JP2009205897A - Organic light-emitting device and manufacturing method of the same - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide an organic light-emitting device, improved in generation of light and dark caused by joints between organic light-emitting elements, and its manufacturing method. <P>SOLUTION: The organic light-emitting device 10 comprises: a plurality of organic light-emitting elements 11, in which an organic light-emitting layer 3 sandwiched between an anode 2 and a cathode 4 is arranged on a substrate 1, and the organic light-emitting layer 3 as well as the anode 2 and the cathode 4 are sealed with a sealing plate 7; and a supporting substrate 8 having attachment holes 9 for fixing the organic light-emitting elements 11. Each of the organic light-emitting elements 11 has a plurality of bent end parts 11a, and the organic light-emitting layer 3 is arranged so as to be extended to a region of the bent end parts 11a. The organic light-emitting elements 11 are arranged adjacent to each other by inserting the bent end parts 11a of the organic light-emitting elements 11 in the attachment holes 9. <P>COPYRIGHT: (C)2009,JPO&INPIT

Description

  The present invention relates to an organic light-emitting device having a plurality of organic light-emitting elements and a method for manufacturing the organic light-emitting device. .

  In recent years, lighting devices using organic EL (EL) elements as organic light-emitting elements have been developed for practical use. 2. Description of the Related Art Conventionally, an organic EL element sealed with sealing glass or the like in order to protect an organic light emitting unit or an electrode is known (for example, see Patent Document 1).

  FIG. 6 shows an example of a conventional organic EL element structure. In the conventional organic EL element, the anode 20 formed by laminating on the glass substrate 100, the light emitting layer 30, and the cathode 40 insulated from the anode 20 through the insulating film 70 are replaced with a sealing plate 80 made of glass. The glass substrate 100 is adhesively sealed with sealing materials 50 and 60.

When a large-area lighting panel is manufactured using the organic EL elements described above, it is necessary to arrange a plurality of organic EL elements side by side. However, when such an illumination panel is turned on, as shown in FIG. 6, the organic EL element has a light emitting region above the light emitting layer 30 and a non-light emitting region above the sealing materials 50, 60. There is a problem in that uniform brightness cannot be obtained, for example, brightness and darkness occur due to the non-light-emitting region at the next between the EL elements, and the dark part looks like stripes.
JP 2007-128726 A

  The objective of this invention is providing the manufacturing method of the organic light-emitting device which improved generation | occurrence | production of the light and dark by the next between organic light emitting elements, and an organic light-emitting device.

  According to one aspect of the present invention for achieving the above object, an organic light emitting layer sandwiched between an anode and a cathode is disposed on a substrate, and the organic light emitting layer is sealed with a sealing plate together with the anode and the cathode. The organic light emitting device includes a plurality of organic light emitting devices and a support substrate having a mounting hole for fixing the organic light emitting devices, the organic light emitting devices have a plurality of bent ends, and the organic light emitting devices. A layer is disposed to extend in the region of the bent end portion, and the bent end portion of the organic light emitting device is inserted into the attachment hole and is disposed adjacent to each other. An organic light emitting device is provided.

  According to another aspect of the present invention for achieving the above object, a step of forming an anode and an organic light emitting layer on a substrate, a step of forming an insulating layer and a cathode, and forming an insulating layer and a sealing plate are formed. An organic light emitting device comprising: a step of fabricating an organic light emitting element; a step of forming a mounting hole in a support substrate; and a step of bending an end portion of the organic light emitting element and mounting the end portion to the mounting hole. A manufacturing method is provided.

  According to the organic light emitting device and the method for manufacturing the organic light emitting device of the present invention, it is possible to improve the occurrence of light and darkness due to the next between the organic light emitting elements.

  Hereinafter, an organic light emitting device according to an embodiment of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic, differ from actual ones, and also include portions having different dimensional relationships and ratios between the drawings.

[First embodiment]
(Structure of organic light-emitting device)
In the organic light emitting device according to the first embodiment of the present invention, as shown in FIG. 1, an organic light emitting layer 3 sandwiched between an anode 2 and a cathode 4 is disposed on a substrate 1. A plurality of organic light emitting elements 11 in which the organic light emitting layer 3 is sealed with a sealing plate 7 and a support substrate 8 having a mounting hole 9 for fixing the organic light emitting elements 11 are provided. A plurality of bent end portions 11 a are provided, and the organic light emitting layer 3 is extended and arranged in the bent end portion 11 a region. The bent end portion 11 a of the organic light emitting element 11 is attached to the attachment hole 9. And are arranged adjacent to each other.

 In the first embodiment, the bent end portion 11a of one organic light emitting element 11 and the bent end portion 11a of the other organic light emitting element 11 adjacent to each other are inserted into the mounting hole 9. The surfaces of the inserted end portion 11a are in contact with each other.

  The organic light emitting element 11 is formed by laminating an anode 2, an organic light emitting layer 3, and a cathode 4 in this order on a substrate 1. The anode 2 and the cathode 4 are insulated through insulating layers 5 and 6, the anode 2 has an anode terminal 2 a arranged with the anode 2 extended, and the cathode 4 has the cathode 4 arranged with an extension. Cathode terminals 4a are respectively formed. A portion sandwiched between the anode 2 and the cathode 4 of the organic light emitting layer 3 is a light emitting region.

  The organic light emitting element 11 is sealed on the cathode 4 side by the sealing plate 7 except for the anode terminal 2a and the cathode terminal 4a.

  As shown in FIG. 2, the organic light emitting element 11 has a substantially quadrangular shape in a plan view, and has an end portion 11 a formed by extending in each direction of four sides. The length of the end portion 11 a is preferably longer than at least the thickness of the support substrate 8. The organic light emitting layer 3 has a substantially quadrangular shape in plan view, and is formed to extend in the region of the end portion 11a that is bent at least in each direction of the four sides.

  The organic light emitting element 11 preferably has flexibility. Since the organic light emitting element 11 has flexibility, the end portion 11a of the organic light emitting element 11 can be bent and easily attached to the attachment hole 9 of the support substrate 8 as described later.

  Since the organic light emitting device 10 is configured such that light is extracted from the substrate 1 side, the substrate 1 is a transparent substrate that has flexibility and transmits light. Examples of the material of the substrate 1 include transparent resins such as polycarbonate and polyethylene terephthalate, and glass. The thickness is preferably about 50 to 500 μm, for example.

  As with the substrate 1, the anode 2 can transmit light and has a thickness of, for example, a transparent electrode of ITO (indium-tin oxide) having a thickness of about 150 to 160 nm.

  A gas barrier layer (schematically illustrated) is preferably disposed between the substrate 1 and the anode 2. Thereby, invasion of water vapor, oxygen, or the like that causes the deterioration of the lifetime of the organic light emitting element 11 can be prevented. Examples of the gas barrier layer include metal oxides such as silicon oxide and aluminum oxide, or metal nitrides such as aluminum nitride and silicon nitride.

  In the organic light emitting layer 3, a hole transport layer, a light emitting portion, and an electron transport layer are sequentially laminated from the substrate 1 side.

  The hole transport layer is for smoothly transporting holes injected from the anode 2 to the light emitting portion, and has a thickness of, for example, about NPB (N, N-di (naphthalyl) -N of about 60 nm. N-diphenyl-benzylidene).

The electron transport layer is for smoothly transporting electrons injected from the cathode 4 to the light emitting portion, and is made of, for example, Alq ₃ (aluminum quinolinol complex) having a thickness of about 35 nm.

The light emitting portion is for emitting light by recombination of injected holes and electrons. For example, a coumarin compound (C ₅₄₅ T), which is a luminescent species, is doped with, for example, about 1% and has a thickness of For example, it is made of Alq _{3 of} about 30 nm.

  In addition, you may comprise the organic light emitting layer 3 using layers other than the above-mentioned hole transport layer and electron transport layer, for example, a hole injection layer, an electron injection layer, etc.

  The cathode 4 is made of aluminum having a thickness of about 150 nm, for example.

  The sealing plate 7 protects the anode 2, the cathode 4 and the organic light emitting layer 3 and seals them, and is made of a flexible material. Examples of the material of the sealing plate 7 include resin, glass, and the like, and metals such as stainless steel (SUS) and copper. The thickness is preferably about 50 to 500 μm, for example.

  The support substrate 8 is for fixing the plurality of organic light emitting elements 11. The support substrate 8 has a mounting hole 9 for inserting and fixing the end portion 11 a of the organic light emitting element 11 in order to fix the organic light emitting element 11. The length of the attachment hole 9 is about 2 to 4 cm, for example, and the width is about 0.1 to 1 mm, for example. The support substrate 8 also has a function of a heat radiating plate for radiating heat generated in the organic light emitting element 11.

  The material of the support substrate 8 is not particularly limited as long as, for example, the thermal conductivity is good. For example, a metal, resin, etc. are mentioned. Preferably, copper or aluminum is used. The thickness is, for example, about 0.5 to 10 mm.

(Operating principle)
The operation principle of the organic light emitting device according to the first embodiment of the present invention is as follows.

  First, a constant voltage is applied between the anode 2 and the cathode 4 from the external electrode (illustrated) via the anode terminal 2 a and the cathode terminal 4 a of the organic light emitting element 11. As a result, holes are injected from the anode 2 into the light emitting part through the hole transport layer, and electrons are injected from the cathode 4 into the light emitting part through the electron transport layer. Then, the holes and electrons injected into the light emitting portion recombine to emit light. The emitted light is emitted to the outside through the substrate 1.

(Production method)
3 and 4 are diagrams illustrating a method for manufacturing the organic light emitting device according to the first embodiment of the present invention.

  The organic light emitting device manufacturing method according to the first embodiment of the present invention includes a step of forming an anode 2 and an organic light emitting layer 3 on a substrate 1, a step of forming an insulating layer 5 and a cathode 4, and an insulating layer. 6 and the sealing plate 7 to form the organic light emitting device 11, the step of forming the attachment hole 9 in the support substrate 8, the end portion 11 a of the organic light emitting device 11 is bent, and the end portion 11 a Attaching to the attachment hole 9.

  Below, a manufacturing process is explained in full detail.

(A) First, as shown in FIG. 3A, after patterning and etching the anode 2 on the substrate 1, a gas barrier layer (illustrated) made of silicon oxide or the like is formed by vacuum deposition or the like. As shown in FIG. 2, the substrate 1 has a substantially rectangular shape in plan view and is formed in a shape extending in each direction of four sides.

  Next, using a mask or the like with a vacuum deposition apparatus or the like, as shown in FIG. 2, the hole has a substantially rectangular shape in plan view and extends in the direction of the end 11a in each of the four sides. The organic light emitting layer 3 is formed by sequentially forming a transport layer, a light emitting portion, and an electron transport layer.

(B) Next, as shown in FIG. 3B, after the insulating layer 5 made of SiO ₂ is formed by a CVD (Chemical Vapor Deposition) method or the like, the cathode 4 is formed by sputtering or the like.

(C) Next, as shown in FIG. 3C, after forming the insulating layer 6 made of SiO ₂ by the CVD method or the like, the sealing plate 7 is removed by sputtering or the like except the anode terminal 2a and the cathode terminal 4a. It is formed on the surfaces of the cathode 4 and the insulating layers 5 and 6. The anode terminal 2a and the cathode terminal 4a are formed in pairs on the outer edges of one set of end portions 11a that are opposed to each other among the four end portions 11a. You may form in a pair further on the outer edge of the other one set of edge part 11a which opposes among the four edge parts 11a.

(D) Next, as shown in FIG. 4D, the attachment holes 9 are formed in the support substrate 8 made of aluminum by dry etching or wet etching using photolithography or the like.

(E) Next, as shown in FIG. 4 (e), the end portion 11 a of the organic light emitting element 11 is bent, and together with the bent end portion 11 a of the adjacent organic light emitting element 11, The organic light-emitting element 11 and the support substrate 8 are fixed by inserting into the attachment hole 9 from the surface and winding. Thereby, the organic light emitting device 10 shown in FIG. 1 is completed. The organic light emitting element 11 may be fixed to the surface of the support substrate 8 via an adhesive or the like.

  In such an organic light-emitting device 10, the organic light-emitting layer 3 is also disposed in the bent region of the end 11 a of the organic light-emitting element 11, so that the next is between the plurality of organic light-emitting elements 11 disposed adjacent to each other. This portion also includes a light emitting region. As a result, good luminance is obtained even at the next portion, and the organic light emitting device 10 having uniform luminance as a whole is obtained.

  Further, since the support substrate 8 is made of a heat conductive member, the heat generated from the organic light emitting element 11 can be efficiently removed.

  According to the organic light emitting device and the method for manufacturing the organic light emitting device according to the first embodiment of the present invention, it is possible to improve the occurrence of light and darkness between the organic light emitting elements 11.

[Second Embodiment]
As shown in FIG. 5, the organic light emitting device according to the second embodiment of the present invention has the other organic light emitting element 11 adjacent to the bent end portion 11 a of one organic light emitting element 11 in the mounting hole 9. The bent end portions 11a are inserted, and there is a predetermined distance between the surfaces of the inserted end portions 11a. Since other configurations are the same as those of the first embodiment, description thereof is omitted.

  The manufacturing method of the organic light emitting device according to the second embodiment is different from the manufacturing method in the first embodiment in the method of forming the attachment hole 9, and the other is the same as in the first embodiment. Because of this, duplicate explanation is omitted.

  In the method of manufacturing the organic light emitting device according to the second embodiment, when forming the attachment hole 9, the length of the attachment hole 9 is, for example, about 2 to 4 cm, and the width is, for example, about 0.3 to By forming to about 2 mm, for example, a distance of about 0.1 to 1 mm is provided between the surface of the bent end portion 11 a of the organic light emitting element 11 and the bent end portion 11 a of the adjacent organic light emitting element 11. The organic light emitting device 10A can be manufactured.

  According to the second embodiment, since there is a predetermined distance between the bent end portion 11a of the organic light emitting device 11 and the surface of the bent end portion 11a of the adjacent organic light emitting device 11, the organic light emitting device The heat generated at 11 can be radiated well.

  According to the second embodiment, since the organic light emitting layer 3 is also disposed in the bent region of the end portion 11a of the organic light emitting element 11, even if there is a predetermined distance between the surfaces of the end portions 11a, Good luminance is obtained at the next portion, and the organic light emitting device 10A having uniform luminance as a whole is obtained.

  According to the organic light emitting device and the method for manufacturing the organic light emitting device according to the second embodiment of the present invention, it is possible to improve the occurrence of light and darkness between the organic light emitting elements 11.

[Other embodiments]
The present invention has been described in detail with the first and second embodiments described above. However, for those skilled in the art, the present invention is limited to the first and second embodiments described in the present specification. Obviously it is not. The present invention can be implemented as modifications and changes without departing from the spirit and scope of the present invention defined by the description of the scope of claims. Therefore, the description of the present specification is for illustrative purposes and does not have any limiting meaning to the present invention. Hereinafter, a modified embodiment in which the first and second embodiments described above are partially modified will be described.

  For example, it is possible to change dimensions such as the thickness of each layer and the constituent materials.

  In the organic light emitting device according to the first embodiment described above, the organic light emitting element 11 has been described as having a substantially square shape, but may have a substantially triangular shape, a substantially hexagonal shape, or the like.

  In the organic light emitting devices according to the first and second embodiments described above, the anode 2 is disposed on the substrate 1 side and the cathode 4 is disposed on the sealing plate 7 side. An anode may be disposed on the stop plate 7 side. In this case, in the organic light emitting layer 3, the electron transport layer, the light emitting part, and the hole transport layer are sequentially laminated from the substrate 1 side.

  Further, in the organic light emitting devices according to the first and second embodiments described above, the light is extracted from the substrate 1 side. However, the light is extracted from the substrate 1 side and is extracted from the sealing plate 7 side. Also good. For example, in the second embodiment, a transparent electrode made of ITO is used for the cathode 4 and a transparent member is used for the support substrate 8. Then, for example, by providing a reflecting plate or the like that reflects light emitted from the sealing plate 7 side to the next portion, the luminance at the next portion is obtained by the light emitted from the next portion to the substrate 1 side. Can be increased.

1 is a schematic cross-sectional structure diagram of an organic light-emitting device according to a first embodiment of the present invention. FIG. 2 is a schematic development view showing a positional relationship between the substrate 1 and the organic light emitting layer 3 of the organic light emitting element according to the first embodiment of the present invention. It is explanatory drawing of the manufacturing method of the organic light-emitting device which concerns on the 1st Embodiment of this invention, Comprising: (a) Process drawing which forms the anode 2 and the organic light emitting layer 3 on the board | substrate 1, (b) Insulating layer 5 And (c) a process diagram for forming the insulating layer 6 and the sealing plate 7. It is explanatory drawing of the manufacturing method of the organic light-emitting device concerning the 1st Embodiment of this invention, Comprising: (d) Process drawing which forms the attachment hole 9 in the support substrate 8, (e) The organic light emitting element 11 is a support substrate. FIG. The typical cross-section figure of the organic light-emitting device which concerns on the 2nd Embodiment of this invention. The typical cross-section figure of the conventional organic light-emitting device.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 ... Board | substrate 2 ... Anode 3 ... Organic light emitting layer 4 ... Cathode 5,6, Insulating layer 7 ... Sealing board 8 ... Support substrate 9 ... Mounting hole 10, 10A ..Organic light emitting device 11 ..Organic light emitting element 11a

Claims (6)

A plurality of organic light emitting elements, wherein an organic light emitting layer sandwiched between an anode and a cathode is disposed on a substrate, and the organic light emitting layer is sealed together with the anode and the cathode with a sealing plate;
A support substrate having a mounting hole for fixing the organic light emitting element,
The organic light emitting device has a plurality of bent ends, and the organic light emitting layer is disposed extending in the bent end region, and the organic light emitting device has a bent end. An organic light emitting device characterized in that a portion is inserted into the mounting hole and arranged adjacent to each other.  A bent end of one of the organic light emitting elements and a bent end of the other adjacent organic light emitting element are inserted into the mounting hole, and the surfaces of the inserted end are in contact with each other The organic light-emitting device according to claim 1, wherein  A bent end of one of the organic light emitting elements and a bent end of the other organic light emitting element adjacent to each other are inserted into the mounting hole, and a predetermined gap is formed between the surfaces of the inserted end. The organic light-emitting device according to claim 1, wherein   The organic light-emitting device according to claim 1, wherein the organic light-emitting element has flexibility.   The organic light-emitting device according to claim 1, wherein the support substrate is made of a heat conductive member. Forming an anode and an organic light emitting layer on a substrate;
Forming an insulating layer and a cathode;
Forming an insulating layer and a sealing plate to produce an organic light emitting device;
Forming a mounting hole in the support substrate;
Bending the end portion of the organic light emitting element, and attaching the end portion to the attachment hole.

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