WO2016031877A1 - 有機エレクトロルミネッセンス素子 - Google Patents
有機エレクトロルミネッセンス素子 Download PDFInfo
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- WO2016031877A1 WO2016031877A1 PCT/JP2015/074077 JP2015074077W WO2016031877A1 WO 2016031877 A1 WO2016031877 A1 WO 2016031877A1 JP 2015074077 W JP2015074077 W JP 2015074077W WO 2016031877 A1 WO2016031877 A1 WO 2016031877A1
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/84—Passivation; Containers; Encapsulations
- H10K50/842—Containers
- H10K50/8423—Metallic sealing arrangements
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/02—Details
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/02—Details
- H05B33/04—Sealing arrangements, e.g. against humidity
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/84—Passivation; Containers; Encapsulations
- H10K50/842—Containers
- H10K50/8426—Peripheral sealing arrangements, e.g. adhesives, sealants
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/80—Constructional details
- H10K50/84—Passivation; Containers; Encapsulations
- H10K50/844—Encapsulations
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K77/00—Constructional details of devices covered by this subclass and not covered by groups H10K10/80, H10K30/80, H10K50/80 or H10K59/80
- H10K77/10—Substrates, e.g. flexible substrates
- H10K77/111—Flexible substrates
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K2102/00—Constructional details relating to the organic devices covered by this subclass
- H10K2102/301—Details of OLEDs
- H10K2102/311—Flexible OLED
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K2102/00—Constructional details relating to the organic devices covered by this subclass
- H10K2102/301—Details of OLEDs
- H10K2102/351—Thickness
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/10—Deposition of organic active material
- H10K71/12—Deposition of organic active material using liquid deposition, e.g. spin coating
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- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02E—REDUCTION OF GREENHOUSE GAS [GHG] EMISSIONS, RELATED TO ENERGY GENERATION, TRANSMISSION OR DISTRIBUTION
- Y02E10/00—Energy generation through renewable energy sources
- Y02E10/50—Photovoltaic [PV] energy
- Y02E10/549—Organic PV cells
Definitions
- the present invention relates to an organic electroluminescence element.
- An organic electroluminescence element deteriorates when oxygen gas, water vapor, or the like penetrates into the element, resulting in a defective emission portion called a dark spot, resulting in a reduction in emission quality. Therefore, in the field of organic electroluminescence devices, it has been proposed to use a sealing material or the like in order to suppress oxygen gas or water vapor from entering the device.
- Patent Document 1 an organic electroluminescence device in which at least a transparent anode layer, an organic layer including a light emitting layer, and a cathode layer are laminated in this order on a transparent substrate.
- the first sealing film is disposed on the transparent anode layer side
- the second sealing film is disposed on the cathode layer side
- thermosetting is performed on the surface of the cathode layer opposite to the organic layer side.
- An organic electroluminescence element having a sealing layer made of a conductive resin is disclosed.
- the conventional organic electroluminescence element as described in Patent Document 1 is not necessarily sufficient from the viewpoint of preventing a short circuit from occurring after bending.
- the present invention has been made in view of the problems of the prior art, and an object of the present invention is to provide an organic electroluminescence element that can sufficiently suppress the occurrence of a short circuit after bending. .
- organic electroluminescence element hereinafter referred to simply as “organic EL element”
- OLED organic electroluminescence element
- a light emitting element portion disposed on the transparent support substrate includes at least a pair of electrodes and a light emitting layer disposed between the electrodes
- the surface roughness of the surface of the sealing substrate on the sealing material layer side with respect to the roughness has a value smaller than the surface roughness of the other surface of the sealing substrate.
- the organic electroluminescence element of the present invention a transparent support substrate having flexibility, A light-emitting element unit that is disposed on the transparent support substrate and includes a pair of electrodes and a light-emitting layer disposed between the electrodes; A sealing material layer disposed on the transparent support substrate so as to cover and seal the light emitting element portion; A sealing substrate disposed on the sealing material layer; With Based on the arithmetic average roughness of JIS B 0601-1994, the surface roughness of the surface of the sealing substrate on the sealing material layer side is smaller than the surface roughness of the other surface of the sealing substrate.
- the arithmetic average roughness (Ra) of the surface of the sealing substrate on the sealing material layer side is preferably 0.1 to 1.0 ⁇ m.
- the sealing material layer preferably has a thickness of 5 to 120 ⁇ m.
- the said sealing substrate consists of a metal material in any one of copper, a copper alloy, aluminum, and an aluminum alloy, and the copper foil manufactured by the electrolytic method More preferably, it consists of.
- an organic electroluminescence element that can sufficiently suppress the occurrence of a short circuit after being bent.
- the organic electroluminescence element of the present invention is a transparent support substrate having flexibility, A light-emitting element unit that is disposed on the transparent support substrate and includes a pair of electrodes and a light-emitting layer disposed between the electrodes; A sealing material layer disposed on the transparent support substrate so as to cover and seal the light emitting element portion; A sealing substrate disposed on the sealing material layer; With Based on the arithmetic average roughness of JIS B 0601-1994, the surface roughness of the surface of the sealing substrate on the sealing material layer side is smaller than the surface roughness of the other surface of the sealing substrate.
- FIG. 1 is a schematic longitudinal sectional view schematically showing a preferred embodiment of the organic electroluminescence element of the present invention.
- the organic electroluminescent element of the embodiment shown in FIG. 1 includes a transparent support substrate 1, a light emitting element portion 2, a sealing material layer 3, and a sealing substrate 4.
- a transparent support substrate 1 a transparent support substrate 1
- a light emitting element portion 2 a sealing material layer 3
- a sealing substrate 4 a sealing substrate 4.
- the transparent support substrate 1 shown in FIG. 1 has flexibility (flexibility).
- the “flexibility” here is not particularly limited as long as it has the flexibility required for a substrate of a general flexible organic EL element. Is preferably a plastic substrate from the viewpoint of thin glass, light weight, and fracture resistance.
- the transparent support substrate 1 is not particularly limited as long as it has light transmittance (transparency) to the extent that it can be used for the substrate on the light extraction side of the organic EL element.
- a known transparent substrate used for the light extraction side substrate for the organic EL element can be appropriately used, and a transparent substrate having a total light transmittance of 80% or more can be preferably used.
- such a transparent support substrate 1 preferably has a gas barrier property even when plastic is used as a base material.
- a known gas barrier film that can be used as a flexible transparent substrate of an organic EL element can be appropriately used.
- Japanese Patent Application Laid-Open No. 2011-73430 The gas barrier laminate film described above (in particular, a laminate formed by laminating a plurality of the films using an adhesive is more preferable) can be suitably used.
- the first and second thin film layers having gas barrier properties, the first and second base material layers, And a laminated structure in which the first thin film layer, the first base material layer, the adhesive layer, the second thin film layer, and the second base material layer are laminated in this order.
- a gas barrier laminate film is preferred.
- one electrode of the light emitting element portion is the first electrode of the gas barrier laminate film from the viewpoint of highly suppressing deterioration of the organic EL element due to water vapor or the like. It is preferable to laminate on one thin film layer.
- the gas barrier laminate film that can be suitably used for the transparent support substrate 1 according to the present invention will be described below with reference to FIG.
- the gas barrier laminate film of the embodiment shown in FIG. 2 includes a first base layer 100 (a), a second base layer 100 (b), and a first thin film layer 101 (a) having gas barrier properties.
- the gas barrier laminate film includes two base material layers, a first base material layer 100 (a) and a second base material layer 100 (b).
- the number of such base material layers is only one layer (in the case of a configuration in which either the first base material layer or the second base material layer is not included in the gas barrier laminate film) )
- the first base material is further dried after forming a thin film layer having gas barrier properties on the first base material layer. Even if it passes through the process of making it, the surface opposite to the thin film layer which has the gas barrier property of the 1st substrate will be in the state where it was exposed outside, and moisture will be in the 1st substrate from the surface exposed to the outside. There is a tendency for the time taken to penetrate and reach the saturated water content of the first substrate significantly. Therefore, even if the drying process is performed at the time of manufacture, the drying effect tends to be unable to be fully utilized.
- the second base material layer 100 (a) is not provided, if the second and third thin film layers are formed on both surfaces of the second base material, the second base material is formed after the thin film layer is formed. Even if the step of drying the layer is carried out, the base material layer is sandwiched between the thin film layers that express the barrier properties, and it becomes difficult to remove the water inside the second base material. There is a tendency that it cannot be obtained sufficiently.
- the base materials forming the base material layer 100 (a) and the base material layer 100 (b) may be the same or different, and form a gas barrier laminate film.
- a known base material that can be used for the above can be used as appropriate.
- the 1st base material layer 100 (a) and the 2nd base material layer 100 It is preferable that at least one layer of b) is made of an organic polymer material, so that higher flexibility (flexibility) is obtained, and workability such as cutting and bending of the base material is improved. It is preferable that both the one base material layer 100 (a) and the second base material layer 100 (b) are made of an organic polymer material.
- polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN); polyethylene (PE ), Polypropylene resins such as polypropylene (PP) and cyclic polyolefin; Polyamide resins; Polycarbonate resins; Polystyrene resins; Polyvinyl alcohol resins; Saponified ethylene-vinyl acetate copolymers; Polyacrylonitrile resins; Acetals Resin; Polyimide resin or the like can be suitably used.
- PET polyethylene terephthalate
- PEN polyethylene
- PE Polypropylene resins
- Polypropylene resins such as polypropylene (PP) and cyclic polyolefin
- Polyamide resins Polycarbonate resins
- Polystyrene resins Polyvinyl alcohol resins
- Saponified ethylene-vinyl acetate copolymers Saponified ethylene-vinyl acetate copolymers
- Polyacrylonitrile resins Acetal
- a polymer material made of a polymer containing a hetero atom (oxygen, nitrogen, etc.) other than carbon and hydrogen is preferable.
- Polymer materials (polyolefins, etc.) consisting of hydrocarbon polymers consisting only of carbon and hydrogen are nonpolar polymers, and since there is almost no polarization in the molecule, it is generally difficult to fully exhibit hydrophilicity.
- a polymer material made of a polymer containing a heteroatom (oxygen, nitrogen, etc.) is likely to show polarization due to the heteroatom, and is generally sufficiently hydrophilic.
- the highly hydrophilic polymer material has a high water content under the usage environment (usually at room temperature (about 25 ° C.) and under normal humidity), and the internal moisture is sufficiently removed by drying. Then, hygroscopicity can be efficiently provided. Therefore, when a polymer material composed of a polymer containing a heteroatom other than carbon and hydrogen is used as the base material, it is possible to produce a gas barrier laminated film having a higher efficiency of moisture absorption more efficiently. It becomes possible, and when used as a substrate of an organic EL element, a higher level of water vapor permeation prevention performance can be exhibited. In addition, as a heteroatom in a polymer containing a heteroatom other than carbon and hydrogen, when the base material is used for a gas barrier laminate film, the film can also exhibit high moisture absorption performance. Therefore, an oxygen atom is preferable.
- polyester having an ester bond is preferable.
- polyesters having a benzene ring for example, for example, from the viewpoint that the transparency of the base material and the processability to the film become more advanced, and the strength and heat resistance are further improved
- PET polyethylene terephthalate
- PEN polyethylene naphthalate
- the thickness of such a substrate is not particularly limited, but when a thin film layer is directly formed on the surface of the substrate, the thickness is appropriately set according to the type of the thin film layer to be formed. It is preferable to do.
- the thickness of such a base material is such that when forming a thin film layer on the surface of the base material, the base material can be transported even in a vacuum.
- the thickness is preferably 5 to 500 ⁇ m because a thin film can be formed.
- the thickness of the base material is 50 to 50 from the viewpoint that it is possible to adopt a method of forming the thin film layer while discharging through the base material.
- the thickness is more preferably 200 ⁇ m, and particularly preferably 50 to 100 ⁇ m.
- the thickness of such a base material is, for example, particularly in the step of bonding by the thickness of the base material even when a gas barrier laminate film is manufactured by bonding members having thin film layers formed on the base material. Since it does not have the property of being affected, it can be used without particular limitation as long as it has a thickness capable of forming a thin film layer regardless of the method for producing the gas barrier laminate film.
- the thickness of such a substrate may be any thickness that can form a thin film layer on the surface of the substrate and can sufficiently support the thin film layer. It can be designed as appropriate.
- the gas barrier laminate film of the embodiment shown in FIG. 2 includes two thin film layers, a first thin film layer 101 (a) and a second thin film layer 101 (b).
- the number of such thin film layers is only one (when the gas barrier laminate film is configured so that one of the first thin film layer and the second thin film layer is not included).
- both the first thin film layer 101 (a) and the second thin film layer 101 (b) need to be layers (thin film layers) made of a thin film having gas barrier properties.
- the “gas barrier property” herein refers to the following conditions (A) to (C): [Condition (A)] “Gas permeability of substrate (unit: mol / m 2 ⁇ s ⁇ P)” and “gas permeability of substrate on which a thin film layer is formed” measured by a method in accordance with JIS K 7126 (issued in 2006) (Unit: mol / m 2 ⁇ s ⁇ P) ”,“ Gas permeability of base material on which thin film layer is formed ”is smaller by 2 digits or more than“ Gas permeability of base material ” Show value (value of 1/100 or less).
- the water vapor permeability of a substrate on which a thin film layer having a water vapor barrier property (gas barrier property) is formed exhibits a value of 10 ⁇ 2 g / m 2 / day or less
- the above condition (B) When (C) is examined, it is preferable that the “water vapor permeability of the substrate on which the thin film layer is formed” is a value of 10 ⁇ 2 g / m 2 / day or less.
- the thin film layer having such gas barrier properties those satisfying the above condition (C) are more preferable.
- the thickness of one layer of such a gas barrier thin film layer is preferably in the range of 5 to 3000 nm, more preferably in the range of 10 to 2000 nm, and particularly preferably in the range of 100 to 1000 nm. preferable. If the thickness of the thin film layer is less than the lower limit, gas barrier properties such as oxygen gas barrier properties and water vapor barrier properties tend to be inferior.
- the kind of the first and second thin film layers having such gas barrier properties is not particularly limited, and a known thin film having gas barrier properties can be used as appropriate.
- These thin film layers are respectively metal oxide and metal nitride. It is preferable that it is a thin film layer containing at least one of a metal and a metal oxynitride.
- the first and second thin film layers may be multilayer films in which organic layers / inorganic layers / organic layers, inorganic layers / organic layers / inorganic layers, and the like are laminated on the base material.
- the inorganic layer mainly exhibits gas barrier properties.
- the composition of the inorganic layer is preferably a metal oxide, metal nitride, metal oxynitride, silicon oxide, or silicon oxide carbide described below.
- the organic layer has the effect of relieving the stress of the base material and the inorganic layer, or smoothing by filling the surface of the base material with irregularities and particles.
- the organic layer may have a water capturing function. What is the composition of the organic layer? Organic materials used in thermosetting adhesives and photocurable adhesives described below and two-part curable adhesives are preferred. Note that the types of the first thin film layer 101 (a) and the second thin film layer 101 (b) may be the same or different.
- metal oxides, metal nitrides and metal oxynitrides used for such thin film layers are sputter methods, vacuums from the viewpoint of being able to exhibit high water vapor permeation prevention performance with a thinner film, and transparency. It is preferable to form a film by a method such as an evaporation method, an ALD (atomic layer deposition) method, or an ion plating method. From the viewpoint of ease of production and low production cost, sputtering and ALD are more preferred.
- such a thin film layer is made of a thin film containing at least silicon and oxygen from the viewpoints of exhibiting a higher level of water vapor permeation prevention performance, bending resistance, ease of production, and low production cost. More preferably, it is a layer. Further, the layer made of a thin film containing pre-silicon and oxygen is preferably a thin film layer using a plasma chemical vapor deposition method or a thin film forming method in which a precursor is formed on a substrate surface and plasma treatment is performed.
- the layer containing silicon, oxygen and carbon is a layer containing silicon, oxygen and carbon, and The distance from the surface of the layer in the thickness direction of the layer, the ratio of the amount of silicon atoms to the total amount of silicon atoms, oxygen atoms and carbon atoms (atom ratio of silicon), the ratio of the amount of oxygen atoms (the ratio of oxygen In the silicon distribution curve, the oxygen distribution curve, and the carbon distribution curve showing the relationship between the atomic ratio) and the ratio of the amount of carbon atoms (carbon atomic ratio), the following conditions (i) to (iii): (I) In a region where the atomic ratio of silicon, the atomic ratio of oxygen, and the atomic ratio of carbon are 90% or more of the film thickness of the layer, the following formula (1): (Atomic ratio of oxygen)> (atomic ratio of silicon)> (atomic ratio of carbon) (1) Satisfying the condition represented by (Ii) the carbon distribution curve has at least one extreme value; (Iii) The absolute value of the difference between the maximum value and the minimum value
- Such a silicon oxide-based thin film layer first has a distance from the surface of the layer in the thickness direction of the layer and a ratio of the amount of silicon atoms to the total amount of silicon atoms, oxygen atoms and carbon atoms (silicon In the silicon distribution curve, the oxygen distribution curve and the carbon distribution curve respectively showing the relationship between the atomic ratio), the oxygen atom ratio (oxygen atomic ratio) and the carbon atom ratio (carbon atomic ratio), i) In a region where the atomic ratio of silicon, the atomic ratio of oxygen, and the atomic ratio of carbon are 90% or more (more preferably 95% or more, particularly preferably 100%) of the thickness of the layer, the following formula (1): (Atomic ratio of oxygen)> (atomic ratio of silicon)> (atomic ratio of carbon) (1) It is necessary to satisfy the condition expressed by When the atomic ratio of silicon, the atomic ratio of oxygen, and the atomic ratio of carbon do not satisfy the above conditions, the gas barrier properties of the resulting gas barrier laminate film are insufficient.
- such a silicon oxide-based thin film layer (ii) requires that the carbon distribution curve has at least one extreme value.
- the carbon distribution curve more preferably has at least two extreme values, and particularly preferably has at least three extreme values.
- the carbon distribution curve does not have an extreme value, the gas barrier property when the obtained film of the gas barrier laminate film is bent is insufficient.
- the absolute value of the difference in distance is preferably 200 nm or less, and more preferably 100 nm or less.
- the “extreme value” means a maximum value or a minimum value of the atomic ratio of the element to the distance from the surface of the thin film layer in the film thickness direction of the silicon oxide-based thin film layer.
- the maximum value is a point where the value of the atomic ratio of the element changes from increasing to decreasing when the distance from the surface of the silicon oxide thin film layer is changed, and It means that the value of the atomic ratio of the element at a position where the distance from the surface of the thin film layer in the film thickness direction of the thin film layer is further changed by 20 nm from the point is reduced by 3 at% or more.
- the minimum value is a point where the value of the atomic ratio of an element changes from a decrease to an increase when the distance from the surface of the silicon oxide thin film layer is changed, and the element of that point It means that the value of the atomic ratio of the element at a position where the distance from the surface of the thin film layer in the film thickness direction of the thin film layer is further changed by 20 nm from the point increases by 3 at% or more.
- such a silicon oxide-based thin film layer (iii) requires that the absolute value of the difference between the maximum value and the minimum value of the atomic ratio of carbon in the carbon distribution curve be 5 at% or more.
- the absolute value of the difference between the maximum value and the minimum value of the atomic ratio of carbon is more preferably 6 at% or more, and particularly preferably 7 at% or more.
- the absolute value is less than 5 at%, the gas barrier property when the obtained gas barrier laminate film is bent is insufficient.
- the oxygen distribution curve preferably has at least one extreme value, more preferably at least two extreme values, and at least three extreme values. Particularly preferred.
- the gas barrier property tends to decrease when the resulting gas barrier laminate film is bent.
- the absolute value of the difference in distance is preferably 200 nm or less, and more preferably 100 nm or less.
- the absolute value of the difference between the maximum value and the minimum value of the oxygen atomic ratio in the oxygen distribution curve of the layer is preferably 5 at% or more, and 6 at% or more. More preferably, it is more preferably 7 at% or more. If the absolute value is less than the lower limit, the gas barrier property tends to be lowered when the obtained gas barrier laminate film is bent.
- the absolute value of the difference between the maximum value and the minimum value of the atomic ratio of silicon in the silicon distribution curve of the layer is preferably less than 5 at%, and preferably less than 4 at%. Is more preferable, and it is especially preferable that it is less than 3 at%.
- the absolute value exceeds the upper limit, the gas barrier properties of the obtained gas barrier laminate film tend to be lowered.
- the absolute value of the difference between the maximum value and the minimum value of the total atomic ratio of oxygen and carbon in the oxygen carbon distribution curve is less than 5 at%. Preferably, it is less than 4 at%, more preferably less than 3 at%.
- the absolute value exceeds the upper limit, the gas barrier properties of the obtained gas barrier laminate film tend to be lowered.
- the silicon distribution curve, the oxygen distribution curve, the carbon distribution curve, and the oxygen carbon distribution curve are obtained by using X-ray photoelectron spectroscopy (XPS) measurement and rare gas ion sputtering such as argon in combination. It can be created by so-called XPS depth profile measurement in which surface composition analysis is sequentially performed while exposing the inside of the sample.
- XPS depth profile measurement in which surface composition analysis is sequentially performed while exposing the inside of the sample.
- a distribution curve obtained by such XPS depth profile measurement can be created, for example, with the vertical axis as the atomic ratio (unit: at%) of each element and the horizontal axis as the etching time (sputtering time).
- the etching time is generally correlated with the distance from the surface of the thin film layer in the film thickness direction of the thin film layer in the film thickness direction.
- the distance from the surface of the thin film layer in the film thickness direction of the thin film layer the distance from the surface of the thin film layer calculated from the relationship between the etching rate and the etching time employed in the XPS depth profile measurement may be adopted. it can.
- etching rate is 0.05 nm / It is preferable to set to sec (SiO 2 thermal oxide film conversion value).
- the layer is substantially in the film surface direction (direction parallel to the surface of the thin film layer). Preferably it is uniform.
- the fact that the silicon oxide thin film layer is substantially uniform in the film surface direction means that the oxygen distribution curve is measured at any two measurement points on the film surface of the thin film layer by XPS depth profile measurement.
- the carbon distribution curve and the oxygen carbon distribution curve are created, the number of extreme values of the carbon distribution curve obtained at any two measurement locations is the same, and the carbon atoms in the respective carbon distribution curves
- the absolute value of the difference between the maximum value and the minimum value of the ratio is the same as each other or within 5 at%.
- the carbon distribution curve of the layer is preferably substantially continuous.
- the carbon distribution curve being substantially continuous means that the carbon distribution curve does not include a portion in which the atomic ratio of carbon changes discontinuously.
- the etching rate, the etching time From the relationship between the distance (x, unit: nm) from the surface of the layer in the film thickness direction of at least one of the thin film layers calculated from the above, and the atomic ratio of carbon (C, unit: at%) The following mathematical formula (F1): (DC / dx) ⁇ 0.5 (F1) This means that the condition represented by
- the atomic ratio of the silicon atom content to the total amount of silicon atoms, oxygen atoms and carbon atoms in the layer is preferably 25 to 45 at%, More preferably, it is 40 at%.
- the atomic ratio of the oxygen atom content to the total amount of silicon atoms, oxygen atoms and carbon atoms in the silicon oxide-based thin film layer is preferably 33 to 67 at%, and preferably 45 to 67 at%. It is more preferable.
- the atomic ratio of the carbon atom content to the total amount of silicon atoms, oxygen atoms and carbon atoms in the silicon oxide thin film layer is preferably 3 to 33 at%, and preferably 3 to 25 at%. It is more preferable.
- the atomic ratio of the silicon atom content to the total amount of silicon atoms, oxygen atoms and carbon atoms in the layer is preferably 25 to 45 at%, More preferably, it is 40 at%.
- the atomic ratio of the oxygen atom content to the total amount of silicon atoms, oxygen atoms and carbon atoms in the silicon oxide thin film layer is preferably 1 to 33 at%, and preferably 10 to 27 at%. It is more preferable.
- the atomic ratio of the carbon atom content to the total amount of silicon atoms, oxygen atoms and carbon atoms in the silicon oxide-based thin film layer is preferably 33 to 66 at%, and preferably 40 to 57 at%. It is more preferable.
- the silicon oxide-based thin film layer is preferably a layer formed by plasma enhanced chemical vapor deposition.
- a thin film layer formed by such a plasma enhanced chemical vapor deposition method the base material is placed on a pair of film forming rolls, and plasma is generated by generating a plasma by discharging between the pair of film forming rolls.
- a layer formed by a phase growth method is more preferable.
- the film forming gas used in such a plasma chemical vapor deposition method preferably contains an organosilicon compound and oxygen, and the content of oxygen in the film forming gas is the organic gas in the film forming gas.
- the thin film layer is preferably a layer formed by a continuous film formation process.
- Such a silicon oxide-based thin film layer can be manufactured by employing the method described in Japanese Patent Application Laid-Open No. 2011-73430.
- first thin film layer 101 (a) and the second thin film layer 101 (b) it is possible to exhibit a higher level of water vapor permeation prevention performance. It is preferable that all of them are the above-described silicon oxide-based thin film layers.
- the adhesive that can be used to form the adhesive layer 102 include a thermosetting adhesive, a photocurable adhesive, and a two-component mixture from the viewpoint of ease of production and low volatile components.
- a curable adhesive such as a curable adhesive is preferred.
- thermosetting resin adhesive is not particularly limited, and a known thermosetting resin adhesive can be appropriately used.
- thermosetting resin adhesives include epoxy adhesives and acrylate adhesives.
- examples of such an epoxy adhesive include an adhesive containing an epoxy compound selected from a bisphenol A type epoxy resin, a bisphenol F type epoxy resin, and a phenoxy resin.
- examples of the acrylate adhesive include a monomer as a main component selected from acrylic acid, methacrylic acid, ethyl acrylate, butyl acrylate, 2-hexyl acrylate, acrylamide, acrylonitrile, hydroxyl acrylate, and the like.
- An adhesive containing a copolymerizable monomer can be used.
- the photocurable adhesive is not particularly limited, and a known photocurable adhesive can be appropriately used.
- examples thereof include a radical adhesive and a cationic adhesive.
- examples of such radical adhesives include adhesives containing epoxy acrylate, ester acrylate, ester acrylate, and the like.
- examples of the cationic adhesive include an adhesive including an epoxy resin and a vinyl ether resin.
- the adhesive layer 102 may further contain a moisture adsorbent (so-called desiccant or hygroscopic agent), a bluing agent, an ultraviolet absorber, an antioxidant, and the like.
- a moisture adsorbent so-called desiccant or hygroscopic agent
- a bluing agent an ultraviolet absorber
- an antioxidant an antioxidant
- the laminated film when used as a substrate for an organic EL for illumination, it may contain a dye or a pigment having the same color as the emission color of the organic EL, and the emission color of the organic EL for the purpose of a color mixing effect. It may contain dyes and pigments of different colors.
- inorganic particles having a refractive index different from that of the adhesive layer may be included.
- Such an adhesive layer 102 when the adhesive contains moisture, the moisture in the adhesive layer can be reduced and the performance can be sufficiently prevented from being deteriorated based on the moisture generated from the adhesive layer.
- a moisture adsorbent drying agent
- examples thereof include silica gel, zeolite (molecular sieve), metal oxides such as magnesium oxide, calcium oxide, barium oxide, and strontium oxide, and dry hydroxide.
- metal hydroxides such as aluminum.
- moisture adsorbents (desiccants) calcium oxide and dried aluminum hydroxide are particularly preferable from the viewpoint of sufficiently high light transmittance.
- Such a moisture adsorbent is preferably in the form of particles.
- a particulate water adsorbent has an average particle diameter in the range of 0.01 to 10 ⁇ m (more preferably 0.01 to 5 ⁇ m, and still more preferably 0.1 to 5 ⁇ m). preferable.
- the average particle size is less than 0.01 ⁇ m, the primary particles tend to aggregate easily, and not only the large aggregated particles (secondary particles) tend to be formed, but also the hygroscopicity is too strong.
- the moisture absorption has already ended and the moisture absorption ability tends not to be exhibited.
- the average particle diameter exceeds 10 ⁇ m, it becomes difficult to form a smooth layer when formed into a film, and sufficient moisture absorption ability tends to be not obtained.
- the content of such a moisture adsorbent is not particularly limited, but it should be 5 to 50% by mass (more preferably 10 to 30% by mass) in the adhesive. Is preferred. If the content of such an absorbent (drying agent) is less than the lower limit, moisture existing in the adhesive tends to be absorbed and the water supply ability tends to decrease. And the light extraction from the organic EL light emitting layer tends to decrease.
- such an adhesive layer 102 preferably contains a bluing agent, for example, depending on the use of the organic EL element.
- a bluing agent is not particularly limited, and a known bluing agent can be appropriately used.
- Bayer Macrolex Violet B and Macrolex Blue RR, Sand Corp. Triazole blue RLS and the like can be suitably used.
- Solvent Violet-3, Solvent Blue-94, Solvent Blue-78, Solvent Blue-95, Solvent Violet-13, and the like by color index classification can be used.
- the thickness of the adhesive layer 102 is not particularly limited, but solid content such as powder (for example, the above-mentioned moisture adsorbent (drying agent), refractive index adjusting particles, etc.) is used for the adhesive.
- the thickness is more preferably 1 to 20 ⁇ m.
- the thickness is preferably about the maximum secondary particle diameter of the powder particles. In this case, the thickness is usually 5 to 50 ⁇ m. More preferred.
- the thickness of the adhesive layer 102 is determined depending on the adhesive strength and workability. From the viewpoint, it is preferably 0.2 to 30 ⁇ m, and more preferably 0.5 to 10 ⁇ m.
- the thickness of the adhesive layer 102 is preferably 1 to 100 ⁇ m from the viewpoint of workability. More preferably, it is 5 to 50 ⁇ m.
- the adhesive agent processed into the film form can be utilized.
- the water vapor transmission rate of the adhesive film is 100 g / m 2 / day or less (more preferably 30 g / m 2 / day or less) in an environment where the film thickness is 100 ⁇ m, 60 ° C., and 90% RH
- the light transmittance is preferably 70% or more (more preferably 80% or more).
- Such water vapor transmission rate is, for example, the calcium-light transmission method (when Ca metal absorbs moisture, it changes to calcium oxide, calcium hydroxide, etc., and the light transmission changes), or MOCON water vapor A value measured by a transmittance measuring device or the like can be adopted.
- the light transmittance can be measured by, for example, an optical thin film measuring system apparatus of Film-Tek (USA).
- the adhesive layer has a ratio of the light refractive index of the first base material layer 100 (a) to the light refractive index of the adhesive layer ([the light refractive index of the first base material layer 100 (a). ] / [The optical refractive index of the adhesive layer]) is preferably a layer having a value of 0.88 to 1.18 (more preferably 1.01 to 1.11). If the ratio of the optical refractive index is less than the lower limit, it is necessary to further increase the refractive index of the adhesive layer. If the refractive index of the adhesive layer is larger than that of the second thin film layer, the outgoing light to the outside decreases.
- a light refractive index can be measured by, for example, an optical thin film measuring system apparatus of Film-Tek (USA) or a general-purpose ellipsometer.
- the gas barrier laminate film (transparent support substrate 1) of the embodiment shown in FIG. 2 includes a thin film layer 101 (a), a base material layer 100 (a), an adhesive layer 102, a thin film layer 101 (b), and a base material. It has a stacked structure in which the layers 100 (b) are stacked in this order. With such a laminated structure, a light emitting element portion described later can be laminated directly on the surface of the thin film layer, and the thin film layer can highly suppress the intrusion of water vapor into the element.
- Such a gas barrier laminate film (transparent support substrate 1) preferably has a total thickness of 50 to 300 ⁇ m, more preferably 100 to 2500 ⁇ m.
- the thickness of such a film is less than the above lower limit, when the gas barrier laminate film is a long substrate, wrinkles and creases tend to occur in the manufacturing process of the organic EL element, and it is difficult to control the film.
- the thickness of the base material layer exceeds the upper limit, the amount of light absorbed by the film increases, so that light emission from the light emitting layer to the outside tends to decrease. is there.
- the base material layer is formed from the direction parallel to the surface of the gas barrier laminate film (end side: direction perpendicular to the end face). It is difficult to maintain the dry state of the base material for a sufficiently long period of time, for example, when a dry base material is used at the time of manufacturing the gas barrier laminate film. Tend to be.
- such a gas barrier laminate film has a moisture absorption performance of absorbing water of 0.1% by mass or more (more preferably 0.2% by mass or more of its own weight) of its own weight (mass of the gas barrier laminate film itself). It is preferable to have. When such moisture absorption performance is less than the lower limit, it tends to be difficult for the gas barrier laminate film to exhibit further advanced moisture permeation prevention performance.
- the moisture absorption performance of the gas barrier laminate film is preferably 5% by mass or less of its own weight from the viewpoints of the load applied to the substrate during drying, the time required for drying, and the decrease in the adhesion of the adhesive layer accompanying the increase in the amount of the moisture absorbent. .
- the moisture absorption performance is more preferably 3% by mass or less of its own weight, and further preferably 2% by mass or less of its own weight.
- the moisture absorption performance of such a gas barrier laminate film can be measured as follows. That is, first, a gas barrier laminate film (50 mm square) having a vertical and horizontal length of 50 mm (50 mm square) is prepared for measuring the moisture absorption performance of the gas barrier laminate film. Next, a 50 mm square film is cut into a strip shape every 1 mm to prepare a strip-shaped sample having a length of 50 mm and a width of 1 mm. Next, in a constant temperature room, the mass (unit: g) of a strip-shaped sample (50 pieces) having a size of 50 mm in length and 1 mm in width at room temperature (25 ° C.) in the atmosphere is accurately weighed up to 4 digits.
- the mass at this time be the above-mentioned film's own weight (W1: initial mass before use).
- W1 initial mass before use
- the 50 samples are allowed to stand under a constant temperature and humidity atmosphere (25 ° C., humidity 50%, weight absolute humidity 10 g / kg), and the mass of the sample is accurately weighed to 4 decimal places every 24 hours. .
- Such weighing is performed until the mass of the sample (50 pieces) becomes constant, and the mass at a constant value is defined as Wn.
- Such hygroscopic performance is basically a performance exhibited based on the hygroscopicity of the base material layer disposed between the first and second thin film layers having gas barrier properties.
- the base layer is made of a polymer containing a heteroatom other than hydrogen (more preferably a polyester having an ester bond) so that the base layer disposed between the first and second thin film layers can absorb moisture sufficiently. More preferably, a layer made of a base material made of PET, PEN), and a base material sufficiently dried at the time of producing the gas barrier laminate film is disposed between the first and second thin film layers. Thus, it is preferable to produce a gas barrier laminate film.
- the ratio of the total thickness of all the base material layers present in the film to the total thickness of the film is preferably 90% or more, and more preferably 95% or more. If such a ratio is less than the lower limit, the flexibility tends to decrease, or the substrate is deformed by the stress of the thin film layer formed on the substrate, and the productivity tends to decrease.
- Ratio of total thickness of base material layer ( ⁇ [total thickness of all base material layers existing between first thin film layer and second thin film layer] / [present in gas barrier laminate film]
- the thickness of all base material layers] ⁇ ⁇ 100) is preferably 50% or more, more preferably 90% or more. If the ratio of the thickness of the base material layer between the thin film layers is less than the lower limit, it tends to be difficult to exhibit a sufficiently high hygroscopic performance when the base material is dried and used to exhibit the hygroscopic performance. There is a tendency.
- the ratio of the thickness of the base material layer which exists between the 1st thin film layer and the 2nd thin film layer with respect to the whole thickness of the gas-barrier laminated film (transparent support substrate 1) of embodiment shown in FIG. is 50% or more. In particular, it is more preferably 90% or more.
- the ratio of the thickness of the base material layer between the thin film layers is less than the lower limit, the mechanical strength of the first film member on which the organic EL element is formed is reduced. There is a tendency that the possibility of being destroyed tends to increase, and it tends to be difficult to exhibit a sufficiently high hygroscopic performance when the substrate is dried and used to exhibit the hygroscopic performance.
- the yellowness YI is preferably a lower value, more preferably 10 or less. More preferably, it is 5 or less.
- Such yellowness YI can be measured by using a spectrophotometer capable of calculating tristimulus values XYX as a measuring device and conforming to JIS K 7373: 2006.
- the gas barrier laminate film (transparent support substrate 1) preferably has a higher total light transmittance when used for organic EL device illumination and display. From such a viewpoint, the total light transmittance of the gas barrier laminate film is more preferably 80% or more, and further preferably 85% or more. Such total light transmittance can be measured by using a transmission measuring device having an integrating sphere as a measuring device and conforming to JIS K7375: 2008.
- multilayer film when using for the board
- the gas barrier laminate film when it is used for a substrate for an organic EL element for illumination, not only is the haze not noticeable from the application, but the light emission surface of the organic EL emits light unevenly in a state where shading or spots occur. In such a case, the higher the haze, on the contrary, blurs the uneven light emission, and from this point of view, the one having a higher haze can be suitably used.
- the gas barrier laminate film (transparent support substrate 1) can be used while appropriately changing the characteristics so as to have a suitable design according to the use of the organic EL element.
- the gas barrier laminate film transparent support substrate 1 shown in FIG. 2
- at least one of the first base layer and the first base layer A first film member comprising a first thin film layer having gas barrier properties formed on the surface of the gas, and a gas barrier formed on at least one surface of the second base material layer and the second base material layer
- a step of preparing a second film member comprising a second thin film layer having a property step (A))
- a step of obtaining a gas barrier laminate film by bonding with an adhesive so that the second thin film layer in the second film member is laminated on the surface of the base material layer of the first film member step (step (B))
- a method including: Hereinafter, these steps (A) and (B) will be described separately.
- Step (A) is a step of preparing the first and second film members.
- the method for preparing such first and second film members is not particularly limited, and a known method can be appropriately employed.
- a film member (first and second film members) comprising a base material layer and a thin film layer by forming a thin film layer having a gas barrier property on at least one surface on the base material.
- the film member (first and second film members) may be prepared by a film member (laminate) having a commercially available base material layer and a thin film layer having gas barrier properties. ) May be prepared.
- the well-known method in which the film formation of such a thin film layer can be employ adopted suitably, From a gas-barrier viewpoint, plasma chemical vapor deposition method ( It is preferable to employ plasma CVD).
- the plasma chemical vapor deposition method may be a Penning discharge plasma type chemical vapor deposition method.
- a method for forming such a thin film layer on a substrate it is preferable to employ the method described in JP 2011-73430 A, whereby the above-described silicon oxide thin film layer is formed. And can be efficiently formed on a substrate.
- step (B) the gas barrier laminate film is formed by laminating with an adhesive so that the second thin film layer in the second film member is laminated on the surface of the base material layer of the first film member. It is the process of obtaining.
- stacking is bonded by using an adhesive so that the 2nd thin film layer in a 2nd film member may laminate
- the method of bonding the first and second film members using an adhesive is not particularly limited, and a known method capable of bonding the film member using an adhesive may be appropriately employed.
- a method of bonding the first and second film members can be appropriately used.
- the temperature conditions that can be employed in these methods are not particularly limited, and optimal conditions may be employed as appropriate according to the types of the first and second film members, the type of adhesive, and the like. .
- the application method and application thickness of the adhesive are not particularly limited, and a known application method (for example, a doctor blade, a wire bar, An optimal method and its conditions may be appropriately selected from among coating methods such as die coater, comma coater, gravure coater, screen printing, and inkjet.
- the first film member and the second film member when bonding the first film member and the second film member in this manner, at least a step of drying the first film member (one film member) in advance is performed. preferable.
- sufficient moisture absorption performance preferably water having a weight of 0.1% by mass or more of its own weight
- a method (drying method) that can be employed as a step of drying such a film member is not particularly limited, and a known method capable of drying such a film member can be appropriately employed.
- vacuum drying, heat drying, vacuum heat drying, or the like can be appropriately employed.
- vacuum heat drying it is most preferable to employ vacuum heat drying in which vacuum drying and heat drying are combined from the viewpoint of drying speed.
- the conditions (heating conditions, pressure conditions, etc.) in the case of drying by such vacuum drying, heat drying, or vacuum heat drying may be appropriately set to conditions that allow the film member to be dried, and are particularly limited. It is not a thing.
- such a drying method includes a heating step, it becomes possible to dry the film member more efficiently.
- the heating temperature is preferably set to 50 ° C. or higher, and is set to 100 ° C. or higher. Is particularly preferred.
- the upper limit of the heating temperature may be appropriately set according to the type of the substrate. Although not particularly limited, it is preferably 200 ° C. or less, more preferably 150 ° C. or less, from the viewpoint of sufficiently preventing deformation of the substrate due to high temperature.
- the pressure condition is set to a pressure lower than the atmospheric pressure of 760 mmHg (101325 Pa).
- the pressure is not particularly limited, but is preferably a pressure lower than 76 mmHg (10132.5 Pa), and more preferably a pressure lower than 7.6 mmHg (1013.25 Pa).
- vacuum drying may be drying performed by reducing the pressure to a pressure lower than the atmospheric pressure of 760 mmHg (101325 Pa).
- the drying time of the film member is not particularly limited, and the implementation time (drying time) is appropriately set so that the film member is sufficiently dried according to the employed conditions.
- the drying time is set from the viewpoint of obtaining a more fully dried state. Is preferably 3 hours (180 minutes) or longer, more preferably 6 hours (360 minutes) or longer.
- what is necessary is just to set such drying time suitably according to the thickness, kind, etc. of a base material.
- the time during which the dried film member is exposed to an atmosphere having a weight absolute humidity of 10 g / kg or more is less than 1 hour. It is preferable that the first and second film members are bonded to each other.
- moisture-content adsorption agent with a base material layer will also exist fundamentally between thin film layers.
- the adhesive layer containing the moisture adsorbent is laminated between the thin film layers in this way, the first base material disposed between the first and second thin film layers by the moisture adsorbent in the adhesive layer. It is possible to dry the layer.
- the base material layer existing between the thin film layers can be dried after bonding, and the base material layer can exhibit moisture absorption performance.
- the gas barrier laminate film obtained in this manner includes an adhesive layer containing a moisture adsorbent between the thin film layers, the moisture adsorbent itself in the adhesive layer can also exhibit moisture absorption performance. Is also possible. Therefore, sufficient moisture absorption performance (preferably a weight of 0.1% by mass or more of its own weight) is also obtained by bonding the first film member and the second film member using an adhesive containing the moisture adsorbent. It is possible to more efficiently form a gas barrier laminate film having a moisture absorption capability of absorbing water.
- first film member and the second film member are bonded using the adhesive containing the moisture adsorbent, before the first and second film members are bonded.
- it may or may not include at least the step of drying the first film member, but it is possible to develop a higher level of moisture absorption performance, and a gas barrier laminate film (transparent support substrate 1). It is preferable that a drying step is included from the viewpoint that it is possible to develop a further advanced water vapor permeation prevention performance.
- the first and second film members are bonded under a temperature condition of 20 to 150 ° C. If such a temperature exceeds the upper limit, the substrate tends to be damaged such as deformation, whereas if it is less than the lower limit, the adhesiveness between the adhesive and the substrate or the thin film layer decreases, and water vapor from the interface There is a tendency to increase the likelihood of infiltration.
- the gas-barrier laminated film (transparent support substrate 1) of embodiment shown in FIG. 2 which can be utilized suitably for this invention is obtained. Can do.
- first and second are used for convenience in describing two or more identical or corresponding elements (for example, a base material layer, a thin film layer, a film member, etc.). There is no special meaning to the numbers or the order of explanation (no dominance by numbers), and these elements may be the same or different.
- the step (B) may be performed after the light emitting element portion 2 is formed on the first thin film layer of the first film member, which will be described later, or before the light emitting element portion 2 is formed.
- the step (B) may be performed, and then the light emitting element portion 2 may be formed.
- you may form the light emitting element part 2, or the said drying process after forming the light emitting element part 2 May be performed.
- the light emitting element portion 2 includes a pair of electrodes and a light emitting layer disposed between the electrodes.
- the pair of electrodes (first electrode 201, second electrode 203) constituting the light emitting element portion 2 and the light emitting layer 202 disposed between the electrodes are not particularly limited, and may be a known organic EL element.
- the used electrodes and light emitting layers can be used as appropriate.
- the light extraction surface side electrode may be transparent or semi-transparent, and a low molecular and / or high molecular organic light emitting material may be used for the light emitting layer.
- the first electrode 201, the light emitting layer 202, and the second electrode 203 will be described separately.
- the first electrode 201 is one of an anode and a cathode.
- the first electrode 201 is an electrode that exhibits light transmittance so that light emitted from the light emitting layer 202 can be emitted outside the element portion 2 ( A transparent or translucent electrode).
- the first electrode 201 exhibiting light transmittance is used as the anode.
- the first electrode 201 (anode) exhibiting such light transmittance
- thin films such as metal oxides, metal sulfides, and metals can be used, and those having higher electrical conductivity and light transmittance are preferable.
- Examples of such an electrode formed of a thin film of metal oxide, metal sulfide and metal include, for example, indium oxide, zinc oxide, tin oxide, ITO, indium zinc oxide (abbreviated as IZO), gold, platinum , Silver, copper and the like.
- a metal oxide, metal sulfide and metal thin film a thin film made of ITO, IZO or tin oxide is more preferable.
- a method for producing such a metal oxide, metal sulfide and metal thin film is not particularly limited, and a known method can be appropriately employed. For example, a vacuum deposition method, a sputtering method, an ion plating method can be employed. Method, plating method, etc. can be adopted.
- the first electrode 201 an organic transparent conductive film such as polyaniline or a derivative thereof, polythiophene or a derivative thereof may be used.
- a film-like electrode (A ) As such a light-transmitting resin, those having higher light transmittance are preferable. For example, low density or high density polyethylene, ethylene-propylene copolymer, ethylene-butene copolymer, ethylene-hexene copolymer are used.
- Polymer ethylene-octene copolymer, ethylene-norbornene copolymer, ethylene-dimethano-octahydronaphthalene copolymer, polypropylene, ethylene-vinyl acetate copolymer, ethylene-methyl methacrylate copolymer, ionomer resin, etc.
- Polyester resins such as polyethylene terephthalate, polybutylene terephthalate, and polyethylene naphthalate; Nylon-6, nylon-6,6, metaxylenediamine-adipic acid condensation polymers; Amide resins such as polymethylmethacrylamide Acrylic resins such as polymethyl methacrylate; Styrene-acrylonitrile resins such as polystyrene, styrene-acrylonitrile copolymer, styrene-acrylonitrile-butadiene copolymer, polyacrylonitrile; Hydrophobized cellulose systems such as cellulose triacetate and cellulose diacetate Resins; Halogen-containing resins such as polyvinyl chloride, polyvinylidene chloride, polyvinylidene fluoride, and polytetrafluoroethylene; Hydrogen-bonding resins such as polyvinyl alcohol, ethylene-vinyl alcohol copolymers, and cellulose derivatives; Polycarbonate
- thermosetting resin a photocurable resin, or a photoresist material is preferably used.
- the wire-like conductor is preferably a small diameter.
- the diameter of the wire-like conductor is preferably 400 nm or less, more preferably 200 nm or less, and even more preferably 100 nm or less.
- Such a wire-like conductor diffracts or scatters the light passing through the first electrode 201, so that the haze value of the first electrode 201 is increased and the light transmittance is reduced, but the wavelength of visible light or visible light is reduced.
- the haze value for visible light can be kept low, and the light transmittance can be improved.
- the optical characteristics of the first electrode 201 can be set as appropriate according to the device in which the organic EL element is used.
- the number of wire-like conductors included in such a film-like electrode (A) may be one or a plurality.
- Such a wire-like conductor preferably forms a network structure in the electrode (A). That is, in the electrode (A), one or a plurality of wire-like conductors are arranged so as to be intertwined in a complicated manner throughout the resin, and have a network structure (one wire-like conductor is complicated). Or a plurality of wire-like conductors are arranged in contact with each other to form a two-dimensional or three-dimensional network structure). Furthermore, such a wire-like conductor may be, for example, curved or needle-like.
- the first electrode 201 having a low volume resistivity can be realized by forming a network structure by contacting curved and / or needle-shaped conductors with each other. This network structure may be regular or non-regular.
- the volume resistivity of the first electrode 201 can be lowered by a wire-like conductor that forms a network structure.
- At least a part of the wire-shaped conductor may be disposed in the vicinity of the surface opposite to the transparent support base 1 on which the first electrode 201 is disposed (in this embodiment, the surface on the light emitting layer 202 side). preferable.
- the wire-like conductor By arranging the wire-like conductor in this way, the resistance of the surface portion of the first electrode 201 can be lowered.
- a material of such a wire-like conductor for example, a low resistance metal such as Ag, Au, Cu, Al, and alloys thereof is preferably used.
- the wire-like conductor is, for example, N.I. R. Jana, L. Gearheartt and C.I. J. et al. Murphy's method (Chm.
- Such an electrode (A) may have the same configuration as the electrode described in JP 2010-192472 A, and the manufacturing method thereof adopts the method described in JP 2010-192472 A. Can do.
- the film thickness of the first electrode 201 is appropriately set in consideration of required characteristics and process simplicity, and is, for example, 10 nm to 10 ⁇ m, preferably 20 nm to 1 ⁇ m. More preferably, it is 50 nm to 500 nm.
- the light emitting layer 202 may be a layer made of a known material that can be used for the light emitting layer (layer having a function of emitting light) of the organic EL element, and the material is not particularly limited, but is a light emitting layer made of an organic material. Preferably there is.
- a light emitting layer made of an organic material is not particularly limited.
- an organic material low molecular compound and high molecular compound
- the high molecular compound here has a polystyrene-equivalent number average molecular weight of 10 3 or more. Although there is no particular reason for defining such an upper limit of the number average molecular weight, the upper limit of the number average molecular weight in terms of polystyrene is usually preferably 10 8 or less.
- luminescent materials include dye-based materials, metal complex-based materials, and polymer-based materials.
- dye-based materials include cyclopentamine derivatives, tetraphenylbutadiene derivative compounds, triphenylamine derivatives, oxadiazole derivatives, pyrazoloquinoline derivatives, distyrylbenzene derivatives, distyrylarylene derivatives, pyrrole derivatives, Examples include thiophene ring compounds, pyridine ring compounds, perinone derivatives, perylene derivatives, oligothiophene derivatives, oxadiazole dimers, and pyrazoline dimers.
- metal complex-based material examples include aluminum quinolinol complex, benzoquinolinol beryllium complex, benzoxazolyl zinc complex, benzothiazole zinc complex, azomethyl zinc complex, porphyrin zinc complex, europium complex, etc.
- the polymer material includes polyparaphenylene vinylene derivatives, polythiophene derivatives, polyparaphenylene derivatives, polysilane derivatives, polyacetylene derivatives, polyfluorene derivatives, polyvinyl carbazole derivatives, the above chromophores and metal complex light emitting materials. And the like.
- materials that emit blue light include distyrylarylene derivatives, oxadiazole derivatives, and polymers thereof, polyvinylcarbazole derivatives, polyparaphenylene derivatives, polyfluorene derivatives, and the like. it can. Of these, polymer materials such as polyvinyl carbazole derivatives, polyparaphenylene derivatives, and polyfluorene derivatives are preferred.
- examples of the luminescent material that emits green light include quinacridone derivatives, coumarin derivatives, and polymers thereof, polyparaphenylene vinylene derivatives, polyfluorene derivatives, and the like. Of these, polymer materials such as polyparaphenylene vinylene derivatives and polyfluorene derivatives are preferred.
- examples of the luminescent material that emits red light include coumarin derivatives, thiophene ring compounds, and polymers thereof, polyparaphenylene vinylene derivatives, polythiophene derivatives, and polyfluorene derivatives.
- polymer materials such as polyparaphenylene vinylene derivatives, polythiophene derivatives, and polyfluorene derivatives are preferable.
- the light emitting layer 202 it is preferable to add a dopant for the purpose of improving the light emission efficiency and changing the light emission wavelength.
- dopants include perylene derivatives, coumarin derivatives, rubrene derivatives, quinacridone derivatives, squalium derivatives, porphyrin derivatives, styryl dyes, tetracene derivatives, pyrazolone derivatives, decacyclene, phenoxazone, and the like.
- the thickness of such a light emitting layer is usually preferably about 20 to 2000 mm.
- the formation method of the light emitting layer 202 is not particularly limited, and a known method can be appropriately employed. Among such formation methods of the light emitting layer 202, it is preferable to form by the coating method.
- the coating method is preferable in that the manufacturing process can be simplified and the productivity is excellent. Examples of such coating methods include casting methods, spin coating methods, bar coating methods, blade coating methods, roll coating methods, gravure printing, screen printing, and ink jet methods.
- a composition in a solution state containing a light emitter and a solvent is prepared as a coating solution, and this coating solution is formed into a desired layer or electrode by the predetermined coating method described above.
- a light emitting layer having a desired film thickness can be formed by applying it on the substrate and drying it.
- the second electrode 203 is an electrode having a polarity opposite to that of the first electrode 201, and is disposed to face the first electrode 201.
- the second electrode is a cathode.
- the material of the second electrode 203 is not particularly limited, and a known material can be used as appropriate.
- the work function is small, the electron injection into the light emitting layer is easy, and the electric conductivity is low. It is preferable to use high materials.
- the material of the second electrode 203 (cathode) is preferably a material having a high visible light reflectance.
- the material of the second electrode 203 for example, alkali metal, alkaline earth metal, transition metal, Group 13 metal of the periodic table, and the like can be used. More specifically, as the material of the second electrode 203 (cathode), lithium, sodium, potassium, rubidium, cesium, beryllium, magnesium, calcium, strontium, barium, aluminum, scandium, vanadium, zinc, yttrium, indium, Metals such as cerium, samarium, europium, terbium, ytterbium, two or more alloys of the metals, one or more of the metals, gold, silver, platinum, copper, manganese, titanium, cobalt, nickel, An alloy with one or more of tungsten and tin, graphite, or a graphite intercalation compound can be suitably used.
- Such alloys include magnesium-silver alloys, magnesium-indium alloys, magnesium-aluminum alloys, indium-silver alloys, lithium-aluminum alloys, lithium-magnesium alloys, lithium-indium alloys, calcium-aluminum alloys, etc. Can be mentioned.
- the second electrode 203 (cathode)
- a transparent conductive electrode made of a conductive metal oxide, a conductive organic material, or the like can be used as the second electrode 203 (cathode).
- the conductive metal oxide include indium oxide, zinc oxide, tin oxide, ITO, and IZO
- examples of the conductive organic substance include polyaniline or a derivative thereof, polythiophene or a derivative thereof, and the like.
- the 2nd electrode 203 (cathode) may be comprised by the laminated body which laminated
- the film thickness of the second electrode 203 (cathode) can be appropriately designed in consideration of required characteristics and process simplicity, and is not particularly limited, but is preferably 10 nm to 10 ⁇ m, preferably Is 20 nm to 1 ⁇ m, more preferably 50 nm to 500 nm.
- Examples of a method for producing the second electrode 203 (cathode) include a vacuum deposition method, a sputtering method, and a laminating method in which a metal thin film is thermocompression bonded.
- the second electrode 203 (cathode) is electrically connected to a connection portion (extraction electrode 203 (a)) that can be electrically connected to the outside.
- the extraction electrode 203 (a) is formed of the same material as the first electrode 201.
- Such an extraction electrode 203 (a) can be appropriately manufactured and designed by a known method.
- the portion of the extraction electrode 203 (a) is also patterned. It can be easily manufactured, for example, by forming a film.
- the sealing material layer 3 is disposed on the transparent support substrate 1 so as to cover and seal the light emitting element portion 2.
- a sealing material layer 3 is a layer disposed on the transparent support substrate 1 so as to seal the light emitting element portion 2, and is a known sealing material (for example, water vapor permeability is sufficiently low).
- a layer made of an adhesive sheet or the like can be used as appropriate. That is, such a sealing material layer 3 is a layer that covers the periphery of the light emitting element portion 2 on the transparent support substrate 1 and seals the light emitting element so that it does not come into contact with outside air.
- a connection portion for electrically connecting a pair of electrodes to the outside [for example, a connection wiring or a so-called extraction electrode portion (implementation shown in FIG. 1
- the portion indicated by 203 (a) connected to the second electrode 203 and the portion that can come into contact with the outside air of the first electrode 201 (a portion of the first electrode drawn out) correspond. .)] Is removed and sealed.
- the sealing material for forming such a sealing material layer 3 may be appropriately formed using any conventionally known suitable material in consideration of adhesiveness, heat resistance, barrier properties against moisture, oxygen, and the like.
- any conventionally known suitable material in consideration of adhesiveness, heat resistance, barrier properties against moisture, oxygen, and the like.
- an epoxy resin a silicone resin, an acrylic resin, a methacrylic resin, etc.
- the same materials as those described as the adhesive that can be used to form the adhesive layer are appropriately used. be able to.
- Such a sheet-like sealing material can be formed by appropriately forming by a known method.
- the thickness (t) of such a sealing material layer 3 has the thickness which can cover the light emitting element part 2 so that the light emitting element part 2 can be sealed.
- Well (only if it has a value larger than the height of the light emitting element portion 2 from the surface of the transparent support substrate 1), although not particularly limited, it is preferably 5 to 120 ⁇ m, preferably 5 to 60 ⁇ m. More preferably, it is 10 to 60 ⁇ m, further preferably 10 to 40 ⁇ m.
- the second electrode 203 and the sealing substrate 4 are easily in contact with each other at the time of bending, Not only can the short circuit not be sufficiently suppressed, but the light emission quality tends to be lowered, and the second electrode 203 is pressed and pressed by the irregularities on the surface of the sealing substrate 4 when bent, so that the first electrode 201 comes into contact. It tends to be short-circuited.
- the sealing substrate 4 is disposed on the sealing material layer 3. Since the sealing material layer 3 is disposed so as to cover the light emitting element portion 2, the light emitting element portion 2 and the sealing material layer 3 exist between the light emitting element portion 2 and the sealing substrate 4. It will be. Thus, the sealing substrate 4 is disposed on the sealing material layer 3 such that the light emitting element portion 2 and the sealing material layer 3 are interposed between the transparent support substrate 1 and the sealing substrate 4. .
- Such a sealing substrate 4 is formed from the surface of the surface opposite to the surface in contact with the transparent support substrate 1 of the sealing material layer 3 (the surface in contact with the sealing substrate 4) to the inside of the light emitting element portion 2. It is used from the viewpoint of more efficiently suppressing the intrusion of water vapor, oxygen, etc., and improving the heat dissipation.
- Such a sealing substrate 4 has a surface roughness of the surface S1 on the sealing material layer 3 side of the sealing substrate 4 on the basis of the arithmetic average roughness Ra of JIS B 0601-1994.
- One surface S2 is used so as to have a value smaller than the surface roughness (outside surface roughness).
- the arithmetic average roughness Ra of the surface S1 of the sealing substrate 4 is larger than the arithmetic average roughness Ra of the other surface S2 of the sealing substrate, when the organic EL element is bent, The uneven shape on the surface S1 of the sealing substrate 4 (the uneven shape present due to the roughness of the surface) is likely to cause a short circuit, for example, by scratching the light emitting element portion.
- the sealing is performed such that the arithmetic average roughness Ra of the surface S1 on the sealing material layer 3 side of the sealing substrate 4 is smaller than the arithmetic average roughness Ra of the other surface S2 of the sealing substrate.
- a stop substrate 4 is used.
- the surface roughness of the sealing substrate 4 is smoothed.
- the organic EL Not only is the economic efficiency of the device lowered and mass production becomes difficult, but if the surface is made too smooth, the adhesiveness with the sealing material layer 3 is lowered and easily peeled off, and the organic EL device can be used for a long time. It becomes difficult to use.
- the productivity of the organic EL element can be made sufficiently high.
- the arithmetic average roughness of the surface S1 on the sealing material layer 3 side of the sealing substrate 4 and the thickness of the sealing material layer 3 are represented by the following formula (I): 0.002 ⁇ (Ra / t) ⁇ 0.2 (I)
- Ra represents the arithmetic mean roughness of JIS B 0601-1994 on the surface of the sealing substrate on the sealing material layer side
- t represents the thickness of the sealing material layer.
- Adhesiveness with the sealing material layer 3 is lowered, and it is easy to peel off, and moisture enters from the interface between the sealing material layer 3 side surface of the sealing substrate 4 and the sealing material layer 3, and the organic EL element There is a tendency to accelerate deterioration. Moreover, since the thickness of the sealing material layer 3 tends to increase, moisture tends to enter from the portion exposed to the outside of the end portion of the sealing material layer 3 to accelerate the deterioration of the organic EL element. On the other hand, when the thickness is 0.2 or more, the unevenness of the surface of the sealing substrate 4 on the sealing material layer 3 side becomes large and the thickness of the sealing material layer 3 is relatively reduced.
- the ratio of the arithmetic average roughness Ra of the surface S1 of the sealing substrate 4 on the sealing material layer 3 side to the thickness t of the sealing material layer 3 is preferably in the range of 0.003 to 0.03, and more preferably in the range of 0.005 to 0.01.
- the thickness t of the sealing material layer 3 here refers to the thickness from the surface of the transparent support substrate 1 and has the same value as the distance between the transparent support substrate 1 and the sealing substrate 4.
- the arithmetic average roughness Ra of the surface S1 on the sealing material layer 3 side of the sealing substrate 4 is preferably 0.1 to 1.0 ⁇ m, and more preferably 0.2 to 0.5 ⁇ m. .
- the arithmetic average roughness Ra of the surface S1 is less than the lower limit, not only the adhesion to the sealant layer 3 is lowered, but also the heat radiation tends to be lowered.
- the EL element is bent, the peak of the convex portion of the surface breaks through the sealing material layer and the element is easily short-circuited, and the sealing substrate 4 and the second electrode 203 come into contact with each other to cause a short circuit.
- the sealing substrate 4 in the case of an element configured such that the sealing substrate 4 can be seen through the transparent support substrate 1, it tends to be low in appearance due to light reflection.
- the arithmetic average roughness Ra is less than or equal to the above upper limit, the surface of the sealing substrate 4 visible from the transparent support substrate 1 in the case of an element having a configuration in which the sealing substrate 4 can be seen through the transparent support substrate 1
- the surface roughness of S1 becomes a relatively small surface, and the design property tends to be further improved.
- the arithmetic average roughness Ra of the outer surface S2 of the sealing substrate 4 is preferably 0.25 to 3.8 ⁇ m, and more preferably 0.5 to 2.5 ⁇ m.
- the arithmetic average roughness Ra of the surface S2 is less than the lower limit, the surface area of the surface S2 is reduced, the amount of heat released from the light emitting element portion is reduced, and the organic EL element is heated to promote deterioration.
- a heat dissipation layer or a heat transfer layer is provided on the surface of the outer surface S2, the adhesiveness at the interface between the heat dissipation layer or the heat dissipation layer and the surface S2 is lowered and easily peeled off. The element tends to break down easily.
- the upper limit is exceeded, a special roughening step is applied to the surface S2, and the productivity tends to decrease.
- a contact type step surface roughness measuring device may be employed as a measuring device. Good.
- the ten-point average roughness Rz of JIS B 0601-1994 of the surface S1 on the sealing material layer 3 side of the sealing substrate 4 is preferably 0.4 to 4.0 ⁇ m, and 0.8 to 2. More preferably, it is 0 ⁇ m.
- the ten-point average roughness Rz is less than the lower limit, the adhesiveness to the sealing material layer 3 tends to be lowered.
- the upper limit is exceeded, the surface of the organic EL element is bent when bent. The peak of the convex portion tends to break through the sealing material layer and easily cause a short circuit in the organic EL element, and the sealing substrate 4 and the second electrode 203 tend to come into contact with each other to easily cause a short circuit.
- the ten-point average roughness Rz of JIS B 0601-1994 on the surface (outer surface) S2 of the sealing substrate 4 is preferably 1.0 to 15 ⁇ m, and more preferably 2 to 10 ⁇ m. More preferred.
- the ten-point average roughness Rz is less than the lower limit, the surface area of the surface S2 is reduced, the amount of heat released from the light emitting element portion is reduced, and the organic EL element is heated to promote deterioration.
- a heat dissipation layer or a heat transfer layer is provided on the surface S2, the adhesion at the interface between the heat dissipation layer or the heat dissipation layer and the surface S is reduced and the device is easily peeled off. It tends to be easier.
- the upper limit is exceeded, a special roughening process is used for the surface S2, and the productivity tends to deteriorate.
- a contact type step surface roughness measuring device is used as a measuring device. May be.
- the material of such a sealing substrate is not particularly limited, but is preferably made of any metal material of copper, copper alloy, aluminum, and aluminum alloy from the viewpoint of heat dissipation and processability.
- the sealing substrate made of such a metal material include aluminum foil (aluminum foil) and copper foil (copper foil).
- the copper foil produced by the electrolytic method has fewer pinholes, and water vapor, oxygen, and the like tend to have a higher effect in terms of preventing infiltration.
- it is made of a copper foil produced by an electrolytic method. That is, by using the copper foil (copper foil) manufactured by such an electrolytic method for the sealing substrate 4, it becomes possible to seal the organic EL more efficiently, thereby allowing moisture to enter from the pinhole of the copper foil. Thus, it is possible to more sufficiently suppress the deterioration of the organic EL element.
- limit especially as such an electrolysis method The well-known electrolysis method which can manufacture copper foil is employable suitably.
- the thickness of the sealing substrate 4 is not particularly limited, but is preferably 5 to 100 ⁇ m, more preferably 8 to 50 ⁇ m.
- the thickness of the sealing substrate 4 is less than the lower limit, it becomes difficult to sufficiently suppress the generation of pinholes during the manufacturing of the sealing substrate 4, and moisture penetrates from the pinholes to deteriorate the organic EL element.
- the upper limit is exceeded, the flexibility of the sealing substrate 4 decreases, and as a result, sealing is likely to occur.
- the organic EL device bonded with the stop substrate 4 is bent, the radius of curvature increases, and the flexibility of the organic EL element tends to decrease.
- the light emitting element on the transparent support substrate 1 is used.
- a sealing material made of an adhesive material is applied so as to cover the portion 2, a sealing substrate 4 is laminated thereon, and then the sealing material is fixed to seal the sealing material layer 3 and the sealing material.
- a method of laminating (arranging) the substrate 4 on the transparent support substrate 1 may be adopted.
- a layer made of a sealing material is formed in advance on the sealing substrate 4, and the layer made of the sealing material is formed on the sealing substrate 4 in which the layer made of the sealing material is a light emitting element portion.
- a method may be employed in which the sealing material layer 3 and the sealing substrate 4 are stacked (arranged) on the transparent support substrate 1 while being pressed so as to cover the periphery of the transparent support substrate 1.
- the distance between the sealing substrate 4 and the light emitting element portion 2 in the thickness direction (direction perpendicular to the sealing substrate 4) (the sealing material layer 3 between the light emitting element portion 2 and the sealing substrate 4).
- Thickness the distance between the surface of the second electrode 203 in contact with the sealing agent layer 3 and the surface S1 of the sealing substrate 4) is preferably 5 to 120 ⁇ m, and preferably 10 to 60 ⁇ m. More preferred.
- the contact between the substrate 203 and the sealing substrate 4 cannot be sufficiently suppressed, and it is difficult to sufficiently suppress the occurrence of a short circuit, and the light emitting quality tends to be lowered. Due to the unevenness on the surface of the stop substrate 4, pressure is applied to the second electrode 203, and the first electrode 201 is in contact with the first electrode 201. On the other hand, when the upper limit is exceeded, the surface of the sealing material layer that comes into contact with the outside air increases, and the lateral direction of the sealing material layer (direction perpendicular to the thickness direction: parallel to the surface of the transparent support substrate 1). The amount of water vapor entering from (direction) increases, and it tends to be difficult to suppress a decrease in storage life of the organic EL element at a higher level.
- the organic electroluminescent element of this invention is not limited to the said embodiment.
- the light-emitting element unit 2 includes a pair of electrodes (first electrode 201, second electrode 203) and a light-emitting layer 202 disposed between the electrodes.
- the light emitting element portion 2 may appropriately include other layers as long as the object and effect of the present invention are not impaired. Hereinafter, such other layers will be described.
- the layer other than the pair of electrodes (first electrode 201, second electrode 203) and the light emitting layer 202 that can be used in such an organic EL element known layers used in the organic EL element Can be used as appropriate, and examples thereof include a layer provided between the cathode and the light emission, and a layer provided between the anode and the light emission layer.
- the layer provided between the cathode and the light emitting layer include an electron injection layer, an electron transport layer, and a hole blocking layer. When only one layer is provided between the cathode and the light emitting layer, this layer is an electron injection layer.
- the layer in contact with the cathode is referred to as an electron injection layer, and the other layers are referred to as electron transport layers.
- Such an electron injection layer is a layer having a function of improving electron injection efficiency from the cathode
- the electron transport layer is a layer having a function of improving electron injection from the electron injection layer or the electron transport layer closer to the cathode. It is.
- these layers may be referred to as a hole blocking layer. Having such a function of blocking hole transport makes it possible, for example, to produce an element that allows only hole current to flow, and confirm the blocking effect by reducing the current value.
- Examples of the layer provided between the anode and the light emitting layer include a so-called hole injection layer, hole transport layer, and electron block layer.
- a layer is a hole injection layer.
- the layer in contact with the anode is a hole. It is called an injection layer, and the other layers are called a hole transport layer or the like.
- Such a hole injection layer is a layer having a function of improving the hole injection efficiency from the cathode
- the hole transport layer is a hole injection from the hole injection layer or the hole transport layer closer to the anode.
- the hole injection layer or the hole transport layer has a function of blocking electron transport
- these layers may be referred to as an electron block layer. Note that having the function of blocking electron transport makes it possible, for example, to produce an element that allows only electron current to flow, and confirm the blocking effect by reducing the current value.
- the structure of the light-emitting element portion including such other layers includes a structure in which an electron transport layer is provided between the cathode and the light-emitting layer, and a structure in which a hole transport layer is provided between the anode and the light-emitting layer. And a structure in which an electron transport layer is provided between the cathode and the light emitting layer and a hole transport layer is provided between the anode and the light emitting layer.
- the following structures a) to d) can be exemplified.
- the hole transport layer is a layer having a function of transporting holes
- the electron transport layer is a layer having a function of transporting electrons.
- the electron transport layer and the hole transport layer are collectively referred to as a charge transport layer.
- Two or more light emitting layers, hole transport layers, and electron transport layers may be used independently. Further, among the charge transport layers provided adjacent to the electrodes, those having a function of improving the charge injection efficiency from the electrodes and having the effect of lowering the driving voltage of the element are particularly charge injection layers (hole injection layers). , An electron injection layer).
- the charge injection layer or the insulating layer having a thickness of 2 nm or less may be provided adjacent to the electrode, and the adhesion at the interface may be increased.
- a thin buffer layer may be inserted at the interface between the charge transport layer and the light emitting layer. In this manner, the order and number of layers stacked on the light emitting element portion, and the thickness of each layer can be appropriately designed and used in consideration of light emission efficiency and element lifetime.
- the light emitting element portion (organic EL element portion) provided with such a charge injection layer (electron injection layer, hole injection layer) has a structure in which a charge injection layer is provided adjacent to the cathode, and is adjacent to the anode. And a structure having a charge injection layer.
- Examples of the structure of such a light emitting element part include the following structures e) to p).
- e) Anode / charge injection layer / light emitting layer / cathode f) Anode / light emitting layer / charge injection layer / cathode g) Anode / charge injection layer / light emitting layer / charge injection layer / cathode h) Anode / charge injection layer / hole Transport layer / light emitting layer / cathode i) anode / hole transport layer / light emitting layer / charge injection layer / cathode j) anode / charge injection layer / hole transport layer / light emitting layer / charge injection layer / cathode k) anode / charge Injection layer / light emitting layer / charge transport layer / cathode l) anode / light emitting layer / electron transport layer / charge injection layer / cathode m)
- the material of these other layers is not particularly limited, and a known material can be appropriately used.
- a manufacturing method thereof is not particularly limited, and a known method can be appropriately used.
- a hole transporting material for forming a hole transport layer which is a layer provided between an anode and a light emitting layer or between a hole injection layer and a light emitting layer, triphenylamines, bis , Heterocyclic compounds typified by pyrazoline derivatives and porphyrin derivatives, and polymer systems such as polycarbonates, styrene derivatives, polyvinyl carbazole, polysilanes and the like having the above monomers in the side chain.
- the film thickness of such a hole transport layer is preferably about 1 nm to 1 ⁇ m.
- a phenylamine system examples include starburst amine-based, phthalocyanine-based, vanadium oxide, molybdenum oxide, ruthenium oxide, aluminum oxide and other oxides, amorphous carbon, polyaniline, and polythiophene derivatives.
- an electron transport layer which can be provided between the light emitting layer and the cathode or between the light emitting layer and the electron injection layer, for example, oxadiazoles, aluminum quinolinol complexes, etc.
- oxadiazoles aluminum quinolinol complexes
- a substance that forms a stable radical anion and has a high ionization potential can be mentioned.
- Specific examples include 1,3,4-oxadiazole derivatives, 1,2,4-triazole derivatives, imidazole derivatives and the like.
- the thickness of the electron transport layer is preferably about 1 nm to 1 ⁇ m.
- an electron injection layer (it is a layer provided between an electron carrying layer and a cathode or between a light emitting layer and a cathode) among the said charge injection layers, according to the kind of light emitting layer, for example.
- An electron injection layer having a single layer structure of Ca layer, or a metal of group IA and IIA of the periodic table excluding Ca and having a work function of 1.5 to 3.0 eV and an oxide of the metal In addition, an electron injection layer having a laminated structure of a layer formed of any one or two or more of halides and carbonates and a Ca layer can be provided.
- Group IA metals or oxides, halides, and carbonates thereof having a work function of 1.5 to 3.0 eV include lithium, lithium fluoride, sodium oxide, lithium oxide, and lithium carbonate. Can be mentioned.
- metals of Group IIA of the periodic table excluding Ca having a work function of 1.5 to 3.0 eV or oxides, halides and carbonates thereof include strontium, magnesium oxide, magnesium fluoride, fluorine Strontium fluoride, barium fluoride, strontium oxide, magnesium carbonate and the like.
- the electron injection layer is formed by vapor deposition, sputtering, printing, or the like. The thickness of the electron injection layer is preferably about 1 nm to 1 ⁇ m.
- the gas barrier laminate film has been described with reference to FIG. 2 as a preferred example of the transparent support substrate 1 used in the device.
- the configuration of the gas barrier laminate film is not limited to the embodiment shown in FIG. 2, and may further include a thin film layer or may have another laminate structure.
- the gas-barrier laminated film further provided with a thin film layer for example, “first thin film layer / first base material layer / adhesive layer / second thin film layer / second base material layer / third thin film layer” Examples thereof include a gas barrier laminated film having a structure laminated in this order (where "/" indicates that each layer is laminated).
- the gas barrier laminate film having a structure laminated in this order of “first thin film layer / first base material layer / adhesive layer / second thin film layer / second base material layer / third thin film layer”
- the method includes the above-described steps (A) and (B) except that a second film member having a thin film layer formed on both sides is prepared and used. The same method as that described above can be adopted for appropriate production.
- Preparation Example 1 ⁇ Preparation of film member (A)> A biaxially stretched polyethylene naphthalate film (PEN film, thickness: adopting the same method as described in Example 1 of JP 2011-73430 A except that the degree of vacuum in the vacuum chamber was changed to 1 Pa.
- a laminated film laminated body laminated in the order of thin film layer / base material layer: hereinafter referred to as “film member (A)”) was obtained.
- film member (B) ⁇ Preparation of film member (B)> After obtaining the film member (A) as described above, the film member (A) is used instead of the substrate, and the film member (A) is formed on the surface on the side where the thin film layer is not formed.
- XPS depth profile measurement was performed on the thin film layers formed on the film members (A) and (B) under the following conditions to obtain a silicon distribution curve, an oxygen distribution curve, a carbon distribution curve, and an oxygen carbon distribution curve.
- the carbon distribution curve of each thin film layer has a plurality of distinct extreme values, the absolute value of the difference between the maximum value and the minimum value of the atomic ratio of carbon is 5 at% or more, and silicon
- the atomic ratio, the oxygen atomic ratio, and the carbon atomic ratio are represented by the formula (1): (Atomic ratio of oxygen)> (atomic ratio of silicon)> (atomic ratio of carbon) (1) It was confirmed that the conditions indicated in were satisfied.
- Etching ion species Argon (Ar + ) Etching rate (SiO 2 thermal oxide equivalent value): 0.05 nm / sec Etching interval (SiO 2 equivalent value): 10 nm
- X-ray photoelectron spectrometer Model “VG Theta Probe”, manufactured by Thermo Fisher Scientific Irradiation X-ray: Single crystal spectroscopy AlK ⁇ X-ray spot and size: 800 ⁇ 400 ⁇ m oval.
- the gas barrier property of such a film member (A) was measured by a method based on the calcium corrosion method (method described in JP-A-2005-283561). That is, after drying treatment, metal calcium is vapor-deposited on the film member, sealed with metal aluminum from above, fixed to glass, and sealed with resin. The temperature is 40 ° C. and the humidity is 90% RH.
- the water vapor permeability was calculated by examining the increase of the corrosion point with time in the image analysis. In calculating the water vapor transmission rate, the corrosion point is photographed with a microscope, the image is taken into a personal computer, the image of the corrosion point is binarized, and the corrosion area is calculated and obtained. The water vapor permeability was calculated.
- the water vapor permeability of the film member was 1 ⁇ 10 ⁇ 5 g / m 2 / day.
- gas barrier properties were measured by a method based on the above calcium corrosion method (method described in JP-A-2005-283561) using a sample consisting only of the substrate (PEN film), the substrate The gas barrier property was 1.3 g / m 2 / day. From these results, it was confirmed that the “water vapor permeability of the base material on which the thin film layer was formed” showed a value two or more digits smaller than the “water vapor permeability of the base material”. The thin film layer was confirmed to have gas barrier properties. From these results, it was found that the thin film layers in the film members (A) and (B) each have gas barrier properties.
- a thin film layer facing each other with a silicon rubber roll laminating apparatus having a rubber hardness of 60 was obtained.
- the time required to take out the two film members from the vacuum oven and start the process of bonding them was 10 minutes, and the time required for bonding was 15 minutes.
- the laminated structure of the gas barrier laminate film thus obtained is in the order of “first thin film layer / first base material layer / adhesive layer / second thin film layer / second base material layer / third thin film layer”. It became the laminated structure.
- the laminated structure portion of “first thin film layer / first base material layer” in the gas barrier laminate film is a structure derived from the film member (A), and “second thin film layer / second base material layer / first
- the laminated structure portion of “three thin film layers” is a structure derived from the film member (B).
- the gas barrier laminate film thus obtained was measured for the moisture absorption performance of the gas barrier laminate film as described above (the ratio Bn of the amount of moisture absorption described above). It was confirmed that the water can be absorbed and retained.
- Example 1 An ITO film having a thickness of 150 nm by sputtering using a metal shadow mask on the first thin film layer (thin film layer derived from the film member (A)) in the gas barrier laminate film obtained in Preparation Example 1. A pattern was formed. In this pattern formation, the ITO film is formed in a pattern so that two regions are formed on the surface of the gas barrier laminate film, and one region is used as an extraction electrode for the cathode, The region was used as an anode (ITO electrode).
- the with respect to the plane ITO film of the gas barrier laminate film (ITO electrode) are formed by performing UV-O 3 treatment for 15 minutes using a UV-O 3 apparatus (manufactured by Techno Vision Inc.) The surface on which the ITO film was formed was cleaned and surface-modified.
- a suspension of poly (3,4) ethylenedioxythiophene / polystyrene sulfonic acid (trade name “AI4083” manufactured by Heraeus) is applied on the surface of the gas barrier laminate film on which the ITO film is formed.
- the filtrate obtained by filtering with a 0.2 micron diameter filter was formed into a film by spin coating, dried in air at a temperature of 130 ° C. for 30 minutes on a hot plate, and 65 nm thick on the ITO film.
- a hole injection layer having a thickness was formed.
- a xylene solution in which a light emitting material (polymer compound 1) was dissolved in xylene as an organic solvent was prepared.
- a light emitting material (polymer compound 1) was prepared by a method similar to the method for preparing the composition 1 described in Example 1 of JP2012-144722A.
- the concentration of the polymer compound 1 in such a xylene solution was 1.2% by mass.
- the xylene solution is applied by spin coating on the surface on which the hole injection layer of the gas barrier laminate film on which the ITO film and the hole injection layer have been formed is formed in an air atmosphere by spin coating.
- a coating film for the light emitting layer having a thickness of 80 nm is formed, and then dried by holding for 10 minutes at a temperature of 130 ° C. in a nitrogen gas atmosphere in which the oxygen concentration and water concentration are each controlled to 10 ppm or less by volume.
- a light emitting layer was laminated on the hole injection layer.
- the hole injection layer and the light emitting layer formed on the contact portion with the external electrode (the portion of the extraction electrode for the anode and the cathode) are removed so that the contact with the external electrode becomes possible.
- the gas barrier laminated film on which the ITO film, the hole injection layer, and the light emitting layer are formed is transferred to the vapor deposition chamber, and the position of the light emitting layer is adjusted (aligned) with the cathode mask.
- the cathode In order to form the cathode so that the cathode is electrically connected to the portion of the cathode extraction electrode while the cathode is stacked on the surface, the cathode was deposited while rotating the mask and the substrate.
- the cathode thus formed is first heated to deposit sodium fluoride (NaF) at a deposition rate of about 0.5 mm / sec until the thickness reaches 4 nm, and then aluminum (Al) is deposited at a deposition rate of about 4 mm / sec. It was set as the structure laminated
- NaF sodium fluoride
- Al aluminum
- the thickness is 35 ⁇ m
- one surface hereinafter simply referred to as “first surface” in some cases for convenience
- the other surface hereinafter simply referred to as “second surface” in some cases for convenience
- the size is such that the cathode and the entire light-emitting layer are hidden, and a contact portion with an external electrode
- the electrolytic copper foil (sealing substrate 4) is viewed from the upper side as shown in FIG. It has a larger area than the cathode so that the cathode is not visible.
- One part of the contact portion with the outside formed on the gas barrier laminate film (a portion of the anode and cathode take-out electrode portion) has a size that can be seen to protrude outside the foil) It cut out using the roller cutter and prepared the sealing substrate.
- the copper foil thus prepared had a length of 40 mm, a width of 40 mm, and a thickness of 35 ⁇ m. Furthermore, as such a copper foil, an electrolytic copper foil produced by an electrolytic method was used.
- a two-pack type epoxy adhesive that cures at room temperature (25 ° C.) by mixing with a main agent composed of a bisphenol A type epoxy resin and a curing agent composed of a modified polyamide as a sealing material was prepared. Further, the sealing substrate (the copper foil) was heated in a nitrogen atmosphere at a temperature condition of 130 ° C. for 15 minutes to remove water adsorbed on the surface thereof (dried).
- a sealing material is applied to the sealing material so as to cover a light emitting portion composed of a laminated structure portion of ITO film / hole injection layer / light emitting layer / cathode, and a sealing substrate is formed on the sealing material layer. Sealing was performed by bonding a sealing substrate so that the light emitting layer and the light emitting layer face each other.
- the sealing material (adhesive) is applied so as to cover the laminated structure portion composed of ITO film / hole injection layer / light emitting layer / cathode (however, each electrode and the outside are electrically connected) Except for a part of the connecting part (extraction electrode part) for enabling the above-mentioned), and sealing material on the surface of the gas barrier laminate film after forming the cathode so as not to allow bubbles in nitrogen
- a light-emitting element part (ITO film / hole injection layer / light-emitting layer) is formed by bonding a sealing substrate on the (adhesive) layer so that the first surface (surface with Ra of 0.25 ⁇ m) is in contact therewith.
- Such an organic EL element is flexible and has a structure in which a hole injection layer is further laminated on the light emitting element portion 2 of the organic EL element of the embodiment shown in FIG.
- the light-emitting element portion 2 is different from the light-emitting element portion 2 shown in FIG. 1 in that the structure of the light-emitting element portion is different in that it further has a hole injection layer.
- the transparent support substrate 1 has a gas barrier property of a structure in which “first thin film layer / first base material layer / adhesive layer / second thin film layer / second base material layer / third thin film layer” are laminated in this order.
- FIG. 3 the schematic diagram at the time of seeing such an organic EL element from the sealing substrate side is shown in FIG.
- FIG. 3 when the organic EL element obtained in Example 1 is viewed from the sealing substrate 4 side, the transparent support substrate 1 and a portion drawn out of the anode 201 (connection portion with the outside: The portion of the extraction electrode), the connection portion (extraction electrode) 203 (a) between the cathode and the outside, and the sealing substrate 4 can be confirmed.
- the light emitting element portion (ITO film) was made while keeping a part of the extraction electrode of each electrode connectable to the outside. Sealing was performed so as to cover the periphery of (a laminated structure portion comprising / hole injection layer / light emitting layer / cathode) (see FIGS. 1 and 3).
- the arithmetic average roughness of the surface in contact with the sealing material layer of the sealing substrate is smaller than the arithmetic average roughness of the surface not in contact with the sealing material layer.
- the ratio (Ra / t) between the arithmetic average roughness Ra of the surface in contact with the sealing material layer and the thickness t of the sealing material layer was 0.025.
- the horizontal length X of the gas barrier laminate film (transparent support substrate 1) shown in FIG. 3 was 50 mm, and the horizontal length Y of the sealing substrate 4 was 40 mm.
- the size of the light emitting area (the area of the light emitting portion) in the light emitting element portion was 10 mm long and 10 mm wide.
- the sealing substrate is pasted on the sealing material layer so that the surface (first surface) having an arithmetic average roughness Ra of 0.25 ⁇ m is in contact with the sealing substrate.
- the sealing substrate was put on the sealing material layer so that the surface (second surface) having an arithmetic average roughness Ra of 2.4 ⁇ m was in contact with the sealing substrate.
- an organic EL device was produced.
- the arithmetic average roughness Ra of the surface in contact with the sealing material layer of the sealing substrate is larger than the arithmetic average roughness Ra of the surface not in contact with the sealing material layer.
- the ratio (Ra / t) between the arithmetic average roughness Ra of the surface in contact with the sealing material layer and the thickness t of the sealing material layer was 0.24.
- each organic EL element obtained in Example 1 and Comparative Example 1 had a current density of ⁇ 0.29 mA after the bending test. / Cm 2 (Example 1), ⁇ 0.4 mA / cm 2 or more (Comparative Example 1).
- the organic EL device obtained in Example 1 since the current density is -0.29mA / cm is 2 and after bending test at -0.29mA / cm 2 in the initial state, the bending It was found that there was no difference in current density values before and after the test (equivalent values), and no failure due to a short circuit (short circuit failure) occurred.
- the organic EL element obtained in Comparative Example 1 has a current density of ⁇ 0.29 mA / cm 2 in the initial state, but has a current density of ⁇ 0.4 mA / cm 2 or more after the bending test.
- the bending test it is confirmed by the bending test that the current density is large enough to exceed the measurement error, and it is confirmed that a failure due to a short circuit (short failure) has occurred after the bending test. It was.
- the organic EL element obtained in Example 1 had almost the same light emission state before and after the bending test, and the light emission quality was sufficiently maintained, whereas the comparative example In the organic EL device obtained in No. 1, the luminous quality could not be sufficiently maintained by a bending test, such as emission luminance being lowered or dark spots being generated.
- the organic electroluminescence element of the present invention is a highly reliable element that can sufficiently suppress a failure due to bending, for example, a flexible lighting device, a flexible planar light source, and a flexible display It can be suitably used for an apparatus or the like.
- SYMBOLS 1 Transparent support substrate, 2 ... Light emitting element part, 3 ... Sealing material layer, 4 ... Sealing substrate, 100 (a) ... 1st base material layer, 100 (b) ... 2nd base material layer, 101 (a): first thin film layer having gas barrier properties; 101 (b): second thin film layer having gas barrier properties; 102: adhesive layer; 201: first electrode; 202: light emitting layer; Second electrode, 203 (a): take-out electrode of second electrode, X: lateral length of transparent support substrate, Y: lateral length of sealing substrate, S1 and S2: surface of sealing substrate.
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Abstract
Description
0.002<(Ra/t)<0.2 (I)
[式(I)中、Raは前記封止基板の前記封止材層側の表面のJIS B 0601-1994の算術平均粗さを示し、tは前記封止材層の厚みを示す。]
に示す条件を満たすようにすることにより、有機EL素子を屈曲させた後に短絡(ショート)が発生することを十分に抑制することが可能となることを見出し、本発明を完成するに至った。
前記透明支持基板上に配置され、かつ一対の電極及び該電極間に配置されている発光層を備える発光素子部と、
前記発光素子部を覆って封止するように前記透明支持基板上に配置されている封止材層と、
前記封止材層上に配置されている封止基板と、
を備えており、
JIS B 0601-1994の算術平均粗さを基準として、前記封止基板の前記封止材層側の表面の表面粗さが、該封止基板のもう一方の表面の表面粗さよりも小さな値を有し、かつ、
前記封止基板の前記封止材層側の表面の前記算術平均粗さと、前記封止材層の厚みとが、下記式(I):
0.002<(Ra/t)<0.2 (I)
[式(I)中、Raは前記封止基板の前記封止材層側の表面のJIS B 0601-1994の算術平均粗さを示し、tは前記封止材層の厚みを示す。]
に示す条件を満たすものである。
前記透明支持基板上に配置され、かつ一対の電極及び該電極間に配置されている発光層を備える発光素子部と、
前記発光素子部を覆って封止するように前記透明支持基板上に配置されている封止材層と、
前記封止材層上に配置されている封止基板と、
を備えており、
JIS B 0601-1994の算術平均粗さを基準として、前記封止基板の前記封止材層側の表面の表面粗さが、該封止基板のもう一方の表面の表面粗さよりも小さな値を有し、かつ、
前記封止基板の前記封止材層側の表面の前記算術平均粗さと、前記封止材層の厚みとが、下記式(I):
0.002<(Ra/t)<0.2 (I)
[式(I)中、Raは前記封止基板の前記封止材層側の表面のJIS B 0601-1994の算術平均粗さを示し、tは前記封止材層の厚みを示す。]
に示す条件を満たすものである。
図1に示す透明支持基板1は、フレキシブル性(可撓性)を有するものである。ここにいう「フレキシブル性」としては、一般的なフレキシブルな有機EL素子の基板に要求されるような可撓性を有していてればよく特に制限されるものではないが、ガスバリア性の観点からは薄膜ガラス、軽量化、破壊耐性の観点からはプラスチック基材であることが好ましい。また、透明支持基板1は、有機EL素子の光取出し側の基板に利用することが可能な程度の光の透過性(透明性)を有するものであればよく、特に制限されるものではなく、有機EL素子用の光取出し側の基板に利用される公知の透明基板を適宜利用することができ、全光線透過率が80%以上の透明性を有するものを好適に利用できる。
[条件(A)]
JIS K 7126(2006年発行)に準拠した方法で測定された「基材のガス透過度(単位:mol/m2・s・P)」と「薄膜層を成膜した基材のガス透過度(単位:mol/m2・s・P)」を比較して、「基材のガス透過度」に対して「薄膜層を成膜した基材のガス透過度」の方が2桁以上小さい値(100分の1以下の値)を示すこと。
[条件(B)]
JIS K 7129(2008年発行)に記載される方法に準拠した方法で測定された「基材の水蒸気透過度(単位:g/m2・s・P)」と「薄膜層を成膜した基材の水蒸気透過度(単位:g/m2・s・P)」を比較して、「基材の水蒸気透過度」に対して「薄膜層を成膜した基材の水蒸気透過度」の方が2桁以上小さい値(100分の1以下の値)を示すこと。
[条件(C)]
特開2005-283561号公報に記載される方法に準拠した方法で測定された「基材の水蒸気透過度(単位:g/m2・s・P)」と「薄膜層を成膜した基材の水蒸気透過度(単位:g/m2・s・P)」を比較して、「基材の水蒸気透過度」に対して「薄膜層を成膜した基材の水蒸気透過度」の方が2桁以上小さい値(100分の1以下の値)を示すこと。
のうちの少なくとも1つの条件を満たすものであればよい。なお、一般的に、水蒸気バリア性(ガスバリア性)を有する薄膜層を成膜した基材の水蒸気透過度は10-2g/m2/day以下の値を示すことから、上記条件(B)及び(C)を検討する場合に、「薄膜層を成膜した基材の水蒸気透過度」が10-2g/m2/day以下の値となっていることが好ましい。また、このようなガスバリア性を有する薄膜層としては、上記条件(C)を満たすものがより好ましい。
該層の膜厚方向における該層の表面からの距離と、珪素原子、酸素原子及び炭素原子の合計量に対する珪素原子の量の比率(珪素の原子比)、酸素原子の量の比率(酸素の原子比)及び炭素原子の量の比率(炭素の原子比)との関係をそれぞれ示す珪素分布曲線、酸素分布曲線及び炭素分布曲線において、下記条件(i)~(iii):
(i)珪素の原子比、酸素の原子比及び炭素の原子比が、該層の膜厚の90%以上の領域において下記式(1):
(酸素の原子比)>(珪素の原子比)>(炭素の原子比)・・・(1)
で表される条件を満たすこと、
(ii)前記炭素分布曲線が少なくとも1つの極値を有すること、
(iii)前記炭素分布曲線における炭素の原子比の最大値及び最小値の差の絶対値が5at%以上であること、
を全て満たす珪素酸化物系の薄膜層であることが特に好ましい。
(酸素の原子比)>(珪素の原子比)>(炭素の原子比)・・・(1)
で表される条件を満たすことが必要である。珪素の原子比、酸素の原子比及び炭素の原子比が前記条件を満たさない場合には、得られるガスバリア性積層フィルムのガスバリア性が不十分となる。
(dC/dx)≦ 0.5 ・・・(F1)
で表される条件を満たすことをいう。
[吸湿量の割合Bn]={(Wn-W1)/W1}×100
を計算することにより求められる値を、本発明においては、ガスバリア性積層フィルムの吸湿性能として採用する。
前記第一のフィルム部材の基材層の表面上に第二のフィルム部材中の第二の薄膜層が積層するように接着剤を用いて貼り合せることによりガスバリア性積層フィルムを得る工程(工程(B))と、
を含む方法を採用することが好ましい。以下、これらの工程(A)及び(B)を分けて説明する。
工程(A)は、前記第一及び第二のフィルム部材を準備する工程である。このような第一及び第二のフィルム部材を準備する方法は特に制限されず、公知の方法を適宜採用することができる。例えば、基材上の少なくとも一方の表面上にガスバリア性を有する薄膜層を形成して、基材層と薄膜層とを備えるフィルム部材(第一及び第二のフィルム部材)を製造することが可能な方法を適宜採用することにより準備してもよく、また、市販の基材層とガスバリア性を有する薄膜層とを備えるフィルム部材(積層体)により、フィルム部材(第一及び第二のフィルム部材)を準備してもよい。また、前記薄膜層を基材上に形成する場合、そのような薄膜層の成膜が可能な公知の方法を適宜採用することができるが、ガスバリア性の観点から、プラズマ化学気相成長法(プラズマCVD)を採用することが好ましい。なお、前記プラズマ化学気相成長法はペニング放電プラズマ方式のプラズマ化学気相成長法であってもよい。また、このような前記薄膜層を基材上に形成する方法としては、特開2011-73430号公報に記載された方法を採用することが好ましく、これにより前述の珪素酸化物系の薄膜層を、基材上に効率よく形成することができる。
工程(B)は、前記第一のフィルム部材の基材層の表面上に第二のフィルム部材中の第二の薄膜層が積層するように接着剤を用いて貼り合せることによりガスバリア性積層フィルムを得る工程である。
発光素子部2は、一対の電極及び該電極間に配置されている発光層を備えるものである。このような発光素子部2を構成する一対の電極(第一電極201、第二電極203)及び該電極間に配置されている発光層202としては、特に制限されず、公知の有機EL素子に利用されている電極や発光層を適宜利用することができる。例えば、光の取り出し面側の電極を透明又は半透明として、発光層に低分子及び/又は高分子の有機発光材料を用いること等が挙げられる。以下、このような第一電極201、発光層202、第二電極203について分けて説明する。
第一電極201は、陽極および陰極のうちの一方の電極である。図1に示す実施形態の発光素子部2において、第一電極201は、素子部2の外部に発光層202から放射される光を出射することを可能とすべく、光透過性を示す電極(透明又は半透明の電極)を用いる。このような図1に示す実施形態においては、光透過性を示す第一電極201を陽極として利用する。
発光層202としては、有機EL素子の発光層(発光する機能を有する層)に利用できる公知の材料からなる層とすればよく、その材料等は特に制限されないが、有機材料からなる発光層であることが好ましい。このような、有機材料からなる発光層としては特に制限されないが、例えば、発光性材料としての蛍光又はりん光を発光する有機物(低分子化合物および高分子化合物)と、これを補助するドーパントとから形成される層とすることが好ましい。なお、ここにいう高分子化合物とは、ポリスチレン換算の数平均分子量が103以上のものである。なお、このような数平均分子量の上限を規定する理由は特にないが、ポリスチレン換算の数平均分子量の上限は通常、108以下であることが好ましい。
第二電極203は、第一電極201とは反対の極性を有する電極であり、第一電極201に対向して配置されるものである。なお、図1に示す実施形態において、第2電極は陰極である。
封止材層3は、発光素子部2を覆って封止するように透明支持基板上1に配置されている。このような封止材層3は、発光素子部2を封止するようにして、透明支持基板1上に配置される層であり、公知の封止材(例えば、水蒸気透過性が十分に低い接着材のシート等)からなる層を適宜利用することができる。すなわち、このような封止材層3は、透明支持基板1上において発光素子部2の周囲を覆うようにして、発光素子が外気と接触することのないように封止する層である。なお、このような封止に際しては、発光素子として機能させるために、一対の電極を外部と電気的に接続するための接続部[例えば、接続配線やいわゆる取り出し電極の部分(図1に示す実施形態においては、第二電極203と接続された203(a)で示す部分並びに第一電極201の外気と接触可能となっている部分(外部に引き出されている第一電極の一部分)が相当する。)]は除いて封止する。
封止基板4は、封止材層3上に配置されている。なお、封止材層3は発光素子部2を覆うように配置されているため、発光素子部2と封止基板4との間には、発光素子部2及び封止材層3が存在することとなる。このように、封止基板4は、透明支持基板1と封止基板4との間に発光素子部2及び封止材層3が介在するように、封止材層3上に配置されている。このような封止基板4は、封止材層3の透明支持基板1と接する面とは反対側の面の表面(封止基板4と接触している面)から、発光素子部2の内部に水蒸気や酸素などが浸入することをより効率よく抑制するとの観点や放熱性を向上させるとの観点から用いられるものである。
0.002<(Ra/t)<0.2 (I)
[式(I)中、Raは前記封止基板の前記封止材層側の表面のJIS B 0601-1994の算術平均粗さを示し、tは前記封止材層の厚みを示す。]
に示す条件を満たす必要がある。このような算術平均粗さRaと封止材層3の厚みtとの比(Ra/t)が0.002以下では、封止基板4の封止材層3側の表面が平滑になりすぎ封止材層3との密着性が低下し、剥がれやすくなるとともに、封止基板4の封止材層3側の表面と封止材層3との界面から水分が侵入し、有機EL素子の劣化を速めてしまう傾向にある。また、封止材層3の厚みが増す傾向になるので、封止材層3端部の外部に露出している部分から水分が侵入し有機EL素子の劣化を速めてしまう傾向にある。他方、0.2以上では、封止基板4の封止材層3側の表面の凹凸が大きくなり、相対的に封止材層3の厚みが減少するので、屈曲時に第二電極203と封止基板4とが容易に接触して、ショートを十分に抑制できないばかりか、発光品位が低下し易くなる傾向にあり、また、屈曲時に封止基板4表面の凹凸により第二電極203に圧力がかかり押され、第一電極201が接触することでショートしてしまう傾向にある。また、同様の観点で、より高い効果が得られることから、封止基板4の封止材層3側の表面S1の算術平均粗さRaと、封止材層3の厚みtとの比(Ra/t)は、0.003~0.03の範囲にあることが好ましく、0.005~0.01の範囲にあることがより好ましい。なお、ここにいう封止材層3の厚みtは、透明支持基板1の表面からの厚みをいい、透明支持基板1と封止基板4と間の距離と同じ値となる。
a)陽極/発光層/陰極 (図1に示す実施形態)
b)陽極/正孔輸送層/発光層/陰極
c)陽極/発光層/電子輸送層/陰極
d)陽極/正孔輸送層/発光層/電子輸送層/陰極
(ここで、/は各層が隣接して積層されていることを示す。以下同じ。)
ここで、正孔輸送層とは、正孔を輸送する機能を有する層であり、電子輸送層とは、電子を輸送する機能を有する層である。なお、以下において、電子輸送層と正孔輸送層を総称して電荷輸送層と呼ぶ。また、発光層、正孔輸送層、電子輸送層は、それぞれ独立に2層以上用いてもよい。また、電極に隣接して設けた電荷輸送層のうち、電極からの電荷注入効率を改善する機能を有し、素子の駆動電圧を下げる効果を有するものは、特に電荷注入層(正孔注入層、電子注入層)と一般に呼ばれることがある。
e)陽極/電荷注入層/発光層/陰極
f)陽極/発光層/電荷注入層/陰極
g)陽極/電荷注入層/発光層/電荷注入層/陰極
h)陽極/電荷注入層/正孔輸送層/発光層/陰極
i)陽極/正孔輸送層/発光層/電荷注入層/陰極
j)陽極/電荷注入層/正孔輸送層/発光層/電荷注入層/陰極
k)陽極/電荷注入層/発光層/電荷輸送層/陰極
l)陽極/発光層/電子輸送層/電荷注入層/陰極
m)陽極/電荷注入層/発光層/電子輸送層/電荷注入層/陰極
n)陽極/電荷注入層/正孔輸送層/発光層/電荷輸送層/陰極
o)陽極/正孔輸送層/発光層/電子輸送層/電荷注入層/陰極
p)陽極/電荷注入層/正孔輸送層/発光層/電子輸送層/電荷注入層/陰極
なお、発光層と他の層(例えば、後述する電荷輸送層等)とを積層する場合には、発光層を設ける前に、陽極上に正孔輸送層を形成する、または、発光層を設けた後に電子輸送層を形成することが望ましい。また、これらの他の層の材料は特に制限されず、公知の材料を適宜利用することができ、その製造方法も特に制限されず、公知の方法を適宜利用することができる。例えば、陽極と発光層との間、又は正孔注入層と発光層との間に設けられる層である、正孔輸送層を形成する正孔輸送性材料としては、トリフェニルアミン類、ビス類、ピラゾリン誘導体、ポリフィリン誘導体に代表される複素環化合物、ポリマー系では前記単量体を側鎖に有するポリカーボネート、スチレン誘導体、ポリビニルカルバゾール、ポリシラン等が挙げられる。また、このような正孔輸送層の膜厚としては、1nm~1μm程度が好ましい。
〈フィルム部材(A)の調製〉
真空チャンバー内の真空度を1Paに変更した以外は特開2011-73430号公報の実施例1に記載の方法と同様の方法を採用して、2軸延伸ポリエチレンナフタレートフィルム(PENフィルム、厚み:100μm、幅:350mm、帝人デュポンフィルム(株)製、商品名「テオネックスQ65FA」)からなる基材上にプラズマCVD法による薄膜形成を行い、厚みが1.2μmの薄膜層が形成された基材からなる積層フィルム(薄膜層/基材層の順に積層された積層体:以下「フィルム部材(A)」という。)を得た。
上述のようにしてフィルム部材(A)を得た後、前記基材の代わりにフィルム部材(A)を用いて、フィルム部材(A)の薄膜層が形成されていない側の表面上に、フィルム部材(A)の調製時に採用した成膜条件と同様の条件を採用して新たに薄膜層を形成して、厚みが1.2μmの薄膜層が両面に形成された基材からなる積層フィルム((薄膜層/基材層/薄膜層の順に積層された積層体:以下「フィルム部材(B)」という。)を得た。
(酸素の原子比)>(珪素の原子比)>(炭素の原子比)・・・(1)
で示された条件を満たしていることが確認された。
〈XPSデプスプロファイル測定の条件〉
エッチングイオン種:アルゴン(Ar+)
エッチングレート(SiO2熱酸化膜換算値):0.05nm/sec
エッチング間隔(SiO2換算値):10nm
X線光電子分光装置:Thermo Fisher Scientific社製、機種名「VG Theta Probe」
照射X線:単結晶分光AlKα
X線のスポット及びそのサイズ:800×400μmの楕円形。
上述のようにして得られたフィルム部材(A)とフィルム部材(B)とを共に真空オーブン中で100℃の温度条件で360分間乾燥した。その後、前記2枚のフィルム部材を真空オーブンから大気中(気温:25℃、相対湿度:50%、重量絶対湿度:10g/kg(乾燥空気))に取り出し、接着剤としてビスフェノールA型エポキシ樹脂からなる主剤からなる主剤と変性ポリアミドからなる硬化剤との混合により室温(25℃)で硬化する2液型エポキシ接着剤を用いて、フィルム部材(A)の基材側の表面とフィルム部材(B)の薄膜層とが向かい合うようにして、ゴム硬度60のシリコンゴムロールの貼合装置で貼り合わせて、ガスバリア性積層フィルムを得た。ここにおいて、前記2枚のフィルム部材を真空オーブンから取り出して、これらを貼り合せる工程を開始するまでに要した時間は10分であり、貼り合せに要した時間は15分であった。このように、乾燥工程後の前記2枚のフィルム部材を真空オーブンから取り出してガスバリア性積層フィルムを形成するまでに合計25分の時間を要した。このようにして得られたガスバリア性積層フィルムの積層構造は「第一薄膜層/第一基材層/接着剤層/第二薄膜層/第二基材層/第三薄膜層」の順で積層した構造となった。なお、ガスバリア性積層フィルム中の「第一薄膜層/第一基材層」の積層構造部分はフィルム部材(A)に由来する構造であり、「第二薄膜層/第二基材層/第三薄膜層」の積層構造部分はフィルム部材(B)に由来する構造である。また、このようにして得られたガスバリア性積層フィルムは、上述のようにしてガスバリア性積層フィルムの吸湿性能(前述の吸湿量の割合Bn)を測定したところ、自重の0.29質量%の重さの水を吸収して保持することが可能なものであることが確認された。
調製例1で得られたガスバリア性積層フィルム中の前記第一薄膜層(フィルム部材(A)に由来する薄膜層)上に、メタルシャドウマスクを用いて、スパッタリング法にて膜厚150nmのITO膜をパターン成膜した。なお、かかるパターン成膜において、ITO膜は、前記ガスバリア性積層フィルムの表面上において2つの領域が形成されるようにパターン成膜され、一方の領域を陰極用の取り出し電極として利用し、他方の領域を陽極(ITO電極)として利用した。
前記封止用積層体の製造時に、前記封止基板の算術平均粗さRaが0.25μmの表面(第一の表面)が接触するように前記封止材層上に前記封止基板を貼り合せる代わりに、前記封止基板の算術平均粗さRaが2.4μmの表面(第二の表面)が接触するように前記封止材層上に前記封止基板を貼り合せた以外は、実施例1と同様にして、有機EL素子を製造した。このような有機EL素子は、前記封止基板の封止材層と接触している面の算術平均粗さRaが封止材層と接触していない面の算術平均粗さRaよりも大きな値を有し、封止材層と接触している面の算術平均粗さRaと、封止材層の厚みtとの比(Ra/t)が0.24となっていた。
実施例1及び比較例1で得られた各有機EL素子に、逆バイアス電圧を印加してから、順バイアス電圧を印加して発光させた。そして、逆バイアス電圧-5Vの時の電流密度を測定したところ、実施例1及び比較例1で得られた各有機EL素子の初期状態のもの(後述の屈曲試験前の状態のもの)は、電流密度はそれぞれ-0.29mA/cm2(実施例1)、-0.29mA/cm2(比較例1)であった。なお、このような電流密度は測定装置として、直流電電装置とマルチメーターをを用いて電流電圧を測定することで測定した。
Claims (5)
- フレキシブル性を有する透明支持基板と、
前記透明支持基板上に配置され、かつ一対の電極及び該電極間に配置されている発光層を備える発光素子部と、
前記発光素子部を覆って封止するように前記透明支持基板上に配置されている封止材層と、
前記封止材層上に配置されている封止基板と、
を備えており、
JIS B 0601-1994の算術平均粗さを基準として、前記封止基板の前記封止材層側の表面の表面粗さが、該封止基板のもう一方の表面の表面粗さよりも小さな値を有し、かつ、
前記封止基板の前記封止材層側の表面の前記算術平均粗さと、前記封止材層の厚みとが、下記式(I):
0.002<(Ra/t)<0.2 (I)
[式(I)中、Raは前記封止基板の前記封止材層側の表面のJIS B 0601-1994の算術平均粗さを示し、tは前記封止材層の厚みを示す。]
に示す条件を満たす、有機エレクトロルミネッセンス素子。 - 前記封止基板の前記封止材層側の表面の算術平均粗さが0.1~1.0μmである、請求項1に記載の有機エレクトロルミネッセンス素子。
- 前記封止材層の厚みが5~120μmである、請求項1又は2に記載の有機エレクトロルミネッセンス素子。
- 前記封止基板が、銅、銅合金、アルミニウム及びアルミニウム合金のうちのいずれかの金属材料からなる、請求項1~3のうちのいずれか一項に記載の有機エレクトロルミネッセンス素子。
- 前記封止基板が、電解法で製造された銅箔からなる、請求項1~4のうちのいずれか一項に記載の有機エレクトロルミネッセンス素子。
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