其形狀。 又,即便於塗佈液乾燥、蒸發之後,於形成成膜層之材料存在玻璃轉移點之情形時,亦能夠藉由於將成膜層加熱至玻璃轉移點以上之狀態下壓抵模具而賦予形狀。 於壓模步驟中,將本發明之一態樣之模具壓抵於在塗佈步驟所形成之塗佈層之最外層。所謂最外層係指塗佈步驟中所形成之最後之層,且係於塗佈步驟結束之階段距基體最遠之層。例如,於利用塗佈形成至圖12之發光層133為止之情形時,將模具壓抵於發光層133之第2電極140側之面而轉印模具之反轉形狀。 如上所述,本發明之一態樣之模具具有複數個凸部及平坦面,該等複數個凸部具有特定之彎曲面。因此,於將模具壓抵於發光層133時,施加至發光層133之力沿著特定之彎曲面而分散。其結果,可避免發光層133之層厚變得極薄之情況或發光層133被切斷之情況等。 <真空成膜步驟> 於真空成膜步驟中,藉由真空成膜法而形成構成有機半導體層之層中未於塗佈步驟形成之層及第2電極。 作為真空成膜法,可使用真空蒸鍍法、濺鍍法、CVD(chemical vapor deposition,化學氣相成長法)等。為了減少對有機層之損傷,較佳為使用真空蒸鍍法作為真空成膜法。 真空成膜法與塗佈法比較反映基底之形狀之反映性較高。因此,於壓模步驟中形成於塗佈層之最外層之凸部與平坦面之形狀亦反映於積層於塗佈層之最外層上部之層。 於藉由壓抵模具而形成於塗佈層之最外層之凹部中,較佳為凹部與平坦面利用特定之彎曲面而連結。即,較佳為凹部與平坦面之交界平緩。可更加抑制藉由真空成膜而形成之層之層厚不均勻。 藉由於塗佈層之最外層形成上述之凹部與平坦面,而於第2電極之發光層側之面如圖12所示形成與塗佈層之最外層反轉之形狀。該形狀為反映壓模步驟中壓抵之模具之形狀之形狀。 於本發明之一態樣之有機發光二極體之製造方法中,由於具有使用具有特定形狀之模具之壓模步驟,故而可於第2電極之發光層側簡單地形成所期望之凹凸。利用該方法製造之有機發光二極體可取出表面電漿子,從而可獲得較高之發光特性。Hereinafter, each structure will be described using drawings. The drawings used in the following descriptions may be enlarged for the sake of easy understanding of the features and for convenience, and the size ratios of the components may not be the same as the actual conditions. The materials, dimensions, etc. exemplified in the following description are examples, and the present invention is not limited to these and the like, and can be implemented with appropriate changes without changing the scope of the gist thereof. "Mold" FIG. 1 is a perspective view schematically showing a mold of one aspect of the present invention. In the mold 10 of one aspect of the present invention, a plurality of flat surfaces 1a to 1n and a plurality of convex portions 2a to 2n are provided on the main surface 10A. The plurality of flat surfaces 1a to 1n are arranged in an area surrounded by the most adjacent convex portions among the plurality of convex portions 2a to 2n. In FIG. 1, if the center points of the most adjacent convex portions are connected, a hexagon viewed from above is depicted, and a flat surface is provided in the central area. A plurality of convex portions 2a to 2n are connected in part. FIG. 2 is a cross-sectional view taken along the plane connecting the center point of the convex portion of the mold of one aspect of the present invention and the center point of the flat surface. The cross section shown in FIG. 2 is obtained in the form of an AFM (Atomic Force Microscopy, Atomic Force Microscope) image or a microscope image obtained by observing and cutting the sample with an electron microscope. The cross section of the AFM image is an AFM image obtained by photographing a square area 30 to 40 times the average pitch P of the convex portions 2a to 2n, and the central point 2An of the convex portion 2n and the central point 1An of the flat surface 1n are taken out The cross-sectional profile information is obtained. The cross-section is obtained by cutting the mold 10 through FIB (Focused Ion Beam, focused ion beam) or the like through the center point 2An of the convex portion 2n. The microscope image of the section is obtained by observing the section with an optical microscope. When there is a possibility that the cross-sectional shape of the mold may be deformed by cutting, it is preferable to cover the surface of the convex portion with a material that can withstand cutting or to embed the convex portion with resin or the like for cutting. In the case where any one of the cross section measured by the AFM image and the cross section observed by the microscope image is available, the cross section measured by the AFM image is preferred. The reason is that the cross-section measured by the AFM image can easily obtain the measurement surface of the specific cut surface, and it is easy to confirm the cross-sectional shape. In the case where the convex portions 2a to 2n are regularly arranged, it is preferable to set the cutting direction used to obtain the cross section as the direction along the arrangement direction of the convex portions 2a to 2n. The center points 2Aa to 2An of the convex portions 2a to 2n are set based on the measurement results of AFM. Specifically, a plurality of contour lines are drawn for each of the convex portions 2a to 2n parallel to the reference plane at intervals of 20 nm, and the center of gravity of each contour line (a point determined by the x coordinate and the y coordinate) is obtained. The average position of the center of gravity points (position value determined by the average value of each x coordinate and the average value of y coordinate) is set as the center points 2Aa to 2An of the convex portions 2a to 2n. The reference plane is a measurement plane after the slope is corrected by the image information with the slope measured by AFM. The center points 1Aa to 1An of the flat surfaces 1a to 1n are set based on the measurement results of AFM. Specifically, each of the plurality of flat surfaces 1a to 1n is provided with an inscribed circle inscribed in plan view. Let the center of the inscribed circle be the center points 1Aa to 1An of the flat surfaces 1a to 1n. The convex portions 2a to 2n are portions that protrude from the flat surfaces 1a to 1n. The flat surfaces 1a to 1n refer to a region whose slope is within ±5゜ with respect to a plane parallel to the reference plane of the AFM by the center of gravity of the region connecting the most adjacent convex portions. The convex portions 2a to 2n are two-dimensionally arranged on one surface of the mold 10. The so-called "two-dimensional arrangement" refers to a state in which a plurality of convex portions are arranged on the same plane. The two-dimensional structure in which a plurality of convex portions are two-dimensionally arranged may be periodic or aperiodic. The mold 10 can be preferably used when a metal-containing electrode of an organic light-emitting diode is used to make an uneven shape. The uneven shape helps to remove the surface plasmons generated on the electrode surface. When the organic light emitting diode manufactured by the mold 10 emits light in a narrower frequency band, the two-dimensional arrangement of the plurality of convex portions is preferably periodic. As a preferable specific example of the periodic two-dimensional structure, the alignment direction of the straight line connecting adjacent convex portions is two directions and the intersection angle is 90° (square lattice), and the adjacent convex portion The alignment direction of the connected straight lines is 3 directions and the crossing angle is 120° (hexagonal lattice, honeycomb lattice), etc. The so-called "positional relationship where the crossing angle is 120°" specifically refers to a relationship that satisfies the following conditions. First, a line segment L1 having a length equal to the average pitch P is drawn from one center point 2Aa to the direction of the adjacent center point 2Ab. Then, a line segment L2 having a length equal to the average pitch P is drawn from the center point 2Aa in the direction of 120° with respect to the line segment L1. If the center point adjacent to the center point 2Aa is within 15% of the average pitch P from the end point of each line segment L1 opposite to the center point 2Aa, the intersection angle is at a positional relationship of 120°. The positional relationship where the crossing angle is 90 degrees is defined by replacing the above description of "120°" with "90°". If the convex portions 2a to 2n are periodically arranged in a manner satisfying the above relationship, the period of the arrangement of the convex portions 2a to 2n resonates with the period of the surface plasmon, and the extraction efficiency of light in a specific frequency band is improved. In addition, when the convex portions 2a to 2n are arranged in a honeycomb lattice shape, the strength of the mold 10 increases, and the durability during repeated use is particularly improved. In other words, the honeycomb lattice shape is a relationship in which the tops of the plurality of convex portions 2a to 2n are located at the apexes of the hexagon when viewed from above in a direction perpendicular to the flat surfaces 1a to 1n. On the other hand, when the organic light-emitting diode manufactured using the mold 10 emits light of a wider frequency band or lights of plural frequency bands different from each other, the two-dimensionality of the plural convex portions 2a to 2n is preferable The configuration is acyclic. The so-called "aperiodic arrangement" refers to a state in which the interval between the centers of the convex portions 2a to 2n and the arrangement direction are not fixed. Here, the average pitch P is the distance between adjacent convex portions, and specifically, it can be obtained as follows. Here, the adjacent convex portion refers to the case where the convex portion is adjacent without the flat surface in FIG. 1. First, an AFM image is obtained for a randomly selected area in the main surface 10A of the mold 10 for a square area whose side is 30 to 40 times the average pitch P. For example, in the case where the design spacing is about 300 nm, an image of an area of 9 μm×9 μm to 12 μm×12 μm is obtained. Further, the distance between adjacent parts of the convex portions in the obtained area is measured, and the measured distance between adjacent parts is averaged to obtain the average pitch P 1 in the region. Randomly select a total of 25 or more areas of the same area to perform this process in the same way, and find the average pitch P 1 to P 25 in each area. The average value of the average pitches P 1 to P 25 in the 25 or more regions thus obtained is the average pitch P. At this time, the regions are preferably selected at least 1 mm apart from each other, and more preferably selected from 5 mm to 1 cm apart. The average pitch P of the convex portions 2a to 2n is 50 nm to 5 μm, preferably 50 nm to 500 nm. If the average pitch of the convex portions 2a to 2n is within this range, in the organic light-emitting diode manufactured using the mold 10, surface plasmons can be efficiently extracted from the metal electrode. The convex portions 2a to 2n are formed of Ca to Cn in a periodic structure in each region. As a whole in the macro, the Ca to Cn of each area can also be a non-periodic structure. Each of the regions Ca to Cn shown in FIG. 3 is a region in which the center point of each convex portion has a cross angle of 120° with respect to the center point of the flat surface. In FIG. 3, for the sake of convenience, the position of the center point of each convex portion 2a to 2n is represented by a circle u with the center point as the center. The most frequent area Q of each area Ca to Cn (the most frequent value of each area) is preferably in the following range. When the average pitch P is less than 500 nm, the most frequent area Q in the AFM image measurement range of 10 μm×10 μm is preferably 0.026 μm 2 to 6.5 μm 2 . When the average pitch P is 500 nm or more and less than 1 μm, the most frequent area Q in the AFM image measurement range of 10 μm×10 μm is preferably 0.65 μm 2 to 26 μm 2 . When the average pitch P is 1 μm or more, the most frequent area Q in the AFM image measurement range of 50 μm×50 μm is preferably 2.6 μm 2 to 650 μm 2 . If the most frequent area Q is within a better range, the periodic structure macroscopically becomes a polycrystal with random lattice orientation, so when the surface plasmons are converted into propagating light for radiation on the metal surface, it can be suppressed in a plane The emission angle of the directional radiant light becomes random, so that the luminous light extracted from the device has anisotropy. As shown in FIG. 3, the areas Ca to Cn are random in area, shape, and lattice orientation. Specifically, the degree of randomness of the area preferably satisfies the following conditions. First, draw the ellipse of the largest area circumscribed by the boundary of an area, and express the ellipse by the following formula (1). X 2 /a 2 + Y 2 /b 2 = 1 (1) When the average pitch P is less than 500 nm, the standard deviation of πab in the AFM image measurement range of 10 μm×10 μm is preferably 0.08 μm 2 the above. When the average pitch P is 500 nm or more and less than 1 μm, the standard deviation of πab in the AFM image measurement range of 10 μm×10 μm is preferably 1.95 μm 2 or more. When the average pitch P is 1 μm or more, the standard deviation of πab in the AFM image measurement range of 50 μm×50 μm is preferably 8.58 μm 2 or more. If the standard deviation of πab is within a preferable range, the effect of averaging the discharge angle of the surface plasmon radiating from the metal surface to a specific angle to the outside of the device in the plane direction is excellent, thereby suppressing the luminous light from having a directional opposite sex. The degree of randomness of the shapes of Ca to Cn in each region is specifically, the ratio of a to b and the standard deviation of a/b in formula (1) are preferably 0.1 or more. The randomness of the lattice orientation of Ca to Cn in each region specifically, preferably satisfies the following conditions. First, draw a straight line K0 connecting the center points of any two adjacent convex parts in the arbitrary region (I). Next, select one area (II) adjacent to the area (I), and draw three strips connecting any convex part in the area (II) with the center points of the three convex parts adjacent to the convex part Straight line K1~K3. When the straight lines K1 to K3 have an angle that differs by more than 3 degrees with respect to the six straight lines that rotate 60° each time based on the straight line K0, it is defined that the lattice orientations of the region (I) and the region (II) are different. In the area adjacent to the area (I), the area where the lattice orientation is different from the area orientation of the area (I) is preferably 2 or more, preferably 3 or more, and more preferably 5 or more . At this time, the convex side lattices are located in the respective regions Ca to Cn, but they are macroscopically polycrystalline structures. The randomness of the macroscopic lattice orientation can be evaluated by the ratio of the maximum value to the minimum value of the FFT (Fast Fourier Transform). The ratio of the maximum value and the minimum value of the FFT fundamental wave is to obtain the AFM image, find its 2D Fourier transformed image, draw the circle of the wave number leaving the fundamental wave from the origin, and select the point with the largest amplitude and the smallest amplitude on the circle The point is calculated as the ratio of its amplitude. It can be considered that in the case where the maximum value and the minimum value of the FFT fundamental wave are relatively large, the lattice orientation of the convex portion is the same, and when the convex portion is regarded as a two-dimensional crystal, the structure with high single crystallinity is considered. Conversely, it can be considered that when the maximum value and the minimum value of the FFT fundamental wave are relatively small, the lattice orientation of the convex portion is inconsistent, and when the convex portion is regarded as a two-dimensional crystal, it has a polycrystalline structure. The average aspect ratio of the plurality of convex portions 2a to 2n is 0.01 to 1, preferably 0.05 to 0.5. The average aspect ratio refers to the average height H of the convex portions 2a to 2n relative to the average width D of the convex portions 2a to 2n. If the average aspect ratio of the mold 10 is 0.01 or less, the effect of taking out surface plasmons as radiant light cannot be sufficiently obtained in the organic light-emitting diode manufactured using the mold 10. On the other hand, if the average aspect ratio is 1 or more, it is difficult to form the convex portion with the specific curved surface described below. In addition, it is difficult to transfer the shape using the mold 10 when manufacturing the organic light-emitting diode. The average aspect ratio of the convex portions 2a to 2n is measured by AFM. First, an AFM image was obtained for one area of 25 μm 2 (5 μm×5 μm) randomly selected for the main surface 10A of the mold 10. Then, a line is drawn in the diagonal direction of the obtained AFM image, and the height and width of each of the plurality of convex portions 2a to 2n intersecting the line are measured. The height of the convex portion refers to the distance from the flat surfaces 1a to 1n to the top of the convex portion, and the width of the convex portion refers to the diameter of the inscribed circle with the center point of the convex portion as the center in a plan view. Then, the average value of the height and width of the convex portion in this region is obtained. Do the same for the 25 randomly selected areas. Then, the average value of the heights and widths of the convex portions of each region obtained at 25 places is averaged to obtain the average height and average width. Then, the average height divided by the average width is the average aspect ratio. More than 80% of the convex portions 2a to 2n are formed by specific curved surfaces. The ratio of the convex portions having a specific curved surface among the plurality of convex portions is more preferably 90% or more, and further preferably 95% or more. The specific curved surface is defined as follows. FIG. 4 is a schematic cross-sectional view of the mold at an arbitrary cross-section passing through the center point of the convex portion, and enlarging one of the convex portions. First, an arbitrary point is selected as the first point p1 from the curved surface 2B constituting the convex portion 2n. Let the tangent plane with respect to this 1st point p1 be 1st tangent plane t1. In addition, a point that deviates from the first point p1 toward the center point 2An of the convex portion 2n by only 1/10 of the average pitch is set as the second point p2. Here, the deviation from only 1/10 of the average pitch refers to a distance L that moves parallel to the flat surface 1 from the first point p1 toward the center point 2An. Let the tangent plane with respect to the second point p2 be the second tangent plane t2. At this time, the inclination angle of the second tangent plane t2 with respect to the first tangent plane t1 is θ. That is, it is convenient for any part of the curved surface 2B of the convex portion 2n to satisfy the relationship that the convex portion 2n is specific when the angle of inclination θ of the second tangent plane t2 relative to the first tangent plane t1 is within 60°. Curved surface. The inclination angle θ is preferably within 45°, and more preferably within 30°. FIG. 5 is a schematic cross-sectional view when the mold of one aspect of the present invention is pressed against the surface of the laminate formed by coating. The laminate 20 includes a first layer 21, a second layer 22, and a third layer 23. When the mold 10 is pressed against the third layer 23 of the laminate 20, the convex portions 2 a to 2 n of the mold 10 are initially pressed against the laminate 20. Therefore, a force F1 is applied to each layer constituting the layered body 20 from the top of the convex portions 2a to 2n toward the outer peripheral portion. By the force F1, the material constituting each layer is also supplied to the space between the plurality of convex portions 2a to 2n of the mold 10. As a result, each layer constituting the laminate 20 is deformed to have a shape corresponding to the mold 10. The force F1 applied to each layer of the laminated body 20 does not concentrate stress and spreads from the top of the pressed convex portions 2a to 2n toward the outer peripheral portion. The reason is that the convex portions 2a to 2n of the mold 10 include a specific curved surface and have a gentle shape. If the force F1 does not concentrate stress, each of the first layer 21, the second layer 22, and the third layer 23 diffuses uniformly in the in-plane direction. Therefore, the thickness of each can be prevented from becoming extremely thin. In addition, generally, the material of each layer is sufficiently supplied along the specific curved surface 2B to the boundary portion 3 between the plurality of convex portions 2a to 2n and the flat surface of the mold 10 which is a portion where voids easily occur. That is, it is also possible to prevent voids from occurring at the boundary 3. In contrast, FIG. 6 is a schematic cross-sectional view when a mold having no specific curved surface is pressed against the surface of the laminate formed by coating. The convex portion 152n of the mold 15 shown in FIG. 6 has a corner portion 155 whose shape changes abruptly. The corner portion 155 is a tangent plane passing through two points of the corner portion 155 and does not satisfy the relationship of a specific curved surface. Therefore, the force F2 applied to each layer constituting the laminate 20 is not uniformly dispersed along the shape of the convex portion 152n, but the stress is concentrated near the corner portion 155. As a result, each of the first layer 21, the second layer 22, and the third layer 23 cannot diffuse uniformly in the in-plane direction. Therefore, each layer may be cut near the corner 155 or the layer thickness may become extremely thin. In addition, a sufficient amount of material cannot be supplied to the boundary 153 between the convex portion 152n and the flat surface, and voids are likely to occur. The layer constituting the laminate 20 corresponds to any layer constituting the organic light-emitting diode. If a part of each layer constituting the organic light-emitting diode is cut off, a problem arises that the cut-off part of the organic light-emitting diode does not emit light, or does not show sufficient light-emitting characteristics. That is, by using the mold 10 of the present embodiment, it is possible to avoid the problem that the organic light emitting diode does not emit light or does not exhibit sufficient light emitting characteristics. Returning to FIG. 5, in order to avoid voids between the mold 10 and the laminate 20, it is preferable that the boundary portion 3 is also gentle. That is, in any of the connecting portions between the convex portions 2a to 2n and the flat surface, it is preferable that the tangent plane at a point that deviates from 1/10 of the average pitch from any 1 point to the tangent at any 1 point The inclination angle of the plane is within 60°. FIG. 7 is a schematic cross-sectional view when another mold of the present invention is pressed against the surface of the laminate formed by coating. The mold 30 shown in FIG. 7 has a plurality of convex portions and a flat surface 31, and a boundary portion 33 of the plurality of convex portions and the flat surface 31 is connected by a specific curved surface. That is, in the connection portion of the flat surface 31 and the convex portion 32n, the inclination angle of the tangent plane at a point deviating from 1 point by 1/10 of the average pitch with respect to the tangent plane at any point is within 60° Relationship. That is, the border 33 becomes gentle. When the mold 30 shown in FIG. 7 is pressed against the laminate 20, neither the force F1 applied from the top of the convex portion 32n toward the outer peripheral portion nor the force F3 applied to the vicinity of the boundary portion 33 is stress-concentrated. Therefore, the materials constituting each layer smoothly diffuse along the main surface of the mold 30. As a result, the gap between the mold 10 and the laminate 20 can be avoided, and the thickness of each layer of the laminate 20 can be made uniform in the in-plane direction. In the mold 30, so that the flat surface 31 and the boundary portion of the plurality of convex portions 33 gentle can meet particular by the bent portion of the convex portion having constituted at least a portion of the inflection p in, and the inflection portion The first curved portion p1 in that is closest to the flat surface 31 in the pin is curved downward and connected to the flat surface 31. Inflection portion p in a cross-section of the convex portion of the inflection point of the assembly, the curved surface is changed from the upwardly convex portion of the convex curved surface of the downwardly or downwardly from the convex curved surface of the upwardly convex curved change of section . If a top portion of inflection p in, a convex portion 32n is formed along the line. The closest distance from the first curved portion p1 in to the flat surface 31 is preferably 1/10 or more of the average pitch P of the plurality of convex portions, and more preferably 1/5 or more. The closest distance refers to the distance of the narrowest part of the width between the first curved portion p1 1n and the flat surface 31 in the plan view of the convex portion 32n. If the closest distance from the first recurved portion p1 in to the flat surface 31 is 1/10 or more of the average pitch P of the plurality of convex portions, the inclination of the boundary portion 33 can be made gentler. In addition, if the boundary portion 33 of the mold 30 is smoothed, the layer formed by the vacuum film forming method reflects the reflection of the shape of the transferred object when the layer is formed by the vacuum film forming method on the object to be transferred made using the mold 30 Sexual improvement. FIG. 8 is a schematic cross-sectional view when a layer is formed on the transfer material shown in FIG. 7 by a vacuum film forming method. In the mold 30 shown in FIG. 7, the boundary portion 33 between the flat surface 31 and the convex portion 32n is gentle. Therefore, the boundary portion 23A of the curved surface 20A formed on the outermost surface of the laminate 20 using the mold 30 is also gentle. The part whose shape changes abruptly is generally a large change in the dispersion of film-forming particles during vacuum film-forming. On the other hand, if the shape of the curved surface 20A including the boundary portion 23A is gentle, the dispersion of the film-forming particles does not change significantly, and a uniform layer can be formed. The main surface (outermost surface) 20A of the transfer material layered body 20 shown in FIG. 8 is relatively gentle. Therefore, the outer surface 26B of the vacuum-formed layer 26 can sufficiently reflect the shape of the main surface 20A. Here, the "fully reflected" means that it is not necessary to fully reflect the shape formed in the stamping step. If the average pitch of the convex portions constituting the outer surface 26B of the vacuum film-forming layer 26 is within ±10% compared to the average pitch of the convex portions constituting the main surface 20A, and the outer surface of the layer 26 constituting the vacuum film forming The average height of the convex portions of 26B is within ±10% compared to the average height of the convex portions constituting the main surface 20A, and it can be said that the outer surface 26B of the vacuum-formed layer 26 sufficiently reflects the shape of the main surface 20A. For the measurement of the average pitch mentioned here, the above-mentioned method for measuring the average pitch P can be applied. In addition, the measurement method of the average height H mentioned above can be applied to the measurement of the average height. In the case where the vacuum-formed layer 26 is an electrode, it is not necessary for the outer surface 26B to sufficiently reflect the shape of the main surface 20A. In this case, since the main surface 20A is gentle, the film thickness of the layer 26 does not become thin or cut. As a method of confirming the shape of the curved surface 22B or the outer surface 26B, a cross-sectional observation using a scanning electron microscope (SEM) or a transmission electron microscope (TEM) may be mentioned, or the three-dimensional after removing the layer covering the observation surface Observed by electron microscope or AFM. Returning to FIG. 1, the area ratio of the flat surfaces 1a to 1n in the main surface 10A is preferably 5 to 50%, and more preferably 5% to 30%. If the area ratio of the flat surfaces 1a to 1n in the main surface 10A is 5% or more, the aspect ratio of the irregularities that can be used to extract the surface plasmons in the organic light-emitting diode manufactured using the mold becomes smaller. On the other hand, if the area ratio of the flat surfaces 1a to 1n in the main surface 10A is 50% or less, in the organic light-emitting diode manufactured using this mold, surface plasmons can be suppressed from being trapped by the flat surface. 9 is a schematic cross-sectional view of a mold of one aspect of the present invention cut by connecting the surfaces between the centers of adjacent convex portions. More specifically, it is a cross-sectional view taken along the plane connecting the center points of the adjacent convex portions in FIG. 1. The broken line in FIG. 9 is an approximate curve of the convex portions 2a to 2n. The approximate curve can be obtained by approximating the normal distribution by setting the center points 2Aa to 2An of the convex portions 2a to 2n as vertices. The boundary between the convex portions 2a to 2n and the ridge portion 4 is an approximate curve. The adjacent convex portions are connected by the ridge portion 4. The sides closer to the center point 2Aa to 2An of the approximate curve are the convex portions 2a to 2n, and the opposite side is the ridge portion 4. Preferably, the connection portion of the ridge portion 4 and the convex portions 2a to 2n and the connection portion of the ridge portion 4 and the flat surfaces 1a to 1n are connected in such a manner as to satisfy the condition of a specific curved surface. By connecting these connecting portions in such a manner as to satisfy the conditions of the specific curved surface, the force generated when the mold 10 is pressed against the laminate can be more evenly dispersed. In other words, it is possible to suppress the layer constituting the laminate pressed against the mold 10 from being cut. Further, as shown in FIG. 9, it is preferable that at least a part of the ridge portion 4 exists on the flat surface 1n side of the convex portion 2n connecting the ridge portion 4. That is, it is preferable that the height h of the portion of the ridge portion 4 closest to the flat surface 1n is smaller than the height H of the convex portion 2n connecting the ridge portion 4 from the flat surface 1n. FIG. 13 is a view of the main part of the mold of the present embodiment viewed from the direction perpendicular to the flat surface. If the height h of the ridge portion 4 is lower than the height H of the convex portion 2n, when the mold is pressed against the transferred object, the air interposed between the mold and the transferred object is removed through this portion (Fig. 13 arrow). In other words, it is possible to prevent air from being mixed into the object to be transferred, thereby performing uniform transfer. In addition, as shown in FIG. 13, in a plan view from a direction perpendicular to the flat surface 1n, the tops of the plurality of convex portions 2a to 2n are located at the apexes of hexagons constituting a honeycomb lattice (hexagonal lattice) At this time, the diffusion of resin and the like when the mold is pressed against the transferred object becomes equal, and pressure can be applied to the transferred object equally. If the pressure can be uniformly applied, for example, even when the transfer object is a thin layer, the layer can be prevented from being cut or the layer thickness becomes extremely thin. Further, the height h from the flat surface 1n of the portion of the ridge portion 4 shown in FIG. 9 closest to the flat surface 1n is preferably higher than the height H from the flat surface 1n of the convex portion 2n connecting the ridge portion 4 50% to 90%, more preferably 60 to 85%. If the height h of the ridge portion 4 is too low, the strength of the mold decreases, and if the height h of the ridge portion 4 is too high, the escape path of air becomes less. So far, one embodiment of the present invention has been described using the mold 10 of FIG. 1 as an example, but the shape of the mold is not limited to this configuration. 10 is a perspective schematic view of another aspect of the mold of the present invention. The mold 40 shown in FIG. 10 is different from the above-described mold 10 in that the convex portions 42a to 42n are arranged apart from each other and includes one flat surface 41. In addition, for example, it may be configured as shown in FIG. 11. FIG. 11 is a perspective schematic view of another aspect of the mold of the present invention. As shown in FIG. 11, the mold 50 has a plurality of convex portions 52a to 52n and a plurality of flat surfaces 51a to 51n. The mold 10 shown in FIG. 1 and the mold 50 shown in FIG. 11 are such that the positional relationship between the convex portion and the flat surface is reversed. That is, in the mold 50, the plurality of convex portions 52a to 52n are arranged in a region surrounded by the most adjacent flat surface among the plurality of flat surfaces 51a to 51n. In FIG. 11, if the center point of the most adjacent flat surface is connected, a hexagon is viewed from above, and a convex portion is provided in the central area. That is, when the positional relationship between a plurality of convex portions 52a to 52n and the flat surfaces 51a to 51n is reversed like the mold 50, each convex portion 52a to 52n is also formed by a specific curved surface, so it is pressed against the mold 50 In the stamping step, the layer constituting the laminate can be suppressed from being cut. The mold of one aspect of the present invention has a convex portion having a specific curved surface. Therefore, the organic light-emitting diode manufactured by using the mold 10 does not have a portion with a thin layer thickness or a portion where no layer is formed, and the surface plasmon can be taken out efficiently. "Mold manufacturing method" The mold can use electron beam lithography, mechanical cutting, laser lithography, laser thermal lithography, interference exposure, narrow exposure, aluminum anodic oxidation method and particle masking method. form. Among them, it is preferable to use a method of using a particle mask to make a mold. The method of using a particle mask refers to a method of performing an etching process after forming a particle single-layer film on the flat surface of the base material of the mold as an etching mask. In the method of using a particle mask, the base material directly below the particles is not etched and becomes a convex portion. Hereinafter, a specific example of the method of using the particle mask will be described. 14 is a diagram schematically showing a method of manufacturing a mold. First, a single-particle film etching mask 62 containing a plurality of particles M is formed on the base 61 (FIG. 14(a)). As a method of forming the single-particle film etching mask 62 on the substrate 61, for example, a method using the so-called LB method (Langmuir-Blodgett method) can be used. Specifically, the method of forming the single-particle film etching mask 62 includes: a dropping step, which adds dispersed droplets formed by dispersing particles in a solvent to the liquid surface in the water tank; a single-particle film forming step, which uses A single particle film F containing particles is formed by volatilizing the solvent; and a migration step, which is to take the single particle film F onto the substrate. Each step will be specifically described below. (Dropping step and single particle film forming step) First, in a hydrophobic organic solvent containing one or more hydrophobic solvents such as chloroform, methanol, ethanol, methyl ethyl ketone, etc., the surface is hydrophobic Particles to prepare dispersions. In addition, as shown in FIG. 15, a water tank (tank) V is prepared, and water W is added as a liquid for spreading particles on the liquid surface (hereinafter, sometimes referred to as lower layer water). Then, the dispersed droplets are added to the liquid surface of the lower layer water (dropping step). Then, the solvent as the dispersion medium evaporates, and the particles spread out in a single layer on the liquid surface of the lower layer water, thereby forming the two-dimensionally most densely packed single particle film F (single particle film forming step). As such, in the case of selecting a hydrophobic one as particles, a hydrophobic one must also be selected as a solvent. On the other hand, in this case, the lower layer water must be hydrophilic, and generally, water is used as described above. By such a combination, the self-assembly of particles is advanced as described below to form a two-particle densely packed single particle film F. However, hydrophilic particles can also be selected as the particles and the solvent. In this case, as the lower layer water, a hydrophobic liquid is selected. (Transition step) As shown in FIG. 15, the single-particle film F formed on the liquid surface by the single-particle film formation step is transferred onto the substrate 61 that is the object to be etched while maintaining the single-layer state (transition step). The base 61 may have a planar shape, or may include a non-planar shape such as a curved surface, an inclination, and a step difference in part or all. The single particle film F covers the surface of the substrate while maintaining the two-dimensional densest filling state even if the substrate 61 is not flat. The specific method of transferring the single-particle film F onto the substrate 61 is not particularly limited. For example, as the first method, it is also possible to keep the basal substrate 61 on the one hand while keeping it substantially parallel to the single-particle film F, and to touch the single-particle film F while descending from above. The affinity of the film F with the base 61 causes the single-particle film F to move to the base 61. In addition, as a second method, before forming the single-particle film F, the substrate 61 may be arranged in a substantially horizontal direction in the water under the water tank in advance, and after forming the single-particle film F on the liquid surface, the liquid surface may be gradually lowered, thereby reducing The single particle film F is transferred onto the base 61. According to these methods, the single particle film F can be transferred onto the substrate 61 without using a special device. Even if it is a single-particle film F having a larger area, it can be easily transferred to the substrate 1 while maintaining its second most densely packed state. In this respect, the so-called LB tank method is preferably used. By this transition step, a plurality of particles M are arranged in a substantially single layer on a flat surface 61a which is a surface of the base 61. That is, the single particle film F of the particles M is formed on the flat surface 61a. (Etching step) The single particle film F thus formed functions as a single particle etching mask 62. The substrate 61 provided with the single-particle etching mask 62 on one side is subjected to vapor-phase etching to perform surface processing (etching step). Specifically, when vapor phase etching is started, first, as shown in FIG. 14(b), the etching gas passes through the gap of the particles M constituting the etching mask 62 and reaches the surface of the base 61, and a groove is formed in this portion. Then, cylinders 63 appear at positions corresponding to the particles M, respectively. A groove portion 61m is formed between the columns 63. The groove portion 61m is formed at the center of the three particles M arranged on the regular triangle by the closest packing. Therefore, the groove portion 61m is located at the vertex of the regular hexagon with the cylinder 63 as the center. The particles M constituting the single-particle film etching mask 62 are not particularly limited, and for example, gold particles, colloidal silicon oxide particles, or the like can be used. As the etching gas, generally used gas can be used. For example, Ar, SF 6 , F 2 , CF 4 , C 4 F 8 , C 5 F 8 , C 2 F 6 , C 3 F 6 , C 4 F 6 , CHF 3 , CH 2 F 2 , CH 3 can be used F, C 3 F 8 , Cl 2 , CCl 4 , SiCl 4 , BCl 2 , BCl 3 , BC 2 , Br 2 , Br 3 , HBr, CBrF 3 , HCl, CH 4 , NH 3 , O 2 , H 2 , N 2 , CO, CO 2 etc. The particles M and the etching gas can be changed according to the substrate 61 to be etched. For example, in the case where gold particles are selected as the particles M constituting the single-particle film etching mask 62, and the glass substrate is selected as the base 61 and these combinations are used, if the etching gas uses CF 4 , CHF 3, etc. and the glass has For the reactive ones, the etching speed of the gold particles relatively slows down, and the glass substrate is selectively etched. The molds of various shapes shown in FIGS. 1, 10, and 11 can obtain a desired shape by changing dry etching conditions. In addition, in order to make the surface shape of the convex portion smoother, wet etching may be used together. Examples of the conditions for dry etching include the material of the particles constituting the particle mask, the material of the original plate, the type of etching gas, the bias power, the power supply, the flow rate and pressure of the gas, and the etching time. The flat surface can be obtained by increasing the initial etching gas flow rate and gradually decreasing the flow rate. In addition, when the ridge portion remains as in the mold 10 shown in FIG. 1, it can be obtained by increasing the hardness of the particles used for the particle mask. The average pitch of the convex portions and the like can be freely changed by changing the particle size of the particles used. In addition, when a non-periodic structure is formed using a single-layered particle film, it can be produced by using a plurality of particles having different particle diameters. (Odd number transfer step) Then, the base 61 shown in FIG. 14(b) is subjected to odd number transfer. The transfer body 71 shown in FIG. 14(c) is obtained by an odd number of transfers. Specifically, first, the produced base 61 is transferred with resin. On the surface of the obtained resin transfer product, metal plating such as Ni is coated by electroforming or the like. The hardness of the transfer body 71 is increased by coating metal plating, and the following shape adjustment and the like can be performed. The top of the cylinder 63 of the base 61 is flat because it is covered with particles M. Therefore, a flat surface 71n is formed in the transfer body 71 at a position corresponding to the cylinder 63 of the base 61. In addition, a convex portion 72n is formed in the transfer body 71 at a position corresponding to the groove portion 61m of the base 61. Therefore, the convex portion 72 is located at the vertex of the regular hexagon with the flat surface 71n as the center. That is, the shape corresponding to FIG. 1 is obtained. (Shape adjustment step) However, there is a case where a specific curved surface is not formed on the surface of the transfer body 71. For example, a corner 72a may be formed on the top of the convex portion 72n. The corner 72a is a part that does not satisfy the specified curved surface. Therefore, the corner portion 72a is removed to make the outer surface of the convex portion 72n a specific curved surface. Further etching can be performed either by wet etching or dry etching. Hereinafter, the case of dry etching will be specifically described. In order to remove the corner portion 72a, as shown in FIG. 14(d), the transfer body 71 is irradiated with plasma P generated by a plasma etching device to perform physical etching. The physical etching is different from the reactive etching used in the etching step. Reactive etching advances etching by reacting the plasma chemical species with the transfer body 71. On the other hand, the physical etching is performed by the physical force that the plasma chemical species conflict with the transfer body 71. Therefore, the physical etching is caused by the uneven probability of etching between the higher probability and the lower probability of the chemical species conflict in plasma, and has anisotropic etching compared with reactive etching. Physical etching is similar to ashing. In the plasma etching device, the chemical species plasmatized is used between the upper electrode and the lower electrode. Specifically, the lower electrode at a low potential is electrically connected to the transfer body 71 to charge the transfer body 71. The chemical species plasmatized between the upper electrode and the lower electrode are attracted by the transfer body 71 at a low potential and collide toward the transfer body 71 at high speed. At this time, there is a property that if there is a sharp portion like the corner portion 72a in the charged transfer body 71, the electric charge is concentrated in this portion. Therefore, most of the plasma chemical species are attracted to the sharp parts. That is, the sharp part is more likely to collide with the plasma chemical species than other parts. If the probability of conflict with the plasma chemical species increases, this part will be etched faster than other parts. That is, the corner portion 72a of the convex portion 72 is gradually removed to form a convex portion 2n having a specific curved surface (FIG. 14(e)). As an etching gas used for physical etching, for example, a rare gas such as argon, oxygen, or the like can be used. The lack of reactivity of these gases promotes physical etching. In addition, as an etching gas for physical etching, a reactive etching gas may also be used. For example, reactive gases such as CF 4 and CHF 3 can be used. In this case, the etching conditions are adjusted in such a way that the etching using physical conflicts becomes more prominent than the chemical reactivity of the ion species. For example, the etching conditions are adjusted so that the potential difference between the upper electrode and the lower electrode becomes larger. If the potential difference between the upper electrode and the lower electrode becomes larger, the collision speed of plasma chemical species increases, and the effect of physical etching becomes more significant than the effect of reactive etching. Preferably, the physical etching is performed under low pressure and high bias using argon or oxygen. The specific conditions vary depending on the device, so they cannot be determined at all. For example, in the case of dry etching using inductively coupled plasma (ICP), it is preferable to apply 0.5 to 1.5 W/cm at a pressure of 0.5 to 1.0 Pa 2 bias. Even when it is convenient to use other dry etching gas, it will not deviate greatly from the above range, but it is preferable to shorten the processing time. The reason for this is that there is a faster etching speed, and the corner portion 62a is supposed to be etched as described above. So far, only the corner portion 72a has been mentioned. For example, a sharp portion may be formed in the ridge portion (refer to FIGS. 1 and 9) between adjacent convex portions 72n. To facilitate this situation, the sharp portion of the ridge portion can be removed simultaneously with the corner portion 72a by physical etching. (Replication step) The mold produced by the above method can be used directly as a mold, or a replica made with the produced mold as the original version can be used as a mold for real-time use. Reproduction can be made by transferring the produced mold even times. Specifically, first, the produced mold is transferred with resin. On the surface of the obtained odd-numbered transfer body, metal plating such as Ni is coated by electroforming or the like. By coating the metal plating to increase the hardness of the odd-numbered transfer body, further transfer can be performed. Then, the odd-numbered transfer body is further transferred to produce an even-numbered transfer body. The even-numbered transfer body has the same shape as the produced mold. Finally, on the surface of the even-numbered transfer body, metal such as Ni is plated by electroforming or the like, thereby completing the replication of the mold. In addition, a mold 30 in which the boundary portions 33 of the plurality of convex portions 32n and the flat surface 31 shown in FIG. 7 are also connected by a specific curved surface can be produced by the following method. For example, as the first method, there is a method of performing physical etching between the above-mentioned etching step and the odd number of transfer steps. By performing physical etching between the etching step and the odd number of transfer steps, the top of the cylinder 63 becomes gentle, and the shape of the concave portion of the transfer body 71n becomes gentle. As another method, there is a method of performing physical etching during the transfer process in the copying step. By performing physical etching, the shape of the portion that becomes the convex portion after transfer can be smoothed. "Organic Light Emitting Diode" FIG. 12 is a schematic cross-sectional view of an organic light emitting diode device 100 according to one aspect of the present invention. The organic light-emitting diode element 100 includes a base 110, a first electrode 120, an organic semiconductor layer 130 including a light-emitting layer 133, and a second electrode 140 in this order. The organic semiconductor layer 130 shown in FIG. 12 has a hole injection layer 131 and a hole transport layer 132 between the first electrode 120 and the light emitting layer 133 in addition to the light emitting layer 133, and the light emitting layer 133 and the second electrode 140 An electron transport layer 134 and an electron injection layer 135 are provided between them. Each of the hole injection layer 131, the hole transport layer 132, the electron transport layer 134, and the electron injection layer 135 is not necessary or required. The organic light-emitting diode element 100 of the present invention may further include other layers as long as the effects of the present invention are not impaired. The first electrode 120 and the second electrode 140 of the organic light emitting diode apply a voltage to the organic semiconductor layer 130. When a voltage is applied between the first electrode 120 and the second electrode 140, electrons and holes are injected into the light-emitting layer 133, and the coupling generates light. The generated light directly passes through the first electrode 120 and is taken out to the outside of the device, or after being reflected once by the second electrode 140, it is taken out to the outside of the device. The second electrode 140 has a two-dimensional structure in which a plurality of convex portions 142a to 142n are two-dimensionally arranged on the surface 140A on the side of the light emitting layer 133. The two-dimensional structure is the same as the above-mentioned mold, which can be periodic or non-periodic. The average pitch of the plurality of convex portions 142a to 142n is 50 nm to 5 μm, preferably 50 nm to 500 nm. The average pitch can be obtained by the same method as the average pitch in the mold. If the average pitch of the convex portions 142a to 142n is within this range, the energy captured in the form of surface plasmons on the surface 140A of the second electrode which is a metal electrode can be efficiently radiated and can be extracted as light. The average aspect ratio of the plurality of convex portions 142a to 142n is 0.01 to 1, preferably 0.05 to 0.5. The average aspect ratio can be obtained by the same method as the average aspect ratio in the mold. If the average aspect ratio of the convex portions 142a to 142n in the surface of the second electrode 140 on the light emitting layer side is within this range, the surface 140A of the second electrode which is a metal electrode can be captured by surface plasmon The energy is radiated efficiently so that it can be taken out as light. The capture of surface plasmons is generated in the following process. When the light-emitting layer 133 emits light from the light-emitting molecules, near-field light is generated in the extreme vicinity of the light-emitting point. Since the distance between the light-emitting layer 133 and the second electrode 140 is very close, the near-field light is converted into the energy of the propagating surface plasmon on the surface of the second electrode 140. The propagating surface plasmons on the metal surface are those in which the sparse and dense waves of free electrons generated by incident electromagnetic waves (near-field light, etc.) accompany the surface electromagnetic fields. In the case of surface plasmons existing on a flat metal surface, the dispersion curve of the surface plasmons does not cross the dispersion line of light (spatially propagating light). Therefore, the energy of the surface plasmons cannot be extracted as light. In contrast, if the metal surface has a two-dimensional periodic structure, the dispersion curve of the surface plasmon diffracted by the two-dimensional periodic structure crosses the dispersion curve of the spatially propagated light. As a result, the energy of the surface plasmons can be taken out as radiation light to the outside of the device. In this way, if a two-dimensional periodic structure is provided, the energy of light lost in the form of surface plasmons is extracted. The extracted energy is radiated from the surface of the second electrode 140 as space propagating light. At this time, the directivity of the light radiated from the second electrode 140 is high, and most of it is directed to the extraction surface. Therefore, high-intensity light is emitted from the extraction surface, thereby improving extraction efficiency. More than 80% of the plurality of convex portions 142a to 142n have a specific curved surface. The specific curved surface is defined in the same way as the specific curved surface in the mold. A flat surface 141 is formed between the plurality of convex portions 142a to 142n on the surface 140A of the second electrode. The area ratio occupied by the flat surface 141 is preferably 5-50%, more preferably 5%-30%. If the area ratio of the flat surface 141 in the surface 140A of the second electrode is 5% or more, the aspect ratio of the irregularities used to extract the surface plasmons can be reduced. On the other hand, if the area ratio of the flat surface 141 in the surface 140A of the second electrode is 50% or less, the surface plasmons captured by the surface 140A of the second electrode can be efficiently converted into light. The second electrode 140 is preferably a material having a larger negative absolute value of the real part of the complex dielectric constant, and it is preferable to select a metal material with a higher plasma frequency that is advantageous for the extraction of surface plasma . Examples of this material include monomers such as gold, silver, copper, aluminum, and magnesium, or alloys of gold and silver, and alloys of silver and copper. If the light emission of the organic light-emitting diode is taken into consideration, it is preferably a metal material having a resonance frequency in the entire visible light region, and particularly preferably silver or aluminum. The second electrode 140 may have a laminated structure of two or more layers. The thickness of the second electrode 140 is not particularly limited. For example, it is 20 to 2000 nm, preferably 50 to 500 nm. If it is thinner than 20 nm, the reflectance becomes lower and the front brightness decreases. If it is thicker than 500 nm, heat or radiation-induced damage during film formation, and mechanical damage due to film stress accumulate in the organic light-emitting layer 133 etc. include organic layers. The organic semiconductor layer 130 contains an organic material. In FIG. 12, a concave-convex shape is formed at the interface between the light-emitting layer 133 and the electron transport layer 134 of the organic semiconductor layer 130 and the interface between the electron transport layer 134 and the electron injection layer 135. This uneven shape becomes the opposite shape of the main surface 10A of the mold 10. The uneven shape does not necessarily need to be formed at the interface between the light emitting layer 133 and the electron transport layer 134 of the organic semiconductor layer 130 and the interface between the electron transport layer 134 and the electron injection layer 135. The details will be described below in the method of manufacturing an organic light-emitting diode, and the uneven shape only needs to be formed on the surface of the second electrode 140 side of any layer constituting the organic semiconductor layer. The layer on the second electrode 140 side has a shape that reflects the uneven shape as compared to the layer formed with the uneven shape. The light emitting layer 133 includes an organic light emitting material. Examples of the organic light-emitting material include tri[1-phenylisoquinoline-C2,N]iridium(III)(Ir(piq)3), 1,4-bis[4-(N,N-diphenylamino Pigment compounds such as styrylbenzene)] (DPAVB), bis[2-(2-benzoxazolyl)phenol] zinc (II) (ZnPBO). In addition, those obtained by doping a fluorescent dye compound or a phosphorescent material with another substance (host material) may also be used. In this case, examples of the host material include hole transport materials and electron transport materials. As materials constituting the hole injection layer 131, the hole transport layer 132, the electron transport layer 134, and the electron injection layer 135, organic materials are generally used, respectively. For example, examples of the material (hole injection material) constituting the hole injection layer 131 include 4,4',4''-tri[2-naphthylphenylamino]triphenylamine (2-TNATA), etc. Compounds etc. Examples of the material (hole transport material) constituting the hole transport layer 132 include N,N'-diphenyl-N,N'-bis(1-naphthyl)-(1,1'-biphenyl) -4,4'-diamine (NPD), copper phthalocyanine (CuPc), N,N'-diphenyl-N,N'-bis(m-methylphenyl)aminobiphenyl (TPD) and other aromatic Amine compounds, etc. Examples of the material (electron transport material) constituting the electron transport layer 134 and the material (electron injection material) constituting the electron injection layer 135 include 2,5-bis(1-naphthyl)-1,3,4-
Figure 105126135-A0304-12-0015-1
Diazole (BND), 2-(4-tert-butylphenyl)-5-(4-biphenyl)-1,3,4-
Figure 105126135-A0304-12-0015-1
Diazole (PBD), etc.
Figure 105126135-A0304-12-0015-1
Metal complex compound compounds such as oxadiazole compounds and tris(8-quinolinyl) aluminum (Alq). The thickness of the entire organic semiconductor layer including the light-emitting layer 133 is usually 30 to 500 nm. For the first electrode 120, a transparent conductor that transmits visible light is used. The transparent conductor constituting the first electrode 120 is not particularly limited, and a known one can be used as a transparent conductive material. For example, indium tin oxide (Indium Tin Oxide (ITO)), indium zinc oxide (Indium Zinc Oxide (IZO)), zinc oxide (Zinc Oxide (ZnO)), zinc tin oxide (Zinc Tin Oxide (ZTO)), etc. . The thickness of the first electrode 120 is usually 50 to 500 nm. The base 110 uses a transparent body that transmits visible light. The material constituting the base 110 may be an inorganic material, an organic material, or a combination thereof. Examples of the inorganic material include various glasses such as quartz glass, alkali-free glass, and white glass, and transparent inorganic minerals such as mica. Examples of the organic material include resin films such as cycloolefin-based films and polyester-based films, and fiber-reinforced plastic materials obtained by mixing fine fibers such as cellulose nanofibers with the resin films. Although depending on the application, generally, the base 110 uses a higher visible light transmittance. The following is used, that is, the transmittance in the range of visible light (wavelength 380 nm to 800 nm) is not biased in the spectrum and is 70% or more, preferably 80% or more, and more preferably 90% or more. The thickness of each layer constituting the organic light-emitting diode 100 can be measured by a spectroscopic ellipsometer, a contact step difference meter, AFM, or the like. "Manufacturing method of organic light-emitting diode" The manufacturing method of an organic light-emitting diode according to one aspect of the present invention is on a surface of a substrate with electrodes having a transparent first electrode on which the first electrode is formed, A manufacturing method of forming an organic light-emitting diode including an organic semiconductor layer including a light-emitting layer and a second electrode through a coating step and a subsequent vacuum film-forming step. Between the coating step and the vacuum film-forming step, the outermost surface of the coating layer formed by the coating step is pressed against the outermost surface of the coating layer, and the shape of the main surface of the mold is formed on the outermost surface of the coating layer Invert the shape of the stamper step. <Preparation step of substrate with electrode> The substrate system with electrode forms a transparent first electrode on a transparent substrate. The substrate and the first electrode can be used as described above. As a method of forming the first electrode on the substrate, a known method can be used. For example, a transparent electrode material such as ITO can be formed on the substrate by sputtering. In addition, commercially available substrates with electrodes can also be purchased. <Coating Step> In the coating step, a part of or all of the layers constituting the organic semiconductor layer are formed by coating. Generally speaking, in the coating step, the solvent of the coating liquid must be selected in such a way as not to invade the layers that have been formed to the previous step, so the more the number of layers formed by coating, the more difficult it is to select the appropriate Solvent. Therefore, in the coating step, it is preferable to form up to the light emitting layer among the layers constituting the organic semiconductor layer. A well-known method can be used for a coating method, For example, spin coating, bar coating, slit coating, die coating, spray coating, an inkjet method, etc. can be used. The coating method does not need to make the environment during lamination to be vacuum, and does not require large-scale equipment. In addition, since time such as vacuuming is not required, the output of manufacturing organic light-emitting diodes can be increased. <Stamping step> The stamping step is a method of forming an uneven shape by a so-called imprint method. If the mold is pressed against the coating layer formed in the coating step, the coating liquid constituting the coating layer follows the shape of the mold. Since the coating liquid has a viscosity that can maintain the shape, the shape is maintained even after the mold is removed. In addition, even after the coating liquid is dried and evaporated, when the material forming the film-forming layer has a glass transition point, the shape can be given by pressing the mold against the mold while heating the film-forming layer above the glass transition point . In the stamping step, the mold of one aspect of the present invention is pressed against the outermost layer of the coating layer formed in the coating step. The so-called outermost layer refers to the last layer formed in the coating step, and is the layer farthest from the substrate at the end of the coating step. For example, in the case where the light-emitting layer 133 of FIG. 12 is formed by coating, the mold is pressed against the surface of the light-emitting layer 133 on the side of the second electrode 140 to transfer the inverted shape of the mold. As described above, the mold of one aspect of the present invention has a plurality of convex portions and a flat surface, and the plurality of convex portions have a specific curved surface. Therefore, when the mold is pressed against the light-emitting layer 133, the force applied to the light-emitting layer 133 is dispersed along a specific curved surface. As a result, it is possible to avoid the case where the thickness of the light-emitting layer 133 becomes extremely thin or the case where the light-emitting layer 133 is cut. <Vacuum film forming step> In the vacuum film forming step, the layer and the second electrode that are not formed in the coating step among the layers that constitute the organic semiconductor layer are formed by the vacuum film forming method. As the vacuum film formation method, a vacuum evaporation method, a sputtering method, a CVD (chemical vapor deposition) method, or the like can be used. In order to reduce damage to the organic layer, it is preferable to use a vacuum evaporation method as the vacuum film formation method. Compared with the coating method, the vacuum film forming method reflects the shape of the substrate with higher reflectivity. Therefore, the shapes of the convex portion and the flat surface formed on the outermost layer of the coating layer in the stamping step are also reflected in the layer stacked on the uppermost layer of the coating layer. In the concave portion formed in the outermost layer of the coating layer by pressing against the mold, the concave portion and the flat surface are preferably connected by a specific curved surface. That is, it is preferable that the boundary between the concave portion and the flat surface is gentle. It is possible to further suppress the uneven thickness of the layer formed by vacuum film formation. Since the outermost layer of the coating layer forms the above-mentioned concave portion and flat surface, the surface on the light emitting layer side of the second electrode is formed as shown in FIG. 12 in a shape reverse to the outermost layer of the coating layer. The shape is a shape reflecting the shape of the mold pressed in the compression molding step. In the method for manufacturing an organic light-emitting diode according to one aspect of the present invention, since there is a stamping step using a mold having a specific shape, it is possible to easily form desired irregularities on the light-emitting layer side of the second electrode. The organic light-emitting diode manufactured by this method can take out the surface plasmon, so as to obtain higher light-emitting characteristics.

1a~1n‧‧‧平坦面 1Aa~1An‧‧‧中心點 2a~2n‧‧‧凸部 2Aa~2An‧‧‧中心點 2B‧‧‧彎曲面 3‧‧‧交界部 4‧‧‧稜線部 10‧‧‧模具 10A‧‧‧主面 15‧‧‧模具 20‧‧‧積層體 20A‧‧‧彎曲面 21‧‧‧第1層 22‧‧‧第2層 23‧‧‧第3層 23A‧‧‧交界部 26‧‧‧層 26B‧‧‧外表面 30‧‧‧模具 31‧‧‧平坦面 32n‧‧‧凸部 33‧‧‧交界部 40‧‧‧模具 41‧‧‧平坦面 42a~42n‧‧‧凸部 50‧‧‧模具 51a~51n‧‧‧平坦面 52a~52n‧‧‧凸部 61‧‧‧基體 61m‧‧‧槽部 62‧‧‧單粒子膜蝕刻遮罩 63‧‧‧圓柱 71‧‧‧轉印體 71n‧‧‧平坦面 72a‧‧‧角部 72n‧‧‧凸部 100‧‧‧有機發光二極體 110‧‧‧基體 120‧‧‧第1電極 130‧‧‧有機半導體層 131‧‧‧電洞注入層 132‧‧‧電洞傳輸層 133‧‧‧發光層 134‧‧‧電子傳輸層 135‧‧‧電子注入層 140‧‧‧第2電極 140A‧‧‧表面 141‧‧‧平坦面 142a~142n‧‧‧凸部 152n‧‧‧凸部 155‧‧‧角部 F1‧‧‧力 F2‧‧‧力 F3‧‧‧力 h‧‧‧高度 H‧‧‧平均高度 K0、K1~K3‧‧‧直線 M‧‧‧粒子 p1‧‧‧第1點 p1in‧‧‧第1反曲部 p2‧‧‧第2點 pin‧‧‧反曲部 P‧‧‧平均間距 P‧‧‧電漿 t1‧‧‧第1切平面 t2‧‧‧第2切平面 u‧‧‧圓 V‧‧‧水槽(槽) W‧‧‧水 θ‧‧‧傾斜角1a~1n‧‧‧Flat surface 1Aa~1An‧Center point 2a~2n‧‧‧Convex part 2Aa~2An‧‧‧Center point 2B‧‧‧Curved surface 3‧‧‧Boundary part 4‧‧‧Edge part 10‧‧‧Mold 10A‧‧‧Main surface 15‧‧‧Mold 20‧‧‧Layered body 20A‧‧‧Curved surface 21‧‧‧1st layer 22‧‧‧second layer 23‧‧‧third layer 23A ‧‧‧Boundary 26‧‧‧ Layer 26B‧‧‧Outer surface 30‧‧‧Mold 31‧‧‧Flat surface 32n‧‧‧Convex portion 33‧‧‧Border 40 40‧‧‧Mold 41‧‧‧Flat surface 42a~42n‧‧‧Convex part 50‧‧‧Mold 51a~51n‧‧‧Flat surface 52a~52n‧‧‧Convex part 61‧‧‧Matrix 61m‧‧‧Slot part 62‧‧‧Single particle film etching mask 63‧‧‧Cylinder 71‧‧‧Transfer body 71n‧‧‧Flat surface 72a‧‧‧Corner 72n‧‧‧Convex part 100‧‧‧Organic light-emitting diode 110‧‧‧Substrate 120‧‧‧ 1st Electrode 130‧‧‧ organic semiconductor layer 131‧‧‧ hole injection layer 132‧‧‧ hole transport layer 133‧‧‧ light emitting layer 134‧‧‧ electron transport layer 135‧‧‧ electron injection layer 140‧‧‧ 2nd Electrode 140A‧‧‧surface 141‧‧‧flat surface 142a~142n‧‧‧convex part 152n‧‧‧convex part 155‧‧‧corner part F1‧‧‧force F2‧‧‧force F3‧‧‧force h‧‧ ‧Height H‧‧‧Average height K0, K1~K3 ‧‧‧Straight line M‧‧‧Particle p1‧‧‧1st point p1 in ‧‧‧1st curvature part p2‧‧‧2nd point p in ‧‧ ‧Recurve P‧‧‧Average pitch P‧‧‧Plasma t1‧‧‧First cut plane t2‧‧‧Second cut plane u‧‧‧Circular V‧‧‧Sink (groove) W‧‧‧Water θ‧‧‧Tilt angle

圖1係本發明之一態樣之模具之立體模式圖。 圖2係將本發明之一態樣之模具於通過形成於模具之凸部之中心點與平坦面之中心點之面切斷的剖視模式圖。 圖3係本發明之一態樣之模具之俯視模式圖。 圖4係將本發明之一態樣之模具於通過形成於模具之凸部之中心點之面切斷的圖,且係將一個凸部放大之剖視圖。 圖5係將本發明之一態樣之模具壓抵於藉由塗佈而形成之積層體表面時之剖視模式圖。 圖6係將不具有特定之彎曲面之模具壓抵於藉由塗佈而形成之積層體表面時之剖視模式圖。 圖7係將本發明之另一態樣之模具壓抵於藉由塗佈而形成之積層體表面時之剖視模式圖。 圖8係以真空成膜法於圖7所示之轉印物上形成層之情形時之剖視模式圖。 圖9係沿著本發明之一態樣之模具之鄰接之凸部而切斷之剖視模式圖。 圖10係本發明之另一態樣之模具之立體模式圖。 圖11係本發明之另一態樣之模具之立體模式圖。 圖12係本發明之一態樣之有機發光二極體元件之剖視模式圖。 圖13係自相對於平坦面垂直之方向俯視本實施形態之模具之主要部分之圖。 圖14A~E係模式性地表示模具之製造方法之圖。 圖15A、B係模式性地表示模具之製造過程中之滴加步驟及單粒子膜形成步驟之圖。FIG. 1 is a perspective schematic view of a mold of one aspect of the present invention. 2 is a schematic cross-sectional view of a mold of one aspect of the present invention cut along a plane passing through a center point of a convex portion formed on the mold and a center point of a flat surface. FIG. 3 is a schematic top view of a mold of one aspect of the present invention. FIG. 4 is a view of a mold of one aspect of the present invention cut at a plane passing through a center point of a convex portion formed in the mold, and an enlarged cross-sectional view of one convex portion. FIG. 5 is a schematic cross-sectional view when the mold of one aspect of the present invention is pressed against the surface of the laminate formed by coating. FIG. 6 is a schematic cross-sectional view when a mold having no specific curved surface is pressed against the surface of the laminate formed by coating. FIG. 7 is a schematic cross-sectional view when another mold of the present invention is pressed against the surface of the laminate formed by coating. 8 is a schematic cross-sectional view when a layer is formed on the transfer material shown in FIG. 7 by a vacuum film forming method. 9 is a schematic sectional view taken along the adjacent convex portion of the mold of one aspect of the present invention. 10 is a perspective schematic view of another aspect of the mold of the present invention. FIG. 11 is a perspective schematic view of another aspect of the mold of the present invention. 12 is a schematic cross-sectional view of an organic light-emitting diode device according to an aspect of the present invention. FIG. 13 is a view of the main part of the mold of the present embodiment viewed from the direction perpendicular to the flat surface. 14A to 14E are diagrams schematically showing a method of manufacturing a mold. 15A and 15B are diagrams schematically showing a dropping step and a single particle film forming step in the manufacturing process of a mold.

1a~1n‧‧‧平坦面 1a~1n‧‧‧flat surface

1Aa~1An‧‧‧中心點 1Aa~1An‧‧‧Center

2a~2n‧‧‧凸部 2a~2n‧‧‧Convex part

2Aa~2An‧‧‧中心點 2Aa~2An‧‧‧Center

10‧‧‧模具 10‧‧‧Mold

10A‧‧‧主面 10A‧‧‧Main

P‧‧‧平均間距 P‧‧‧ average spacing

Claims (9)

一種有機發光二極體之製造方法,其特徵在於,其係藉由塗佈步驟與其後之真空成膜步驟而於在基體上具有透明之第1電極之帶電極之基體的形成有上述第1電極之面,形成包含發光層之有機半導體層及第2電極者,且於上述塗佈步驟與上述真空成膜步驟之間具有壓模步驟,該壓模步驟係將模具壓抵於上述塗佈步驟中所形成之塗佈層之最外表面,而將上述模具之主面之形狀之反轉形狀形成於上述塗佈層的最外表面,上述模具於主面具有平坦面及複數個凸部,上述複數個凸部之平均間距為50nm~5μm,上述複數個凸部之平均縱橫比為0.01~1,上述複數個凸部中80%以上具有特定之彎曲面,上述特定之彎曲面於將上述特定之彎曲面之任意之點設為第1點,且將自上述第1點僅偏離上述平均間距之1/10之點設為第2點時,與上述第2點相接之第2切平面相對於與上述第1點相接之第1切平面的傾斜角為60°以內。 A method for manufacturing an organic light-emitting diode, characterized in that the first step described above is formed on a substrate with an electrode having a transparent first electrode on the substrate through a coating step and a subsequent vacuum film-forming step On the surface of the electrode, an organic semiconductor layer including a light-emitting layer and a second electrode are formed, and there is a stamper step between the coating step and the vacuum film forming step, which presses the mold against the coating The outermost surface of the coating layer formed in the step, and the inverted shape of the main surface of the mold is formed on the outermost surface of the coating layer, the mold has a flat surface and a plurality of convex portions on the main surface , The average pitch of the plurality of convex portions is 50 nm to 5 μm, the average aspect ratio of the plurality of convex portions is 0.01 to 1, more than 80% of the plurality of convex portions have a specific curved surface, the specific curved surface is The arbitrary point of the specific curved surface is set as the first point, and when the point deviating from the first point by only 1/10 of the average pitch is set as the second point, the second point that is in contact with the second point The inclination angle of the tangent plane with respect to the first tangent plane that is in contact with the first point is within 60°. 如請求項1之有機發光二極體之製造方法,其中上述主面中之上述平坦面所占之面積率為5~50%。 The method for manufacturing an organic light emitting diode according to claim 1, wherein the area ratio of the flat surface among the main surfaces is 5 to 50%. 如請求項1之有機發光二極體之製造方法,其中上述平坦面與具有上述特定之彎曲面之凸部,以滿足上述特定之彎曲面之條件之方式連結。 The method for manufacturing an organic light emitting diode according to claim 1, wherein the flat surface and the convex portion having the specific curved surface are connected in a manner satisfying the condition of the specific curved surface. 如請求項3之有機發光二極體之製造方法,其中構成上述複數個凸部之上述特定之彎曲面具有至少1個以上之反曲部,上述反曲部中自最接近上述平坦面之第1反曲部至上述平坦面為止之最接近距離為上述複數個凸部的平均間距之1/10以上。 The method for manufacturing an organic light-emitting diode according to claim 3, wherein the specific curved surface constituting the plurality of convex portions has at least one recurved portion, and among the recurved portions, the closest to the flat surface 1 The closest distance from the curved portion to the flat surface is 1/10 or more of the average pitch of the plurality of convex portions. 如請求項1之有機發光二極體之製造方法,其中上述複數個凸部形成蜂巢晶格,於自相對於上述平坦面而垂直之方向之俯視下,上述複數個凸部之頂部位於構成上述蜂巢晶格之六邊形之頂點。 The method for manufacturing an organic light-emitting diode according to claim 1, wherein the plurality of convex portions form a honeycomb lattice, and the top of the plurality of convex portions is located to constitute the above in a plan view from a direction perpendicular to the flat surface The apex of the hexagon of the honeycomb lattice. 如請求項5之有機發光二極體之製造方法,其中位於上述六邊形之頂點之凸部於與位於上述六邊形之鄰接的頂點之凸部之間具有稜線部,上述稜線部之至少一部分存在於較將上述稜線部連接之凸部靠上述平坦面側。 The method for manufacturing an organic light emitting diode according to claim 5, wherein the convex portion at the vertex of the hexagon has a ridge portion between the convex portion at the vertex adjacent to the hexagon, and at least the ridge portion A part exists on the flat surface side of the convex portion connecting the ridge portion. 如請求項6之有機發光二極體之製造方法,其中上述稜線部之最接近上述平坦面之部分距上述平坦面之高度,相對於將上述稜線部連接之凸部距上述平坦面之高度為50%~90%。 The method for manufacturing an organic light emitting diode according to claim 6, wherein the height of the portion of the ridge portion closest to the flat surface is from the flat surface, and the height of the convex portion connecting the ridge portion from the flat surface is 50%~90%. 一種有機發光二極體,其特徵在於依序具有基體、透明之第1電極、包含發光層之有機半導體層、及第2電極,上述第2電極之上述有機半導體層側之面具有平坦面、及自上述平坦 面朝向上述基體突出之複數個凸部,上述複數個凸部之平均間距為50nm~5μm,上述複數個凸部之平均縱橫比為0.01~1,上述複數個凸部中80%以上具有特定之彎曲面,上述特定之彎曲面於將上述特定之彎曲面之任意之點設為第1點,且將自上述第1點朝向上述凸部之中心點僅偏離上述平均間距之1/10之點設為第2點時,與上述第2點相接之第2切平面相對於與上述第1點相接之第1切平面的傾斜角為60°以內。 An organic light-emitting diode, characterized in that it has a substrate, a transparent first electrode, an organic semiconductor layer including a light-emitting layer, and a second electrode, and the surface of the second electrode on the side of the organic semiconductor layer has a flat surface, And flat from above A plurality of convex portions protruding toward the base, the average pitch of the plurality of convex portions is 50 nm to 5 μm, the average aspect ratio of the plurality of convex portions is 0.01 to 1, and more than 80% of the plurality of convex portions have specific Curved surface, the specific curved surface is defined as any point where the specific curved surface is the first point, and the point that deviates from the first point toward the center point of the convex portion by only 1/10 of the average pitch When the second point is set, the inclination angle of the second tangent plane contacting the second point with respect to the first tangent plane contacting the first point is within 60°. 如請求項8之有機發光二極體,其中上述第2電極之上述有機半導體層側之面中之上述平坦面所占之面積率為5~50%。 The organic light emitting diode according to claim 8, wherein the area ratio of the flat surface in the surface of the second electrode on the side of the organic semiconductor layer is 5 to 50%.
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