WO2016017061A1 - 有機el素子及びその製造方法 - Google Patents
有機el素子及びその製造方法 Download PDFInfo
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- WO2016017061A1 WO2016017061A1 PCT/JP2015/003027 JP2015003027W WO2016017061A1 WO 2016017061 A1 WO2016017061 A1 WO 2016017061A1 JP 2015003027 W JP2015003027 W JP 2015003027W WO 2016017061 A1 WO2016017061 A1 WO 2016017061A1
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- H—ELECTRICITY
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- 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
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- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/805—Electrodes
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- 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
- H10K50/842—Containers
- H10K50/8426—Peripheral sealing arrangements, e.g. adhesives, sealants
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- 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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- 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
- H10K59/122—Pixel-defining structures or layers, e.g. banks
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- 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
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- 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
- H10K59/17—Passive-matrix OLED displays
- H10K59/173—Passive-matrix OLED displays comprising banks or shadow masks
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- H—ELECTRICITY
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- 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
- H10K59/17—Passive-matrix OLED displays
- H10K59/179—Interconnections, e.g. wiring lines or terminals
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- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
Definitions
- the present invention relates to an organic EL (Electro-Luminescence) element and a manufacturing method thereof.
- Organic EL elements are light-emitting elements that can be driven with a low voltage and a low current, and have the advantages of high emission luminance and good emission efficiency with respect to the supplied power. For this reason, various devices using organic EL elements, such as lighting devices and display devices using organic EL elements, have been developed.
- Patent Document 1 discloses an organic EL element in which an EL laminated structure is provided on a transparent substrate.
- an organic material layer including a light emitting layer is sandwiched between an anode and a cathode, and an anode insulating layer for insulating the anode from the cathode is provided along the end of the EL laminated structure. It has been.
- the EL laminated structure is covered with a resin layer in order to protect it from moisture and the like.
- the moisture permeability of the anode insulating layer is higher than that of the resin layer, and thus the infiltrated moisture is drawn into the anode insulating layer. That is, the anode insulating layer accelerates the intruded moisture to reach the light emitting layer. For this reason, in the said conventional organic EL element, there exists a problem that deterioration of a light emitting layer becomes quick and the lifetime of an organic EL element becomes short.
- an object of the present invention is to provide an organic EL element having a longer lifetime and a method for producing the same.
- an organic EL device includes an organic light emitting device provided between a first substrate and a second substrate which are disposed to face each other and between the first substrate and the second substrate.
- a first electrode stacked in sequence on the first substrate, an organic layer including a light emitting layer, and an organic light emitting unit including a second electrode, and connecting the first substrate and the second substrate.
- a sealing material provided so as to surround the organic light emitting portion, a first electrode lead portion that is partially exposed to the outside of the sealing material and electrically connected to the first electrode, A second electrode lead portion that is partly exposed to the outside of the sealing material and electrically connected to the second electrode; and the first electrode provided along an end of the organic layer; An insulating layer that electrically insulates the second electrode, and the second electrode lead portion and the second electrode are electrically connected. And the insulating layer is provided between the first insulating portion provided between the first electrode lead portion and the organic layer, and between the second electrode lead portion and the organic layer. And a second insulating part covered by the connection part, and a distance between the sealing material and the first insulating part is longer than a distance between the sealing material and the second insulating part.
- the manufacturing method of the organic EL element which concerns on 1 aspect of this invention is a manufacturing method of an organic EL element provided with the 1st electrode laminated
- a fourth step of forming the second electrode so as to surround the organic light emitting part, and to expose a part of the first electrode lead part and a part of the second electrode lead part to the outside.
- a fifth step of forming a sealing material on at least one of the first substrate and the second substrate; and the first substrate and the front substrate A sixth step of sealing the organic light emitting unit by bonding the second substrate, and the insulating layer is a first insulating layer provided between the first electrode lead portion and the organic layer.
- a second insulating part provided between the second electrode lead part and the organic layer, and in the fourth step, the second electrode and the second insulating part are further formed on the second insulating part.
- the distance between the sealing material and the first insulating portion is set such that the sealing material and the second insulating portion
- the insulating layer is formed to be longer than the distance between the two.
- FIG. 1 is a schematic plan view showing an organic EL element according to Embodiment 1 of the present invention.
- FIG. 2 is a schematic cross-sectional view showing a cross section (AA cross section) passing through the first electrode lead portion according to Embodiment 1 of the present invention.
- FIG. 3 is a schematic cross-sectional view showing a cross section (BB cross section) passing through the second electrode lead portion according to Embodiment 1 of the present invention.
- FIG. 4 is a schematic plan view showing a region (C region) in the vicinity of the boundary between the first electrode lead portion and the second electrode lead portion according to Embodiment 1 of the present invention.
- FIG. 1 is a schematic plan view showing an organic EL element according to Embodiment 1 of the present invention.
- FIG. 2 is a schematic cross-sectional view showing a cross section (AA cross section) passing through the first electrode lead portion according to Embodiment 1 of the present invention.
- FIG. 3 is a schematic cross-sectional view showing a cross section (
- FIG. 5A is a schematic cross-sectional view showing a step of forming a first electrode in the method for manufacturing an organic EL element according to Embodiment 1 of the present invention.
- FIG. 5B is a schematic cross-sectional view showing the step of forming the auxiliary electrode in the method for manufacturing the organic EL element according to Embodiment 1 of the present invention.
- FIG. 5C is a schematic cross-sectional view showing the step of forming the insulating layer in the method for manufacturing the organic EL element according to Embodiment 1 of the present invention.
- FIG. 5D is a schematic cross-sectional view showing an organic layer forming step in the method of manufacturing an organic EL element according to Embodiment 1 of the present invention.
- FIG. 5A is a schematic cross-sectional view showing a step of forming a first electrode in the method for manufacturing an organic EL element according to Embodiment 1 of the present invention.
- FIG. 5B is a schematic cross-sectional view showing the step of forming
- FIG. 5E is a schematic cross-sectional view showing a step of forming a second electrode in the method for manufacturing an organic EL element according to Embodiment 1 of the present invention.
- FIG. 5F is a schematic cross-sectional view showing a coating process of a sealing material and a filler material in the method for manufacturing an organic EL element according to Embodiment 1 of the present invention.
- FIG. 5G is a schematic cross-sectional view showing a bonding step in the method for manufacturing an organic EL element according to Embodiment 1 of the present invention.
- FIG. 6 is a schematic cross-sectional view showing a cross section passing through the first electrode lead portion according to a modification of the first embodiment of the present invention.
- FIG. 7 is a schematic perspective view showing an illumination apparatus according to Embodiment 2 of the present invention.
- FIG. 1 is a schematic plan view showing an organic EL element 10 according to the present embodiment.
- FIG. 2 is a schematic cross-sectional view showing a cross section (cross section AA in FIG. 1) passing through the first electrode lead-out portion 160 according to the present embodiment.
- FIG. 3 is a schematic cross-sectional view showing a cross-section (cross-section BB in FIG. 1) passing through the second electrode lead-out portion 170 according to the present embodiment.
- FIG. 4 is a schematic plan view showing a region (region C in FIG. 1) in the vicinity of the boundary between the first electrode lead portion 160 and the second electrode lead portion 170 according to the present embodiment.
- the organic EL element 10 is, for example, a substantially rectangular planar light emitter.
- the organic EL element 10 emits light in a substantially rectangular plane shape in the depth direction of the paper. That is, the organic EL element 10 has a substantially rectangular light emitting region (corresponding to the organic light emitting unit 120 shown in FIG. 1) and a non-light emitting region (so-called frame) surrounding the light emitting region in plan view.
- the organic EL element 10 includes a first substrate 100, a second substrate 110, an organic light emitting unit 120, a sealing material 130, a filler 140, an insulating layer 150, a first substrate, A one-electrode lead portion 160, a protective film 161, a second electrode lead portion 170, a connection portion 171, and an auxiliary electrode 180 are provided.
- the organic light emitting unit 120 includes a first electrode 121, an organic layer 122, and a second electrode 123.
- the second substrate 110, the filler 140, the protective film 161, the shape of the organic light emitting unit 120, the sealing material 130, and the insulating layer 150 in a plan view and the positional relationship are easily understood.
- the connection part 171 and the auxiliary electrode 180 are not shown.
- end portions of the protective film 161, the connection portion 171, and the second electrode 123 are indicated by thick long broken lines.
- the second substrate 110, the organic layer 122, the filler 140, and the auxiliary electrode 180 are not shown.
- the first substrate 100 and the second substrate 110 are disposed to face each other. Specifically, the first substrate 100 and the second substrate 110 are arranged to face each other with a predetermined distance apart. For example, the distance between the first substrate 100 and the second substrate 110 is 6 ⁇ m to 100 ⁇ m, and is 20 ⁇ m as an example. Further, the first substrate 100 and the second substrate 110 are bonded by a sealing material 130.
- the organic light emitting unit 120 is disposed between the first substrate 100 and the second substrate 110.
- a filler 140 that covers and protects the organic light emitting unit 120 is filled between the first substrate 100 and the second substrate 110.
- the first substrate 100 has translucency and transmits at least part of visible light.
- the first substrate 100 is, for example, a glass substrate such as soda glass or non-alkali glass, or a resin substrate made of a translucent resin material such as polycarbonate resin or acrylic resin.
- a plate-shaped transparent substrate having a thickness of 0.03 mm to 1.2 mm can be used from the viewpoint of convenience of handling and mechanical characteristics.
- the second substrate 110 has, for example, translucency and transmits at least part of visible light.
- the second substrate 110 is made of the same material as the first substrate 100.
- the second substrate 110 may have light reflectivity.
- the second substrate 110 may be made of a metal material such as stainless steel or aluminum.
- the plan view shape of the first substrate 100 is substantially rectangular as shown in FIG.
- the plan view shape of the second substrate 110 is also substantially rectangular.
- the first substrate 100 has a substantially rectangular shape larger than the second substrate 110.
- the second substrate 110 may have the same size as the first substrate 100, specifically, the same shape, or may be larger than the first substrate 100.
- the organic light emitting unit 120 emits light in a planar shape when a voltage is applied.
- the first electrode 121, the organic layer 122, and the second electrode 123 included in the organic light emitting unit 120 are stacked on the first substrate 100 in this order.
- the planar view shape of the organic light emitting unit 120 is substantially rectangular like the first substrate 100. Note that the planar shape of the organic light emitting unit 120 is smaller than that of the first substrate 100 and the second substrate 110.
- an insulating layer 150, a sealing material 130, a first electrode lead portion 160, and a second electrode lead portion 170 are formed.
- the first electrode 121 is an electrode provided on the light emitting surface side, and is provided on the first substrate 100, for example.
- the first electrode 121 is, for example, an anode, and has a higher potential than the second electrode 123 when the organic EL element 10 emits light.
- the first electrode 121 is made of a light-transmitting conductive material.
- the first electrode 121 is made of a transparent conductive material that transmits at least part of visible light.
- the first electrode 121 is made of, for example, indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide doped with aluminum (AZO), or the like.
- the first electrode 121 may be a thin metal film such as silver or aluminum that can transmit light. Alternatively, Ag nanowires or Ag particles may be dispersed. Alternatively, as the first electrode 121, a conductive polymer such as PEDOT or polyaniline, a conductive polymer doped with any acceptor, or a conductive light-transmitting material such as a carbon nanotube can be used. .
- the first electrode 121 is formed by forming a transparent conductive film on the first substrate 100 by vapor deposition, coating, sputtering, ion beam assist, or the like, and patterning the formed transparent conductive film.
- the film thickness of the first electrode 121 is 60 nm to 200 nm, for example, 100 nm.
- the organic layer 122 is provided between the first electrode 121 and the second electrode 123.
- the organic layer 122 includes a light emitting layer, and emits light in a planar shape when a voltage is applied between the first electrode 121 and the second electrode 123.
- the organic layer 122 includes a hole injection layer, a hole transport layer, a light emitting layer (organic EL layer), an electron transport layer, and an electron injection layer.
- the organic layer 122 such as a light emitting layer is made of an organic material such as diamine, anthracene, or metal complex.
- Each layer constituting the organic layer 122 is formed by an evaporation method, a spin coating method, a casting method, an ion beam assist method, or the like.
- the film thickness of the organic layer 122 is 150 nm to 350 nm, for example, 210 nm.
- the organic layer 122 is formed by doping the emission layer with dopant pigments of three colors of red, green, and blue.
- the organic layer 122 may have a stacked structure of a blue hole transporting light emitting layer, a green electron transporting light emitting layer, and a red electron transporting light emitting layer.
- the organic layer 122 may have a multi-unit structure in which red, green, and blue light-emitting units are stacked via an intermediate layer having light transmission and conductivity, and are electrically connected directly.
- the second electrode 123 is an electrode provided on the side opposite to the light emitting surface, and is provided on the organic layer 122, for example.
- the second electrode 123 is, for example, a cathode, and has a lower potential than the first electrode 121 when the organic EL element 10 emits light.
- the second electrode 123 is made of a conductive material having light reflectivity.
- the second electrode 123 reflects the light emitted from the organic layer 122 and emits it to the light emitting surface side.
- the second electrode 123 is made of, for example, a metal material such as aluminum, silver, or magnesium, or an alloy containing at least one of these.
- the second electrode 123 is formed by forming a conductive film on the organic layer 122 by vapor deposition, coating, sputtering, ion beam assist, GCIB (Gas Cluster Ion Beam) vapor deposition, or the like.
- the film thickness of the second electrode 123 is 20 nm to 200 nm, for example, 100 nm.
- the second electrode 123 can protect the organic layer 122 from moisture.
- the second electrode 123 may be made of, for example, a conductive resin material. However, in this case, the second electrode 123 is made of a material having a moisture permeability lower than that of the insulating layer 150.
- the second electrode 123 may be made of a light-transmitting conductive material.
- the same material as the first electrode 121 can be used for the second electrode 123.
- the organic EL element 10 can be utilized for a window of a building or a vehicle as a double-sided light emitting type lighting device, for example.
- the sealing material 130 is a connection member that connects the first substrate 100 and the second substrate 110.
- the sealing material 130 is an adhesive that bonds the first substrate 100 and the second substrate 110.
- the sealing material 130 is disposed so as to surround the organic light emitting unit 120 along the outer periphery of the first substrate 100 in a plan view. Accordingly, the organic light emitting unit 120 can be sealed in a space (hereinafter referred to as “sealing space”) surrounded by the first substrate 100, the second substrate 110, and the sealing material 130.
- the sealing material 130 is formed in an annular shape in plan view.
- the sealing material 130 is a substantially rectangular frame-like body in plan view.
- the sealing material 130 is provided in a substantially rectangular frame shape along the outer periphery of the substantially rectangular first substrate 100.
- the line width (that is, the sealing width) of the sealing material 130 is substantially constant.
- sealing material 130 for example, a photocurable, thermosetting, or two-component curable adhesive resin such as an epoxy resin, an acrylic resin, or a silicone resin can be used.
- a thermoplastic adhesive resin made of an acid-modified product such as polyethylene or polypropylene may be used.
- an inorganic filler or the like may be mixed in the sealing material 130. Thereby, the transmittance
- the inorganic filler include silica, calcium hydroxide, calcium carbonate, and other resin materials.
- the sealing material 130 for example, a material having a higher viscosity than the filler 140 is used. Thereby, the sealing material 130 functions as a dam material when the filler 140 is applied. That is, by applying the filler 140 after applying the sealing material 130, it is possible to prevent the filler 140 from leaking outward from the region surrounded by the sealing material 130.
- the sealing material 130 is formed by applying and curing a sealing material made of a resin material.
- a sealing material made of a resin material.
- the sealing material is applied by a printing method such as roll coating, spin coating, screen printing, spray coating, slit coating, squeegee coating, or drawing coating with a dispenser. .
- the filler 140 is a member for sealing the organic light emitting unit 120.
- the filler 140 is provided between the first substrate 100 and the second substrate 110 so as to cover and cover the organic light emitting unit 120.
- the filler 140 is a resin material that is filled and cured in the sealed space.
- a photocurable, thermosetting, or two-component curable adhesive resin such as an epoxy resin, an acrylic resin, or a silicone resin can be used.
- a thermoplastic adhesive resin made of an acid-modified product such as polyethylene or polypropylene may be used.
- the filler 140 may contain a desiccant.
- the desiccant is, for example, a hygroscopic material having fine pores that adsorb moisture, and specifically, calcium oxide (CaO), zeolite, and the like.
- CaO calcium oxide
- zeolite zeolite
- the filler 140 is formed by applying and curing a filler material made of a resin material.
- a filler material made of a resin material.
- the filler material is applied by a printing method such as roll coating, spin coating, screen printing, spray coating, slit coating, squeegee coating, or drawing coating with a dispenser. .
- the insulating layer 150 is provided along the end of the organic layer 122 and electrically insulates the first electrode 121 and the second electrode 123.
- the insulating layer 150 is in contact with the end portion of the organic layer 122.
- the insulating layer 150 covers the end portion of the organic layer 122 together with the second electrode 123 so that the end portion of the organic layer 122 is not exposed.
- the end portion of the organic layer 122 corresponds to a boundary portion between the light emitting region and the non-light emitting region of the organic EL element 10.
- the insulating layer 150 is made of, for example, an insulating resin material such as polyimide.
- the insulating layer 150 is formed by applying and curing an insulating resin material.
- the insulating layer 150 may be made of an inorganic material such as a nitride film.
- the insulating layer 150 includes a first insulating portion 151 and a second insulating portion 152 as shown in FIG. Each detailed structure will be described in detail later.
- the first electrode lead-out portion 160 and the second electrode lead-out portion 170 are provided so as to be partially exposed to the outside of the sealing material 130.
- the first electrode lead portion 160 and the second electrode lead portion 170 are provided along a part of the circumference of the first substrate 100 as shown in FIG.
- the first electrode lead-out portion 160 and the second electrode lead-out portion 170 are provided on each of two opposite sides of the substantially rectangular first substrate 100 in plan view.
- the first electrode lead portion 160 and the second electrode lead portion 170 are arranged point-symmetrically with the center of the first substrate 100 as the center of symmetry. Thereby, the voltage drop in each surface of the 1st electrode 121 and the 2nd electrode 123 can be suppressed, and the surface uniformity of light emission can be improved.
- the first electrode lead portion 160 and the second electrode lead portion 170 are made of the same material as the first electrode 121.
- a conductive film is formed on the first substrate 100 and patterned, so that the first electrode lead portion 160 and the second electrode lead portion 170 are formed simultaneously with the first electrode 121.
- the first electrode extraction unit 160 is, for example, an anode extraction electrode and is electrically connected to the first electrode 121. Specifically, as shown in FIG. 2, the first electrode lead-out portion 160 is formed so that a part of the first electrode 121 extends. That is, the first electrode lead portion 160 is a conductive film formed integrally with the first electrode 121.
- the portion located in the light emitting region is the first electrode 121, and the portion located in the non-light emitting region is the first electrode extraction portion 160. Therefore, for example, the first insulating portion 151 of the insulating layer 150 is provided on the first electrode extraction portion 160 along the end portion of the first electrode 121.
- a protective film 161 covering the first insulating portion 151 is formed on the first insulating portion 151.
- the protective film 161 is, for example, a conductive film whose moisture permeability is lower than that of the first insulating part 151.
- the protective film 161 protects the first insulating part 151 from moisture. Since the first insulating portion 151 is covered with the protective film 161, it is possible to suppress the moisture that has entered the sealing space from being drawn into the first insulating portion 151, thereby extending the life of the organic EL element 10. can do.
- the protective film 161 is made of, for example, a material having higher conductivity than the first electrode lead-out portion 160.
- the protective film 161 since the protective film 161 is provided in contact with the first electrode lead-out portion 160, it functions as an auxiliary electrode of the first electrode lead-out portion 160. Thereby, the voltage drop in the 1st electrode extraction part 160 can be suppressed, and the surface uniformity of light emission can be improved.
- the protective film 161 is made of the same material as the second electrode 123, for example. Specifically, the protective film 161 is formed simultaneously with the second electrode 123. For example, a conductive film is formed over the organic layer 122 and the insulating layer 150 and patterned to form the connection portion 171 and the protective film 161 together with the second electrode 123.
- the protective film 161 is separated from the second electrode 123 and the connection portion 171. Specifically, insulating grooves are formed between the protective film 161 and the second electrode 123 and between the protective film 161 and the connection portion 171. In other words, the protective film 161 is formed in an island shape. Thereby, the protective film 161 is electrically insulated from the second electrode 123 and the second electrode lead portion 170.
- the protective film 161 is separated from the second electrode 123, a part of the first insulating portion 151 is exposed in the sealing space. That is, a part of the first insulating portion 151 is in contact with the filler 140.
- the second electrode extraction unit 170 is, for example, a cathode extraction electrode and is electrically connected to the second electrode 123. Specifically, as shown in FIG. 3, the second electrode lead-out portion 170 is electrically connected to the second electrode 123 through the connection portion 171.
- the second electrode lead portion 170 is separated from the first electrode 121 and the first electrode lead portion 160. Specifically, insulating grooves are formed between the second electrode lead portion 170 and the first electrode 121 and between the second electrode lead portion 170 and the first electrode lead portion 160. In other words, the second electrode lead-out portion 170 is formed in an island shape. As a result, the second electrode lead portion 170 is electrically insulated from the first electrode 121 and the first electrode lead portion 160.
- connection part 171 is a part where a part of the second electrode 123 extends. That is, the connection portion 171 is a conductive film formed integrally with the second electrode 123. Therefore, the connection part 171 is made of the same material as the second electrode 123.
- the connecting portion 171 is formed on the second insulating portion 152.
- the connection part 171 protects the second insulating part 152 from moisture, like the protective film 161. Since the second insulating portion 152 is covered with the connecting portion 171, it is possible to suppress the moisture that has entered the sealing space from being drawn into the second insulating portion 152, thereby extending the life of the organic EL element 10. can do.
- the auxiliary electrode 180 is made of a material having higher conductivity than the first electrode 121.
- the auxiliary electrode 180 is made of a metal material.
- the auxiliary electrode 180 has a laminated structure of, for example, molybdenum / aluminum / molybdenum.
- the auxiliary electrode 180 is formed by laminating and patterning a metal thin film by a vapor deposition method, a coating method, a sputtering method, an ion beam assist method, or the like.
- the auxiliary electrode 180 is provided along the circumference of the first electrode 121. Specifically, it is formed in an annular shape along the circumference of the first electrode 121.
- the auxiliary electrode 180 is electrically connected to the first electrode 121. Specifically, as shown in FIGS. 2 and 3, the auxiliary electrode 180 is provided on the first electrode 121 and the first electrode lead-out portion 160.
- the power supplied from both sides of the organic EL element 10 can be efficiently transmitted along the circumference of the first electrode 121 by the auxiliary electrode 180 provided in an annular shape. That is, the voltage drop in the first electrode 121 can be suppressed and the surface uniformity of light emission can be improved.
- the insulating layer 150 is formed in an annular shape in plan view.
- the insulating layer 150 is a substantially rectangular frame-like body in plan view.
- the insulating layer 150 is provided along the sealing material 130 inside the annular sealing material 130.
- the first insulating portion 151 of the insulating layer 150 is a portion provided between the first electrode lead-out portion 160 and the organic layer 122. Specifically, as shown in FIG. 2, the first insulating portion 151 is provided on the first electrode lead-out portion 160 along the end portion of the first electrode 121.
- the second insulating portion 152 of the insulating layer 150 is a portion provided between the second electrode extraction portion 170 and the organic layer 122. Specifically, as shown in FIG. 3, the second insulating portion 152 covers the end portion of the second electrode lead portion 170 and the end portion of the first electrode 121 along the end portion of the first electrode 121. It is provided as follows.
- the distance d1 between the sealing material 130 and the first insulating portion 151 is longer than the distance d2 between the sealing material 130 and the second insulating portion 152. That is, the first insulating portion 151 is provided at a position farther from the sealing material 130 than the second insulating portion 152.
- the distance d1 is 2.3 mm to 2.5 mm
- the distance d2 is 1.7 mm to 1.9 mm.
- the line width w ⁇ b> 1 of the first insulating portion 151 is shorter than the line width w ⁇ b> 2 of the second insulating portion 152.
- the line width w1 is 0.4 mm to 0.6 mm
- the line width w2 is 0.9 mm to 1.1 mm.
- the first insulating portion 151 and the second insulating portion 152 are formed, for example, by drawing and applying an insulating resin material such as polyimide in a ring shape using a dispenser or the like.
- the first insulating portion 151 is formed by drawing for one line
- the second insulating portion 152 is formed by drawing for two lines. That is, for example, the line width w2 of the second insulating portion 152 is approximately twice the line width w1 of the first insulating portion 151.
- an annular frame along the edge of the organic layer 122 is drawn with an insulating resin material such as polyimide.
- a line is drawn along a part of the frame so as to contact the outside of the drawn frame.
- the dropping amount is set to be the same in drawing the frame and drawing a line along a part of the frame.
- the insulating resin material including the first insulating portion 151 and the second insulating portion 152 is formed by curing the insulating resin material by light irradiation.
- the amount of dripping or the drawing speed may be changed when drawing.
- an insulating resin material is drawn and applied in a predetermined dropping amount
- a dropping amount for example, a larger amount
- the insulating resin material may be drawn and applied.
- an insulating resin material is drawn and applied at a predetermined drawing speed
- a drawing speed lower than the drawing speed
- the insulating resin material may be drawn and applied at a double rate.
- the drawing speed is, for example, the moving speed of the nozzle that injects the insulating resin material.
- 5A to 5G respectively show the steps of forming the first electrode 121, the auxiliary electrode 180, the insulating layer 150, the organic layer 122, and the second electrode 123 in the method for manufacturing the organic EL element 10 according to the present embodiment, and the seal. It is a schematic sectional drawing which shows the application
- the first electrode 121, the first electrode lead portion 160, and the second electrode lead portion 170 are formed on the first substrate 100.
- the first electrode 121, the first electrode lead portion 160, and the second electrode lead portion 170 are simultaneously formed using the same material.
- a transparent conductive film such as ITO is formed on the entire surface of the first substrate 100 and patterned, so that the first electrode 121, the first electrode lead portion 160, and the second electrode lead portion 170 are formed. And form.
- the auxiliary electrode 180 is formed on the first electrode 121 along the end of the first electrode 121.
- the auxiliary electrode 180 is formed by sequentially laminating and patterning a molybdenum film, an aluminum film, and a molybdenum film.
- the insulating layer 150 is formed along the end portion of the first electrode 121. Specifically, the insulating layer 150 is formed so as to cover the auxiliary electrode 180. At this time, the first insulating portion 151 is formed in the vicinity of the first electrode lead portion 160, and the second insulating portion 152 is formed in the vicinity of the second electrode lead portion 170.
- the first insulating portion 151 and the second insulating portion 152 are formed by applying and curing an insulating resin material using a dispenser or the like. At this time, the insulating layer 150 is formed so that the distance between the sealing material 130 and the first insulating portion 151 is longer than the distance between the sealing material 130 and the second insulating portion 152. In other words, the insulating layer 150 is formed so that the first insulating portion 151 is formed at a position farther from the sealing material 130 than the second insulating portion 152.
- the insulating layer 150 is formed so that the line width of the second insulating portion 152 is larger than the line width of the first insulating portion 151.
- the line width of the first insulating portion 151 and the line width of the second insulating portion 152 are changed by changing the number of lines to be applied, the amount of application, or the drawing speed. Make it.
- the organic layer 122 is formed on the first electrode 121.
- the end portion of the organic layer 122 may be formed on the insulating layer 150.
- the organic layer 122 is formed by laminating functional layers including a light emitting layer by an evaporation method or the like.
- the second electrode 123 is formed on the organic layer 122.
- a connecting portion 171 is further formed on the second insulating portion 152, and a protective film 161 is formed on the first insulating portion 151.
- the second electrode 123, the protective film 161, and the connection portion 171 are formed simultaneously using the same material.
- the second electrode 123, the connection portion 171 and the protective film 161 are formed by forming a metal thin film such as aluminum on the entire surface and patterning it.
- the sealant 130 and the filler 140 are formed.
- the sealing material is provided on the first substrate 100 so as to surround the organic light emitting unit 120 and to expose a part of the first electrode lead part 160 and a part of the second electrode lead part 170 to the outside. Apply material. Further, a filler material is applied to a space (specifically, a sealing space) surrounded by the sealing material 130.
- the sealant 130 and the filler 140 are formed by curing the sealant material and the filler material after the first substrate 100 and the second substrate 110 are bonded to each other. In this step, a sealing material may be applied to the second substrate 110.
- the organic light emitting unit 120 is sealed by bonding the first substrate 100 and the second substrate 110 together.
- the first substrate 100 and the second substrate 110 are bonded to each other under a predetermined vacuum, and the first substrate 100 and the second substrate 110 are bonded to each other by gradually releasing to the atmosphere.
- the organic EL element 10 includes the first substrate 100 and the second substrate 110 that are disposed to face each other, and the organic light emission provided between the first substrate 100 and the second substrate 110.
- the insulating layer 150 that electrically insulates the second electrode lead portion 170 and the second electrode 123 from each other, and the insulating layer 150 includes the first electrode lead portion 160 and the organic layer 122. Including a first insulating part 151 provided between the second electrode lead part 170 and the organic layer 122, and a second insulating part 152 covered with the connecting part 171. The distance between the first insulating portion 151 and the first insulating portion 151 is longer than the distance between the sealing material 130 and the second insulating portion 152.
- the first insulating part 151 can be provided with a protective film 161 as shown in FIG. 4, but in order to ensure insulation between the first electrode 123 and the first insulating part 151, the first insulating part 151 is provided in the sealed space. The part is exposed. Accordingly, the first insulating portion 151 draws moisture from the exposed portion.
- the first insulating portion 151 is provided at a position farther from the sealing material 130 than the second insulating portion 152. Therefore, the time until the moisture that has entered from the sealing material 130 reaches the first insulating portion 151 can be made longer than the time until it reaches the second insulating portion 152 (specifically, the connecting portion 171). it can.
- the lifetime of the organic EL element 10 can be extended.
- the insulating layer 150 is provided in a frame shape along the end of the organic layer 122, and the line width of the first insulating portion 151 is shorter than the line width of the second insulating portion 152.
- the first insulating portion 151 can be further away from the sealing material 130 than the second insulating portion 152 due to the width of the insulating layer 150. Therefore, it is not necessary to make the light emitting region smaller than necessary, and the lifetime can be extended while realizing a narrow frame.
- the organic EL element 10 further includes a protective film 161 that covers the first insulating portion 151.
- the protective film 161 covering the first insulating portion 151 is provided, it is possible to further suppress the first insulating portion 151 from drawing moisture. Therefore, the lifetime can be extended.
- the first insulating portion 151 cannot be completely covered with the protective film 161, and a part of the first insulating portion 151 is exposed and is in contact with the filler 140.
- the first insulating portion 151 may draw moisture that has penetrated into the filler 140 from the exposed portion of the first insulating portion 151. For this reason, the exposed portion of the first insulating portion 151 is provided in a portion closer to the organic layer 122. Thereby, it is possible to lengthen the time required for the moisture to reach the exposed portion by moving the exposed portion away from the sealing material 130.
- the protective film 161 is made of the same material as that of the second electrode 123 and is electrically insulated from the second electrode 123.
- the manufacturing process can be reduced and the manufacturing cost can be reduced.
- the protective film 161 is further provided so as to contact the first electrode lead-out portion 160.
- the protective film 161 since the protective film 161 has conductivity, the protective film 161 can be used as an auxiliary electrode. Therefore, a voltage drop in the first electrode lead-out portion 160 and the first electrode 121 can be suppressed, and the surface uniformity of light emission can be improved.
- the second electrode 123 is made of a metal material.
- the metal material generally has a lower moisture permeability than the resin material, the organic layer 122 can be effectively protected from moisture that has entered the sealed space.
- FIG. 6 is a schematic cross-sectional view showing a cross section passing through the first electrode lead-out portion 160 of the organic EL element 20 according to a modification of the present embodiment.
- FIG. 6 shows a cross section corresponding to the CC cross section of FIG.
- the organic EL element 20 according to this modification is different from the organic EL element 10 shown in FIG. 4 in that the protective film 161 is not provided.
- the protective film 161 since the distance between the first insulating portion 151 and the sealing material 130 is long, the moisture that has permeated the sealing material 130 and entered the sealing space is the first insulating portion 151.
- the time required to reach is longer than the time required to reach the second insulating portion 152 (specifically, the connecting portion 171). Thereby, the lifetime of the organic EL element 20 can be lengthened.
- FIG. 7 is an overview perspective view showing the illumination device 30 according to the present embodiment.
- the lighting device 30 includes a light emitting unit 31 composed of a plurality of organic EL elements 10, a hanging tool 32 for installing the light emitting unit 31 on the ceiling, and a power cord 33 that connects the light emitting unit 31 and the hanging tool 32.
- the light emitting unit 31 is configured by arranging a plurality of organic EL elements 10 so as to be adjacent to each other, for example. Further, the end of the light emitting unit 31 is covered and protected by the lamp case 34.
- the hanger 32 has a remote control light receiving unit 35 for receiving a remote control signal transmitted from a remote control (not shown) on its surface.
- the illumination device 30 according to the present embodiment includes, for example, the organic EL element 10 according to the first embodiment.
- the illuminating device 30 which concerns on this Embodiment has an effect similar to Embodiment 1.
- the lighting device 30 is not limited to a configuration that is suspended from the ceiling, and the same effect can be obtained even when the configuration is installed on a wall.
- the hermetic sealing structure in which the filler 140 covering the organic light emitting unit 120 is provided has been described, but the present invention is not limited thereto.
- the organic EL element may have a hollow sealing structure in which the filler 140 is not provided. That is, the sealing space may be hollow. The hollow sealed space is maintained in a reduced pressure state when the first substrate 100 and the second substrate 110 are bonded to each other, for example.
- the distance between the insulating layer 150 and the sealing material 130 is changed by changing the line width of the insulating layer 150, but the present invention is not limited to this.
- the distance between the insulating layer 150 and the sealing material 130 may be varied by changing the position where the insulating layer 150 having a constant line width is arranged.
- the distance between the insulating layer 150 and the sealing material 130 may be varied by changing the position where the sealing material 130 is disposed.
- the first electrode extraction portion 160 and the first electrode 121 are integrally formed.
- the 1st electrode extraction part 160 and the 1st electrode 121 may be comprised from another member.
- the 2nd electrode extraction part 170 and the 2nd electrode 123 may be formed integrally.
- the first electrode 121 is an anode and the second electrode 123 is a cathode is shown, but the reverse may be possible. That is, the first electrode 121 may be a cathode and the second electrode 123 may be an anode.
- the auxiliary electrode 180 is provided on the first electrode 121 and the first electrode extraction portion 160, but the auxiliary electrode 180 is connected to the first electrode 121 and the first electrode extraction portion 160 and the first electrode extraction portion 160. It may be provided between one substrate 100.
- planar view shape of the organic EL element 10 is rectangular has been described, but the present invention is not limited thereto.
- the planar view shape of the organic EL element 10 may be a closed shape drawn by a straight line or a curve, such as a polygon, a circle, or an ellipse.
- the bottom emission type organic EL element 10 that emits light toward the first substrate 100 is shown, but a top emission type that emits light toward the second substrate 110 may be used.
- the first electrode 121 is made of a light reflective material
- the second electrode 123 and the second substrate 110 are made of a light transmissive material.
- the embodiment can be realized by arbitrarily combining the components and functions in each embodiment without departing from the scope of the present invention, or a form obtained by subjecting each embodiment to various modifications conceived by those skilled in the art. Forms are also included in the present invention.
Abstract
Description
[有機EL素子]
まず、実施の形態1に係る有機EL素子の構成について、図1~図4を用いて説明する。
第1基板100及び第2基板110は、対向配置されている。具体的には、第1基板100と第2基板110とは、所定の距離を離間して互いに対向するように配置されている。例えば、第1基板100と第2基板110との間の距離は、6μm~100μmであり、一例として20μmである。また、第1基板100と第2基板110とは、シール材130によって接着されている。
有機発光部120は、電圧が印加された場合に平面状に発光する。有機発光部120が備える第1電極121と、有機層122と、第2電極123とは、この順で第1基板100に積層されている。
シール材130は、第1基板100と第2基板110とを接続する接続部材である。例えば、シール材130は、第1基板100と第2基板110とを接着する接着剤である。シール材130は、図1に示すように、平面視において第1基板100の外周に沿って有機発光部120を囲むように配置される。これにより、第1基板100と、第2基板110と、シール材130とに囲まれた空間(以下、「封止空間」と記載する)に有機発光部120を封止することができる。
充填材140は、有機発光部120を封止するための部材である。例えば、充填材140は、有機発光部120を接触して覆うように第1基板100と第2基板110との間に設けられる。具体的には、充填材140は、封止空間に充填されて硬化した樹脂材料である。
絶縁層150は、有機層122の端部に沿って設けられ、第1電極121と第2電極123とを電気的に絶縁する。絶縁層150は、有機層122の端部に接触している。絶縁層150は、第2電極123とともに、有機層122の端部が露出しないように有機層122の端部を覆っている。なお、有機層122の端部は、有機EL素子10の発光領域と非発光領域との境界部分に相当する。
第1電極引出部160及び第2電極引出部170は、一部がシール材130の外側に露出するように設けられている。例えば、第1電極引出部160及び第2電極引出部170は、図1に示すように、第1基板100の周の一部に沿って設けられる。具体的には、平面視において、略矩形の第1基板100の互いに対向する2つの辺のそれぞれに、第1電極引出部160及び第2電極引出部170が設けられている。例えば、第1電極引出部160及び第2電極引出部170は、第1基板100の中心を対称の中心とする点対称に配置されている。これにより、第1電極121及び第2電極123のそれぞれの面内での電圧降下を抑制し、発光の面均一性を向上させることができる。
補助電極180は、第1電極121より導電性が高い材料から構成される。例えば、補助電極180は、金属材料から構成される。補助電極180は、例えば、モリブデン/アルミニウム/モリブデンの積層構造から構成される。例えば、補助電極180は、蒸着法、塗布法、スパッタリング法又はイオンビームアシスト法などによって金属薄膜を積層し、パターニングすることで形成される。
絶縁層150は、図1に示すように、平面視において環状に形成されている。例えば、絶縁層150は、平面視において略矩形の枠状体である。具体的には、絶縁層150は、環状のシール材130の内側に、シール材130に沿って設けられている。
続いて、本実施の形態に係る有機EL素子10の製造方法について、図5A~図5Gを用いて説明する。
以上のように、本実施の形態に係る有機EL素子10は、対向配置された第1基板100及び第2基板110と、第1基板100と第2基板110との間に設けられた有機発光部120であって、第1基板100に順に積層された第1電極121、発光層を含む有機層122、及び、第2電極123を含む有機発光部120と、第1基板100と第2基板110とを接続し、かつ、有機発光部120を囲むように設けられたシール材130と、一部がシール材130の外側に露出し、かつ、第1電極121に電気的に接続された第1電極引出部160と、一部がシール材130の外側に露出し、かつ、第2電極123に電気的に接続された第2電極引出部170と、有機層122の端部に沿って設けられた、第1電極121と第2電極123とを電気的に絶縁する絶縁層150と、第2電極引出部170と第2電極123とを電気的に接続する接続部171を備え、絶縁層150は、第1電極引出部160と有機層122との間に設けられた第1絶縁部151と、第2電極引出部170と有機層122との間に設けられ、接続部171に覆われた第2絶縁部152とを含み、シール材130と第1絶縁部151との間の距離は、シール材130と第2絶縁部152との間の距離より長い。
以下では、実施の形態に係る有機EL素子10の変形例について、図6を用いて説明する。
続いて、実施の形態2に係る照明装置について、図7を用いて説明する。
以上、本発明に係る有機EL素子及びその製造方法について、上記実施の形態及びその変形例に基づいて説明したが、本発明は、上記の実施の形態に限定されるものではない。
100 第1基板
110 第2基板
120 有機発光部
121 第1電極
122 有機層
123 第2電極
130 シール材
150 絶縁層
151 第1絶縁部
152 第2絶縁部
160 第1電極引出部
161 保護膜
170 第2電極引出部
171 接続部
Claims (9)
- 対向配置された第1基板及び第2基板と、
前記第1基板と前記第2基板との間に設けられた有機発光部であって、前記第1基板に順に積層された第1電極、発光層を含む有機層、及び、第2電極を含む有機発光部と、
前記第1基板と前記第2基板とを接続し、かつ、前記有機発光部を囲むように設けられたシール材と、
一部が前記シール材の外側に露出し、かつ、前記第1電極に電気的に接続された第1電極引出部と、
一部が前記シール材の外側に露出し、かつ、前記第2電極に電気的に接続された第2電極引出部と、
前記有機層の端部に沿って設けられた、前記第1電極と前記第2電極とを電気的に絶縁する絶縁層と、
前記第2電極引出部と前記第2電極とを電気的に接続する接続部を備え、
前記絶縁層は、
前記第1電極引出部と前記有機層との間に設けられた第1絶縁部と、
前記第2電極引出部と前記有機層との間に設けられ、前記接続部に覆われた第2絶縁部とを含み、
前記シール材と前記第1絶縁部との間の距離は、前記シール材と前記第2絶縁部との間の距離より長い
有機EL素子。 - 前記絶縁層は、前記有機層の端部に沿った枠状に設けられ、
前記第1絶縁部の線幅は、前記第2絶縁部の線幅より短い
請求項1に記載の有機EL素子。 - 前記有機EL素子は、さらに、前記第1絶縁部を覆う保護膜を備える
請求項1又は2に記載の有機EL素子。 - 前記保護膜は、前記第2電極と同じ材料から構成され、前記第2電極とは電気的に絶縁されている
請求項3に記載の有機EL素子。 - 前記保護膜は、さらに、前記第1電極引出部に接触するように設けられている
請求項4に記載の有機EL素子。 - 前記第2電極は、金属材料から構成される
請求項1~5のいずれか1項に記載の有機EL素子。 - 順に積層された第1電極、発光層を含む有機層、及び、第2電極を含む有機発光部を備える有機EL素子の製造方法であって、
第1基板上に、前記第1電極と、当該第1電極に電気的に接続される第1電極引出部と、前記第2電極に電気的に接続される第2電極引出部とを形成する第1工程と、
前記第1電極の端部に沿って絶縁層を形成する第2工程と、
前記第1電極上に前記有機層を形成する第3工程と、
前記有機層上に前記第2電極を形成する第4工程と、
前記有機発光部を囲むように、かつ、前記第1電極引出部の一部及び前記第2電極引出部の一部が外側に露出するように、前記第1基板及び第2基板の少なくとも一方にシール材を形成する第5工程と、
前記第1基板と前記第2基板とを貼り合わせることで、前記有機発光部を封止する第6工程とを含み、
前記絶縁層は、
前記第1電極引出部と前記有機層との間に設けられた第1絶縁部と、
前記第2電極引出部と前記有機層との間に設けられた第2絶縁部とを含み、
前記第4工程では、さらに、
前記第2絶縁部上に、前記第2電極と前記第2電極引出部とを電気的に接続する接続部を形成し、
前記第2工程では、
前記シール材と前記第1絶縁部との間の距離が、前記シール材と前記第2絶縁部との間の距離より長くなるように、前記絶縁層を形成する
有機EL素子の製造方法。 - 前記第4工程では、さらに、前記第1絶縁部上に、前記第1絶縁部を覆う保護膜を形成する
請求項7に記載の有機EL素子の製造方法。 - 前記第1工程では、前記第1電極、前記第1電極引出部及び前記第2電極引出部を、同じ材料を用いて同時に形成し、
前記第2工程では、前記第2電極、前記接続部及び前記保護膜を、同じ材料を用いて同時に形成する
請求項8に記載の有機EL素子の製造方法。
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JP2007323953A (ja) * | 2006-05-31 | 2007-12-13 | Optrex Corp | 有機led素子 |
JP2008091237A (ja) * | 2006-10-03 | 2008-04-17 | Seiko Epson Corp | 発光装置および電子機器 |
JP2007227397A (ja) * | 2007-04-23 | 2007-09-06 | Tohoku Pioneer Corp | 発光ディスプレイパネル及びその製造方法 |
JP2013030306A (ja) * | 2011-07-27 | 2013-02-07 | Panasonic Corp | 有機エレクトロルミネッセンス素子 |
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US20170133619A1 (en) | 2017-05-11 |
US9853234B2 (en) | 2017-12-26 |
JPWO2016017061A1 (ja) | 2017-04-27 |
JP6226312B2 (ja) | 2017-11-08 |
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