WO2012050043A1 - 有機エレクトロルミネッセンス発光装置およびその製法 - Google Patents
有機エレクトロルミネッセンス発光装置およびその製法 Download PDFInfo
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- WO2012050043A1 WO2012050043A1 PCT/JP2011/073090 JP2011073090W WO2012050043A1 WO 2012050043 A1 WO2012050043 A1 WO 2012050043A1 JP 2011073090 W JP2011073090 W JP 2011073090W WO 2012050043 A1 WO2012050043 A1 WO 2012050043A1
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/12—Light sources with substantially two-dimensional radiating surfaces
- H05B33/14—Light sources with substantially two-dimensional radiating surfaces characterised by the chemical or physical composition or the arrangement of the electroluminescent material, or by the simultaneous addition of the electroluminescent material in or onto the light source
- H05B33/145—Arrangements of the electroluminescent material
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/805—Electrodes
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/10—OLED displays
- H10K59/12—Active-matrix OLED [AMOLED] displays
- H10K59/131—Interconnections, e.g. wiring lines or terminals
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/90—Assemblies of multiple devices comprising at least one organic light-emitting element
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/851—Division of substrate
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K77/00—Constructional details of devices covered by this subclass and not covered by groups H10K10/80, H10K30/80, H10K50/80 or H10K59/80
- H10K77/10—Substrates, e.g. flexible substrates
- H10K77/111—Flexible substrates
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2924/00—Indexing scheme for arrangements or methods for connecting or disconnecting semiconductor or solid-state bodies as covered by H01L24/00
- H01L2924/0001—Technical content checked by a classifier
- H01L2924/0002—Not covered by any one of groups H01L24/00, H01L24/00 and H01L2224/00
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K2102/00—Constructional details relating to the organic devices covered by this subclass
- H10K2102/301—Details of OLEDs
- H10K2102/311—Flexible OLED
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/805—Electrodes
- H10K50/81—Anodes
- H10K50/814—Anodes combined with auxiliary electrodes, e.g. ITO layer combined with metal lines
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/84—Passivation; Containers; Encapsulations
- H10K50/844—Encapsulations
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
- Y02E10/549—Organic PV cells
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P70/00—Climate change mitigation technologies in the production process for final industrial or consumer products
- Y02P70/50—Manufacturing or production processes characterised by the final manufactured product
Definitions
- the present invention relates to an organic electroluminescence light-emitting device that can be manufactured at low cost and has little luminance unevenness, and a method for manufacturing the same.
- Organic electroluminescence (hereinafter referred to as “organic EL”) light-emitting devices which are expected as next-generation low-power-consumption light-emitting devices, can emit light of various colors derived from organic light-emitting materials. Therefore, it is also attracting attention as a display for TVs and the like.
- the organic EL element used in such an organic EL light emitting device is a thin film element and a surface light emitting element as compared with the inorganic EL element, it is a lighting device utilizing these characteristics.
- Applications such as backlights for liquid crystal displays, light-emitting parts for display decoration, and digital signage are also expected.
- the thickness of the organic EL layer is as thin as several hundreds of nanometers, a transparent see-through type can be obtained by making the support substrate transparent and allowing the light transmitted through the transparent substrate to be extracted from the opposite side of the substrate. A light emitting element can be formed. Therefore, development of a new decoration and digital signage is also expected using an organic EL light emitting device in which a transparent see-through light emitting element is mounted.
- an organic EL light emitting device As a method for increasing the size of an organic EL light emitting device, there is a conventional method of increasing the size of the device by increasing the substrate (mother glass) of the organic EL element itself, and reducing the cost. As a method, there is a method of increasing the number of production in one batch.
- formation of the organic EL layer of the organic EL element generally uses a vacuum vapor deposition method, and when the size of the substrate is increased, the equipment for forming and manufacturing by vacuum vapor deposition becomes expensive.
- the organic EL element used in the organic EL light-emitting device has a total thickness of the organic EL layer (distance between the electrodes) as very small as several hundred nm, so that it is short-circuited due to extremely fine dust. There is a limit to increasing the number of products manufactured in one batch, and the risk increases as the substrate size increases.
- the organic EL element substrate itself is not enlarged, but the organic EL element substrate is elongated in a fiber shape, and a plurality of fiber-like organic EL elements are placed on a large base material.
- the organic EL light-emitting device can be made larger, and the number of products manufactured in one batch can be increased, but the cost can be reduced by manufacturing in a roll-to-roll process. (For example, refer to Patent Documents 1 and 2).
- a terminal is provided on each of a plurality of subdivided organic EL layers and is electrically connected by pressing a contact to the terminal.
- the thin organic EL layer is damaged and brightness unevenness easily occurs.
- the linear light emitting device described in Patent Document 2 since the terminal is not provided on the organic EL layer, the organic EL layer is not damaged, but the shape of the substrate itself is a fiber shape (linear body).
- the terminal region is provided at the end in the longitudinal direction.
- the present invention has been made in view of such circumstances, and an object of the present invention is to provide an organic EL light-emitting device that can be manufactured at low cost and has little luminance unevenness, and a manufacturing method thereof.
- an organic EL light-emitting device of the present invention includes an organic EL element including a substrate, an organic EL layer, and first and second electrodes provided in a state where the organic EL layer is sandwiched from above and below.
- an organic EL light-emitting device formed by arranging a plurality of elements on a base material, and the entire organic EL element has a ribbon shape, and is sandwiched between a first electrode and a second electrode.
- the organic EL layer is formed in a state along the longitudinal direction of the ribbon-like substrate, and for terminals for connecting to the power source along the organic EL layer on at least one side edge of both side edges along the longitudinal direction of the organic EL layer
- the first gist is that the area is provided.
- an organic EL light-emitting device in which a plurality of organic EL elements formed through the following steps (A) to (F) are arranged on a base material and electrically connected to an arbitrary portion of the terminal region
- This manufacturing method is the second gist of the present invention.
- the present inventors have repeated research in order to produce a large organic EL light emitting device at low cost.
- organic EL elements with small size and excellent performance are manufactured at high throughput and at low cost, and by combining a plurality of these small organic EL elements, organic He recalled that when the EL light emitting device was enlarged, a large-sized organic EL light emitting device with low cost and high performance could be manufactured. Therefore, further research was conducted on a method for producing a low-cost and high-performance small organic EL element.
- the organic EL element is formed in a ribbon shape, the organic EL layer is formed in a state along the longitudinal direction of the substrate, and the organic EL layer is formed on at least one side edge of both side edges along the longitudinal direction of the organic EL layer. If a region for a terminal for connection with a power source is provided along the line, there is no damage to the organic EL layer due to the connection of the terminal as described in Patent Document 1, and as described in Patent Document 2, The present inventors have found that an organic EL element having no luminance unevenness can be efficiently and continuously manufactured without causing the problem of intermittently moving the roll in terms of manufacturing, and has reached the present invention.
- the organic EL light-emitting device of the present invention is an organic EL light-emitting device formed by arranging a plurality of organic EL elements, wherein the organic EL element is in a ribbon shape, and the first electrode and the first electrode An organic EL layer sandwiched between two electrodes is formed in a state along the longitudinal direction of the substrate, and along the organic EL layer on at least one side edge of both side edges along the longitudinal direction of the organic EL layer Thus, a terminal area for connecting to the power source is provided. Therefore, when manufacturing the organic EL element, it is possible to continuously manufacture the roll without intermittently driving the roll to reduce productivity.
- a terminal region for connecting to a power source along the organic EL layer is continuously provided on at least one side edge of both side edges along the longitudinal direction of the organic EL layer.
- the organic EL light emitting device as a whole can be downsized.
- the organic EL light-emitting device of the present invention does not have a terminal region on the organic EL layer and does not connect a power source by pressing a contact on the organic EL layer. Does not cause damage and does not cause uneven brightness.
- the terminal region can be connected to a power source via an auxiliary electrode, the voltage can be applied more uniformly to the entire organic light emitting layer, so that uneven brightness is less likely to occur.
- an organic EL light-emitting device in which a plurality of organic EL elements formed through the following steps (A) to (F) are arranged on a base material and electrically connected to an arbitrary portion of the terminal region
- an organic EL light-emitting element can be more efficiently manufactured by a roll-to-roll process, and the manufacturing cost of the organic EL light-emitting device can be further reduced.
- the formation cost and time can be reduced.
- steps (C) to (E) are performed in a vacuum or in an inert gas atmosphere, and each step and between the steps are performed without being exposed to the atmosphere.
- the efficiency in each process can be increased, and the thickness of each deposited film can be formed more uniformly, so that a higher-quality organic EL light-emitting device can be obtained.
- organic EL light emission in which at least the steps (I), (D), and (E) are performed in a vacuum or in an inert gas atmosphere, and the respective steps and steps are not exposed to the air.
- the efficiency in each process can be improved and the thickness of each deposited film can be formed more uniformly, so that a higher quality organic EL light emitting apparatus can be obtained.
- the “ribbon shape” is a strip or tarp as a whole, and usually has a short side of 10 to 50 mm and a long side of 50 to 500 mm.
- the terminal area refers to an area portion that can be used as a terminal, and specifically means an area that can be connected to a wire or the like connected to a power source.
- FIG. 1 is an explanatory diagram for realizing the organic EL light emitting device of the present invention.
- a plurality of ribbon-shaped organic EL elements 2 are arranged in parallel (in the length direction) on a base material 1 made of substantially flat glass. In an aligned state). And each said organic EL element 2 is formed in the area
- the left end portion of one terminal region 3 is connected to the energizing electrode terminal 5 by the wire 4, and the right end portion of the other terminal region 3 is connected to the energizing electrode terminal 5 ′ by the wire 4 ′.
- this organic EL light emitting device is a bottom emission type light emitting device in which each organic EL element 2 emits light toward the back side of the figure (the lower side of the paper, that is, the base material 1 side). Moreover, in the figure, each part is shown typically and is different from the actual size or the like (the same applies to the following figures).
- one organic EL element 2 is formed in a ribbon shape having a width of 20 mm and a length of 300 mm as shown in the plan view of FIG. 2, and the width h is 13 mm along the longitudinal direction.
- the organic EL layer 10 is formed, and terminal regions 3 that can be connected to the wires 4 are provided on the left and right side edges along the longitudinal direction of the organic EL layer 10.
- FIG. 3 which is a cross-sectional view taken along the line XX of FIG. 2, first, a planarizing layer 7 and a second layer are formed on a thin glass substrate 6 having flexibility.
- the first electrode 8, the organic EL layer 10, and the second electrode 11 are laminated in this order.
- an insulating layer 9 is provided between the first electrode 8 and the second electrode 11 so as not to contact each other.
- the pre-barrier layer 12, the sealing resin 13, and the barrier sheet 14 are laminated in this order with the terminal region 3 portion for later connection to the wire 4 remaining.
- Such an organic EL element 2 can be obtained by, for example, the following roll-to-roll process. That is, a long sheet-like thin glass having a width i of 300 mm, a length j of 140 m, and a thickness of 100 ⁇ m is prepared as the substrate 6 (see FIG. 4A). Then, an organic EL insulating material (manufactured by JSR, JEM-477) is applied, dried, and post-baked at 220 ° C. for 1 hour to form a planarizing layer 7 having a thickness of 1 ⁇ m. Then, the first electrode 8 is formed on the planarizing layer 7 by a long sputtering apparatus. Note that the first electrode 8 may be formed by patterning. As such patterning, for example, a method of etching the first electrode 8 by patterning an etching resist through a photomask can be used.
- an organic EL layer formation planned portion ( ⁇ ) that is a portion in contact with the organic EL layer 10 in a later step and an auxiliary electrode 15 are formed on the first electrode 8.
- An insulating layer 9 is formed in which openings for exposing the auxiliary electrode formation scheduled portion ( ⁇ ), which is a portion, are arranged in a plurality of rows. Specifically, the formation of the insulating layer 9 is performed by patterning by repeating a process of coating a photosensitive insulating material, exposing through a photomask, and developing.
- the organic EL layer formation planned portion ( ⁇ ) has a width k of 11 mm and a length l of 280 mm
- the auxiliary electrode formation planned portion ( ⁇ ) has a width m of 2.5 mm and a length of 140 m ( The total length of the thin glass).
- the light emitting area can be defined by the overlapping portion of the first electrode 8 and the second electrode 11, and the first electrode 8 and the second electrode can be defined. 11 can be prevented, so that the insulating layer 9 need not be formed.
- the organic EL layer 10 is formed on the long ribbon-shaped laminate by filling the organic EL layer formation scheduled portion ( ⁇ ) by vacuum deposition, and then the organic EL layer 10 is covered.
- the pre-barrier layer 12 is evacuated in a state where the second electrode 11 is formed and the terminal region 3 (both side edges along the longitudinal direction of the organic EL layer 10) that is connectable to the wires 4 and 4 ′ is left. Form consistently below.
- the auxiliary electrode 15 is formed simultaneously with the second electrode 11 by vacuum deposition.
- the long ribbon-shaped formed body is sealed except for the terminal region 3. Sealing is performed by applying an epoxy-based adhesive to the portion excluding the terminal region 3 in the long ribbon-shaped formed body, and attaching a barrier sheet with less moisture and oxygen permeation thereon. Do. As a result, as shown in FIG. 5A, the sealing resin 13 and the barrier sheet 14 are laminated on the portion of the long ribbon-like formed body excluding the terminal region 3, and the sealing is completed. After the sealing is completed, the ribbon-shaped organic EL element having a width n of 20 mm and a length o of 300 mm is cut every predetermined length (300 mm in this example) with the organic EL layer 10 included. 2 can be obtained [FIG. 5 (b)].
- a plurality of ribbon-like organic EL elements 2 obtained in this way are arranged on the base material 1 and fixed with an adhesive, and wires 4 and 4 are placed at arbitrary locations in the terminal region 3.
- the organic EL light-emitting device of the present invention can be obtained by connecting 'and performing electrical connection (mounting) via the energizing electrode terminals 5 and 5'.
- the organic EL element 2 can be continuously manufactured with a high throughput by a roll-to-roll process, the cost can be reduced.
- the process is performed on the long sheet-like substrate 6 having a wide width until the patterning of the insulating layer 9, and the subsequent steps are performed on the long ribbon-like substrate 6 cut into a predetermined width, the manufacturing efficiency is high. .
- the steps after the formation of the organic EL layer 10 are performed on the long ribbon-like substrate 6 cut to a predetermined width, the thickness of each deposited film under vacuum can be formed more uniformly.
- the cost for introducing the manufacturing equipment can be reduced.
- the both-sides edge along the longitudinal direction of the organic EL layer 10 is made into the area
- An arbitrary portion in the terminal region 3 can be used as a terminal depending on the form to be mounted (the shape and size of the base material 1) instead of the portion. Therefore, when mounting the ribbon-shaped organic EL element 2, when two adjacent ribbon-shaped organic EL elements 2 are arranged without a gap, and the terminal regions 3 are connected by a single wire 4 (4 ′), The number of wires 4 (4 ′) can be reduced, and the cost can be further reduced.
- auxiliary electrode 15 is formed on the terminal region 3 on one side edge in the terminal region 3 on both side edges along the longitudinal direction of the organic EL layer 10, the wire 4 is formed on the auxiliary electrode 15. As shown in FIG. 6, when this portion is the anode terminal 16, the current first reaches the entire auxiliary electrode 15 through the anode terminal 16, and from there, as shown by the dotted arrow, the organic EL layer 10. To flow throughout. For this reason, a voltage is uniformly applied to the entire organic EL layer 10, and luminance unevenness is less likely to occur.
- the organic EL light-emitting device of the present invention uses the ribbon-shaped organic EL element 2 in which unevenness in luminance is less likely to occur, uneven luminance does not occur even when the number is increased and the size is increased.
- the organic EL layer 10 is not electrically connected, the organic EL layer 10 is not damaged, and the luminance unevenness is hardly generated in the organic EL element 2 in this respect as well.
- uneven brightness does not occur.
- the organic EL element 2 manufactured at low cost is used as mentioned above, the whole organic EL light-emitting device can be manufactured at low cost.
- the organic EL element 2 is a bottom emission type having the structure shown in FIG. 3, but can have various other structures.
- a top emission type as shown in FIG.
- the terminal region 3 has one side edge (see the figure) of both side edges along the longitudinal direction of the organic EL layer 10 of the organic EL element 2. Only in the upper right).
- the structure can also be made into various variations. For example, as shown in FIGS. 8A and 8B, FIGS. 9A and 9B, FIGS. 10A and 10B, and FIG. It can also be.
- description of various sealing layers is abbreviate
- the substrate 6 of the organic EL element 2 is made of a thin glass with flexibility, but in addition to this, the substrate 6 is highly transparent to transmit the emitted light, and the organic EL layer 10 is formed.
- those having a barrier property can be used.
- examples of such materials include polyimide resins, polyester resins, epoxy resins, polyurethane resins, polystyrene resins, polyethylene resins, polyamide resins, acrylonitrile-butadiene-styrene (ABS) with barrier properties.
- thermosetting resin such as a copolymer resin, a polycarbonate resin, a silicone resin, and a fluorine resin
- a synthetic resin film such as a thermoplastic resin.
- the thickness is usually appropriately selected from the range of 5 to 500 ⁇ m, preferably 10 to 300 ⁇ m, from the viewpoint of the balance between mechanical strength and flexibility.
- stacking a thin organic layer and an inorganic layer alternately can be used.
- the substrate 6 is made of stainless steel, 36 alloy, 42 alloy, etc. in addition to the above example. It is also possible to use metals such as copper, nickel, iron, aluminum and titanium. Among these, copper, aluminum, stainless steel, and titanium are preferably used from the viewpoints of high thermal conductivity and easy application to a roll-to-roll process in order to efficiently release the heat of the organic EL layer 10.
- the thickness of the substrate 6 is preferably 5 to 200 ⁇ m. If the thickness is too thin, the handleability tends to be deteriorated. On the other hand, if the thickness is too large, it is difficult to wind the substrate 6 in a roll shape, which tends to be unsuitable for the roll-to-roll process.
- the planarization layer 7 of the organic EL element 2 is made of an organic EL insulating material (JEM-477, manufactured by JSR Corporation).
- an inorganic layer is provided by plating or vacuum deposition to planarize the organic EL element 2.
- the layer 7 may be formed, or a resin or an inorganic film may be wet coated to form the planarization layer 7.
- the flattening layer 7 may not be provided. Note that the surface roughness Ra of the surface of the substrate 6 or the planarization layer 7 is preferably 20 nm or less and Rmax is 50 nm or less.
- the organic EL layer 10 formed on the surface is thin, so that a short circuit occurs between the first electrode 8 and the second electrode 11. This is because it tends to be easy to do.
- the first electrode 8 of the organic EL element 2 when the first electrode 8 is used as an anode, it is preferable to use a material having a high work function from the viewpoint of hole injection properties.
- a material having a high work function examples thereof include various transparent conductive materials such as indium tin oxide (ITO) and indium zinc oxide (IZO), metals such as gold, silver, platinum, and aluminum, and alloy materials.
- ITO indium tin oxide
- IZO indium zinc oxide
- metals such as gold, silver, platinum, and aluminum
- alloy materials when the organic EL element 2 is a bottom emission type as in the above example or a see-through type, a material having high transparency and high conductivity is preferable.
- the first electrode 8 when the first electrode 8 is a cathode, it is preferable to use a material with a small work coefficient that facilitates electron injection.
- Such a material examples include metals such as aluminum and magnesium, and these materials. And alloys containing.
- the substrate 6 itself can be used as the first electrode, and therefore it is not necessary to form the first electrode 8 separately. If it is difficult to inject carriers due to the influence of an oxide film or the like, a sputtering method or the like is used to form a metal, an alloy, a transparent conductive film or the like with a work coefficient appropriately on the surface of the substrate 6 to a thickness of 5 to 200 nm. May be used.
- the insulating layer 9 of the organic EL element 2 is provided to prevent a short circuit between the first electrode 8 and the second electrode 11, and when the light emitting area is defined by the insulating layer 9, the positional deviation in the width direction is performed. And the continuous production in the roll-to-roll process can be further facilitated.
- a material for such an insulating layer 9 a material having an insulating property and having little moisture and outgassing which adversely affects the characteristics and life of the organic EL element is preferable.
- the organic EL layer 10 of the organic EL element 2 is a layer having at least a light emitting layer, and a hole injection layer, a hole transport layer, an electron block layer, a hole block layer, an electron transport layer, an electron injection layer, etc. Depending on the above, they are used in combination as appropriate or alone.
- the film thickness of the organic EL layer 10 is several nm to several hundred nm, and the film thickness is selected according to the purpose from the viewpoints of light emission efficiency and lifetime.
- the second electrode 11 of the organic EL element 2 is preferably formed of a highly conductive material because it is necessary to efficiently pass a current.
- electron injection is performed. It is preferable to use a material that is easy to perform and has a small work coefficient. Examples of such materials include metals such as aluminum and magnesium, and alloys containing these. Moreover, in order to improve electron injection property, you may contain the material containing an alkaline-earth metal.
- the second electrode 11 is an anode, it is preferable to use a material having a large work function from the viewpoint of hole injection. Examples of such materials include metals such as gold, silver and platinum, and alloy materials.
- a material having high transparency and high conductivity is preferably used.
- the pre-barrier layer 12 of the organic EL element 2 prevents damage due to moisture, oxygen, or the like until sealing in the subsequent process, or prevents damage in the sealing process.
- the material of the pre-barrier layer 12 is preferably a material with less moisture and outgas.
- a highly transparent material is used. Is preferred. Examples of such a material include inorganic oxides such as silicon oxide. Note that when the second electrode 11 itself has the pre-barrier function, the pre-barrier layer 12 may not be provided separately.
- the sealing of the organic EL element 2 used in the present invention is performed in order to completely prevent moisture and oxygen from entering.
- an epoxy adhesive is applied to the long ribbon-like formed body on the pre-barrier layer 12 other than the terminal region 3 (sealing resin 13), and moisture and oxygen are added.
- a barrier sheet (barrier sheet 14) with little permeation is attached.
- the sealing resin 13 an adhesive material with less moisture and outgas can be used.
- the organic EL element 2 is a top emission type or a see-through type, it is transparent. It is preferable to use a material having high properties.
- the sealing resin 13 may contain a material having an action of removing moisture and oxygen.
- the barrier sheet 14 a film-like sheet having a barrier property with a low permeability of moisture and oxygen can be used.
- a metal etc. can also be used.
- the auxiliary electrode 15 of the organic EL element 2 used in the present invention is formed by the same method at the same time when the second electrode 11 is formed. However, the second electrode 11 and the auxiliary electrode 15 are formed at the same time. It may not be necessary, and it may be formed by another method or another material. For example, when the second electrode 11 is formed, the auxiliary electrode 15 is not formed, and when the organic EL element 2 is mounted on the base material 1, a conductive tape is applied on the terminal region 3, and the auxiliary electrode It may be 15. Although the auxiliary electrode 15 is not necessarily provided, it is preferable to provide the auxiliary electrode 15 in that a voltage can be applied uniformly over the entire organic EL layer 10.
- the auxiliary electrode 15 is provided only on one side edge of the terminal region 3 on both side edges along the longitudinal direction of the organic EL layer, but may be provided on both side edges.
- the auxiliary electrode 15 is provided on both side edges, it becomes possible to apply a voltage to the entire organic EL layer 10 more uniformly, and luminance unevenness is less likely to occur.
- the wide sheet-like substrate 6 is formed, and after the formation of the organic EL layer 10 is performed on the long ribbon-like substrate 6, You may make it perform with respect to the long ribbon-shaped board
- the process up to the patterning of the insulating layer is performed on the wide sheet-like substrate 6 and the organic EL layer 10 is formed after the formation of the long ribbon. This is preferably performed on the substrate 6.
- the base material 1 is made of a substantially flat glass, but in addition to this, a highly transparent material suitable for the light extraction surface can be used. Further, when the organic EL element 2 is a top emission type, the transparency of the base material 1 is not necessary. Therefore, in addition to glass, a component such as a metal plate or a building such as a film, a window glass, a wall, or a ceiling can be used as the base material 1. Furthermore, the shape of the base material 1 is not limited to a substantially flat plate shape, but may be various shapes such as a spherical shape and a cylindrical shape.
- a plurality of the ribbon-like organic EL elements 2 described above are arranged and fixed on the base material 1 on which the wires 4 and 4 ′ are arranged, and are connected to the energizing electrode terminals 5 and 5 ′. It is obtained by sealing (resin sealing, adhesion of a transparent flexible substrate, etc.).
- sealing resin sealing, adhesion of a transparent flexible substrate, etc.
- the organic EL element 2 the sealing resin 13 and the barrier sheet 14
- the organic EL element 2 is highly sealed, the base material 1 and the sealing (resin and transparent flexible base material) do not require high barrier properties, and an inexpensive resin film or the like can be used. it can.
- the organic EL light emitting device of the present invention has a plurality of ribbon-like organic EL elements 2, but each organic EL element 2 may have a different emission color.
- each organic EL element 2 may have a different emission color.
- white organic EL light emitting device white can be expressed by combining the organic EL elements 2 that emit light of the three primary colors of light, red, blue, and green.
- the wires 4 and 4 ′ of the base material 1 can be formed by the same technique and material as those of a normal flexible circuit board or rigid circuit board.
- the organic EL element 2 can be fixed to the base material 1 using an adhesive material or an adhesive, and the heat conductivity of the organic EL layer 10 can be efficiently dissipated.
- electrical bonding between the organic EL element 2 and the wires 4 and 4 ′ can utilize a manufacturing process of a semiconductor package, and wire bonding and solder reflow are preferably used, for example.
- the electrical bonding between the organic EL element 2 and the wires 4 and 4 ′ is preferably a process at a lower temperature in order to avoid adverse effects on the organic EL element 2.
- a top emission type ribbon-like organic EL element was continuously manufactured by a roll-to-roll process. Thereafter, the manufactured plurality of ribbon-shaped organic EL elements were mounted on a base material to manufacture an organic EL light emitting device.
- a square organic EL element (Comparative Example 1) and a fiber-like organic EL element (Comparative Example 2), which are top emission types, are manufactured by a roll-to-roll process, as in the Examples.
- the organic EL light emitting device was manufactured by mounting each on the same base material used in the above.
- Example 1 Prior to the manufacture of the organic EL device, as shown in FIG. 12A, a SUS304 foil having a width of 300 mm, a length of 140 m, and a thickness of 25 ⁇ m was prepared as the long sheet-like substrate 18.
- a JSR organic EL insulating material JEM-477) is applied on the prepared long sheet-like substrate 18, dried, and post-baked at 220 ° C. for 1 hour to form a flat layer having a thickness of 1.5 ⁇ m. Formed.
- the insulating layer was a pattern having an opening 19 having a width of 11 mm and a length of 280 mm and an opening 20 having a width of 2.5 mm and extending over the entire length (see FIG. 12A).
- the long sheet-shaped laminate 21 is cut by a laser in a row so as to have a predetermined width by separating each of the openings (19, 20) in a row in which the both openings (19, 20) are arranged.
- the laminate 22 was a 140 m long ribbon (see FIG. 12B).
- the long ribbon-shaped laminate 22 is subjected to UV / O 3 treatment (surface modification treatment utilizing the cooperative action of ultraviolet light and ozone) and then set in a vacuum vapor deposition machine.
- UV / O 3 treatment surface modification treatment utilizing the cooperative action of ultraviolet light and ozone
- CuPc copper phthalocyanine
- NPB 8-quinolinol aluminum complex
- Lithium fluoride (LiF) 0.5 nm
- aluminum (Al) 1 nm aluminum (Al) 100 nm (only auxiliary electrode portion)
- SiON silicon nitride oxide
- auxiliary electrode portion Al (100 nm) of the auxiliary electrode portion is deposited through a SUS shadow mask having an opening with a width of 2.5 mm, and the width of 2.5 mm is formed on the opening 20 which is a portion where the auxiliary electrode is to be formed.
- the auxiliary electrode was formed.
- the organic EL element 25 was obtained (see FIG. 12C). ⁇ Implementation ⁇ Fifteen ribbon-shaped organic EL elements 25 were mounted on a base material of 300 mm ⁇ 300 mm in a state where their length directions were aligned, and an organic EL light emitting device having a size of 300 mm ⁇ 300 mm was obtained.
- the pattern of the insulating layer is a pattern having an opening 26 having a width of 280 mm and a length of 280 mm and an opening 27 having a width of 5 mm and extending over the entire length (see FIG. 13A), except that cutting along the longitudinal direction is not performed.
- one large organic EL element 28 of 300 mm ⁇ 300 mm was manufactured (see FIG. 13B).
- One manufactured organic EL element 28 was mounted on the same base material as in Example 1 with these length directions aligned, and an organic EL light emitting device having a size of 300 mm ⁇ 300 mm was obtained.
- the pattern of the insulating layer is a pattern having an opening 29 having a width of 0.5 mm and a length of 280 mm and an opening 30 having a width of 0.5 mm and a length of 5 mm, for forming an organic layer, a cathode layer, and a pre-barrier layer, respectively.
- a shadow mask having an opening at a required position is aligned along the longitudinal direction and formed while intermittently feeding the base material to form a long sheet-like laminate 31 (FIG. 14 ( a), see (b)).
- a thin glass 32 (width 1 mm, length 300 mm) is attached to the long sheet-like laminate 31 while being aligned along the longitudinal direction so as to cover the opening 29 and sealed.
- 300 mm fiber-like organic EL element that is cut along the longitudinal direction at 1 mm and is cut every 300 mm in length, including the opening 29 as shown by a one-dot chain line in FIG. 300 pieces of 33 were manufactured.
- 300 manufactured organic EL elements 33 were mounted on the same base material as in Example 1 to obtain an organic EL light emitting device having a size of 300 mm ⁇ 300 mm.
- the organic EL light emitting device of the product of Example 1 since the organic EL light emitting device of the product of Example 1 has excellent performance and is manufactured at a low cost, the organic EL element manufactured at a low cost can be manufactured at a low cost as a whole device, Moreover, no luminance unevenness occurred.
- the performance of the organic EL element was inferior in the organic EL light emitting device of Comparative Example 1 product, the performance of the organic EL light emitting device on which the organic EL light emitting device was mounted was also inferior.
- the organic EL light emitting device of Comparative Example 2 not only the performance of the organic EL element itself is inferior, but also its production cannot be performed in a continuous process. In proportion, costs also increased. In addition, it takes time to mount the organic EL element, which further increases the cost.
- the organic EL light-emitting device of the present invention can be used for lighting equipment, backlights for liquid crystal displays, light-emitting parts for display decoration, digital signage, and the like.
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Abstract
Description
(A)長尺シート状基板の上に第1の電極を形成する工程。
(B)上記第1の電極が形成された長尺シート状基板を長手方向に沿って切断し長リボン状の積層体とする工程。
(C)上記長リボン状の積層体の上に、その長手方向に沿った状態の有機EL層を形成する工程。
(D)上記有機EL層の上に第2の電極を形成する工程。
(E)上記長リボン状の積層体の長手方向に沿う両側縁のうち、電源と接続するための電極が位置する側縁を残した状態で上記積層体上面を封止材により封止し、封止されていない上記電極が位置する側縁を端子用領域とする工程。
(F)上記長リボン状の積層体を切断して、所定長のリボン状にする工程。
(A)長尺シート状基板の上に第1の電極を形成する工程。
(B)上記第1の電極が形成された長尺シート状基板を長手方向に沿って切断し長リボン状の積層体とする工程。
(C)上記長リボン状の積層体の上に、その長手方向に沿った状態の有機EL層を形成する工程。
(D)上記有機EL層の上に第2の電極を形成する工程。
(E)上記長リボン状の積層体の長手方向に沿う両側縁のうち、電源と接続するための電極が位置する側縁を残した状態で上記積層体上面を封止材により封止し、封止されていない上記電極が位置する側縁を端子用領域とする工程。
(F)上記長リボン状の積層体を切断して、所定長のリボン状にする工程。
(G)上記第1の電極の上に、フォトマスクを利用して、所定部分を露出させるための開口が幅方向に複数の列状に並ぶ絶縁層を形成する工程。
(H)上記絶縁層が形成された長尺シート状基板を、上記開口が並ぶ列ごとに切り離すように長手方向に沿って切断し長リボン状の積層体とする工程。
(I)上記長リボン状の積層体の上に、少なくとも上記開口を埋めた状態で有機EL層を形成する工程。
(J)上記長リボン状の積層体の長手方向に沿う両側縁のうち、電源と接続するための電極が位置する側縁に補助電極を形成する工程。
有機EL素子の製造に先立ち、図12(a)に示すように、長尺シート状基板18として、幅300mm、長さ140m、厚み25μmのSUS304箔を準備した。
〔平坦化層の形成〕
準備した長尺シート状基板18の上に、JSR製有機EL絶縁材料(JEM-477)を塗工、乾燥し、220℃で1時間ポストベークを行う事により、厚み1.5μmの平坦層を形成した。
〔第1の電極の形成〕
つぎに、長尺スパッタ装置にて、平坦層上に反射層および陽極として、IZO(20nm)/パラジウムおよび銅を含有する銀系合金(APC:フルヤ金属社製)(100nm)/IZO(100nm)を形成した。
〔絶縁層の形成〕
形成した第1の電極の上に、絶縁層としてJSR製有機EL絶縁材料(JEM-477)を塗工、乾燥し、プロキシミティ露光機で所定のフォトマスクを介して露光後、2.38wt%テトラメチルアンモニウムハイドライド(TMAH)で現像し、水洗後、水分を除去してから220℃で1時間ポストベークを行った。ポストベーク後の絶縁層の膜厚は約1.5μmであった。なお、絶縁層のパターンは、幅11mm、長さ280mmの開口部19および幅2.5mmで全長にわたる開口部20を有するパターンとした(図12(a)参照)。その後、上記長尺シート状の積層体21を、レーザにて上記両開口部(19,20)が並ぶ列ごとに切り離し所定幅となるように、長手方向の切断を行い、幅20mm、長さ140mの長リボン状の積層体22とした(図12(b)参照)。
〔有機EL層、第2の電極、プレバリア層の形成〕
上記長リボン状の積層体22を、UV/O3処理(紫外光とオゾンの協働作用を利用する表面改質処理)を行った後に真空蒸着機にセットし、真空下で、銅フタロシアニン(CuPc)25nm、N,N’-ジフェニル-N-N-ビス(1-ナフチル)-1,1’-ビフェニル)-4,4’-ジアミン(NPB)45nm、8-キノリノールアルミニウム錯体(Alq3)60nm、フッ化リチウム(LiF)0.5nm、アルミニウム(Al)1nm、アルミニウム(Al)100nm(補助電極部のみ)、銀(Ag)15nm、窒化酸化シリコン(SiON)100nmの順に形成した。なお、補助電極部のAl(100nm)は、幅2.5mmの開口を有するSUS製のシャドウマスクを介して蒸着を行い、補助電極形成予定部分である上記開口部20の上に幅2.5mmに形成し、補助電極とした。
〔有機EL素子の封止、切断〕
プレバリア層まで形成した上記長リボン状の積層体22を、一旦、巻き取りロールに巻き取り、窒素ガスを導入し大気圧にした後、窒素雰囲気下で別のチャンバーに移動させ、端子用領域(有機EL層の長手方向に沿う両側縁)以外の部分に、厚さ100μmの日本電気硝子社製薄ガラス24をエポキシ系接着剤で貼り付けた。接着剤の硬化後、上記長リボン状の積層体22を、大気下に取り出し、図12(b)に一点鎖線で示すように、300mmの長さ毎に切断して、20mm×300mmのリボン状の有機EL素子25を得た(図12(c)参照)。
〔実装〕
上記リボン状の有機EL素子25を15個、これらの長さ方向を揃えた状態で、300mm×300mmの母材上に実装し、300mm×300mmの大きさの有機EL発光装置を得た。
絶縁層のパターンを、幅280mm、長さ280mmの開口部26および幅5mmで全長に渡る開口部27を有するパターンとし(図13(a)参照)、長手方向に沿った切断を行わない以外は実施例1と同様にして、300mm×300mmの大型の有機EL素子28を1個、製造した(図13(b)参照)。製造した有機EL素子28を1個、これらの長さ方向を揃えた状態で、実施例1と同様の母材上に実装し、300mm×300mmの大きさの有機EL発光装置を得た。
絶縁層のパターンを、幅0.5mm、長さ280mmの開口部29および幅0.5mm、長さ5mmの開口30を有するパターンとし、有機層、陰極層、プレバリア層の形成のための、それぞれ必要な個所に開口部のあるシャドウマスクを、長手方向に沿ってそれぞれ位置合わせをして、間欠的に基材を送りながら形成し、長尺シート状の積層体31を形成した(図14(a),(b)参照)。この長尺シート状の積層体31に、薄ガラス32(幅1mm、長さ300mm)を、上記開口部29を覆うように長手方向に沿って位置合わせをしながら貼り付けて封止し、幅1mmで長手方向に沿って切断するとともに、図14(a)に一点鎖線で示すように、上記開口部29を含む、長さ300mm毎に切断して、1mm×300mmのファイバー状の有機EL素子33を300個、製造した。製造した有機EL素子33を300個、実施例1と同様の母材上に実装し、300mm×300mmの大きさの有機EL発光装置を得た。
有機EL素子に対する製造設備を導入にかかる費用を評価した。
○:小型の真空設備を利用できるため、導入費用は低額となる。
×:大型の真空設備を建設しなければならないため、導入費用が高額となる。
有機EL素子の製造工程において、ロールトゥロールプロセスを連続工程に容易に実施できるか否かを評価した。
○:連続工程に容易に実施できる。
×:連続工程で実施するのは困難である。
有機EL素子の製造工程において、平坦化層を形成した基板上に、第1の電極を形成した際の、膜厚のバラツキを評価した。評価は、第1の電極の、基板の四隅および中央部の5個所における膜厚を、スローン社製DekTak3ST触針式段差計を用いて測定し、その値を比較して行った。
○:測定個所の5個所の膜厚が、ほぼ同じであった。
×:測定個所の5個所の膜厚が、それぞれ異なっていた。
各有機EL発光装置において、実装前の全有機EL素子を目視で観察し、発光領域に欠陥がある有機EL素子を不良品とし、欠陥がない有機EL素子を良品とした。そして、「良品の有機EL素子の面積/全有機EL素子(良品+不良品)の面積×100」を算出し、この値を歩留まりとして評価した。
有機EL素子を、母材に実装するのに必要な装置と、実装にかかる時間を勘案し、実装コストとした。
○:装置の構造が単純であり、実装にかかる時間が短い。
×:装置の構造が複雑であり、実装にかかる時間が長い。
暗室下で様々な方向から画面を目視観察し、輝度むら(モアレ発生等を含む表示むらの官能評価)の有無を評価した。
○:輝度むらが観察されない
×:輝度むらが明瞭に観察される
2 有機EL素子
3 端子用領域
4,4’ ワイヤー
5,5’ 通電用電極端子
Claims (7)
- 基板と有機エレクトロルミネッセンス層とこの有機エレクトロルミネッセンス層を上下から狭持した状態で設けられる第1、第2の電極とを備えた有機エレクトロルミネッセンス素子が母材上に複数配置されて形成された有機エレクトロルミネッセンス発光装置であって、上記有機エレクトロルミネッセンス素子全体がリボン状になっており、第1の電極と第2の電極との間に狭持された有機エレクトロルミネッセンス層がリボン状基板の長手方向に沿った状態で形成され、その有機エレクトロルミネッセンス層の長手方向に沿う両側縁のうちの少なくとも片側縁に有機エレクトロルミネッセンス層に沿って電源と接続するための端子用領域が設けられていることを特徴とする有機エレクトロルミネッセンス発光装置。
- 上記端子用領域が、補助電極を介して電源と接続可能になっている請求項1記載の有機エレクトロルミネッセンス発光装置。
- 下記(A)~(F)の工程を経由して形成した有機エレクトロルミネッセンス素子を母材上に複数配置し、それらの端子用領域の任意の個所に電気的な接続を行うことを特徴とする有機エレクトロルミネッセンス発光装置の製法。
(A)長尺シート状基板の上に第1の電極を形成する工程。
(B)上記第1の電極が形成された長尺シート状基板を長手方向に沿って切断し長リボン状の積層体とする工程。
(C)上記長リボン状の積層体の上に、その長手方向に沿った状態の有機エレクトロルミネッセンス層を形成する工程。
(D)上記有機エレクトロルミネッセンス層の上に第2の電極を形成する工程。
(E)上記長リボン状の積層体の長手方向に沿う両側縁のうち、電源と接続するための電極が位置する側縁を残した状態で上記積層体上面を封止材により封止し、封止されていない上記電極が位置する側縁を端子用領域とする工程。
(F)上記長リボン状の積層体を切断して、所定長のリボン状にする工程。 - 上記(B)および(C)の工程に代えて、下記の(G)~(I)の工程を経由する請求項3記載の有機エレクトロルミネッセンス発光装置の製法。
(G)上記第1の電極の上に、フォトマスクを利用して、所定部分を露出させるための開口が幅方向に複数の列状に並ぶ絶縁層を形成する工程。
(H)上記絶縁層が形成された長尺シート状基板を、上記開口が並ぶ列ごとに切り離すように長手方向に沿って切断し長リボン状の積層体とする工程。
(I)上記長リボン状の積層体の上に、少なくとも上記開口を埋めた状態で有機エレクトロルミネッセンス層を形成する工程。 - さらに、下記(J)の工程を有する請求項3または4記載の有機エレクトロルミネッセンス発光装置の製法。
(J)上記長リボン状の積層体の長手方向に沿う両側縁のうち、電源と接続するための電極が位置する側縁に補助電極を形成する工程。 - 少なくとも上記(C)~(E)の工程が、真空下または不活性ガス雰囲気下で行われ、かつ、各工程および工程間が大気に晒されずに行われる請求項3記載の有機エレクトロルミネッセンス発光装置の製法。
- 少なくとも上記(I),(D),(E)の工程が、真空下または不活性ガス雰囲気下で行われ、かつ、各工程および工程間が大気に晒されずに行われる請求項4記載の有機エレクトロルミネッセンス発光装置の製法。
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KR1020137009340A KR20130106838A (ko) | 2010-10-15 | 2011-10-06 | 유기 일렉트로루미네센스 발광 장치 및 그 제법 |
US13/878,513 US9516721B2 (en) | 2010-10-15 | 2011-10-06 | Organic electro-luminescence light-emitting device and production method of the same |
CN201180049580.8A CN103155702B (zh) | 2010-10-15 | 2011-10-06 | 有机电致发光装置及其制造方法 |
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JP2011221022A JP5854746B2 (ja) | 2010-10-15 | 2011-10-05 | トップエミッション型の有機エレクトロルミネッセンス発光装置およびその製法 |
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JP (1) | JP5854746B2 (ja) |
KR (1) | KR20130106838A (ja) |
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KR101984734B1 (ko) * | 2012-11-16 | 2019-06-03 | 삼성디스플레이 주식회사 | 신축성 베이스 플레이트와 그것을 사용한 신축성 유기 발광 표시 장치 및 그 제조방법 |
JP6137883B2 (ja) * | 2013-03-11 | 2017-05-31 | 株式会社カネカ | 装飾部材及び自動車内外装品用装飾部材 |
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JP6796853B2 (ja) * | 2016-09-28 | 2020-12-09 | 国立大学法人山形大学 | Oled照明素子の製造方法 |
JP2018067430A (ja) * | 2016-10-18 | 2018-04-26 | 株式会社ジャパンディスプレイ | 表示装置 |
JP6926169B2 (ja) * | 2018-03-28 | 2021-08-25 | 堺ディスプレイプロダクト株式会社 | 有機el表示装置及びその製造方法 |
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US20130193844A1 (en) | 2013-08-01 |
KR20130106838A (ko) | 2013-09-30 |
JP2012104474A (ja) | 2012-05-31 |
CN103155702B (zh) | 2016-11-23 |
US9516721B2 (en) | 2016-12-06 |
CN103155702A (zh) | 2013-06-12 |
JP5854746B2 (ja) | 2016-02-09 |
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