JP2006302694A - Manufacturing system of emission display panel and manufacturing method of emission display panel - Google Patents

Abstract

<P>PROBLEM TO BE SOLVED: To provide a manufacturing system of an emission display panel and a manufacturing method of the emission display panel with high flexibility and high quality of images and capable of obtaining an emission display panel with comparatively less heat generation at the time of light emission with low cost. <P>SOLUTION: The manufacturing system of an emission display panel includes an emission region and a non-emission region, displays a predetermined pattern with a combination of the emission region and the non-emission region, and has an auxiliary electrode forming section S2 forming an auxiliary electrode of a predetermined pattern on a long transparent substrate 100a with a transparent conductive layer formed on one side, an insulation layer forming section S3 forming an electric insulation layer of a predetermined pattern on the transparent conductive layer, an organic emission part forming section S4 forming an organic emission part to cover the transparent conductive layer of a region corresponding to the emission region, and a transportation means TM to transport the long transparent substrate at least in a bridging status from the auxiliary electrode forming section S2 to the organic emission part forming section S4. <P>COPYRIGHT: (C)2007,JPO&INPIT

Description

  The present invention relates to a light-emitting display panel manufacturing system and a light-emitting display panel manufacturing method for displaying patterns such as characters, figures, symbols, patterns, and still images by combining light-emitting areas and non-light-emitting areas.

  An organic electroluminescence element (hereinafter referred to as “organic EL element”), which is known as one of light emitting elements, has been put into practical use as a pixel of a highly flexible flat panel display or as a paper-like surface light source. Is underway. Further, as described in, for example, Patent Document 1, a light-emitting region and a non-light-emitting region generated when an electric insulating layer is formed in a predetermined pattern in a large-area organic EL device and the organic EL device is energized. Paper-like light-emitting display panels that display characters, graphics, symbols, and the like for advertisement and promotion are also being developed. Furthermore, as described in Patent Document 2, a light-emitting display panel having a structure in which a printed material on which an image or the like is printed is bonded to the outer surface of the light-emitting display panel described in Patent Document 1 has also been developed.

  The organic EL element is a light emitting element having a basic layer structure in which a transparent electrode, an organic light emitting unit, and a back electrode are sequentially laminated on a transparent substrate in this order. In many cases, gas barrier layers are provided between the transparent electrode and the transparent substrate and outside the back electrode in order to prevent the portion from deteriorating. Today, raw materials that enable the organic light-emitting portion to be formed by a printing method have been developed. For example, in Patent Document 2, each layer of the organic light-emitting portion in the light-emitting display panel is formed by a printing method. A production line capable of continuously producing an intermediate product of the light emitting display panel is described. When each layer of the organic light emitting portion in the organic EL element is formed by a printing method, the manufacturing cost can be reduced as compared with the case where each layer is formed by a vacuum deposition method, a sputtering method, or the like in a vacuum environment.

In the case of producing a highly flexible organic EL device, a transparent resin film or a transparent resin sheet is usually used as the transparent substrate, but a transparent substrate made of a transparent resin film or a transparent resin sheet is usually used as the transparent substrate. Since the heat resistance is relatively low, the conductivity of the transparent electrode that can be formed is also relatively low. In particular, in a large-area organic EL element, the voltage applied to the transparent electrode is high as a result. And, when a high voltage is applied to the transparent electrode of the organic EL element using a transparent resin film or a transparent resin sheet as the transparent substrate, the organic light-emitting part deteriorates due to heat generated by energization, the transparent substrate deforms, There is a possibility that the transparent base material may burn out. In order to prevent such problems, for example, in the light emitting element described in Patent Document 3, heat generation during light emission is suppressed by providing a plurality of metal bus line electrodes at predetermined intervals on a transparent electrode.
Japanese Unexamined Patent Publication No. 2004-111158 (see claims, 0006 to 0008, FIG. 4 and FIG. 5) Japanese Patent Laying-Open No. 2004-185951 (see claims, stage 0012, and FIG. 1) Japanese Patent Laying-Open No. 2003-133080 (see claims and FIG. 2)

  Providing a plurality of metal bus line electrodes on the transparent electrode as in the light emitting element described in Patent Document 3 is useful for suppressing heat generation during light emission of the organic EL element. However, the light reflectance of the metal bus line electrode is relatively high. For example, when a metal bus line electrode is provided in the light emitting region, the external light reflected by the metal bus line electrode is easily visible. Reflection of external light by the metal bus line electrode is, for example, in a light emitting display panel that displays characters, figures, symbols, etc. for advertisements and promotions, such as the light emitting display panel described in Patent Document 1 or 2. It is desirable to suppress as much as possible because it leads to a reduction in image quality and, in turn, a reduction in appeal effect.

  If the line width of the metal bus line electrode is reduced, it is possible to suppress the external light reflected by the metal bus line electrode from being visually recognized. However, as the line width of the metal bus line electrode is reduced, Since the electric resistance of the metal bus line electrode is increased, there is a problem in that it is difficult to suppress heat generation during light emission of the organic EL element.

  The present invention has been made in view of the above circumstances, and an object of the present invention is to provide a light-emitting display panel that can be manufactured at low cost with high flexibility and image quality and relatively low heat generation during light emission. A display panel manufacturing system and a light emitting display panel manufacturing method are provided.

  The light emitting display panel manufacturing system of the present invention that achieves the above object has a light emitting region and a non-light emitting region, and extends over both the light emitting region and the non light emitting region on one side of a transparent substrate. A transparent electrode is formed, an electrical insulating layer is formed on a region of the transparent electrode corresponding to the non-light emitting region, and an organic light emitting unit is formed on at least a region of the transparent electrode corresponding to the light emitting region And a light emitting display panel manufacturing system in which a back electrode is formed on the organic light emitting unit, and is disposed on the transparent conductive layer on a long transparent substrate having a transparent conductive layer formed on one side. And an auxiliary electrode forming section capable of forming an auxiliary electrode so as to be positioned in the non-light emitting region of each light emitting display panel, and on the transparent conductive layer, the transparent conductive layer Before An insulating layer forming section that does not cover a region corresponding to the light emitting region and can form an electric insulating layer so as to cover the auxiliary electrode, and at least a transparent conductive layer in a region corresponding to the light emitting region. An organic light emitting part forming section capable of forming an organic light emitting part by a printing method, and a state in which the long transparent substrate is bridged from at least the auxiliary electrode forming section to the organic light emitting part forming section. And a transporting means capable of transporting the long transparent base material from the auxiliary electrode forming section side to the organic light emitting unit forming section side (hereinafter referred to as this manufacturing system). Sometimes referred to as “Manufacturing System I”).

  In the light emitting display panel manufactured using this manufacturing system I, an organic EL element is comprised by a transparent electrode, an auxiliary electrode, an organic light emission part, and a back electrode. By using a long transparent film or a transparent sheet as the long transparent substrate, a highly flexible light-emitting display panel can be easily obtained. And if the manufacturing system I of the light emission display panel of this invention is used, the lamination | stacking which consists of a transparent electrode, an auxiliary electrode, an electrically insulating layer, and an organic light emission part among the structural members required in order to produce said light emission display panel. Since a large number of objects can be intermittently or continuously formed on a long transparent substrate, a highly flexible light-emitting display panel can be easily obtained with high productivity.

  In addition, since the auxiliary electrode is formed on the transparent electrode, the conductivity of the entire electrode including the auxiliary electrode and the transparent electrode can be increased. As a result, a light emitting display panel that generates relatively little heat during light emission can be obtained. Obtainable. In the light emitting display panel, since the auxiliary electrode is not distributed in the light emitting region, it is possible to easily suppress the deterioration of the image quality due to the reflection of the external light by the auxiliary electrode.

  For these reasons, according to the light emitting display panel manufacturing system I of the present invention, it is easy to obtain a light emitting display panel having both high flexibility and image quality and relatively little heat generation during light emission at low cost.

  In the light emitting display panel manufacturing system I of the present invention, (1) the hole in which the organic light emitting part forming section can form the hole transport layer by coating the material of the hole transport layer with a printing machine. In the printing machine that includes the transport layer forming portion and constitutes the hole transport layer forming portion, the surface that is in contact with the material of the hole transport layer is formed of a corrosion resistant material against a strong acid (hereinafter, this manufacturing system). Is sometimes referred to as “manufacturing system II”).

  In order to increase the light emission efficiency of the organic EL element, it is desirable that the layer structure is a structure in which a hole transport layer is interposed between the anode and the organic light emitting material layer. Some conductive polymer solutions used to form are strongly acidic. In the production system II of the light emitting display panel of the present invention, the organic light emitting portion forming section includes the hole transport layer forming portion described above, and the hole transport layer in the printing press constituting the hole transport layer forming portion. Because the surface in contact with the material is formed of a material resistant to strong acids, even when the hole transport layer is formed using a strongly acidic conductive polymer solution, the deterioration of the organic light emitting part formation section due to corrosion Can be suppressed. Therefore, according to the light-emitting display panel manufacturing system II of the present invention, it is further easy to obtain a light-emitting display panel that has both flexibility and image quality and generates relatively little heat during light emission at low cost. .

  In any of the light emitting display panel manufacturing systems I and II of the present invention, (2) the organic light emitting part forming section can form the electron transport layer by coating the material of the electron transport layer with a printing machine. In the printing machine that includes the electron transport layer forming portion and that constitutes the electron transport layer forming portion, a surface that is in contact with the material of the electron transport layer is formed of a corrosion resistant material against a strong acid (hereinafter, this manufacturing system is It is sometimes referred to as “manufacturing system III”.

  In order to increase the luminous efficiency of the organic EL element, it is desirable that the layer structure is a structure in which an electron transport layer is interposed between the cathode and the organic light emitting material layer, but the electron transport layer is formed by a printing method. Some of the conductive polymer solutions used for this purpose are strongly acidic. In the light emitting display panel manufacturing system III of the present invention, the organic light emitting portion forming section includes the electron transport layer forming portion, and the electron transport layer material in the printing press constituting the electron transport layer forming portion Since the contact surface is made of a corrosion-resistant material against strong acid, even when an electron transport layer is formed using a strongly acidic conductive polymer solution, it is possible to suppress deterioration of the organic light emitting part forming section due to corrosion. it can. Therefore, according to the light emitting display panel manufacturing system III of the present invention, it is further easy to obtain a light emitting display panel that has both flexibility and image quality and generates relatively little heat during light emission at low cost. .

  In any of the light emitting display panel manufacturing systems I to III of the present invention, (3) a conductive layer forming section capable of forming a transparent conductive layer on a long transparent substrate is further provided. A section is disposed upstream of the auxiliary electrode forming section in the transfer means, and the transfer means extends at least from the conductive layer forming section to the organic light emitting section forming section. The long transparent base material can be transferred from the conductive layer forming section side to the organic light emitting part forming section side in a state where the material is bridged (hereinafter, this manufacturing system is referred to as “manufacturing system IV”) There is).

  Today, a transparent resin film or transparent resin sheet made of only a transparent resin, a transparent resin film or transparent resin sheet having a transparent conductive layer formed on one side, and a transparent resin film or transparent resin sheet having a gas barrier layer formed on one side Various forms of transparent substrates such as transparent resin films or transparent resin sheets having a transparent conductive layer formed on one side through a gas barrier layer have been developed.

  In the light emitting display panel manufacturing system IV of the present invention, since the manufacturing system IV includes the conductive layer forming section described above, even if a long transparent substrate having no transparent conductive layer is used, it is flexible. Therefore, it is easy to obtain a light-emitting display panel that has both high performance and image quality and generates relatively little heat during light emission at low cost.

  A method for manufacturing a light emitting display panel according to the present invention that achieves the above object has a light emitting region and a non-light emitting region, and extends over both the light emitting region and the non light emitting region on one side of a transparent substrate. A transparent electrode is formed, an electrical insulating layer is formed on a region of the transparent electrode corresponding to the non-light emitting region, and an organic light emitting unit is formed on at least a region of the transparent electrode corresponding to the light emitting region A method of manufacturing a light-emitting display panel in which a back electrode is formed on the organic light-emitting portion, wherein a long transparent substrate having a transparent conductive layer formed on one side is positioned on the transparent conductive layer. And forming an auxiliary electrode so as to be located in the non-light-emitting region of each light-emitting display panel, and corresponding to the light-emitting region of the transparent conductive layer on the transparent conductive layer Does not cover the area to be A step of forming an electrical insulating layer so as to cover the auxiliary electrode, and a step of forming an organic light emitting part by a printing method so as to cover at least the transparent conductive layer in a region corresponding to the light emitting region, The auxiliary electrode, the electrical insulating layer, and the organic light emitting part are in-line by continuously transferring the long transparent base material from the step of forming the auxiliary electrode to the step of forming the organic light emitting part. It is formed by these.

  According to the present invention, the long transparent substrate is continuously transferred at least from the step of forming the auxiliary electrode to the step of forming the organic light emitting unit, whereby the auxiliary electrode, the electrical insulating layer, and the organic light emitting unit are transferred. Is formed in-line, so that the productivity of the light-emitting display panel can be increased and the number of windings can be reduced, so that damage to each layer laminated on the flexible substrate can be reduced. There is an advantage.

  In the method for manufacturing a light emitting display panel according to the present invention, the step of forming the organic light emitting portion includes a step of forming a hole transport layer, a step of forming an organic light emitting material layer, and a step of forming an electron transport layer. In this order. According to the present invention, the hole transport layer, the organic light emitting material layer, and the electron transport layer can be sequentially formed in-line, so that the layers can be laminated more efficiently than in the case of forming off-line with a single wafer. As a result, the influence of the forming atmosphere can be reduced.

  In the manufacturing method of the light emission display panel of this invention, it can comprise so that it may have the process of forming a transparent conductive layer on a transparent base material before the process of forming the said auxiliary electrode. According to this invention, the transparent conductive layer can also be formed in-line.

  As described above, according to the light emitting display panel manufacturing system of the present invention, it is easy to obtain a light emitting display panel that has both flexibility and image quality and generates relatively little heat during light emission at low cost. It becomes easy to provide a light emitting display panel for various uses, such as a light emitting display panel for advertising having a high appeal effect, a light emitting display panel for electrical decoration having a high appeal effect, and a light emitting display panel for high-quality decoration.

  Further, according to the method for manufacturing a light emitting display panel of the present invention, at least the auxiliary electrode, the electrical insulating layer, and the organic light emitting portion are formed in-line, so that the productivity of the light emitting display panel can be increased and the number of windings can be increased. Can be reduced. As a result, damage to each layer laminated on the flexible substrate can be reduced.

  Hereinafter, a light emitting display panel manufacturing system and a light emitting display panel manufacturing method of the present invention will be described. In the following, in order to facilitate understanding of the functions of each section of the light emitting display panel manufacturing system, first, a diagram of a configuration of the light emitting display panel that can be manufactured using the light emitting display panel manufacturing system of the present invention is shown. 1 and FIG. 2, and then, the form of the light emitting display panel manufacturing system of the present invention will be described with reference to the reference numerals used in FIG. 1 or 2 as appropriate.

FIG. 1 is a schematic view showing an example of a light-emitting display panel that can be manufactured by using the light-emitting display panel manufacturing system of the present invention, and is a schematic view when the display surface is viewed from the front. The illustrated light-emitting display panel 20 has a combination of eight light-emitting regions R _{1 to} R ₈ and six non-light-emitting regions NR _{1 to} NR _{6 so as} to move a character string “ABC” and a character string “A” up and down. Display in stages. In FIG. 1, in order to facilitate distinguishing a light emitting region _R 1 to R ₈ and a non-light-emitting region _NR 1 _{~NR 6,} are denoted by smudging the respective non-emitting regions _NR 1 _{~NR 6.} Reference numerals 7a and 7b in the figure indicate auxiliary electrodes to be described later.

FIG. 2 is a schematic view of a section taken along line II-II shown in FIG. As shown in the figure, in the light emitting display panel 20, a transparent electrode 5 is formed on one side of a transparent substrate 1 with a gas barrier layer 3 interposed therebetween. On the transparent electrode 5, the non-emission region NR ₁ so as to be positioned (see FIG. 1) the auxiliary electrodes 7a, 7b are formed, a non-emission region _NR 1 of the transparent electrode 5 ～NR ₆ (FIG. 1 One electrical insulating layer is formed on each region corresponding to the reference). In FIG. 2, three electrical insulating layers 9a, 9c, 9d appear. The auxiliary electrodes 7a and 7b are covered with an electrical insulating layer 9a. Hereinafter, the electrical insulating layer provided in the light emitting display panel 20 is collectively referred to as “electrical insulating layer 9”.

  An organic light emitting unit 11 is formed on the electrical insulating layer 9 and on the transparent electrode 5 exposed without being covered by the electrical insulating layer 9. The first back electrode 13 a and the second back surface are formed on the organic light emitting unit 11. The electrodes 13b are formed in this order to form a back electrode 13 having a two-layer structure. Further, a sealing layer 15 is formed so as to cover the exposed surface of the back electrode 13 and the exposed surface of the organic light emitting unit 11. The sealing layer 15 has a laminated structure in which a gas barrier layer 15b is provided on a flexible base material 15a and a bonding agent layer 15c is provided on the gas barrier layer 15b. It is arranged with the inside.

<Manufacturing system (first form)>
FIG. 3 is a schematic diagram showing an example of a light emitting display panel manufacturing system according to the present invention. The light emitting display panel manufacturing system 200 shown in the figure includes a conductive layer forming section S1, an auxiliary electrode forming section S2, an insulating layer forming section S3, an organic light emitting portion forming section S4, and a transfer of a long transparent substrate. And means TM. The transfer means TM has a supply device (not shown), a take-up device (not shown), and a transfer path that connects the supply device and the take-up device. A transparent base material is mounted on a supply device, one end of the transparent base material is passed over to a winding device, and the long transparent base material is transferred by sequentially winding up the winding device. The conductive layer forming section S1, the auxiliary electrode forming section S2, the insulating layer forming section S3, and the organic light emitting unit forming section S4 are arranged in the transfer path in this order from the supply device side to the winding device side. Yes.

  When the light emitting display panel 20 is to be mass-produced using the manufacturing system 200, a large gas barrier layer (the gas barrier layer 3 shown in FIG. 2) that is the basis of the gas barrier layer 3 (see FIG. 2) is distinguished. Therefore, hereinafter, a long transparent base roll 100 (hereinafter referred to as “base film roll 100”) on which “gas barrier layer 3a” is formed on one side is referred to as a feeding device TM. Attach to. Then, one end of a long transparent base material (hereinafter referred to as “base film 100a”) is pulled out from the base film roll 100 and is extended to the winding device, and the base film 100a is sequentially wound by the winding device. By using the roll 170, the base film 100a is transferred. In the process of transferring the base film 100a, a transparent conductive layer, an auxiliary electrode, an electrical insulating layer, and an organic light emitting part are sequentially formed on the base film 100a in this order. The solid line arrows in FIG. 3 indicate the transfer direction of the base film 100a, and the broken line arrows indicate the rotation direction of the roll or member.

  As the base film 100a, a gas barrier layer 3a is provided on one side of a transparent resin molded into a long film or sheet, or a gas barrier is provided on one side of a long transparent glass sheet having a thickness of about 100 μm or less. A layer provided with the layer 3a can be used. A protective plastic layer for mechanically protecting the transparent glass sheet may be provided on one surface of the transparent glass sheet.

  When using a transparent resin formed on a long film or sheet provided with a gas barrier layer 3a on one side as a long transparent substrate, the transparent resin includes fluorine resin, polyethylene, polypropylene, poly Vinyl chloride, polyvinyl fluoride, polystyrene, ABS resin, polyamide, polyacetal, polyester, polycarbonate, modified polyphenylene ether, polysulfone, polyarylate, polyetherimide, polyamideimide, polyimide, polyphenylene sulfide, liquid crystalline polyester, polyethylene terephthalate, polybutylene Terephthalate, polyethylene naphthalate, polyoxymethylene, polyethersulfone, polyetheretherketone, polyacrylate, acrylonitrile-styrene resin, phenol Lumpur resins, urea resins, melamine resins, unsaturated polyester resins, epoxy resins, polyurethane, silicone resins, and amorphous polyolefin. The transparent resin is particularly preferably one that is excellent in solvent resistance, heat resistance, light resistance, and gas barrier properties (meaning barrier properties against water vapor and oxygen) even when molded into a film or sheet.

  If the film thickness of the base film 100a excluding the gas barrier layer 3a is less than about 50 μm, the intermediate product is likely to be deformed or damaged during the manufacturing process of the light emitting display panel 20. The upper limit value of the film thickness of the base film 100a can be appropriately selected according to the intended use of the light emitting display panel 20, the flexibility required for the light emitting display panel 20, and the like.

  As described above, the gas barrier layer 3a is a source of the gas barrier layer 3 (see FIG. 2) in the light emitting display panel 20, and the gas barrier layer 3 in the light emitting display panel 20 has a transparent base material 1 containing oxygen and moisture. This is a layer for preventing light from penetrating and entering the organic light emitting unit 11. The gas barrier layer 3a that is the source of such a gas barrier layer 3 is, for example, silicon oxide, aluminum oxide, titanium oxide, yttrium oxide, germanium oxide, zinc oxide, magnesium oxide, calcium oxide, boron oxide, strontium oxide, barium oxide, It is formed of inorganic oxides such as lead oxide, zirconium oxide, sodium oxide, lithium oxide, and potassium oxide, inorganic nitrides such as silicon nitride, or oxynitrides such as silicon oxynitride.

  The gas barrier layer 3a in the base film 100a may be formed intermittently with a shape and size corresponding to the shape and size of the gas barrier layer 3 in one light emitting display panel 20, or a large number of light emission Only one large one corresponding to the display panel 20 may be formed. The thickness of the gas barrier layer 3a is such that when the gas barrier layer 3 of the light emitting display panel 20 is used, oxygen and moisture can be prevented from entering the organic light emitting unit 11 while keeping the flexibility of the light emitting display panel 20 good. Therefore, it is preferable to select appropriately within a range of about 0.01 to 0.5 μm. Such a gas barrier layer 3a can be formed by, for example, physical vapor deposition (PVD).

  Hereinafter, each of the conductive layer forming section S1, the auxiliary electrode forming section S2, the insulating layer forming section S3, and the organic light emitting unit forming section S4 illustrated in FIG. 3 will be described in detail.

(1) Conductive layer forming section;
The conductive layer forming section S1 is a transparent conductive layer that becomes the transparent electrode 5 (see FIG. 2) on a predetermined surface of the base film 100a, that is, on the surface on which the gas barrier layer 3a (not shown) is formed. Are sections that sequentially form. In the illustrated example, a gravure printing machine including a plate cylinder 102a, an impression cylinder 102b, a feed roll 106 that supplies conductive ink or conductive paste from an ink fountain 104 to the plate cylinder 102a, and a first heating device 108 is provided. 110 constitutes a conductive layer forming section S1. The conductive ink or conductive paste applied by the plate cylinder 102a is heated by the first heating device 108 and solidified or sintered to form a transparent conductive layer.

  In this conductive layer forming section S1, the transparent conductive layer having a shape and size corresponding to the shape and size of the transparent electrode 5 in each light emitting display panel 20 is intermittently or in many light emitting display panels 20. Corresponding large transparent conductive layers are formed sequentially from the edges. Specific examples of the transparent conductive layer that can be formed include thin film electrode materials such as indium tin oxide (ITO), indium oxide, indium zinc oxide (IZO), gold, and polyaniline. Among these, indium tin oxide (ITO) and indium zinc oxide (IZO), which are transparent oxides, are preferably used. The film thickness of the transparent conductive layer can be appropriately selected within the range of about 0.005 to 0.5 μm depending on the material.

  As a material for the transparent conductive layer, for example, a strongly acidic material such as poly (3,4) ethylenedioxythiophene / polystyrene sulfonate (abbreviation PEDOT / PSS, manufactured by Bayer, trade name: Baytron P AI4083, commercially available as an aqueous solution) is used. In this case, it is preferable to form the surface in contact with the strong acid material in the gravure printing machine 110 with a corrosion resistant material against strong acid, for example, gold, silver, platinum or the like. At this time, the entire member in contact with the strong acid material can be formed of the corrosion resistant material, but it is more economical to form a coating of the corrosion resistant material at a predetermined location.

(2) Auxiliary electrode formation section;
The auxiliary electrode formation section S2 is located on the transparent conductive layer formed in the conductive layer formation section S1 so as to be located in the non-light-emitting region NR ₁ (see FIG. 1) in each light-emitting display panel 20. 7b is a section forming 7b. In the illustrated example, the auxiliary electrode forming section S <b> 2 is configured by the screen printer 120 and the second heating device 125. The screen printing machine 120 includes a table 120a, a cylindrical screen plate 120b, and a squeegee 120c disposed in the screen plate 120b, and the conductive ink or the conductive material applied by the screen printing machine 120. The paste is heated by the second heating device 125 to solidify or sinter and become auxiliary electrodes 7a and 7b.

  In the auxiliary electrode formation section S2, auxiliary electrodes 7a and 7b corresponding to the individual light emitting display panels 20 are sequentially formed. Depending on the shape of the auxiliary electrode to be formed, large auxiliary electrodes corresponding to a large number of light emitting display panels 20 can be formed sequentially from the end. Specific examples of the auxiliary electrode that can be formed include low resistance materials such as Cu, Al, Au, conductive paste (for example, silver paste), Cr, Ag, and the like.

The film thickness and line width of the auxiliary electrodes 7a and 7b are such that the volume resistivity of the auxiliary electrodes 7a and 7b and the transparent electrode 5 (see FIG. 2) in the light-emitting display panel 20 is 1 × 10 ⁻⁶ to 1 × 10. ^-4 as appropriate depending on the electrical characteristics of the transparent electrode 5, the size of the transparent electrode 5, the material of the auxiliary electrodes 7a and 7b, and the shape of the auxiliary electrodes 7a and 7b so that they are in the range of about ^-4 Ω · cm. It is preferable to select. However, when selecting the film thickness of the auxiliary electrodes 7a and 7b, the film thickness of the electric insulating layer is also taken into consideration so that the entire auxiliary electrode can be covered with the electric insulating layer described later.

(3) Insulating layer formation section;
The insulating layer forming section S3 is exposed without covering the regions corresponding to the light emitting regions R _{1 to} R ₈ (see FIG. 1) of the transparent conductive layer corresponding to each light emitting display panel 20 and is formed as an auxiliary electrode forming section. The auxiliary electrode formed in S2 is a section that covers the transparent conductive layer so as to cover the auxiliary electrode. In the illustrated example, the roll coater 130, the first staying device 133, the exposure / development device 135, and the second staying device 137 constitute an insulating layer forming section S3.

  The roll coater 130 is a pair of rolls 130a and 130b, and a feed roll that can supply a photocurable resin composition (including an ultraviolet curable resin composition) or an electron beam curable resin composition to the roll 130a. 130c, and the layer of the resin composition formed by the roll coater 130 is patterned by the exposure / development device 135 to form a predetermined pattern of an electrically insulating layer. The exposure / development apparatus 135 performs the above patterning by photolithography or electron beam lithography, and further performs post-baking. In order to suppress deformation of the light emitting display panel 20 during the manufacturing process of the light emitting display panel 20, the thermal expansion coefficient between the transparent resin or transparent glass constituting the base film 100a and the electrical insulating layer is approximated as much as possible. It is preferable to make it.

  The first staying device 133 absorbs the difference in processing speed between the roll coater 130 and the exposure / development device 135 and contributes to the production speed adjustment in the manufacturing system 200, and the second staying device 137 is the exposure / development device 135. And the difference in processing speed with the organic light emitting section forming section S4 described later is absorbed and contributes to the production speed adjustment in the manufacturing system 200. In addition, the 2nd retention device 137 can also be used as the structural member of organic light emission part formation section S4, and can also be considered as an independent structural element which does not belong to any section.

  In the insulating layer formation section S3, the shape and the shape of the electrical insulating layer 9 (see FIG. 2; only three electrical insulating layers 9a, 9c, and 9d appear in FIG. 2) in each light-emitting display panel 20. It is also possible to intermittently form a predetermined pattern of electrical insulation layer having a shape and size corresponding to the size, or to form a large electrical insulation layer of a predetermined pattern corresponding to a large number of light emitting display panels 20 from the end thereof. It can also be formed sequentially. The thickness of the electrical insulating layer is such that the transparent electrode 5 and the back electrode 13 are locally insulated in the light emitting display panel 20 and the auxiliary electrodes 7a and 7b and the back electrode 13 can be insulated. Depending on the material of the insulating layer, the film thickness of the auxiliary electrodes 7a and 7b, the driving voltage of the light emitting display panel 20, etc., it can be selected appropriately within a range of about 0.5 to 7.0 μm.

(4) Organic light emitting part formation section;
The organic light emitting unit formation section S4 covers at least a region corresponding to the light emitting regions R _{1 to} R ₈ (see FIG. 1) among the transparent conductive layers corresponding to the individual light emitting display panels 20, so as to cover the hole transport layer. , A section for forming an organic light emitting portion comprising an organic light emitting material layer and an electron transport layer. In the illustrated example, a hole transport layer forming unit 145 that forms a hole transport layer, an organic light emitting material layer forming unit 155 that forms an organic light emitting material layer, an electron transport layer forming unit 165 that forms an electron transport layer, Thus, an organic light emitting section forming section S4 is configured.

  The hole transport layer forming unit 145 includes a plate cylinder 140a, an impression cylinder 140b, a doctor blade 140c that removes excess ink (material of the hole transport layer) from the plate cylinder 140a, and a third heating device 140d. The gravure printing machine 140 is configured. The hole transport layer material applied by the plate cylinder 140a is heated and solidified or cured by the third heating device 140c to form a hole transport layer.

  Hole transport material such as phthalocyanine, naphthalocyanine, porphyrin, oxadiazole, triphenylamine, triazole, imidazole, imidazolone, pyrazoline, tetrahydroimidazole, hydrazone, stilbene or butadiene, or derivatives thereof As those usually used, it can be used. Also, commercially available as a composition for forming a hole transport layer, for example, poly (3,4) ethylenedioxythiophene / polystyrene sulfonate (abbreviation PEDOT / PSS, manufactured by Bayer, trade name: Baytron P AI4083, marketed as an aqueous solution. When a strongly acidic material such as.) Is used, the surface in contact with the strongly acidic material in the gravure printing machine 140 is preferably formed of a corrosion resistant material against strong acid, such as gold, silver, platinum or the like. At this time, the entire member in contact with the strong acid material can be formed of the corrosion resistant material, but it is more economical to form a coating of the corrosion resistant material at a predetermined location.

  The organic light emitting material layer forming unit 155 includes a plate cylinder 150a, a blanket cylinder 150b, an impression cylinder 150c, a doctor blade 150d that removes excess ink (organic light emitting material) from the plate cylinder 150a, a fourth heating device 150e, The gravure offset printing machine 150 is provided. The organic light emitting material coated on the hole transport layer from the plate cylinder 150a through the blanket cylinder 150b is heated and solidified or cured by the fourth heating device 150e to form an organic light emitting material layer.

  As the organic light emitting material, various materials used for organic EL elements can be used. In order to form an organic EL element having excellent light emitting characteristics and element lifetime, a low molecular weight organic light emitting element can be used. It is preferable to use a polymer organic light emitting material rather than the material.

  The electron transport layer forming unit 165 is a gravure including a plate cylinder 160a, an impression cylinder 160b, a doctor blade 160c that removes excess ink (material of the electron transport layer) from the plate cylinder 160a, and a fifth heating device 160d. The printer 160 is configured. The material of the electron transport layer applied on the organic light emitting material layer by the plate cylinder 160a is heated by the fifth heating device 160d to be solidified or cured to become an electron transport layer.

  As the material for the electron transport layer, anthraquinodimethane, fluorenylidenemethane, tetracyanoethylene, fluorenone, diphenoquinone oxadiazole, anthrone, thiopyran dioxide, diphenoquinone, benzoquinone, malononitrile, niditrobenzene, nitroanthraquinone, What is normally used as an electron transport material, such as maleic anhydride or perylenetetracarboxylic acid, or a derivative thereof, can be used. When using a strongly acidic material, it is preferable to form the surface in contact with the strongly acidic material in the gravure printing machine 160 with a corrosion resistant material against strong acid, such as gold, silver, platinum, or the like. At this time, the entire member in contact with the strong acid material can be formed of the corrosion resistant material, but it is more economical to form a coating of the corrosion resistant material at a predetermined location.

  In the organic light emitting unit formation section S4, an organic light emitting unit having a predetermined pattern having a shape and size corresponding to the shape and size of the organic light emitting unit 11 (see FIG. 2) in each light emitting display panel 20 is intermittently formed. It is also possible to form a large organic light emitting portion having a predetermined pattern corresponding to a large number of light emitting display panels 20 sequentially from the end thereof. The thickness of the organic light emitting unit 11 (consisting of a hole transport layer, an organic light emitting material layer, and an electron transport layer) can be appropriately selected within a range of about 0.1 to 2.5 μm. Note that reference numerals 180a and 180b in FIG. 3 respectively indicate guide rolls that constitute a transfer path in the transfer means TM.

  According to the light emitting display panel manufacturing system 200 described above, the transparent electrode 5, the auxiliary electrodes 7 a and 7 b, the electrical insulating layer 9, and the organic light emitting unit 11 in each light emitting display panel 20 (see FIG. 1 or 2). It is possible to obtain, in the state of a roll 170, a long product in which a laminate having a laminated structure corresponding to is formed on the base film 100a intermittently or continuously. And after obtaining the roll 170, the back electrode 13 is formed on the laminated body corresponding to each light emitting display panel 20, and furthermore, the exposed surface of the back electrode 13 and the exposed surface of the organic light emitting unit 11 are covered. By forming the sealing layer 15, the light emitting display panel 20 can be mass-produced. Before forming the back electrode 13, after forming the back electrode 13 (before forming the sealing layer 15), or after forming the sealing layer 15, the sheet is cut into a desired size. Of course, the light emitting display panel 20 is mass-produced by forming the back electrode 13 and the sealing layer 15 by continuous processing or by single wafer processing on the downstream side of the organic light emitting section forming section S4 without obtaining the roll 170. It is possible.

  In the light emitting display panel 20 manufactured using the manufacturing system 200, an organic EL element is configured by the transparent electrode 5, the auxiliary electrodes 7 a and 7 b, the organic light emitting unit 11, and the back electrode 13. In the light emitting display panel 20, since the organic EL element having the above configuration is formed on the transparent substrate 1 in the form of a film or a sheet, the flexibility thereof can be easily improved. And if the manufacturing system 200 is used, the laminated body which consists of the transparent electrode 5, auxiliary electrode 7a, 7b of the structural members required in order to produce the light emission display panel 20, the electrical insulating layer 9, and the organic light emission part 11 will be shown. Since a large number of long transparent substrates (base film 100a) can be formed intermittently or continuously, it is easy to obtain the light-emitting display panel 20 with high productivity.

In addition, since the auxiliary electrodes 7a and 7b are formed on the transparent electrode 5 in the light emitting display panel 20, the conductivity of the entire electrode including the transparent electrode 5 and the auxiliary electrodes 7a and 7b can be increased. , Heat generation during light emission can be suppressed. Then, the auxiliary electrode 7a to the light-emitting display panel 20 in the light-emitting region R ₁ to R in _8, since 7b is not distributed, easily suppress auxiliary electrode 7a, a reduction in image quality due to reflection of external light on the 7b can do.

  For these reasons, according to the manufacturing system 200, it is easy to obtain a light-emitting display panel having both high flexibility and image quality and relatively low heat generation during light emission at low cost. In order to suppress the deterioration of the organic light emitting part, particularly the organic light emitting material layer, in the manufacturing process, the entire manufacturing system 200 or the organic light emitting part forming section S4 is operated in (1) an inert gas atmosphere such as a nitrogen gas atmosphere. (2) It is preferable to operate in an atmosphere having a dew point of water of −10 ° C. or lower, or (3) to operate in an environment in which the amount of light in the green wavelength range and shorter wavelength range is suppressed.

<Manufacturing system (modification)>
The light emitting display panel manufacturing system of the present invention is not limited to the light emitting display panel manufacturing system 200 of the first embodiment described above. Various changes, modifications, combinations, and the like are possible depending on the form, application, grade, and the like of the light emitting display panel to be finally obtained.

  For example, a long transparent resin film or transparent resin sheet having a transparent conductive layer formed on one side, or a long transparent glass sheet having a transparent conductive layer formed on one side is used as a long transparent substrate. In some cases, the conductive layer formation section S1 can be omitted. The long transparent substrate preferably has a gas barrier layer formed in advance, but the type of transparent resin or transparent glass constituting the long transparent substrate and the intended use of the light-emitting display panel to be obtained Alternatively, the gas barrier layer may be omitted depending on the grade or the like. When using a transparent substrate on which a gas barrier layer has been formed in advance, the transparent conductive layer is preferably formed on the gas barrier layer, but the transparent conductive layer is formed on the surface opposite to the surface on which the gas barrier layer is formed. It is also possible to do.

  The shape of the auxiliary electrode in plan view in the light emitting display panel manufactured using the light emitting display panel manufacturing system of the present invention is limited to a rectangular frame shape such as the auxiliary electrodes 7a and 7b shown in FIG. It is not something. The shape of the auxiliary electrode in plan view is a rectangular frame depending on the shape of a pattern such as characters, figures, symbols, patterns, still images to be displayed on the light-emitting display panel, and the arrangement of parts constituting the pattern. Various closed shapes other than the shape, a straight shape, a curved shape, a planar shape, and the like are appropriately selected. Moreover, the formation method of an auxiliary electrode is not limited to the printing method, The physical vapor deposition method (PVD) using the vapor deposition mask of a predetermined shape can also be applied. The configuration of the auxiliary electrode forming section can be appropriately selected according to the method of forming the auxiliary electrode.

  In addition, the light emitting display panel manufactured using the light emitting display panel manufacturing system of the present invention displays a pattern such as a character, a figure, a symbol, a pattern, and a still image by a combination of a light emitting area and a non-light emitting area. In addition to the configuration in which the pattern to be displayed itself shines, the pattern to be displayed can be configured to shine around without being lit. The shape of the electrical insulating layer formed in the insulating layer forming section is appropriately selected according to the distribution form of the light emitting regions in the light emitting display panel to be obtained.

  The configuration of the organic light emitting unit forming section can be appropriately changed according to the layer configuration of the organic light emitting unit to be formed. For example, the organic light emitting part can have a single-layer structure composed only of an organic light emitting material layer, or a two-layer structure having an organic light emitting material layer and a hole transport layer or an electron transport layer, A three-layer structure having an organic light emitting material layer, a hole transport layer, and an electron transport layer can also be used. Furthermore, the layer having both the function as the organic light emitting material layer and the function as the hole transport layer or the function as the electron transport layer is used alone or in combination with the hole transport layer or the electron transport layer. A light emitting unit can also be configured. In the organic light emitting section forming section, it is desirable to use a number of printing machines or coaters corresponding to the number of layers of the organic light emitting section to be formed.

  Further, the configuration of the organic light emitting section forming section can be appropriately changed depending on whether the light emitting display panel to be obtained is a monocolor display, a multicolor display, or a full color display. For example, in order to obtain a light emitting display panel for multicolor display or full color display, a plurality of types of organic light emitting materials having different emission colors are prepared, and a plurality of organic light emitting material layers or organic layers having different emission colors are prepared. Since it is necessary to form the light emitting portions at predetermined positions, it is desirable to configure the organic light emitting portion forming section using a number of printing machines or coaters corresponding to the light emitting portions. At this time, it is preferable to provide a partition in advance on the transparent electrode using a resin material between different organic light emitting material layers or organic light emitting portions. Since the partition can be formed by a method such as thick film printing, photolithography, or electron beam lithography, it is desirable to configure the organic light emitting unit forming section using an apparatus for forming the partition. Note that, even if the light-emitting display panel to be obtained is any of monocolor display, multicolor display, and full-color display, an organic EL element having high luminance is formed while preventing a short circuit between the transparent electrode and the back electrode. From the viewpoint, the film thickness of the organic light emitting portion is preferably selected as appropriate within a range of about 0.1 to 2.5 μm.

  When using a printing method to form a transparent conductive layer, auxiliary electrode, electrical insulating film, or organic light-emitting part, the printing machine or coater to be used is gravure printing depending on the shape of the material to be formed and its material. A machine, a gravure offset printing machine, a screen printing machine, a flexographic printing machine, an offset printing machine, a roll coater, a die coater, a gravure coater, a micro gravure coater, and the like can be appropriately selected. Regardless of which printing machine or coater is used, when a strongly acidic material is to be applied, the surface in contact with the strongly acidic material in the printing machine or coater should be a corrosion resistant material against strong acid, such as gold, silver, platinum. It is preferable to form by such as.

It is the schematic which shows an example of the light emission display panel which can be manufactured using the manufacturing system of the light emission display panel of this invention, and is a schematic view when a display surface is seen from the front. It is the schematic of the II-II line cross section shown in FIG. It is the schematic which shows an example of the manufacturing system of the light emission display panel of this invention.

Explanation of symbols

DESCRIPTION OF SYMBOLS 1 Transparent base material 3 Gas barrier layer 5 Transparent electrode 7a, 7b Auxiliary electrode 9a, 9c, 9d Electrical insulation layer 11 Organic light emission part 13 Back electrode 13a 1st back electrode 13b 2nd back electrode 15 Sealing layer 15a It has flexibility Base material 15b Gas barrier layer 15c Binder layer 20 Light emitting display panel 100 Base film roll 100a Long transparent base material (base film)
102a plate cylinder 102b impression cylinder 104 ink fountain 106 feed roll 108 first heating device 110 gravure printing machine 120 screen printing machine 120a table 120b screen plate 120c squeegee 125 second heating device 130 roll coater 130a, 130b roll 130c field roll 133 first Retention device 135 Exposure / development device 137 Second retention device 140 Printing machine constituting hole transport layer forming unit 140a Plate cylinder 140b Impression cylinder 140c Doctor blade 140d Third heating device 145 Hole transport layer forming unit 150 Organic light emission Printing machine constituting material layer forming section 150a Plate cylinder 150b Blanket cylinder 150c Impression cylinder 150d Doctor blade 150e Fourth heating device 155 Organic light emitting material layer forming section 160 Electron transport layer forming section Printing machine 160a plate cylinder 160b constitutes a pressure drum 160c doctor blade 160d fifth heating unit 165 electron transport layer formation section 170 rolls 180a, 180b guide roll 200 manufacturing system R ₁ to R ₈ emitting region NR ₁ ~NR ₆ non Light emitting region S1 Conductive layer forming section S2 Auxiliary electrode forming section S3 Insulating layer forming section S4 Organic light emitting part forming section TM Transporting means

Claims (7)

A transparent electrode is formed on one surface of the transparent substrate so as to extend over both the light emitting region and the non-light emitting region, and the light emitting region and the non-light emitting region are formed on the non-light emitting region of the transparent electrode. A light emitting display in which an electrically insulating layer is formed on a corresponding region, an organic light emitting portion is formed on at least a region of the transparent electrode corresponding to the light emitting region, and a back electrode is formed on the organic light emitting portion A panel manufacturing system,
An auxiliary electrode on a long transparent substrate having a transparent conductive layer formed on one side so as to be positioned on the transparent conductive layer and in the non-light-emitting region of each light-emitting display panel An auxiliary electrode forming section that can be formed, and
On the transparent conductive layer, an insulating layer forming section capable of forming an electric insulating layer so as not to cover a region corresponding to the light emitting region of the transparent conductive layer and to cover the auxiliary electrode;
An organic light emitting portion forming section capable of forming an organic light emitting portion by a printing method so as to cover at least the transparent conductive layer in a region corresponding to the light emitting region;
The organic light emitting unit is formed from the auxiliary electrode forming section side in a state where the long transparent base material is bridged at least from the auxiliary electrode forming section to the organic light emitting unit forming section. A light emitting display panel manufacturing system, comprising: a transporting means capable of transporting to the section side.   The organic light emitting part forming section includes a hole transporting layer forming part capable of forming a hole transporting layer by coating a material of the hole transporting layer with a printing machine, and constitutes the hole transporting layer forming part 2. The light emitting display panel manufacturing system according to claim 1, wherein a surface in contact with the material of the hole transport layer in the printing press is formed of a corrosion resistant material against a strong acid.   The organic light emitting portion forming section includes an electron transport layer forming portion that can form an electron transport layer by applying a material of an electron transport layer with a printing machine, and constitutes the electron transport layer forming portion. 3. The light emitting display panel manufacturing system according to claim 1, wherein a surface in contact with the material of the electron transport layer in the printing press is formed of a corrosion resistant material against a strong acid. It further has a conductive layer forming section capable of forming a transparent conductive layer on a long transparent substrate, and the conductive layer forming section is disposed upstream of the auxiliary electrode forming section in the transfer means. And
In a state where the transporting unit spans the long transparent substrate from at least the conductive layer forming section to the organic light emitting unit forming section, the long transparent substrate is removed from the conductive layer forming section side. The light emitting display panel manufacturing system according to claim 1, wherein the light emitting display panel can be transferred to the organic light emitting unit forming section side. A transparent electrode is formed on one surface of the transparent substrate so as to extend over both the light emitting region and the non-light emitting region, and the light emitting region and the non-light emitting region are formed on the non-light emitting region of the transparent electrode. A light emitting display in which an electrically insulating layer is formed on a corresponding region, an organic light emitting portion is formed on at least a region of the transparent electrode corresponding to the light emitting region, and a back electrode is formed on the organic light emitting portion A method of manufacturing a panel,
An auxiliary electrode on a long transparent substrate having a transparent conductive layer formed on one side so as to be positioned on the transparent conductive layer and in the non-light-emitting region of each light-emitting display panel Forming a step;
Forming an electrically insulating layer on the transparent conductive layer so as not to cover a region corresponding to the light emitting region of the transparent conductive layer and to cover the auxiliary electrode;
Forming an organic light emitting part by a printing method so as to cover at least the transparent conductive layer in a region corresponding to the light emitting region,
The auxiliary electrode, the electrical insulating layer, and the organic light emitting part are in-line by continuously transferring the long transparent base material from the step of forming the auxiliary electrode to the step of forming the organic light emitting part. A method for manufacturing a light-emitting display panel, wherein   6. The step of forming the organic light emitting part includes a step of forming a hole transport layer, a step of forming an organic light emitting material layer, and a step of forming an electron transport layer in this order. The manufacturing method of the light emission display panel of description. The method for producing a light-emitting display panel according to claim 5, further comprising a step of forming a transparent conductive layer on a transparent substrate before the step of forming the auxiliary electrode.

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