CN102577603A - Organic el panel and manufacturing method therefor - Google Patents
Organic el panel and manufacturing method therefor Download PDFInfo
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- CN102577603A CN102577603A CN200980161816XA CN200980161816A CN102577603A CN 102577603 A CN102577603 A CN 102577603A CN 200980161816X A CN200980161816X A CN 200980161816XA CN 200980161816 A CN200980161816 A CN 200980161816A CN 102577603 A CN102577603 A CN 102577603A
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- 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
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- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
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- H05B33/04—Sealing arrangements, e.g. against humidity
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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
- H10K59/80—Constructional details
- H10K59/87—Passivation; Containers; Encapsulations
- H10K59/871—Self-supporting sealing arrangements
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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
- H10K59/80—Constructional details
- H10K59/87—Passivation; Containers; Encapsulations
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- H10K59/8722—Peripheral sealing arrangements, e.g. adhesives, sealants
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Abstract
有机EL面板及其制造方法,在缩小有机EL面板的边缘区域时,能够充分确保基板与密封基板的粘结强度并维持有机EL元件的良好的密封性能。对基板(10)上的发光部(11)进行中空密封的密封基板(20)具备容纳发光部(11)的凹部(22)及沿着凹部(22)的外周形成并具有与基板(10)相对的粘结面(23A)的肋部(23),在肋部(23)的粘结剂层形成部分中的横截面上,与肋部(23)的侧面(23B)相切的最陡峭的切线(L1)与沿粘结面(23A)的线(L2)所成的角度(θa)65°~85°,从粘结面(23A)遍及肋部(23)的侧面(23B)被形成有粘结剂层(1)。
The organic EL panel and its manufacturing method can fully ensure the bonding strength between the substrate and the sealing substrate and maintain good sealing performance of the organic EL element when reducing the edge area of the organic EL panel. The sealing substrate (20) for hollowly sealing the light-emitting part (11) on the substrate (10) has a recess (22) for accommodating the light-emitting part (11), and is formed along the outer periphery of the recess (22) and has a The rib (23) of the opposite bonding surface (23A), on the cross-section in the adhesive layer forming part of the rib (23), the steepest part tangent to the side (23B) of the rib (23) The angle (θa) formed by the tangent (L1) and the line (L2) along the bonding surface (23A) is 65°~85°, from the bonding surface (23A) to the side (23B) of the rib (23) An adhesive layer (1) is formed.
Description
技术领域 technical field
本发明涉及一种有机EL面板及有机EL面板的制造方法。The invention relates to an organic EL panel and a method for manufacturing the organic EL panel.
背景技术 Background technique
有机EL面板为具备有机EL元件作为发光元件的自发光面板,例如,作为用于手机的显示画面、车载用或家庭用电子设备的显示器画面、个人电脑或电视接收装置的信息显示画面、宣传用照明板等的各种显示装置;用于扫描仪或打印机等的各种光源;用于一般照明或液晶显示装置的背光源等的照明装置;以及利用光电转换功能的光通信用设备,能够利用于各种用途及机种。An organic EL panel is a self-luminous panel equipped with an organic EL element as a light-emitting element. Various display devices such as lighting panels; various light sources for scanners and printers; lighting devices for general lighting or backlights for liquid crystal display devices; and optical communication equipment using photoelectric conversion functions, which can be used For various purposes and models.
有机EL元件具有与大气中含有的水分等接触就发生发光特性劣化的性质,所以为了使有机EL面板长时间稳定地运转,用于从大气隔离有机EL元件的密封结构是必不可少的。作为有机EL面板的密封结构的一例,已知有贴合被形成有机EL元件的基板和密封基板来形成包围有机EL元件的密封空间并在其密封空间内配备干燥剂的中空密封结构(例如,参考下述专利文献1)。Organic EL elements have the property of deteriorating light emitting characteristics when they come into contact with moisture contained in the atmosphere, so in order to operate the organic EL panel stably for a long time, a sealing structure for isolating the organic EL elements from the atmosphere is essential. As an example of the sealing structure of the organic EL panel, there is known a hollow sealing structure (for example, Refer to the following patent document 1).
图1是表示具有以往的中空密封结构的有机EL面板的结构例的概要图(该图(a)为截面图,该图(b)为俯视图)。基板J1上被形成有1个或多个形成发光部J2的有机EL元件J3,密封基板J5通过粘结剂层J6被贴合于基板J1,以便形成覆盖发光部J2的密封空间J4。密封基板J5的内面被配备有干燥剂J7,通过由干燥剂吸附密封空间J4内的水分来谋求有机EL元件的长寿命化。FIG. 1 is a schematic view showing a structural example of an organic EL panel having a conventional hollow sealing structure (the drawing (a) is a cross-sectional view, and the drawing (b) is a plan view). One or more organic EL elements J3 forming the light emitting portion J2 are formed on the substrate J1, and the sealing substrate J5 is bonded to the substrate J1 through an adhesive layer J6 to form a sealed space J4 covering the light emitting portion J2. The inner surface of the sealing substrate J5 is provided with a desiccant J7, and the desiccant absorbs moisture in the sealed space J4, thereby prolonging the life of the organic EL element.
在先技术文献prior art literature
专利文献patent documents
专利文献1:日本专利公开2002-231439号公报Patent Document 1: Japanese Patent Laid-Open No. 2002-231439
发明内容 Contents of the invention
发明所要解决的课题The problem to be solved by the invention
具有上述中空密封结构的有机EL面板中,在基板J1的表面内被形成有发光部J2的区域成为发光区域J20,但由于需确保用于通过粘结剂层J6粘结基板J1和密封基板J5的区域(粘结区域)等,需在发光区域J20的外侧形成预定宽度JW的区域(边缘区域),无法将整个基板J1设为发光区域J20。In the organic EL panel having the above-mentioned hollow sealing structure, the region in which the light emitting portion J2 is formed in the surface of the substrate J1 becomes the light emitting region J20, but since it is necessary to ensure the bonding of the substrate J1 and the sealing substrate J5 through the adhesive layer J6, For example, it is necessary to form a region (edge region) with a predetermined width JW outside the light-emitting region J20 (adhesion region), and the entire substrate J1 cannot be used as the light-emitting region J20.
然而,将有机EL面板组装于各种装置时或独立设置时,为了避免周边空间的压迫,期望尽量缩小发光区域J20外侧的边缘区域。另外,在大型基板上形成多个发光部J2并贴合该大型基板和大型密封基板来通过一次性贴合工序形成多个面板时,若边缘区域变大,则可从一个大型基板取出的面板数变少,存在制造成品率差且无法充分得到生产率提高效果的问题。However, when the organic EL panel is assembled in various devices or installed independently, it is desirable to reduce the edge area outside the light emitting area J20 as much as possible in order to avoid compression of the surrounding space. In addition, when forming a plurality of light-emitting parts J2 on a large substrate and bonding the large substrate and a large sealing substrate to form a plurality of panels in one bonding process, the panel that can be taken out from one large substrate becomes larger if the edge area becomes larger If the number is reduced, there is a problem that the manufacturing yield is poor and the productivity improvement effect cannot be sufficiently obtained.
另外,通过排列多个有机EL面板来形成大面积面板(瓦面板)时,各个面板的边缘区域位于大面积面板的整体发光区域内而形成非发光区域,因此从提高整体发光区域的性能方面考虑,被要求尽可能缩小该边缘区域。In addition, when a large-area panel (tile panel) is formed by arranging a plurality of organic EL panels, the edge area of each panel is located in the entire light-emitting area of the large-area panel to form a non-light-emitting area. Therefore, it is considered to improve the performance of the entire light-emitting area. , is required to reduce the marginal area as much as possible.
为了缩小边缘区域,不得不缩小粘结区域的宽度(参考图1的JW1),若单纯地缩小粘结区域的宽度,则无法充分确保基板J1与密封基板J5的粘结强度而产生无法维持有机EL元件J3的良好的密封性能的问题。In order to reduce the edge region, the width of the bonding region has to be reduced (refer to JW1 in FIG. 1 ). If the width of the bonding region is simply reduced, the bonding strength between the substrate J1 and the sealing substrate J5 cannot be sufficiently ensured, resulting in failure to maintain the organic substrate. A problem of good sealing performance of the EL element J3.
另外,若单纯地缩小粘结区域,则为了形成密封空间J4而被形成于密封基板J5的肋部J10的宽度变窄。由此,肋部J10的强度下降,肋部J10的强度无法承受作用于密封基板J6的荷载,产生肋部J10破损之类的问题。若肋部J10破损,则有机EL元件J3被暴露于外部空气,产生有机EL元件J3显著劣化的不良情况。另外,若肋部J10的强度下降,则存在有机EL面板的制造工艺中肋部J10破损之虞,还导致成品率下降。In addition, simply reducing the bonding area reduces the width of the rib J10 formed on the sealing substrate J5 to form the sealing space J4. As a result, the strength of the rib J10 decreases, and the strength of the rib J10 cannot withstand the load acting on the sealing substrate J6, causing a problem that the rib J10 is damaged. When the rib J10 is damaged, the organic EL element J3 is exposed to the outside air, causing a disadvantage that the organic EL element J3 deteriorates remarkably. In addition, if the strength of the ribs J10 decreases, there is a possibility that the ribs J10 may be damaged during the manufacturing process of the organic EL panel, resulting in a decrease in yield.
本发明将解决这种问题作为课题的一例。即,本发明的目的在于,提高发光区域在有机EL面板中的占有率来谋求提高有机EL面板的性能;在缩小有机EL面板的边缘区域时,能够充分确保基板与密封基板的粘结强度并维持有机EL元件的良好的密封性能;确保密封基板的肋部强度来防止产生因肋部的破损引起的不良情况等。This invention takes solving such a problem as an example of a subject. That is, the object of the present invention is to improve the performance of the organic EL panel by increasing the occupancy ratio of the light-emitting region in the organic EL panel; Maintain the good sealing performance of the organic EL element; ensure the strength of the ribs of the sealing substrate to prevent defects caused by damage to the ribs, etc.
用于解决课题的手段means to solve the problem
为了实现这种目的,基于本发明的有机EL面板及其制造方法至少具备以下各结构。In order to achieve such an object, the organic EL panel and its manufacturing method according to the present invention have at least the following structures.
一种有机EL面板,其特征在于,该有机EL面板具备基板、被形成于该基板上且具备至少1个层叠有阳极、有机层、阴极的有机EL元件的发光部及为了对该发光部进行中空密封而通过粘结剂层被贴合于所述基板的密封基板,所述密封基板具备容纳所述发光部的凹部及沿该凹部的外周形成且具有与所述基板相对的粘结面的肋部,在所述肋部的粘结剂层形成部分中的横截面上,与所述肋部的侧面相切的最陡峭的切线与沿所述粘结面的线所成的角度呈65°~85°,并且从所述粘结面遍及所述肋部的侧面被形成有所述粘结剂层。An organic EL panel, characterized in that the organic EL panel includes a substrate, a light-emitting portion formed on the substrate and having at least one organic EL element stacked with an anode, an organic layer, and a cathode, and for the light-emitting portion to perform A sealing substrate that is hollow-sealed and bonded to the substrate through an adhesive layer, the sealing substrate includes a recess for accommodating the light-emitting part, and an adhesive surface formed along the outer periphery of the recess and facing the substrate. The rib, in cross-section in the adhesive layer forming part of the rib, the angle formed by the steepest tangent to the side of the rib and the line along the bonding surface is 65 °˜85°, and the adhesive layer is formed from the adhesive surface to the side of the rib.
一种有机EL面板的制造方法,其特征在于,该方法具有:发光部形成工序,在基板形成具备至少1个有机EL元件的发光部;密封基板加工工序,在密封基板上形成容纳所述发光部的凹部及沿该凹部的外周且具有与所述基板相对的粘结面的肋部;及密封工序,通过粘结剂层贴合所述基板与所述密封基板并对所述发光部进行中空密封,在所述密封基板加工工序中,以如下方式加工所述密封基板,即在所述肋部的粘结剂层形成部分中的横截面上,与所述肋部的侧面相切的最陡峭的切线与沿所述粘结面的线所成的角度呈65°~85°,在所述密封工序中,从所述粘结面遍及所述肋部的侧面形成所述粘结剂层。A method for manufacturing an organic EL panel, characterized in that the method comprises: a light-emitting portion forming step of forming a light-emitting portion having at least one organic EL element on a substrate; The concave portion of the concave portion and the rib portion along the outer periphery of the concave portion and having an adhesive surface opposite to the substrate; and a sealing step of bonding the substrate and the sealing substrate through an adhesive layer and sealing the light emitting portion. In the hollow sealing, in the sealing substrate processing step, the sealing substrate is processed in such a manner that, on the cross section in the adhesive layer forming portion of the rib, The angle formed by the steepest tangent and the line along the bonding surface is 65° to 85°, and in the sealing process, the adhesive is formed from the bonding surface to the side of the rib layer.
附图说明 Description of drawings
图1是表示具有以往的中空密封结构的有机EL面板的结构例的概要图(该图(a)为截面图,该图(b)为俯视图)。FIG. 1 is a schematic view showing a structural example of an organic EL panel having a conventional hollow sealing structure (the drawing (a) is a cross-sectional view, and the drawing (b) is a plan view).
图2是表示本发明的一实施方式所涉及的有机EL面板的基本结构的示意图(该图(a)表示整体截面,该图(b)表示局部放大截面。)。2 is a schematic diagram showing a basic structure of an organic EL panel according to an embodiment of the present invention (the figure (a) shows the overall cross section, and the figure (b) shows a partially enlarged cross section.).
图3是表示本发明的实施方式所涉及的有机EL面板的形成例的说明图。FIG. 3 is an explanatory view showing a formation example of the organic EL panel according to the embodiment of the present invention.
图4是表示本发明的实施方式所涉及的有机EL面板的其他形成例的说明图。FIG. 4 is an explanatory diagram showing another formation example of the organic EL panel according to the embodiment of the present invention.
图5是表示本发明的实施方式所涉及的有机EL面板的其他形成例的说明图。FIG. 5 is an explanatory diagram showing another formation example of the organic EL panel according to the embodiment of the present invention.
图6是表示通过发光部形成工序形成的有机EL元件的形成例的说明图(该图(a)表示具备独立的像素电极的有源驱动元件的例子,该图(b)表示在交叉的条纹状电极的交叉部被形成元件的无源驱动元件的例子。)。6 is an explanatory diagram showing an example of the formation of an organic EL element formed by a light-emitting portion forming process (the figure (a) shows an example of an active drive element provided with an independent pixel electrode, and the figure (b) shows an An example of a passively driven element where the intersection of the shaped electrodes is formed.).
具体实施方式 Detailed ways
以下,参考附图对本发明的实施方式进行说明。图2是表示本发明的一实施方式所涉及的有机EL面板的基本结构的示意图(该图(a)表示整体截面,该图(b)表示粘结剂层形成部分的放大截面。)。Hereinafter, embodiments of the present invention will be described with reference to the drawings. 2 is a schematic view showing a basic structure of an organic EL panel according to an embodiment of the present invention (the figure (a) shows an overall cross section, and the figure (b) shows an enlarged cross section of a portion where an adhesive layer is formed.).
如图2(a)所示,有机EL面板1具备有基板10、被形成于由透光性材料形成的基板上的发光部11及密封基板20。发光部11具备有单个或多个层叠有阳极、有机层、阴极的有机EL元件11A,例如以点阵形状排列构成像素的有机EL元件11A来形成图像显示面。如本例,被形成于由透光性材料形成的基板上的有机EL元件11A是能够通过基板10向外部放射光的元件(底部发光型)。另外,本发明的实施方式所涉及的有机EL面板1与此相反,可从后述的密封基板20侧向外部放出光(顶部发光型),也可从基板10和密封基板20的两面向外部放出光(双发光型)。As shown in FIG. 2( a ), the organic EL panel 1 includes a
为了在密封空间C内对发光部11进行中空密封,密封基板20通过粘结剂层21被贴合于基板10。该密封基板20具备有容纳发光部11的凹部22及沿凹部22的外周形成且具有与基板10相对的粘结面23A的肋部23。根据需要在密封基板20的凹部22的底面22A被配备干燥剂24。In order to hollow-seal the
另外,如图2(b)所示,在肋部23的粘结剂层形成部分中的横截面上,与肋部23的侧面23B相切的最陡峭的切线L1与沿粘结面23A的线L2所成的角度θa呈65°~85°,并且从粘结面23A遍及肋部23的侧面23B被形成有粘结剂层21。In addition, as shown in FIG. 2( b ), on the cross section in the adhesive layer forming portion of the
具有这种面板结构的本发明的实施方式所涉及的有机EL面板1即使在通过进一步扩大发光部11的发光区域EA来缩小边缘区域FA(从发光部11的外周边至基板10的外周边的区域)时,也能够确保基板10与密封基板20的粘结强度,并且能够确保密封基板20的密封空间的结构性强度。In the organic EL panel 1 according to the embodiment of the present invention having such a panel structure, the edge area FA (the distance from the outer periphery of the
即,本发明的实施方式的有机EL面板1中,即使在通过缩小肋部23的粘结面23A的宽度来缩小边缘区域FA的宽度时,由于肋部23被形成为从顶部朝向底部逐渐宽幅,因此也能够确保肋部23的结构性强度。另外,被涂布于粘结面23A的粘结剂在贴合基板10与密封基板20时向密封空间C内扩展,但粘结剂层21通过被形成于肋部23的侧面的角度θa的倾斜面被形成为从肋部23的侧面23B的顶部朝向基板10逐渐宽幅状。由此,即使在缩窄粘结面23A时也能够确保粘结剂层21的粘结力,并能够将基板10与密封基板20的粘结强度维持为充分的强度。That is, in the organic EL panel 1 according to the embodiment of the present invention, even when the width of the edge area FA is reduced by reducing the width of the
角度θa的范围优选为65°~85°的范围。若角度θa大于85°,则肋部23整体的坡度变得陡峭,因此肋部23整体的宽度由于缩小肋部23的粘结面23A而变窄,无法得到肋部23的结构性强度。在这种肋部23的结构中,肋部23破损而有机EL元件11A被暴露于外部空气,有可能产生有机EL元件11A显著劣化的不良情况。The range of the angle θa is preferably in the range of 65° to 85°. If the angle θa is greater than 85°, the overall slope of the
另一方面,若角度θa小于65°,则肋部23的侧面过于倾斜,因此无法在粘结面23A的内侧部分确保充分的密封空间,并且,贴合基板10与密封基板20时粘结剂扩展至有机EL元件11A,对有机EL元件11A带来损伤,因此不得不将边缘区域FA较大地确保相应量。另外,若肋部23的侧面过于倾斜,则肋部23的底部的裙部变长而凹部22的平坦部分的宽度变短。由此,配备于凹部22内的平坦部分的干燥剂的配备空间变窄,无法充分得到干燥剂的效果。On the other hand, if the angle θa is less than 65°, the side surfaces of the
本发明的实施方式所涉及的有机EL面板1谋求发光区域EA的扩大化(边缘区域FA的窄面积化),提高面板的有效显示面积率,从而能够谋求显示性能的提高。此时,能够良好地维持有机EL元件11A的密封性能,可有效地谋求抑制发光特性劣化的同时,谋求前述的显示性能的提高。The organic EL panel 1 according to the embodiment of the present invention can increase the effective display area ratio of the panel by enlarging the light-emitting area EA (reducing the area of the edge area FA), thereby improving the display performance. In this case, the sealing performance of the
图3是表示本发明的实施方式所涉及的有机EL面板1的形成例的说明图(与前述说明重复之处附加相同符号并省略部分说明)。在此示出通过基板10与密封基板20的贴合形成多个密封空间的例子。如图所示,当密封空间C1、C2被形成于横跨肋部23的两侧时,在本发明的实施方式所涉及的有机EL面板1中,从肋部23的粘结面23A遍及两个侧面23B被形成有粘结剂层21。FIG. 3 is an explanatory view showing a formation example of the organic EL panel 1 according to the embodiment of the present invention (the same reference numerals are attached to the parts that overlap with the above-mentioned description, and the description of parts is omitted). Here, an example in which a plurality of sealed spaces are formed by bonding the
此时,有时邻接于肋部23的两侧的密封空间C1、C2的容积不同,这种情况下,在由于基板10与密封基板20的贴合而产生于密封空间C1、C2内的内压P1、P2产生差,容积较小的密封空间C2的内压P2大于容积较大的密封空间C1的内压P2(P1<P2)。在这种情况下,由于内压差产生粘结剂被引至内压较低的一方的现象(粘结剂的牵引),由此粘结剂易沿着粘结面23A移动。若产生这种粘结剂的牵引,则粘结剂层21偏于肋部23的一侧而形成,无法得到良好的粘结强度。另外,由于粘结剂层21的牵引,有时粘结面23A内的粘结剂的量变少或脱落,此时产生密封性能下降或者有机EL元件11A显著劣化的不良情况。通过将角度θa设定在65°以上,产生于密封空间C1、C2内的内压P1、P2的差变小,因此不易产生这种粘结剂的牵引,能够在肋部23的顶部形成向左右两侧均匀地扩散的粘结剂层21,并能够确保基板10与密封基板20的良好的粘结强度及密封性能。At this time, the volumes of the sealed spaces C1 and C2 on both sides adjacent to the
图4是表示本发明的实施方式所涉及的有机EL面板1的其他形成例的说明图(与前述说明重复之处附加相同符号并省略部分说明)。其中,在肋部23的顶部对粘结面23A与侧面23B的角部进行倒棱加工。如图所示,通过形成倒棱R,能够更充分地确保粘结剂层21在粘结面23A附近的扩散。由此,即使在缩小粘结面23A的宽度时也能够进一步提高粘结剂层21的粘结强度。FIG. 4 is an explanatory view showing another formation example of the organic EL panel 1 according to the embodiment of the present invention (the same reference numerals are attached to the parts that overlap with the above-mentioned description, and the description of parts is omitted). Among them, the corners of the
图5是表示本发明的实施方式所涉及的有机EL面板1的其他形成例的说明图(与前述说明重复之处附加相同符号并省略部分说明)。其中,将密封基板20的凹部22设为段式槽形。即,对凹部22的底面22A进一步形成凹部22B。通过如此将凹部22设为多段式槽形,能够与角度θa的规定范围无关地确保密封空间的容积,并且能够确保配备于密封空间内的干燥剂24的配备空间。将为了配备干燥剂24所需的凹部加工为一段时,加工深度较深,有时很难以预定值形成角度θa。为了解决此现象,如前述那样将凹部22设为多段式槽形来消除形成角度θa方面的制约。FIG. 5 is an explanatory diagram showing another example of formation of the organic EL panel 1 according to the embodiment of the present invention (the same reference numerals are attached to the parts that overlap with the above-mentioned description, and the description of parts is omitted). Wherein, the
以下,对本发明的实施方式所涉及的有机EL面板1的制造方法进行说明。本发明的实施方式所涉及的有机EL面板1的制造方法具有作为基板10侧的工序的发光部形成工序、作为密封基板20侧的工序的密封基板加工工序、贴合基板10与密封基板20的密封工序。Hereinafter, a method of manufacturing the organic EL panel 1 according to the embodiment of the present invention will be described. The method of manufacturing the organic EL panel 1 according to the embodiment of the present invention includes a light-emitting portion forming step as a step on the
发光部形成工序为在基板10上形成具备至少1个有机EL元件11A的发光部11的工序。有机EL元件11A具有层叠有阳极、有机层、阴极的结构,其在基板10上直接或通过其他层形成阳极或阴极中的一方的电极图案,在被绝缘划分的电极图案上层叠包含发光层的有机层,进而在有机层上形成阳极或阴极中的另一方的电极图案。The light emitting portion forming step is a step of forming the
当对多个有机EL元件11A进行无源矩阵驱动时,例如在基板10上图案形成条纹状的透明电极(阳极),以划分独立的有机EL元件11A的方式形成绝缘膜的图案,并在绝缘膜上沿与前述的透明电极交叉的方向形成条纹状隔壁。并且,在被绝缘划分的透明电极上成膜包含发光层的有机层,在有机层上成膜通过隔壁被图案形成的金属电极(阴极)。When passive matrix driving is performed on a plurality of
当对多个有机EL元件11A进行有源矩阵驱动时,例如在被形成有TFT等驱动元件的基板10上通过平坦化膜形成由透明电极构成的像素电极(阳极),在被绝缘划分的像素电极上成膜包含发光层的有机层,进而在有机层上成膜金属电极(阴极)。When active-matrix driving is performed on a plurality of
密封基板加工工序为在密封基板20上形成容纳发光部11的凹部22及沿凹部22的外周且具有粘结面23A的肋部23的工序。凹部22和肋部23能够通过对平板状的密封基板22的表面中除粘结面23A以外的部分实施挖取加工来同时形成。作为挖取加工,能够采用湿式蚀刻、干式蚀刻、喷砂法等处理方法。采用湿式蚀刻时,在密封基板22上形成与粘结面23A对应的抗蚀剂图案,并将密封基板22的露出面浸渍于蚀刻液中。为了将凹部22形成为段式槽形,首先,在密封基板20的表面形成具有沿凹部22的外边的开口图案的抗蚀剂膜,对其图案进行第1次蚀刻处理,之后在凹部22的内侧形成具有开口图案的抗蚀剂膜,对其图案进行第2次蚀刻处理。在密封基板加工工序中,通过适当设定形成凹部22的挖取加工时的加工条件,实现前述角度θa的设定范围。The sealing substrate processing step is a step of forming, on the sealing
密封工序为通过粘结剂层21贴合基板10与密封基板20来对发光部11进行中空密封的工序。在密封基板20的粘结面23A上涂布适量粘结剂。此时,以贴合之后从粘结面23A遍及肋部23的侧面23B被形成粘结剂层21的方式设定涂布的粘结剂的量。通过贴合基板10与密封基板20并以预定压力加压来形成从肋部23的侧面顶部朝向基板10呈逐渐宽幅状的粘结剂层21。作为粘结剂,能够利用紫外线硬化型或热硬化型树脂等。The sealing step is a step of bonding the
图6是表示通过前述发光部形成工序形成的有机EL元件的形成例的说明图。该图(a)表示具备独立的像素电极的有源驱动元件的例子,该图(b)表示在交叉的条纹状电极的交叉部被形成元件的无源驱动元件的例子。FIG. 6 is an explanatory view showing a formation example of the organic EL element formed by the light emitting portion forming step. The figure (a) shows an example of an active drive element including independent pixel electrodes, and the figure (b) shows an example of a passive drive element in which elements are formed at intersections of intersecting stripe-shaped electrodes.
在该图(a)的例子中,在被形成驱动元件(TFT等)30的基板10上以覆盖驱动元件30的方式形成平坦化膜31,在其平坦化膜31上形成成为像素电极的下部电极32。下部电极32能够在平坦化膜31上成膜电极材料之后在光刻工序中进行图案形成来形成。在形成下部电极32之前,形成连接下部电极32和驱动元件30的连接线30A,并在其周边部分形成绝缘膜33。以覆盖下部电极32上的绝缘膜33的开口图案的方式形成包含发光层34A的有机层34。有机层34能够通过合并掩模开口部与绝缘膜33的开口部的掩模蒸镀获得。之后以覆盖有机层34整体的方式形成上部电极34。In the example in (a) of the figure, a flattening
在该图(b)的例子中,在基板10上以条纹状形成下部电极40,在其上成膜绝缘膜41并以与下部电极40交叉的方式形成条纹状图案。并且,根据需要在绝缘膜41上形成条纹状隔壁42。进一步优选隔壁42为使侧壁带有朝下倾斜的倒锥度的隔壁。并且,沿绝缘膜41及隔壁42的条纹状开口部形成包含发光层43A的有机层43,在其上形成条纹状的上部电极44。隔壁42成为形成上部电极44时的掩模图案。成膜有机层43和上部电极44时,隔壁42的上面被堆积有机材料堆积层43R和上部电极材料堆积层44R。In the example in (b) of this figure, the
以下示出将下部电极32、40设为阳极并将上部电极35、44设为阴极时的有机层34、43的形成例。下部电极32、40能够通过ITO等透明电极形成,在下部电极32、40上形成铜酞菁(CuPc)等空穴注入层,在其上例如成膜NPB(N,N-di(naphtalence)-N,N-dipheneyl-benzidene)作为空穴传输层。该空穴传输层具有将从下部电极32、40注入的空穴传输至发光层34A、43A的功能。该空穴传输层可以是仅层叠1层的传输层,也可以是层叠2层以上的传输层。另外,空穴传输层并非基于单一材料的成膜,可通过多个材料形成1个层,也可以对电荷传输能力较高的主体材料掺杂电荷供给(容纳)性较高的客体材料。Formation examples of the
接着,在空穴传输层上成膜发光层34A、43A。作为一例,通过电阻加热蒸镀法并利用分涂用掩模将红色(R)、绿色(G)、蓝色(B)发光层34A、43A成膜于各个成膜区域。作为红色(R),采用DCM1(4-(二氰基亚甲基)-2-甲基-6-(4’-二甲基氨基苯乙烯基)-4H-吡喃)等苯乙烯色素等发出红色光的有机材料。作为绿色(G),采用喹啉铝配合物(Alq3)等发出绿色光的有机材料。作为蓝色(B),采用二苯乙烯衍生物、三唑衍生物等发出蓝色光的有机材料。当然可以采用其他材料,可以是主体-客体类的层结构,发光形态可以采用荧光发光材料也可采用磷光发光材料。Next, light emitting
关于被成膜于发光层34A、43A上的电子传输层,通过电阻加热蒸镀法等各种成膜方法并利用例如喹啉铝配合物(Alq3)等各种材料进行成膜。电子传输层具有将从上部电极35、44注入的电子传输至发光层34A、43A的功能。该电子传输层可以是仅层叠1层的传输层,也可以具有层叠2层以上的多层结构。另外,电子传输层并非基于单一材料的成膜,可通过多个材料形成1个层,也可以对电荷传输能力较高的主体材料掺杂电荷供给(容纳)性较高的客体材料来形成。The electron transport layers formed on the light-emitting
绝缘膜33、41或隔壁42由聚酰亚胺或抗蚀剂材料构成。上部电极35、44在作为阴极发挥功能时利用功函数低于阳极的材料,以便具有电子注入功能。例如,利用ITO作为阳极时,优选利用铝(Al)或镁合金(Mg-Ag)。其中,Al由于电子注入能力较低,因此优选在Al与电子传输层之间设置如LiF的电子注入层。The insulating
根据这种本发明的实施方式,即使在将边缘区域FA的宽度(从发光部11的外周边至基板10的外周边的宽度)设为0.5mm以下时,也能够获得有机EL元件11A的良好的密封性能。由此,本发明的实施方式所涉及的有机EL面板由于在作为显示装置组装于电子设备等时能够相对于所希望的显示面积缩小组装所需的设置空间,因此可以得到易小型化电子设备的效果。在作为独立的显示装置配置于室内或车内时,也不会压迫周边的空间就能够得到所希望的显示性能。另外,在大型基板上同时形成多个面板时,通过边缘区域FA的窄面积化,能够增多面板的数量,并且能够提高产品产率,谋求提高生产率。According to such an embodiment of the present invention, even when the width of the edge area FA (the width from the outer periphery of the
另外,排列多个有机EL面板1来形成大型面板(瓦面板)时,能够缩小大型面板中存在于整个发光区域内的非发光区域的面积,并能够提高大型面板的显示性能。In addition, when a large panel (tile panel) is formed by arranging a plurality of organic EL panels 1, the area of the non-light emitting region existing in the entire light emitting region of the large panel can be reduced, and the display performance of the large panel can be improved.
以上,参考附图对本发明的实施方式进行了详述,但具体结构不限于这些实施方式,即使有不脱离本发明宗旨的范围的设计变更等也包含于本发明。另外,上述各实施方式只要其目的及结构等没有特别的矛盾或问题,就能够流用彼此的技术并进行组合。As mentioned above, although embodiment of this invention was described in detail with reference to drawings, the specific structure is not limited to these embodiment, Even if there is a design change in the range which does not deviate from the gist of this invention, it is also included in this invention. In addition, as long as there is no particular contradiction or problem in the above-mentioned respective embodiments, their purposes, structures, etc., each other's technology can be shared and combined.
符号说明Symbol Description
1:有机EL面板,1: Organic EL panel,
10:基板,11:发光部,11A:有机EL元件,10: substrate, 11: light emitting part, 11A: organic EL element,
20:密封基板,21:粘结剂层,22:-凹部,20: sealing substrate, 21: adhesive layer, 22: -recess,
23:肋部,23A:粘结面,23B:侧面,23: rib, 23A: bonding surface, 23B: side,
24:干燥剂,24: desiccant,
EA:发光区域,FA:边缘区域,C:密封空间,EA: luminous area, FA: edge area, C: sealed space,
θa:切线L1与线L2所成的角度。θa: The angle formed by the tangent line L1 and the line L2.
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