JP2012028638A - Organic electroluminescent panel, organic electroluminescent device, and method of manufacturing organic electroluminescent panel - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide a novel organic EL panel, a method of manufacturing the same, and an organic EL device capable of making a seam between the organic EL panels inconspicuous.SOLUTION: The organic EL panel includes a support substrate having light permeability, a transparent electrode layer formed on the support substrate, an organic EL layer which is formed on the transparent electrode layer and includes a light emission layer, and a rear surface electrode layer which is formed on the organic EL layer and has light impermeability. An organic EL element having the transparent electrode layer, the organic EL layer, and the rear surface electrode layer is enclosed in the panel. The organic EL panel also has a rear surface electrode layer removal part where no rear surface electrode layer is formed at an outer edge of the rear surface electrode layer near at least one of the panels so that the rear surface electrode layer of the organic EL panel does not overlap with a light emission region of the other organic EL panel in the vicinity where a part of the rear surface electrode layers overlap each other, when the other organic EL panel is arranged on the side of the rear surface electrode layer of the organic EL panel so that a part of the rear surface electrode layers overlap each other.

Description

  The present invention relates to a large panel in which a plurality of organic electroluminescence panels are arranged.

  An organic electroluminescence panel (hereinafter, electroluminescence may be abbreviated as EL) panel includes an organic EL element as a light-emitting element, and is a self-luminous type that can be used for various applications such as a display device, a lighting device, and a light source. It is a panel.

  In recent years, there has been a growing demand for larger organic EL panels, and studies are being made to construct a large organic EL panel by joining small organic EL panels together. However, since a joint between small organic EL panels exists as a non-display area, there is a problem that visibility is inferior. Therefore, a technique for making the joint between organic EL panels inconspicuous has been studied.

  In Patent Document 1, in order to prevent recognition of image breaks between unit flat display elements, the interval between adjacent unit flat display elements is set to 200 μm or less, in particular, the pixel interval between unit flat display elements is a, unit plane 0.6a ≦ b + c + d ≦ 1.3a, where b and c are the distance between the end face of the display element and the outermost peripheral pixel (width of the non-display area in the outer peripheral portion) and d is the distance between the adjacent unit flat display elements. It has been proposed that

In Patent Document 2, for the purpose of reducing the width of the joint of the display panel, the wiring input portion is drawn to the region where the sealing portion is formed (non-display region) and drawn from the lower side of the substrate. A technique is disclosed in which an input portion of wiring of a display panel arranged on the upper side is hidden by a display panel arranged on the lower side.
In Patent Document 3, a plurality of EL display panels in which a light emitting layer is formed between a transparent electrode and a back electrode are connected for the purpose of making a joint of adjacent EL display panels inconspicuous. In the EL display device, the EL display panel includes a power supply unit connected to the transparent electrode, and a protruding portion protruding outward by a length in the width direction of the power supply unit on a part of one of the panel sides. EL display panels in which adjacent EL display panels are arranged and connected so that at least part of the power supply section of one EL display panel is hidden under the back electrode of the other EL display panel Is disclosed.

  In Patent Document 4, for the purpose of improving the discontinuity of the screen at the joint between the panels, at least one of the adjacent pair of panels has a step portion, and the step portion has 2 steps. A multi-display in which two panels are engaged is disclosed.

In Patent Document 5, as a light-emitting panel in which a joint portion between surface light-emitting elements is hardly visible, an electrode composed of a light-impermeable central part and a light-transmitting peripheral part is used as a second electrode of the surface light-emitting element. There has been proposed a light-emitting panel in which a plurality of surface light-emitting elements are arranged so that part of a light-emitting region overlaps each other.
In Patent Document 6, as a surface light emitting panel in which the boundary between surface light emitting elements is difficult to be visually recognized, a top emission type surface light emitting element and a bottom emission type surface light emitting element are used, and the light emission direction of the top emission type surface light emitting element is surface emitting. This is a surface emitting panel arranged so as to be in the light emission direction of the panel, and the light emitting area of the top emission type surface light emitting element and the light emitting area of the bottom emission type surface light emitting element are joined or overlapped. A surface emitting panel has been proposed.

Japanese Patent Laid-Open No. 2004-302087 JP 2004-177891 A JP-A-2005-123153 JP 2008-83701 A JP 2010-62011 A JP 2010-80271 A

Since light emission characteristics of organic EL elements deteriorate when moisture is present, a sealing structure for shielding the organic EL elements from the atmosphere is necessary to stably operate the organic EL panel for a long time.
For example, in Patent Document 1, the interval between adjacent unit flat display elements and the interval between the end surface of the unit flat display element and the outermost peripheral pixel (the width of the non-display area in the outer peripheral portion) are reduced within a predetermined range. By doing so, it becomes possible not to recognize the break of the image between the unit flat display elements. However, when the unit flat display element is an organic EL panel, if the interval between the end face of the unit flat display element and the outermost pixel (the width of the non-display area in the outer peripheral portion) is reduced, the organic EL element is sufficiently sealed The problem arises that it cannot be applied. In particular, this problem becomes significant when the pixel interval is small.

Moreover, in patent document 5, in order to make it difficult to visually recognize the junction part between surface emitting elements, it is necessary to form two types of electrodes, a light-impermeable electrode and a light-transmissive electrode, separately as the second electrode. Yes, productivity is inferior. In Patent Document 6, in order to make it difficult to visually recognize the boundary between the surface light emitting elements, it is necessary to separately produce two different types of surface light emitting elements, a top emission type surface light emitting element and a bottom emission type surface light emitting element. In some cases, productivity is inferior.
Further, as described in Patent Documents 5 and 6, for example, when a plurality of organic EL panels are arranged so that part of the light emitting areas overlap each other, part of the light emitting areas of the organic EL panel are mutually connected. There is a possibility that the luminance of the overlapping portion is higher than the luminance of the other portion, and the seam is conspicuous. Furthermore, in the case of an organic EL panel for full color display, there is a problem that color mixing occurs in a portion where the light emitting areas of the organic EL panel overlap each other.

  The present invention has been made in view of the above problems, and a plurality of novel organic EL panels, a method for manufacturing the same, and a plurality of organic EL panels that can make the joints between the organic EL panels inconspicuous are arranged. The main object is to provide an organic EL device.

  In order to achieve the above object, the present invention provides a light-transmitting support substrate, a transparent electrode layer formed on the support substrate, and an organic EL layer formed on the transparent electrode layer and including a light emitting layer. And a back electrode layer that is formed on the organic EL layer and has light impermeability, and the organic EL element having the transparent electrode layer, the organic EL layer, and the back electrode layer is sealed. An organic EL panel, wherein another organic EL panel is disposed on the back electrode layer side of the organic EL panel, a part of the back electrode layer of the organic EL panel, and a part of a back electrode layer of the other organic EL panel Are arranged so that they overlap each other so that the back electrode layer of the organic EL panel and the light emitting region of the other organic EL panel do not overlap in the vicinity of the portion where the part of the back electrode layer overlaps each other. At least one The outer edge of the back electrode layer of the panel straight sides, to provide an organic EL panel, characterized in that it comprises a back electrode layer removal portion in which the back electrode layer is not formed.

  According to the present invention, in the case where a plurality of organic EL panels are arranged by forming a predetermined back electrode layer removing portion on the outer edge of the back electrode layer in the vicinity of at least one panel side, the organic EL panel The seam between the two can be made inconspicuous, and the visibility can be improved. In addition, since the predetermined back electrode layer removal portion is formed, the seam between the organic EL panels can be made inconspicuous, so the non-display area on the outer periphery of the organic EL panel can be arbitrarily set, It is possible to secure a sufficient region for sealing the organic EL element.

  In the said invention, it is preferable that the said transparent electrode layer is not formed in the said back surface electrode layer removal part. When a plurality of organic EL panels are arranged so that some of them overlap each other, the decrease in luminance due to the transparent electrode layer in the portion where some of the organic EL panels overlap each other is suppressed, luminance unevenness is reduced, and organic EL This is because the joints between the panels can be made less noticeable.

  Moreover, in this invention, it is preferable that the insulating layer is formed on the said support substrate in which the said transparent electrode layer was formed, and the said insulating layer is not formed in the said back surface electrode layer removal part. Similarly to the above case, when a plurality of organic EL panels are arranged so that they partially overlap each other, the luminance decrease due to the insulating layer in the part where the organic EL panels partially overlap each other is suppressed, and luminance unevenness is reduced. This is because the seam between the organic EL panels can be made less noticeable.

  Furthermore, in the present invention, at least one constituent layer of the layers constituting the organic EL layer is formed on one surface on the support substrate on which the transparent electrode layer is formed, and the back electrode layer removing portion is formed on the back electrode layer removing portion. It is preferable that the constituent layer is not formed. Similarly to the above case, when a plurality of organic EL panels are arranged so that they partially overlap each other, the luminance decrease due to the organic EL layer in the part where the organic EL panels partially overlap each other is suppressed, and luminance unevenness is suppressed. This is because the seam between the organic EL panels can be made less noticeable.

  Furthermore, in the present invention, the thickness of the organic EL panel is preferably 300 μm or less. If the thickness of the organic EL panel is within the above range, when a plurality of organic EL panels are arranged so that they partially overlap each other, the level difference in the portion where the organic EL panels partially overlap each other can be reduced. This is because the seam between the organic EL panels can be made less noticeable and the visibility can be improved.

  In the present invention, the extraction electrode for the transparent electrode layer connected to the transparent electrode layer is formed on the support substrate in the vicinity of one panel side, and the back surface is formed on the support substrate in the vicinity of the other panel side. An extraction electrode for the back electrode layer connected to the electrode layer is formed, and an outer edge of the back electrode layer in the vicinity of the two panel sides where the extraction electrode for the transparent electrode layer and the extraction electrode for the back electrode layer are not formed In addition, it is preferable that the back electrode layer removal portion is formed. A back electrode layer removal portion can be formed on the outer edge of the back electrode layer in the vicinity of the panel side where the transparent electrode layer extraction electrode and the back electrode layer extraction electrode are not formed. The back electrode layer removal portion is formed on the outer edge of the back electrode layer in the vicinity of the two panel sides where the extraction electrode for the back electrode layer is not formed, so that the seam between the organic EL panels is not noticeable. This is because a plurality of organic EL panels can be arranged both in the vertical direction and in the vertical direction, and the size can be easily increased.

  The present invention also relates to an organic EL device in which a plurality of the above-mentioned organic EL panels are arranged so that a part of the back electrode layers overlap each other and the light emitting regions do not overlap each other. Of the organic EL panels whose parts overlap each other, the one organic EL panel located on the light emitting surface side is located near the portion where the back electrode layers partially overlap each other. An organic EL device having a back electrode layer removing portion in which the back electrode layer is not formed so that the back electrode layer of the organic EL panel does not overlap the light emitting region of another organic EL panel I will provide a.

  According to the present invention, among the organic EL panels in which part of the back electrode layer overlaps with each other, one organic EL panel located on the light emission surface side is in the vicinity of the part in which part of the back electrode layer overlaps with each other. Therefore, the joint between the organic EL panels can be made inconspicuous, and the visibility can be improved. In addition, since the predetermined back electrode layer removal portion is formed, the seam between the organic EL panels can be made inconspicuous, so the non-display area on the outer periphery of the organic EL panel can be arbitrarily set, It is possible to secure a sufficient region for sealing the organic EL element.

  In the above invention, a light transmitting front substrate is disposed on the light emitting surface side of the plurality of organic EL panels, and the light transmitting resin is provided between the plurality of organic EL panels and the front substrate. It is preferable that the refractive index of the support substrate of the organic EL panel, the front substrate, and the resin is substantially the same. This is because the light emission surface of the organic EL device can be flattened and the visibility can be further improved.

  In the present invention, a color filter layer may be formed outside the front substrate. This is because the color purity can be increased.

  Furthermore, the present invention provides a light-transmissive support substrate, a transparent electrode layer formed on the support substrate, an organic EL layer formed on the transparent electrode layer and including a light-emitting layer, and the organic EL layer. And a back electrode layer having light impermeability, wherein the other organic EL panel is placed on the back electrode layer side of the organic EL panel. When a part of the electrode layer and a part of the back electrode layer of the other organic EL panel are arranged so as to overlap each other, in the vicinity of the part where the part of the back electrode layer overlaps with each other, A back electrode layer removing step of removing a part of the outer edge of the back electrode layer in the vicinity of at least one panel side so that the back electrode layer and the light emitting region of the other organic EL panel do not overlap with each other; Organic To provide a method of manufacturing L panel.

  According to the present invention, an organic EL device having excellent visibility and high reliability is formed by performing a back electrode layer removal step of removing a part of the outer edge of the back electrode layer in the vicinity of at least one panel side. It is possible to obtain an organic EL panel capable of

  In the said invention, it is preferable to remove the said back electrode layer by irradiating a laser beam to the said back electrode layer at the said back electrode layer removal process. This is because the laser beam can process a minute region. Moreover, it is because only a predetermined layer inside the organic EL element can be removed without damaging the support substrate, the sealing substrate, or the sealing film.

  In the above case, it is preferable to simultaneously remove the transparent electrode layer in the laser light irradiation portion in the back electrode layer removing step. When a plurality of organic EL panels are arranged so that some of them overlap each other, the decrease in luminance due to the transparent electrode layer in the portion where some of the organic EL panels overlap each other is suppressed, luminance unevenness is reduced, and organic EL This is because the joints between the panels can be made less noticeable.

  In the above case, it is preferable that an insulating layer is formed on the support substrate on which the transparent electrode layer is formed, and that the insulating layer in the laser light irradiation portion is simultaneously removed in the back electrode layer removing step. . Similarly to the above case, when a plurality of organic EL panels are arranged so that they partially overlap each other, the luminance decrease due to the insulating layer in the part where the organic EL panels partially overlap each other is suppressed, and luminance unevenness is reduced. This is because the seam between the organic EL panels can be made less noticeable.

  In the present invention, when a plurality of organic EL panels are arranged by forming a predetermined back electrode layer removing portion on the outer edge of the back electrode layer in the vicinity of at least one panel side, This makes it possible to make the joints inconspicuous and improve the visibility, and to secure a sufficient region for sealing the organic EL element.

It is the schematic sectional drawing and the top view which show an example of the organic electroluminescent panel of this invention. It is the schematic sectional drawing and top view which show an example of the organic electroluminescent apparatus of this invention. It is the schematic sectional drawing and top view which show an example of the organic electroluminescent apparatus of this invention. It is the schematic sectional drawing and the top view which show the other example of the organic electroluminescent panel of this invention. It is the schematic sectional drawing and the top view which show the other example of the organic electroluminescent apparatus of this invention. It is a schematic plan view which shows the other example of the organic electroluminescent panel of this invention. It is a schematic plan view which shows the other example of the organic electroluminescent panel of this invention. It is a schematic plan view which shows the other example of the organic electroluminescent panel of this invention. It is a schematic plan view which shows the other example of the organic electroluminescent panel and organic electroluminescent apparatus of this invention. It is a schematic sectional drawing which shows the other example of the organic electroluminescent panel of this invention. It is a schematic sectional drawing which shows the other example of the organic EL apparatus of this invention. It is a schematic sectional drawing which shows the other example of the organic EL apparatus of this invention. It is a schematic sectional drawing which shows the other example of the organic EL apparatus of this invention. It is process drawing which shows an example of the manufacturing method of the organic electroluminescent panel of this invention. It is process drawing which shows an example of the manufacturing method of the organic electroluminescent panel of this invention. It is a schematic plan view which shows an example of the organic electroluminescent panel in the manufacturing method of the organic electroluminescent panel of this invention. It is process drawing which shows an example of the manufacturing method of the organic electroluminescent apparatus of this invention.

  Hereinafter, the organic EL panel, the organic EL device, the manufacturing method of the organic EL panel, and the manufacturing method of the organic EL device of the present invention will be described in detail.

A. Organic EL Panel The organic EL panel of the present invention includes a light-transmitting support substrate, a transparent electrode layer formed on the support substrate, an organic EL layer formed on the transparent electrode layer and including a light emitting layer. An organic EL element formed on the organic EL layer and having a light-opaque back electrode layer, wherein the organic EL element having the transparent electrode layer, the organic EL layer, and the back electrode layer is sealed. It is an EL panel, and another organic EL panel is disposed on the back electrode layer side of the organic EL panel, and a part of the back electrode layer of the organic EL panel and a part of the back electrode layer of the other organic EL panel Are arranged so that they overlap each other so that the back electrode layer of the organic EL panel and the light emitting region of the other organic EL panel do not overlap in the vicinity of the portion where the part of the back electrode layer overlaps each other. At least one It has a back electrode layer removal part in which the back electrode layer is not formed at the outer edge of the back electrode layer near one panel side.

The organic EL panel of the present invention will be described with reference to the drawings.
1A to 1C are a schematic cross-sectional view and a plan view showing an example of the organic EL panel of the present invention, which is an example when the organic EL panel is a display panel. FIG.1 (c) is a top view from the support substrate 2 side of Fig.1 (a), (b), except support substrate 2, the light emitting layer 6, the back surface electrode layer 7, and back surface electrode layer removal part 11a-11c. The configuration is omitted. 1A is a cross-sectional view taken along the line AA in FIG. 1C, and FIG. 1B is a cross-sectional view taken along the line BB in FIG. 1C.
An organic EL panel 1 illustrated in FIGS. 1A to 1C covers a support substrate 2, a transparent electrode layer 3 formed in a stripe shape on the support substrate 2, and an end of the transparent electrode layer 3, Insulating layer 4 formed so as to define sub-pixels (sub-pixels) R, G, and B, and barrier ribs 5 formed on the insulating layer 4 in a stripe shape so as to be orthogonal to the stripe pattern of the transparent electrode layer 3 A light emitting layer 6 (red light emitting layer 6R, green light emitting layer 6G, blue light emitting layer 6B) formed on the transparent electrode layer 3 and the partition wall 5, a back electrode layer 7 formed on the light emitting layer 6, and a back surface An adhesive layer 8 formed so as to cover from the electrode layer 7 to the transparent electrode layer 3 and a sealing substrate 9 formed on the adhesive layer 8 are provided. The support substrate 2, the transparent electrode layer 3, the insulating layer 4, the partition wall 5, the adhesive layer 8, and the sealing substrate 9 are all light transmissive. On the other hand, the back electrode layer 7 is light-impermeable. In the organic EL panel 1, one pixel (pixel) P is constituted by three sub-pixels (sub-pixels) R, G, and B. The support substrate 2 and the sealing substrate 9 are bonded to each other with no gap through the adhesive layer 8 to form a solid sealing structure. The organic EL panel 1 is a bottom emission type in which light L is emitted from the support substrate 2 side.

As shown in FIGS. 1A and 1C, the outer edge of the back electrode layer 7 in the vicinity of the panel side 10a of the organic EL panel 1 corresponds to at least a part of the sub-pixels R, G, and B (light emitting region). The back electrode layer removing portions 11a and 11c having the size to be formed and having the back electrode layer 7 not formed are formed. Specifically, the length b1 in the direction parallel to the panel side 10a of the back electrode layer removing portion 11a is equal to or longer than the length a1 in the direction parallel to the panel side 10a of the subpixels R, G, and B. Further, the distance z1 from the end of the back electrode layer removing portion 11a to the end of the outermost peripheral pixel P is equal to or less than the pixel interval x1.
Similarly, as shown in FIGS. 1B and 1C, at the outer edge of the back electrode layer 7 in the vicinity of the panel side 10 b of the organic EL panel 1, at least one of the subpixels R, G, and B (light emitting region) is present. Back electrode layer removal portions 11b and 11c having a size corresponding to the portion and having no back electrode layer 7 formed thereon are formed. Specifically, the length b2 in the direction parallel to the panel side 10b of the back electrode layer removing portion 11b is equal to or longer than the length a2 in the direction parallel to the panel side 10b of the sub-pixels R, G, and B. Moreover, as shown to Fig.1 (a)-(c), the non-display area | region 13 of the outer periphery of the organic electroluminescent panel 1 is set to arbitrary width | variety. In addition, the distance z2 from the end of the back electrode layer removing portion 11b to the end of the outermost peripheral pixel P is equal to or less than the pixel interval x2.

2A and 2B are a schematic cross-sectional view and a plan view showing an example of an organic EL device in which a plurality of organic EL panels exemplified in FIGS. 1A to 1C are arranged. It is an example in case a device is a display device. FIG. 2B is a plan view from the support substrate 2 side of FIG. 2A, and the configuration other than the support substrate 2, the light emitting layer 6, the back electrode layer 7, and the back electrode layer removing portion 11a is omitted. . Fig.2 (a) is CC sectional view taken on the line of FIG.2 (b).
In the organic EL device 20 illustrated in FIGS. 2A and 2B, the organic EL panel 1B is disposed on the back electrode layer 7 side of the organic EL panel 1A, and the organic EL panels 1A and 1B are organic EL. The back electrode layers 7 of the panels 1A and 1B are partially overlapped with each other, and the sub-pixels R · G · B (light emitting regions) of the organic EL panels 1A and 1B are arranged so as not to overlap each other. Of the organic EL panels 1A and 1B in which part of the back electrode layer 7 overlaps with each other, one organic EL panel 1A located on the light emission surface side is in the vicinity of the part in which part of the back electrode layer 7 overlaps with each other, Removal of the back electrode layer having a size corresponding to at least part of the sub-pixels R, G, and B (light emitting region) on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10a and having no back electrode layer 7 formed It has a portion 11a. The back electrode layer removal portion 11a of the organic EL panel 1A is a portion corresponding to the sub-pixel B (light emitting region) of the organic EL panel 1B, and the back-electrode layer 7 of the organic EL panel 1A and the sub-pixel B of the organic EL panel 1B. It is formed so as not to overlap with the (light emitting region).

  As shown in FIGS. 2A and 2B, of the organic EL panels 1A and 1B in which a part of the back electrode layer 7 is overlapped with each other, one organic EL panel 1A located on the light emitting surface side is By having the back electrode layer removing portion 11a, the distance between the outermost peripheral pixel P of the organic EL panel 1A and the outermost peripheral pixel P of the organic EL panel 1B in a part where the organic EL panels 1A and 1B partially overlap each other. y1 and the back electrode layer 7 having light impermeability of one organic EL panel 1A located on the light emitting surface side so that the pixel interval x1 of the organic EL panels 1A and 1B is substantially the same, and the other The organic EL panels 1A and 1B can be arranged so that the sub-pixels R, G, and B (light emitting regions) of the organic EL panel 1B do not overlap. Therefore, it is possible to make the joint between the organic EL panels 1A and 1B inconspicuous.

  Further, in the example shown in FIGS. 2A and 2B, in order to make the joint between the organic EL panels 1A and 1B inconspicuous, among the organic EL panels 1A and 1B in which parts of the back electrode layer 7 overlap each other. The one organic EL panel 1A located on the light emitting surface side only needs to have the back electrode layer removing portion 11a, and it is not necessary to reduce the non-display area 13 on the outer periphery of the organic EL panel 1A. That is, the size of the non-display area 13 can be arbitrarily set regardless of the size of the pixel interval x1. Therefore, it is possible to secure a sufficient region for sealing the organic EL element on the outer periphery of the organic EL panel 1A. Therefore, even in the case of a high-definition pixel arrangement in which the pixel interval x1 is small, the organic EL panels 1A and 1B can be arranged without making the seam conspicuous.

3A and 3B are a schematic cross-sectional view and a plan view showing an example of an organic EL device in which a plurality of organic EL panels exemplified in FIGS. 1A to 1C are arranged. It is an example in case a device is a display device. FIG. 3B is a plan view from the support substrate 2 side in FIG. 3A, and the configuration other than the support substrate 2, the light emitting layer 6, the back electrode layer 7, and the back electrode layer removing portion 11b is omitted. . Fig.3 (a) is the DD sectional view taken on the line of FIG.3 (b).
In the organic EL device 20 illustrated in FIGS. 3A and 3B, the organic EL panel 1B is disposed on the back electrode layer 7 side of the organic EL panel 1A, and the organic EL panels 1A and 1B are organic EL. The back electrode layers 7 of the panels 1A and 1B are partially overlapped with each other, and the sub-pixels R · G · B (light emitting regions) of the organic EL panels 1A and 1B are arranged so as not to overlap each other. Of the organic EL panels 1A and 1B in which part of the back electrode layer 7 overlaps with each other, one organic EL panel 1A located on the light emission surface side is in the vicinity of the part in which part of the back electrode layer 7 overlaps with each other, that is, Removal of the back electrode layer having a size corresponding to at least a part of the sub-pixels R, G, and B (light emitting region) on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10b and having no back electrode layer 7 formed It has a portion 11b. The back electrode layer removal portion 11b of the organic EL panel 1A is a portion corresponding to the sub-pixels R, G, and B (light emitting region) of the organic EL panel 1B, and the back electrode layer 7 of the organic EL panel 1A and the organic EL panel 1B. The sub-pixels R, G, and B (light emitting regions) are formed so as not to overlap each other.

  As shown in FIGS. 3A and 3B, of the organic EL panels 1A and 1B in which a part of the back electrode layer 7 overlaps with each other, one organic EL panel 1A located on the light emitting surface side is By having the back electrode layer removing portion 11b, the distance between the outermost peripheral pixel P of the organic EL panel 1A and the outermost peripheral pixel P of the organic EL panel 1B in a portion where the organic EL panels 1A and 1B partially overlap each other. The back electrode layer 7 having light impermeability of one organic EL panel 1A located on the light emission surface side and the other electrode electrode 2 so that y2 and the pixel interval x2 of the organic EL panels 1A and 1B are substantially the same. The organic EL panels 1A and 1B can be arranged so that the sub-pixels R, G, and B (light emitting regions) of the organic EL panel 1B do not overlap. Therefore, it is possible to make the joint between the organic EL panels 1A and 1B inconspicuous.

  Further, in the example shown in FIGS. 3A and 3B, in order to make the joint between the organic EL panels 1A and 1B inconspicuous, among the organic EL panels 1A and 1B in which part of the back electrode layer 7 overlaps each other. As long as one organic EL panel 1A located on the light emitting surface side has the back electrode layer removing portion 11b, the organic EL panel 1A of the organic EL panel 1A is similar to the example shown in FIGS. It is not necessary to reduce the outer non-display area 13. That is, the size of the non-display area 13 can be arbitrarily set regardless of the size of the pixel interval x2. Therefore, it is possible to secure a sufficient region for sealing the organic EL element on the outer periphery of the organic EL panel 1A. Therefore, even in the case of a high-definition pixel arrangement with a small pixel interval x2, it is possible to arrange the organic EL panels 1A and 1B without making the seam conspicuous.

4A and 4B are a schematic cross-sectional view and a plan view showing another example of the organic EL panel of the present invention, which are examples in the case where the organic EL panel is a lighting panel. FIG. 4B is a plan view from the support substrate 2 side of FIG. 4A, and the configuration other than the support substrate 2, the light emitting layer 6, the back electrode layer 7, and the back electrode layer removing portions 11a to 11d is omitted. ing. FIG. 4A is a cross-sectional view taken along the line EE of FIG.
The organic EL panel 1 illustrated in FIGS. 4A and 4B is formed so as to cover the supporting substrate 2, the transparent electrode layer 3 formed on the supporting substrate 2, and the end of the transparent electrode layer 3. The insulating layer 4, the light emitting layer 6 formed on the insulating layer 4, the back electrode layer 7 formed on the light emitting layer 6, and the back electrode layer 7 to the transparent electrode layer 3 were formed to cover. An adhesive layer 8 and a sealing substrate 9 formed on the adhesive layer 8 are provided. The support substrate 2, the transparent electrode layer 3, the insulating layer 4, the adhesive layer 8, and the sealing substrate 9 are all light transmissive. On the other hand, the back electrode layer 7 is light-impermeable. The support substrate 2 and the sealing substrate 9 are bonded to each other with no gap through the adhesive layer 8 to form a solid sealing structure. The organic EL panel 1 is a bottom emission type in which light L is emitted from the support substrate 2 side.

  As shown in FIGS. 4A and 4B, the outer edge of the back electrode layer 7 in the vicinity of the panel side 10a of the organic EL panel 1 has a size corresponding to at least a part of the light emitting region 16, and the back surface. Back surface electrode layer removal portions 11a and 11c where the electrode layer 7 is not formed are formed. Specifically, the length b1 of the back electrode layer removing portion 11a in the direction parallel to the panel side 10a is equal to or longer than the length a1 of the light emitting region 16 in the direction parallel to the panel side 10a. Similarly, on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10b of the organic EL panel 1, a back electrode layer having a size corresponding to at least a part of the light emitting region 16 and having no back electrode layer 7 formed thereon. Removal portions 11b, 11c, and 11d are formed. Specifically, the length b2 of the back electrode layer removing portion 11b in the direction parallel to the panel side 10b is equal to or longer than the length a2 of the light emitting region 16 in the direction parallel to the panel side 10b. The non-display area 13 on the outer periphery of the organic EL panel 1 is set to an arbitrary width.

5A and 5B are a schematic cross-sectional view and a plan view showing an example of an organic EL device in which a plurality of organic EL panels illustrated in FIGS. 4A and 4B are arranged. It is an example in case an apparatus is an illuminating device. FIG. 5B is a plan view from the support substrate 2 side in FIG. 5A, and the configuration other than the support substrate 2, the light emitting layer 6, the back electrode layer 7, and the back electrode layer removing portions 11a to 11c is omitted. ing. Fig.5 (a) is the FF sectional view taken on the line of FIG.5 (b).
In the organic EL device 20 illustrated in FIGS. 5A and 5B, the organic EL panels 1B, 1C, and 1D are disposed on the back electrode layer 7 side of the organic EL panel 1A, and the back electrode layer of the organic EL panel 1B. The organic EL panels 1C and 1D are disposed on the 7 side, and the organic EL panel 1D is disposed on the back electrode layer 7 side of the organic EL panel 1C. These organic EL panels 1 </ b> A to 1 </ b> D are arranged such that parts of the back electrode layer 7 overlap each other and the light emitting regions 16 do not overlap each other. Of the organic EL panels 1A to 1D in which part of the back electrode layer 7 overlaps with each other, one organic EL panel 1A located on the light emitting surface side emits light in the vicinity of the part in which the back electrode layer 7 overlaps with each other. The back electrode layer removing portions 11 a to 11 c have a size corresponding to at least a part of the region 16 and are not formed with the back electrode layer 7. Similarly, of the organic EL panels 1B and 1D in which part of the back electrode layer 7 overlaps with each other, one organic EL panel 1B located on the light emitting surface side is in the vicinity of a part in which the back electrode layer 7 overlaps with each other. In addition, a back electrode layer removing portion 11b having a size corresponding to at least a part of the light emitting region 16 and having no back electrode layer 7 formed thereon is provided. Similarly, of the organic EL panels 1C and 1D in which a part of the back electrode layer 7 overlaps with each other, one organic EL panel 1C located on the light emitting surface side is in the vicinity of a part in which the back electrode layer 7 partially overlaps with each other. In addition, a back electrode layer removing portion 11a having a size corresponding to at least a part of the light emitting region 16 and having no back electrode layer 7 formed thereon is provided.

  For example, the organic EL panel 1A has a size corresponding to at least a part of the light emitting region 16 in the vicinity of a part where the back electrode layers 7 overlap each other, that is, on the outer edge of the back electrode layer 7 in the vicinity of the panel sides 10a and 10b. It has back electrode layer removal parts 11a-11c in which back electrode layer 7 is not formed. The back electrode layer removal part 11a of the organic EL panel 1A is a part corresponding to the light emitting region 16 of the organic EL panel 1B, and the back electrode layer 7 of the organic EL panel 1A and the light emitting region 16 of the organic EL panel 1B do not overlap. It is formed as follows. The back electrode layer removal part 11b of the organic EL panel 1A is a part corresponding to the light emitting region 16 of the organic EL panel 1C, and the back electrode layer 7 of the organic EL panel 1A and the light emitting region 16 of the organic EL panel 1C do not overlap. It is formed as follows. The back electrode layer removal part 11c of the organic EL panel 1A is a part corresponding to the light emitting region 16 of the organic EL panel 1D, and the back electrode layer 7 of the organic EL panel 1A and the light emitting region 16 of the organic EL panel 1D do not overlap. It is formed as follows.

  As shown in FIGS. 5A and 5B, one organic EL panel 1 </ b> A located on the light emitting surface side is the organic EL panel 1 </ b> A to 1 </ b> D in which part of the back electrode layer 7 overlaps each other. By having the back electrode layer removing portions 11a to 11c, the light of one organic EL panel 1A located on the light emitting surface side in the portion where the organic EL panel 1A and the other organic EL panels 1B to 1D partially overlap each other. It becomes possible to arrange the organic EL panels 1A to 1D so that the back electrode layer 7 having impermeability and the light emitting regions 16 of the other organic EL panels 1B to 1D do not overlap. Therefore, the joint between the organic EL panel 1A and the other organic EL panels 1B to 1D can be made inconspicuous.

  Moreover, in the example shown to Fig.5 (a), (b), in order to make the joint of organic electroluminescent panel 1A and other organic electroluminescent panels 1B-1D inconspicuous, the organic EL with which the part of back surface electrode layer 7 mutually overlaps is made. Of the panels 1A to 1D, one organic EL panel 1A located on the light emitting surface side only needs to have the back electrode layer removal portions 11a to 11c, and the non-display area on the outer periphery of the organic EL panels 1A to 1D It is not necessary to make it small, and can be set arbitrarily. Therefore, it is possible to secure a sufficient area for sealing the organic EL element on the outer periphery of the organic EL panels 1A to 1D.

As described above, in the present invention, when the predetermined back electrode layer removing portion is formed, when a plurality of organic EL panels are arranged, the joint between the organic EL panels can be made inconspicuous, and visibility is improved. Can be improved.
In addition, since the predetermined back electrode layer removal portion is formed, the seam between the organic EL panels can be made inconspicuous, so the non-display area on the outer periphery of the organic EL panel can be arbitrarily set, It is possible to secure a sufficient region for sealing the organic EL element. This is particularly useful in the case of a high-definition pixel array with a small pixel interval.

  In the specification of the present application, the “light emitting region” refers to a region where light emission occurs in the light emitting layer when seen in a plan view. For example, in the case of a display panel for monochrome display, the “light emitting area” refers to one pixel (pixel) that is a unit for forming a monochrome image. In the case of a full-color display panel, the “light emitting region” refers to a plurality of sub-pixels (sub-pixels) constituting one pixel (pixel) that is a unit for forming a full-color image.

  “Pixel” refers to one pixel (pixel) that forms a single color image in the case of monochromatic display, and one pixel (pixel) that is a unit for forming a full color image in the case of full color display. One pixel (pixel) composed of sub-pixels (sub-pixels).

  Hereinafter, each configuration in the organic EL panel of the present invention will be described.

1. Back electrode layer removal portion The back electrode layer removal portion in the present invention is a portion where the back electrode layer is not formed, and another organic EL panel is placed on the back electrode layer side of the organic EL panel of the present invention. When a part of the back electrode layer and a part of the back electrode layer of another organic EL panel are arranged so as to overlap each other, the back surface of the organic EL panel in the vicinity of the part where the part of the back electrode layer overlaps each other It is formed on the outer edge of the back electrode layer in the vicinity of at least one panel side so that the electrode layer and the light emitting region of another organic EL panel do not overlap.

  The organic EL panel of the present invention is at least one of organic EL panels constituting an organic EL device in which a plurality of organic EL panels are arranged so as to partially overlap each other. When a plurality of organic EL panels are arranged so that a part of the back electrode layer overlaps with each other, the back electrode layer of the organic EL panel of the present invention and the part In the organic EL panel of the present invention, the back electrode is disposed on the outer edge of the back electrode in the vicinity of at least one panel side so that the light emitting area of another organic EL panel arranged on the back electrode layer side of the organic EL panel does not overlap. A layer removal portion is formed. When a plurality of organic EL panels are arranged so that a part of the back electrode layers overlap each other, the back electrode layer removal portion of the organic EL panel of the present invention is disposed on the back electrode layer side of the organic EL panel of the present invention. The portion corresponds to the light emitting region of another organic EL panel.

  Usually, an organic EL device is configured by arranging a plurality of the organic EL panels of the present invention so as to partially overlap each other. When a plurality of the organic EL panels of the present invention are arranged so that a part of the back electrode layers overlap each other, the back electrode layer removal part of the one organic EL panel has one back electrode layer removal part. This is a portion corresponding to the light emitting region of another organic EL panel disposed on the back electrode layer side. Therefore, the back electrode layer removal part of the organic EL panel of the present invention has a size corresponding to at least a part of the light emitting region of the organic EL panel of the present invention.

When a plurality of the organic EL panels of the present invention are arranged so that the back electrode layers partially overlap each other, the top, bottom, left, right, right diagonally upper, right diagonally lower, left with respect to one organic EL panel Other organic EL panels are arranged in the diagonally upper and diagonally lower left directions. The back electrode layer removal part in this invention turns into a part corresponding to the light emission area | region of all the other organic EL panels arrange | positioned at the back electrode layer side of one organic EL panel which has a back electrode layer removal part.
For example, in FIG. 1C, the back electrode layer removal unit 11 a is disposed on the back electrode layer 7 side of the organic EL panel 1 and is a subpixel of another organic EL panel disposed in the left direction of the organic EL panel 1. This corresponds to the (light emitting area). The back electrode layer removing portion 11b is a portion corresponding to a sub-pixel (light emitting region) of another organic EL panel that is arranged on the back electrode layer 7 side of the organic EL panel 1 and arranged in the upward direction of the organic EL panel 1. It becomes. The back electrode layer removal unit 11c is disposed on the back electrode layer 7 side of the organic EL panel 1 and corresponds to a sub-pixel (light emitting region) of another organic EL panel disposed in the diagonally upper left direction of the organic EL panel 1. It becomes a part to do.
For example, in FIG. 4B, the back electrode layer removal unit 11 a is disposed on the back electrode layer 7 side of the organic EL panel 1 and emits light from another organic EL panel disposed in the left direction of the organic EL panel 1. This corresponds to the area. The back electrode layer removing portion 11 b is a portion corresponding to the light emitting region of another organic EL panel that is disposed on the back electrode layer 7 side of the organic EL panel 1 and is disposed upward of the organic EL panel 1. The back electrode layer removing portion 11c is a portion corresponding to the light emitting region of another organic EL panel that is disposed on the back electrode layer 7 side of the organic EL panel 1 and is disposed obliquely upward to the left of the organic EL panel 1. . The back electrode layer removing unit 11d is disposed on the back electrode layer 7 side of the organic EL panel 1 and corresponds to a light emitting area of another organic EL panel disposed in the diagonally upper right direction of the organic EL panel 1. .

The back electrode layer removal part should just be a part corresponding to the light emission area | region of the other organic EL panel arrange | positioned at the back electrode layer side of one organic EL panel which has a back electrode layer removal part, and there are multiple organic EL panels. In other words, the light emitting region may be formed for each light emitting region of another organic EL panel, or may be formed for each of two or more light emitting regions of another organic EL panel. The plurality of light emitting regions of the organic EL panel may be included. When the back electrode layer removal portion is formed for each light emitting region of another organic EL panel disposed on the back electrode layer side of the one organic EL panel having the back electrode layer removal portion, the back electrode There is an advantage that time can be shortened when the back electrode layer is removed by irradiating the layer with laser light. Moreover, when the back electrode layer removal part is formed for every 2 or more light emission area | regions of the other organic EL panel arrange | positioned at the back electrode layer side of the one organic EL panel which has a back electrode layer removal part, When the other organic EL panel is formed so as to include all of the light emitting regions, alignment is facilitated when the back electrode layer is removed by irradiating the back electrode layer with laser light. Have advantages. When the sub-pixel interval or the pixel interval is narrow, it is useful that the alignment is easy.
For example, in FIG. 1C and FIG. 6, the back electrode layer removal unit 11 a is disposed on the back electrode layer 7 side of the organic EL panel 1 and is disposed in the left direction of the organic EL panel 1. For each sub-pixel (light emitting region). The back electrode layer removing portion 11b is disposed on the back electrode layer 7 side of the organic EL panel 1 and is provided for each sub-pixel (light emitting region) of another organic EL panel disposed in the upward direction of the organic EL panel 1. Is formed. The back electrode layer removing portion 11c is arranged on the back electrode layer 7 side of the organic EL panel 1, and is one subpixel (light emitting region) of another organic EL panel arranged in the diagonally upper left direction of the organic EL panel 1. It is formed every time.
Further, for example, in FIG. 7, the back electrode layer removal unit 11 a is arranged on the back electrode layer 7 side of the organic EL panel 1, and a plurality of subpixels of another organic EL panel arranged in the left direction of the organic EL panel 1. It is formed so as to include all of the (light emitting region). The back electrode layer removing portion 11b is disposed on the back electrode layer 7 side of the organic EL panel 1 and is arranged for each of the three sub-pixels (light emitting regions) of other organic EL panels disposed in the upward direction of the organic EL panel 1. That is, it is formed for each pixel.
6 and 7 are plan views from the support substrate 2 side, and configurations other than the support substrate 2, the light emitting layer 6, the back electrode layer 7, and the back electrode layer removing portions 11a to 11c are omitted.

In addition, when a plurality of other organic EL panels are arranged on the back electrode layer side of one organic EL panel having a back electrode layer removal section, the back electrode layer removal section is provided by two or more other organic EL panels. You may form so that all the light emission areas may be included. This is because alignment is facilitated when the back electrode layer is removed by irradiating the back electrode layer with laser light.
For example, in FIG. 8, the back electrode layer removal unit 11 a is arranged on the back electrode layer 7 side of the organic EL panel 1 and is arranged in the left direction of the organic EL panel 1. (Light emitting region) is included. The back electrode layer removal unit 11b is disposed on the back electrode layer 7 side of the organic EL panel 1, and is a sub-pixel of two other organic EL panels that are respectively disposed in the upward direction and the diagonally left upward direction of the organic EL panel 1. It is formed so as to include all of the (light emitting region).
FIG. 8 is a plan view from the support substrate 2 side, and the configuration other than the support substrate 2, the light emitting layer 6, the back electrode layer 7, and the back electrode layer removing portions 11a and 11b is omitted.

The back electrode layer removal portion is formed at the outer edge of the back electrode layer in the vicinity of at least one panel side. Of the other organic EL panels arranged on the back electrode layer side of the one organic EL panel having the back electrode layer removing portion, the top, bottom, left, The length of the back electrode layer removal part in a direction parallel to the panel side where the back electrode layer removal part is formed when it becomes a part corresponding to the light emitting area of another organic EL panel arranged in any direction on the right The length is equal to or longer than the length of the light emitting region in the direction parallel to the panel side, and is preferably longer than the length of the light emitting region in the direction parallel to the panel side. When the plurality of organic EL panels of the present invention are arranged so that the back electrode layers partially overlap each other because the length of the back electrode layer removal portion is longer than the length of the light emitting region, a part of the back electrode layer In the vicinity of the portion where the two overlap each other, the back electrode layer of one organic EL panel having the back electrode layer removal portion and the light emitting area of the other organic EL panel arranged on the back electrode layer side of the one organic EL panel are surely It is because it can be made not to overlap. Further, when a plurality of the organic EL panels of the present invention are arranged so that the back electrode layers partially overlap each other, alignment becomes easy. The length of the back electrode layer removal portion may be selected as long as it is equal to or longer than the length of the light emitting region.
For example, in FIG. 1C, a back electrode layer removal portion 11a is formed on the outer edge of the back electrode layer 7 near the panel side 10a of the organic EL panel 1, and is parallel to the panel side 10a of the back electrode layer removal portion 11a. The length b1 in the direction is longer than the length a1 in the direction parallel to the panel side 10a of the subpixels R, G, and B (light emitting region). Similarly, a back electrode layer removal portion 11b is formed on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10b of the organic EL panel 1, and the length b2 in the direction parallel to the panel side 10b of the back electrode layer removal portion 11b. Is longer than the length a2 in the direction parallel to the panel side 10b of the subpixels R, G, and B (light emitting region).
For example, in FIG. 4B, a back electrode layer removal portion 11a is formed on the outer edge of the back electrode layer 7 near the panel side 10a of the organic EL panel 1, and is parallel to the panel side 10a of the back electrode layer removal portion 11a. The length b1 in the direction is longer than the length a1 in the direction parallel to the panel side 10a of the light emitting region 16. Similarly, a back electrode layer removal portion 11b is formed on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10b of the organic EL panel 1, and the length b2 in the direction parallel to the panel side 10b of the back electrode layer removal portion 11b. Is longer than the length a2 of the light emitting region 16 in the direction parallel to the panel side 10b.
For example, in FIG. 7, the back electrode layer removal part 11a is formed in the outer edge of the back electrode layer 7 near the panel side 10a of the organic EL panel 1, and the length of the back electrode layer removal part 11a in the direction parallel to the panel side 10a This is longer than the length of the sub-pixels R, G, B (light emitting region) in the direction parallel to the panel side 10a. Similarly, the back electrode layer removal part 11b is formed in the outer edge of the back electrode layer 7 near the panel side 10b of the organic EL panel 1, and the length of the back electrode layer removal part 11b in the direction parallel to the panel side 10b is The length of the sub-pixels R, G, B (light emitting region) is longer than the length in the direction parallel to the panel side 10b.

Moreover, it is a case where a light emission area | region is a pixel or a subpixel, Comprising: The back electrode layer removal part of other organic EL panels arrange | positioned at the back electrode layer side of one organic EL panel which has a back electrode layer removal part Among them, when it becomes a part corresponding to a pixel or sub-pixel of another organic EL panel arranged in any one of the upper, lower, left, and right directions with respect to one organic EL panel, the innermost back electrode The distance from the end of the layer removal unit to the end of the outermost pixel is equal to or less than the pixel interval. This is because alignment is facilitated when a plurality of the organic EL panels of the present invention are arranged so that a part of the back electrode layers overlap each other. The distance from the end of the innermost back electrode layer removal portion to the end of the outermost pixel may be equal to or less than the pixel interval, and is appropriately selected according to the pixel interval.
For example, in FIG.1 (c), the back electrode layer removal part 11a is formed in the outer edge of the back electrode layer 7 of the panel side 10a vicinity of the organic electroluminescent panel 1, and it is the outermost periphery from the edge part of the back electrode layer removal part 11a. The distance z1 to the end of the pixel P is equal to or less than the pixel interval x1. Similarly, a back electrode layer removing portion 11b is formed on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10b of the organic EL panel 1, and the end of the outermost peripheral pixel P from the end of the back electrode layer removing portion 11b. The distance z2 is up to the pixel interval x2.
For example, in FIG. 6, a back electrode layer removing portion 11a is formed on the outer edge of the back electrode layer 7 near the panel side 10a of the organic EL panel 1, and the outermost periphery from the end of the innermost back electrode layer removing portion 11a. The distance z1 to the end of the pixel P is equal to or less than the pixel interval x1. Similarly, a back electrode layer removing portion 11b is formed on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10b of the organic EL panel 1, and the end of the outermost peripheral pixel P from the end of the back electrode layer removing portion 11b. The distance z2 is up to the pixel interval x2.
For example, in FIG. 7, a back electrode layer removal portion 11a is formed on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10a of the organic EL panel 1, and the outermost pixel P from the end of the back electrode layer removal portion 11a is formed. The distance z1 to the end is less than the pixel interval x1. Similarly, a back electrode layer removing portion 11b is formed on the outer edge of the back electrode layer 7 in the vicinity of the panel side 10b of the organic EL panel 1, and the end of the outermost peripheral pixel P from the end of the back electrode layer removing portion 11b. The distance z2 is up to the pixel interval x2.

  "Distance from the end of the innermost back electrode layer removal part to the end of the outermost pixel" is the center of the organic EL panel in the end of the innermost back electrode layer removal part. The distance from the positioned end to the end positioned on the outer peripheral side of the organic EL panel among the ends of the outermost peripheral pixels.

  As the shape of the back electrode layer removal portion, the back electrode layer removal portion corresponds to the light emitting area of another organic EL panel arranged on the back electrode layer side of one organic EL panel having the back electrode layer removal portion. If it becomes, it will not specifically limit, According to the shape of a light emission area | region, it selects suitably.

  As for the number of back electrode layer removal portions, the back electrode layer removal portion corresponds to the light emitting region of another organic EL panel arranged on the back electrode layer side of one organic EL panel having the back electrode layer removal portion. If it becomes, it will not specifically limit, It selects suitably according to the number of light emission areas, the light emission area space | interval, arrangement | positioning of an organic electroluminescent panel, etc.

The back electrode layer removal portion is formed at the outer edge of the back electrode layer in the vicinity of at least one panel side. The panel side on which the back electrode layer removing portion is formed may be at least one of the panel sides of the organic EL panel, and may be one side, two sides, three sides, or four sides. Especially, it is preferable that the back surface electrode layer removal part is formed in the outer edge of the back surface electrode layer near two panel sides. In the case of a passive matrix driving type organic EL panel, as illustrated in FIG. 9A, in the organic EL panel 1, a transparent electrode connected to the transparent electrode layer 3 on the support substrate 2 in the vicinity of one panel side 10c. A layer extraction electrode 21 may be formed, and a back electrode layer extraction electrode 22 connected to the back electrode layer 7 may be formed on the support substrate 2 in the vicinity of another panel side 10d. It is difficult to form a back electrode layer removal portion on the outer edge of the back electrode layer 7 in the vicinity of the panel sides 10c and 10d where the transparent electrode layer extraction electrode 21 or the back electrode layer extraction electrode 22 is formed. On the other hand, a back electrode layer removal portion can be formed on the outer edge of the back electrode layer 7 in the vicinity of the panel sides 10a and 10b where the transparent electrode layer extraction electrode 21 and the back electrode layer extraction electrode 22 are not formed. is there. Therefore, back electrode layer removal portions 11a to 11d are formed on the outer edges of the back electrode layer 7 in the vicinity of the two panel sides 10a and 10b where the transparent electrode layer extraction electrode 21 and the back electrode layer extraction electrode 22 are not formed. It is preferable. In particular, as illustrated in FIG. 9A, two panel sides 10a and 10b on which the transparent electrode layer extraction electrode 21 and the back electrode layer extraction electrode 22 are not formed are adjacent to each other. It is preferable that back electrode layer removal portions 11a to 11d are formed on the outer edge of the back electrode layer 7 in the vicinity of the sides 10a and 10b. With such a configuration, as illustrated in FIG. 9B, the panel side 10 a of one organic EL panel 1 among the organic EL panels 1 adjacent in the left-right direction is the panel of the other organic EL panel 1. Of the organic EL panels 1 adjacent to each other in the vertical direction, the panel side 10b of one of the organic EL panels 1 overlaps the upper side of the panel side 10c of the other organic EL panel 1, and the left diagonally upper right diagonally downward Among the organic EL panels 1 adjacent to each other in the direction, the corners of the panel sides 10a and 10b of one organic EL panel 1 overlap the upper side of the corners of the panel sides 10c and 10d of the other organic EL panel 1, and Among the organic EL panels 1 adjacent in the direction, the corners of the panel sides 10b and 10d of one organic EL panel 1 overlap with the corners of the panel sides 10a and 10c of the other organic EL panel 1. By placing urchin plurality of organic EL panel 1, inconspicuous seams between the organic EL panel 1, it is possible to improve the visibility of the organic EL device 20. In other words, without making the joints between the organic EL panels conspicuous, a plurality of organic EL panels can be installed in any of the upward, downward, left, right, diagonally upper right, diagonally lower right, diagonally upper left and diagonally lower left directions. It can be arranged and can be easily enlarged.
In addition, in FIG. 9A, configurations other than the support substrate 2, the transparent electrode layer 3, the back electrode layer 7, the back electrode layer removing portions 11a to 11d, the transparent electrode layer extraction electrode 21, and the back electrode layer extraction electrode 22 Is omitted. Further, in FIG. 9B, configurations other than the support substrate 2, the back electrode layer 7, the back electrode layer removal portions 11 a to 11 d, the transparent electrode layer extraction electrode 21, and the back electrode layer extraction electrode 22 are omitted. .

The method for forming the back electrode layer removal portion is not particularly limited as long as it can form the back electrode layer removal portion on the outer edge of the back electrode layer in the vicinity of at least one panel side. A method of irradiating the electrode layer with laser light can be used.
In addition, since the formation method of a back surface electrode layer removal part is described in detail in the section of “C. Manufacturing method of organic EL panel” described later, description here is omitted.

2. Back Electrode Layer The back electrode layer used in the present invention has light impermeability and is formed on the organic EL layer. In the present invention, the back electrode layer removal portion is formed on the outer edge of the back electrode layer in the vicinity of at least one panel side.

  The back electrode layer may be an anode or a cathode, but is usually formed as a cathode. As the cathode, it is preferable to use a conductive material having a small work function so that electrons can be easily injected, and those generally used for the cathode of an organic EL panel can be used. Such a conductive material may be any material that can form a light-opaque back electrode layer. For example, a metal such as Li, Na, Mg, Al, Ca, Ag, In, or the like An alloy containing one or more kinds of metals, for example, an alloy such as MgAg, AlLi, AlCa, and AlMg can be given.

  The thickness of the back electrode layer is not particularly limited as long as it is a thickness of a general electrode in an organic EL panel, but the back electrode layer removal portion is formed by irradiating the back electrode layer with laser light. The thickness is preferably removable by laser light irradiation. The film thickness of such a back electrode layer is preferably in the range of 10 nm to 1 μm, and more preferably in the range of 50 nm to 500 nm.

  The back electrode layer may be formed in a pattern according to the use and driving method of the organic EL panel.

  As a method for forming the back electrode layer, a general electrode forming method can be employed. For example, a vacuum vapor deposition method using a metal mask can be used. In the present invention, after the back electrode layer is formed, a part of the back electrode layer can be removed to form the back electrode layer removal portion, so that high alignment accuracy is not required when forming the back electrode layer.

In the present invention, a back electrode layer extraction electrode connected to the back electrode layer is usually formed.
As the extraction electrode for the back electrode layer, a general extraction electrode in an organic EL panel can be used.
The position for forming the back electrode layer extraction electrode is appropriately selected according to the number of panel sides on which the back electrode layer removal portion is formed. As illustrated in FIG. 9A, the back electrode layer extraction electrode 22 is The back electrode layer take-out electrode may be formed on the outer side of the sealing substrate or the sealing film, although it may be formed on the support substrate 2 and not shown.

3. Transparent electrode layer The transparent electrode layer used in the present invention has optical transparency and is formed on a support substrate.

In this invention, it is preferable that the transparent electrode layer is not formed in the said back surface electrode layer removal part.
1A is a cross-sectional view taken along line AA in FIG. 1C, and FIG. 10 is a cross-sectional view taken along line BB in FIG. In the organic EL panel 1 illustrated in FIGS. 1A and 1C, the transparent electrode layer 3 is not formed on the back electrode layer removing portion 11a. Similarly, in the organic EL panel 1 illustrated in FIG. 10 and FIG. 1C, the transparent electrode layer 3 is not formed on the back electrode layer removing portion 11b.

  2A and 11 are schematic cross-sectional views showing an example of an organic EL device in which a plurality of organic EL panels illustrated in FIGS. 1A, 1C, and 10 are arranged. In the organic EL device 20 illustrated in FIG. 2A and FIG. 11, the organic EL panels 1A and 1B are partially overlapped with each other, and the sub-pixels of the organic EL panels 1A and 1B ( The light emitting areas are arranged so as not to overlap each other. As illustrated in FIG. 2A and FIG. 11, among the organic EL panels 1 </ b> A and 1 </ b> B that partially overlap each other, in one organic EL panel 1 </ b> A located on the light emission surface side, the back electrode layer removal unit 11 a, The transparent electrode layer 3 is not formed on 11b.

  As shown in FIG. 2A and FIG. 11, among the organic EL panels 1A and 1B that partially overlap each other, in one organic EL panel 1A located on the light emitting surface side, the back electrode layer removing portions 11a and 11b Since the transparent electrode layer 3 is not formed, the transparent electrode layer 3 of one organic EL panel 1A located on the light emitting surface side is another organic EL in a portion where the organic EL panels 1A and 1B partially overlap each other. The organic EL panels 1A and 1B can be arranged so as not to overlap with the sub-pixel (light emitting region) of the panel 1B. As a result, it is possible to suppress the luminance of the organic EL panel 1B from being lowered by the transparent electrode layer 3 of the organic EL panel 1A in a portion where the organic EL panels 1A and 1B partially overlap each other, thereby reducing luminance unevenness. Thus, the joint between the organic EL panels 1A and 1B can be made more inconspicuous.

  As described above, in the present invention, when the transparent electrode layer is not formed in the back electrode layer removal portion, when a plurality of organic EL panels are arranged so as to partially overlap each other, a part of the organic EL panel It is possible to suppress a decrease in luminance at a portion where the two overlap each other, reduce luminance unevenness, and make the joint between the organic EL panels more inconspicuous.

In the present invention, since light is emitted from the transparent electrode layer side, the transparent electrode layer has optical transparency. The total light transmittance of the transparent electrode layer is preferably 60% or more, more preferably 70% or more, and particularly preferably 80% or more. When the total light transmittance of the transparent electrode layer is in the above range, the light emitted from the light emitting layer can be sufficiently transmitted through the transparent electrode layer, and a plurality of organic EL panels are partially overlapped with each other. When arranged, even if the transparent electrode layer of one organic EL panel located on the light emitting surface side overlaps the light emitting region of the other organic EL panel, the other part of the organic EL panel overlaps with each other. It is because it can suppress that the brightness | luminance of the light emission area | region of an organic electroluminescent panel falls.
The total light transmittance is a value measured using a haze meter NDH2000 manufactured by Nippon Denshoku Industries Co., Ltd. in accordance with JIS K7361.

The transparent electrode layer may be an anode or a cathode, but is usually formed as an anode.
As the anode, a conductive material having a large work function is preferably used so that holes can be easily injected, and those generally used for an anode of an organic EL panel can be used. As such a conductive material, any material can be used as long as it can form a light-transmitting transparent electrode layer. Examples thereof include ITO (indium tin oxide), IZO (indium zinc oxide), indium oxide, and tin oxide. Can be mentioned.

  The transparent electrode layer may be formed in a pattern according to the use and driving method of the organic EL panel.

As a method for forming the transparent electrode layer, a general method for forming an electrode can be employed.
When the transparent electrode layer is not formed on the back electrode layer removal portion, when forming the back electrode layer removal portion, the back electrode layer and the transparent electrode layer are irradiated with laser light, and the back surface of the laser light irradiated portion You may remove an electrode layer and a transparent electrode layer simultaneously.
In addition, since the method of not forming the transparent electrode layer in the back electrode layer removal portion will be described in detail in the section of “C. Manufacturing method of organic EL panel” described later, description thereof is omitted here.

In the present invention, the extraction electrode for the transparent electrode layer connected to the transparent electrode layer is usually formed.
As the extraction electrode for the transparent electrode layer, a general extraction electrode in an organic EL panel can be used.
The formation position of the extraction electrode for the transparent electrode layer is appropriately selected according to the number of panel sides on which the back electrode layer removal portion is formed. As illustrated in FIG. 9A, the transparent electrode layer extraction electrode 21 is The transparent electrode layer extraction electrode may be formed on the outer side of the sealing substrate or the sealing film, although it may be formed on the support substrate 2 and not shown.

4). Insulating layer In this invention, the insulating layer may be formed on the support substrate in which the transparent electrode layer was formed. The insulating layer can prevent the transparent electrode layer and the back electrode layer from contacting and short-circuiting. This insulating layer is preferably formed so as to cover the end of the transparent electrode layer. Since the thickness of the organic EL layer is reduced at the end portion of the transparent electrode layer, short-circuiting can be made difficult by forming an insulating layer. Further, it is possible to prevent adjacent pixels or subpixels from being electrically connected. The portion where the insulating layer is formed can be a region that does not contribute to light emission.

In this invention, it is preferable that the insulating layer is not formed in the said back surface electrode layer removal part.
1A is a cross-sectional view taken along line AA in FIG. 1C, and FIG. 10 is a cross-sectional view taken along line BB in FIG. In the organic EL panel 1 illustrated in FIGS. 1A and 1C, the insulating layer 4 is not formed on the back electrode layer removing portion 11a. Similarly, in the organic EL panel 1 illustrated in FIGS. 10 and 1C, the insulating layer 4 is not formed on the back electrode layer removing portion 11b.

  2A and 11 are schematic cross-sectional views showing an example of an organic EL device in which a plurality of organic EL panels illustrated in FIGS. 1A, 1C, and 10 are arranged. In the organic EL device 20 illustrated in FIG. 2A and FIG. 11, the organic EL panels 1A and 1B are partially overlapped with each other, and the sub-pixels of the organic EL panels 1A and 1B ( The light emitting areas are arranged so as not to overlap each other. As illustrated in FIG. 2A and FIG. 11, among the organic EL panels 1 </ b> A and 1 </ b> B that partially overlap each other, in one organic EL panel 1 </ b> A located on the light emission surface side, the back electrode layer removal unit 11 a, The insulating layer 4 is not formed on 11b.

  As shown in FIG. 2A and FIG. 11, among the organic EL panels 1A and 1B that partially overlap each other, in one organic EL panel 1A located on the light emitting surface side, the back electrode layer removing portions 11a and 11b Since the insulating layer 4 is not formed, the insulating layer 4 of one organic EL panel 1A located on the light emitting surface side is the other organic EL panel 1B in a portion where the organic EL panels 1A and 1B partially overlap each other. The organic EL panels 1A and 1B can be arranged so as not to overlap with the sub-pixels (light-emitting regions). As a result, in the portion where the organic EL panels 1A and 1B partially overlap each other, it is possible to suppress the luminance of the organic EL panel 1B from being lowered by the insulating layer 4 of the organic EL panel 1A and reduce luminance unevenness. It is possible to make the joint between the organic EL panels 1A and 1B more inconspicuous.

  As described above, in the present invention, since an insulating layer is not formed in the back electrode layer removal portion, when a plurality of organic EL panels are arranged so as to partially overlap each other, a part of the organic EL panel is It is possible to suppress a decrease in luminance in overlapping portions, reduce luminance unevenness, and make the joint between organic EL panels more inconspicuous.

The insulating layer is preferably light transmissive. Specifically, the total light transmittance of the insulating layer is preferably 60% or more, more preferably 70% or more, and particularly preferably 80% or more. When the total light transmittance of the insulating layer is within the above range, the insulating layer can sufficiently transmit the light emitted from the light emitting layer, and a plurality of organic EL panels are arranged so as to partially overlap each other. In this case, even if the insulating layer of one organic EL panel located on the light emitting surface side overlaps the light emitting region of another organic EL panel, the other organic EL panel in a portion where the organic EL panels partially overlap each other It is because it can suppress that the brightness | luminance of this light emission area | region falls.
In addition, about the measuring method of the said total light transmittance, it can be made to be the same as that of the measuring method of the total light transmittance of the said transparent electrode layer.

In addition, in the case where the light emitting region is a pixel or a sub-pixel, the insulating layer of one organic EL panel located on the light emission surface side when a plurality of organic EL panels are arranged so as to partially overlap each other Is overlapped with a pixel or sub-pixel of another organic EL panel, the insulating layer of one organic EL panel located on the light emitting surface side is the other organic EL panel in a portion where a part of the organic EL panel overlaps each other. It is preferably formed so as to overlap all the pixels or sub-pixels of the EL panel. In the example shown in FIG. 12, the insulating layer 4 of the organic EL panel 1 </ b> A overlaps all the sub-pixels B (not shown) of the organic EL panel 1 </ b> B in a portion where the organic EL panels 1 </ b> A and 1 </ b> B partially overlap each other. Is formed. When the total light transmittance of the insulating layer is relatively low, the insulating layer of one organic EL panel located on the light emitting surface side is formed so as to overlap a part of the pixels or sub-pixels of the other organic EL panel. This is because luminance unevenness may occur between the portion where the insulating layer is formed and the portion where the insulating layer is not formed.
Note that the luminance of the portion where the luminance is lowered by the insulating layer can be corrected by adjusting the driving conditions and the like.

  As a material used for the insulating layer, a material generally used for an insulating layer of an organic EL panel can be employed. For example, photosensitive polyimide resin, acrylic resin, novolac resin, styrene resin, melamine Examples thereof include photo-curing resins or thermosetting resins such as resin based resins, and inorganic materials.

As a method for forming the insulating layer, a general method such as a photolithography method or a printing method can be used.
When an insulating layer is not formed on the back electrode layer removal part, when forming the back electrode layer removal part, the back electrode layer and the insulating layer are irradiated with laser light, and the back electrode layer of the laser light irradiation part It is preferable to remove the insulating layer at the same time.
In addition, since the method of not forming the insulating layer in the back electrode layer removal portion will be described in detail in the section of “C. Manufacturing method of organic EL panel” described later, description thereof is omitted here.

5. Partition Wall In the present invention, a partition wall may be formed on the support substrate on which the transparent electrode layer is formed. For example, in the case of a passive matrix driving type organic EL panel, a partition for dividing the back electrode layer may be formed in a stripe shape on the insulating layer so as to be orthogonal to the stripe-shaped transparent electrode layer.

  In the present invention, when a plurality of organic EL panels are arranged so as to partially overlap each other, the partition of one organic EL panel located on the light emitting surface side does not overlap the light emitting region of another organic EL panel. It is preferable to be formed as described above. This is because it is possible to suppress a decrease in luminance in a portion where the organic EL panels overlap each other, reduce luminance unevenness, and make the joint between the organic EL panels more inconspicuous.

  Moreover, it is preferable that no partition wall is formed in the back electrode layer removal portion. Similarly to the fact that the insulating layer is not formed on the back electrode layer removal portion, a partition is not formed on the back electrode layer removal portion, so that a plurality of organic EL panels partially overlap each other. In such a case, it is possible to suppress a decrease in luminance at a portion where the organic EL panels overlap each other, reduce luminance unevenness, and make the joint between the organic EL panels more inconspicuous. is there.

The partition may have optical transparency. When the partition has light transmittance, the total light transmittance of the partition is preferably 60% or more, more preferably 70% or more, and particularly preferably 80% or more.
In addition, about the measuring method of the said total light transmittance, it can be made to be the same as that of the measuring method of the total light transmittance of the said transparent electrode layer.

In the case of a passive matrix driving type organic EL panel, since the back electrode layer can be divided if the partition wall has a predetermined height, the cross-sectional shape of the partition wall is not particularly limited. Examples thereof include a rectangular shape, a trapezoidal shape (forward tapered shape), and a reverse tapered shape. A reverse taper shape is preferable.
The height of the partition is set so that the height from the support substrate surface to the top of the partition is higher than the height from the support substrate surface to the back electrode layer surface in the pixel.

  As a material used for the partition, a material generally used for the partition of the organic EL panel can be adopted. For example, photosensitive polyimide resin, acrylic resin, novolac resin, styrene resin, phenol resin And photocurable resins such as melamine resins or thermosetting resins, and inorganic materials.

As a method for forming the partition wall, a general method such as a photolithography method or a printing method can be used.
In the case where the barrier rib is not formed in the back electrode layer removal portion, when forming the back electrode layer removal portion, the back electrode layer and the barrier rib are irradiated with laser light, and the back electrode layer and the barrier rib of the laser light irradiated portion Are preferably removed simultaneously.
In addition, since the method of not forming a partition in a back surface electrode layer removal part is described in detail in the section of “C. Manufacturing method of organic EL panel” described later, description here is omitted.

6). Organic EL Layer The organic EL layer used in the present invention is formed on the transparent electrode layer and includes a light emitting layer.
The organic EL layer has one or more organic layers including at least a light emitting layer. That is, the organic EL layer is a layer including at least a light emitting layer, and the layer configuration is a layer having one or more organic layers. Usually, when forming an organic EL layer by a wet process, it is often composed of one or two organic layers because it is difficult to stack a large number of layers in relation to the solvent, It is possible to further increase the number of layers by devising organic materials or combining vacuum deposition methods.

  Examples of the layer constituting the organic EL layer other than the light emitting layer include a hole injection layer, an electron injection layer, a hole transport layer, and an electron transport layer. The hole transport layer may be integrated with the hole injection layer by imparting a hole transport function to the hole injection layer. In addition, the electron transport layer may be integrated with the electron injection layer by adding an electron transport function to the electron injection layer. Furthermore, examples of the layer constituting the organic EL layer include a layer for preventing penetration of holes or electrons, such as a carrier block layer, and improving recombination efficiency.

  In the present invention, when at least one constituent layer among the constituent layers of the organic EL layer is formed on one surface on the support substrate on which the transparent electrode layer is formed, the constituent layer is formed on the back electrode layer removing portion. Is preferably not formed. Similarly, it is preferable that the insulating layer is not formed on the back electrode layer removal portion, and a constituent layer is not formed on the back electrode layer removal portion, so that a plurality of organic EL panels are partially connected to each other. When arranged so as to overlap, it is possible to suppress a decrease in luminance at a portion where the organic EL panels overlap each other, reduce luminance unevenness, and make the joint between the organic EL panels more inconspicuous. It is.

  Examples of the layer formed on one surface on the support substrate on which the transparent electrode layer is formed include a hole injection layer, a hole transport layer, an electron transport layer, an electron injection layer, and a carrier block layer. In addition, when the organic EL panel is a lighting panel, or when the organic EL panel is a display panel and is monochromatic display (monochrome or area color), the light emitting layer may be formed over the entire surface.

  In the specification of the present application, the “constituent layer” refers to a layer formed on one surface on a support substrate on which a transparent electrode layer is formed, among the layers constituting the organic EL layer.

  Hereinafter, each structure in the organic EL layer will be described.

(1) Light emitting layer The light emitting layer in the present invention may be monochromatic or multicolored, and is appropriately selected according to the use of the organic EL panel of the present invention.

  Examples of the material used for the light emitting layer include light emitting materials such as pigment materials, metal complex materials, and polymer materials.

  Examples of dye materials include cyclopentadiene derivatives, tetraphenylbutadiene derivatives, triphenylamine derivatives, oxadiazole derivatives, pyrazoloquinoline derivatives, distyrylbenzene derivatives, distyrylarylene derivatives, silole derivatives, thiophene ring compounds, pyridine ring compounds. Perinone derivatives, perylene derivatives, oligothiophene derivatives, trifumanylamine derivatives, oxadiazole dimers, pyrazoline dimers, and the like.

  Examples of metal complex materials include aluminum quinolinol complexes, benzoquinolinol beryllium complexes, benzoxazole zinc complexes, benzothiazole zinc complexes, azomethyl zinc complexes, porphyrin zinc complexes, eurobium complexes, etc. And metal complexes having a rare earth metal such as Eu, Dy, etc., and having an oxadiazole, thiadiazole, phenylpyridine, phenylbenzimidazole, quinoline structure or the like as a ligand.

  Examples of the polymer material include polyparaphenylene vinylene derivatives, polythiophene derivatives, polyparaphenylene derivatives, polysilane derivatives, polyacetylene derivatives, polyvinylcarbazole, polyfluorene derivatives, polyquinoxaline derivatives, and copolymers thereof. it can.

  A dopant may be added to the light emitting layer for the purpose of improving the light emission efficiency and changing the light emission wavelength. Examples of such doping agents include perylene derivatives, coumarin derivatives, rubrene derivatives, quinacridone derivatives, squalium derivatives, porphyrin derivatives, styryl dyes, tetracene derivatives, pyrazoline derivatives, decacyclene, phenoxazone, quinoxaline derivatives, carbazole derivatives, fluorene derivatives. Can be mentioned.

  The thickness of the light emitting layer is not particularly limited as long as it can provide a function of emitting light by providing a recombination field between electrons and holes, and is, for example, about 1 nm to 500 nm. Can do.

The light emitting layer may be formed on one surface or may be formed in a pattern, and is appropriately selected according to the use of the organic EL panel of the present invention.
For example, in the case where the organic EL panel is a display panel and is a monochromatic light emitting layer, the light emitting layer may be formed in a pattern so as to constitute a pixel, and the pixel is defined by the insulating layer. If it is, it may be formed on one side. On the other hand, in the case where the organic EL panel is a display panel and is a multicolor light emitting layer, the light emitting layer may be formed in a pattern so as to constitute a subpixel, and the subpixel is formed by an insulating layer. May be formed continuously in an arbitrary direction.
For example, when the organic EL panel is a lighting panel, the light emitting layer is usually formed on one surface.

  As a method for forming the light emitting layer, a general method for forming a light emitting layer can be adopted, and either a wet process or a dry process can be used. For example, vacuum deposition method, printing method, inkjet method, spin coating method, casting method, dipping method, bar coating method, blade coating method, roll coating method, gravure coating method, flexographic printing method, spray coating method, self-assembly method (Alternate adsorption method, self-assembled monolayer method) and the like.

When the light emitting layer is not formed in the back electrode layer removal portion, when forming the back electrode layer removal portion, the back electrode layer and the light emitting layer are irradiated with laser light, and the back electrode layer of the laser light irradiated portion It is preferable to remove the light emitting layer at the same time.
In addition, since the method of not forming the light emitting layer in the back electrode layer removal portion will be described in detail in the section of “C. Manufacturing method of organic EL panel” described later, description thereof is omitted here.

(2) Hole injection layer and hole transport layer In the present invention, the hole transport layer may be integrated with the hole injection layer by imparting a hole transport function to the hole injection layer. . That is, the hole injection layer may have only a hole injection function, or may have both a hole injection function and a hole transport function.

  The material used for the hole injection layer is not particularly limited as long as the material can stabilize the injection of holes into the light emitting layer. In addition, phenylamine, starburst amine, phthalocyanine, vanadium oxide, molybdenum oxide, ruthenium oxide, aluminum oxide, titanium oxide and other oxides, amorphous carbon, polyaniline, polythiophene, polyphenylene vinylene derivatives, etc. can be used. . Specifically, 4,4′-bis [N- (1-naphthyl) -N-phenylamino] biphenyl (α-NPD), 4,4 ′, 4 ″ -tris (3-methylphenylphenylamino) tri Examples include phenylamine (m-MTDATA), poly (3,4-ethylenedioxythiophene) -polystyrene sulfonic acid (PEDOT-PSS), polyvinylcarbazole (PVCz), and the like.

Further, the thickness of the hole injection layer is not particularly limited as long as the hole injection function and the hole transport function are sufficiently exhibited. Specifically, the thickness is in the range of 0.5 nm to 1000 nm, particularly 10 nm. It is preferable to be within a range of ˜500 nm.
The method for forming the hole injection layer can be the same as the method for forming the light emitting layer.

(3) Electron Injection Layer In the present invention, the electron transport layer may be integrated with the electron injection layer by imparting an electron transport function to the electron injection layer. That is, the electron injection layer may have only an electron injection function, or may have both an electron injection function and an electron transport function.

  The material used for the electron injection layer is not particularly limited as long as the material can stabilize the injection of electrons into the light emitting layer. In addition to the compounds exemplified as the light emitting material of the light emitting layer, Aluminum lithium alloy, lithium fluoride, sodium fluoride, strontium, magnesium oxide, magnesium fluoride, strontium fluoride, calcium fluoride, barium fluoride, aluminum oxide, strontium oxide, calcium, polymethyl methacrylate, sodium polystyrene sulfonate, Alkali metals, alkali metal halides, alkali metal organic complexes, and the like such as lithium, cesium, and cesium fluoride can be used.

  Alternatively, a metal doped layer in which an alkali metal or alkaline earth metal is doped on an electron transporting organic material may be formed and used as an electron injection layer. Examples of the electron-transporting organic material include bathocuproin, bathophenanthroline, and phenanthroline derivatives. Examples of the metal to be doped include Li, Cs, Ba, and Sr.

The thickness of the electron injection layer is not particularly limited as long as the electron injection function and the electron transport function are sufficiently exhibited.
The method for forming the electron injection layer can be the same as the method for forming the light emitting layer.

(4) Electron Transport Layer The material used for the electron transport layer in the present invention is not particularly limited as long as it is a material capable of transporting electrons injected from the cathode into the light emitting layer. For example, bathocuproine , Bathophenanthroline, phenanthroline derivative, triazole derivative, oxadiazole derivative, derivative of tris (8-quinolinolato) aluminum complex (Alq3), and the like.

The thickness of the electron transport layer is not particularly limited as long as the electron transport function is sufficiently exerted.
The method for forming the electron transport layer can be the same as the method for forming the light emitting layer.

7). Support Substrate The support substrate used in the present invention supports the above-described transparent electrode layer, organic EL layer, back electrode layer, and the like.

  In the present invention, since the support substrate side is the light emitting surface, the support substrate has light transmittance. In addition, when removing the back electrode layer, transparent electrode layer, insulating layer, and the like of the laser light irradiated portion by irradiating laser light from the support substrate side, the support substrate is preferably one that transmits laser light. .

The support substrate preferably has a total light transmittance of 70% or more, more preferably 80% or more, and particularly preferably 90% or more.
In addition, about the measuring method of the said total light transmittance, it can be made to be the same as that of the measuring method of the total light transmittance of the said transparent electrode layer.

Examples of such a support substrate include inflexible rigid materials such as glass plates or flexible materials such as resin films and thin glass. A glass plate or a thin plate glass has a barrier property against moisture, oxygen and the like, and has an advantage that damage caused by laser light irradiation is small when a part of the back electrode layer is removed by laser light irradiation. A protective layer may be formed on the surface of the thin glass to prevent cracking or chipping of the thin glass as necessary. The resin film is excellent in processability, is useful in realizing cost reduction, weight reduction, and an organic EL panel that is difficult to break, and has an advantage that the applicability to various applications such as application to a curved surface is widened. A barrier layer having a barrier property that blocks moisture, oxygen, and the like may be formed on the surface of the resin film as necessary.
Among them, a flexible material having flexibility such as a resin film and thin glass is preferably used. The thickness of the organic EL panel can be reduced, and when a plurality of organic EL panels are arranged so as to partially overlap each other, the steps in the portion where the organic EL panels partially overlap each other can be reduced. This is because the seam between the panels is less noticeable and the visibility can be improved. In particular, thin glass is suitable because it is less damaged by laser light irradiation.

  The thickness of the support substrate is not particularly limited as long as it is a general thickness of the support substrate in the organic EL panel, but is preferably 150 μm or less, more preferably 100 μm or less, and still more preferably 50 μm. It is as follows. If the thickness of the support substrate is in the above range, the step can be reduced and the visibility can be improved when a plurality of organic EL panels are arranged so as to partially overlap each other as described above. It is. Since the thickness of the organic EL panel becomes thinner as the thickness of the support substrate is thinner, the lower limit of the thickness of the support substrate is not particularly limited, but is about 10 μm in consideration of strength, barrier properties, and the like.

8). Sealing of Organic EL Element In the present invention, an organic EL element having a transparent electrode layer, an organic EL layer, and a back electrode layer is sealed. The organic EL element may be sealed as long as it is a general organic EL element, and examples thereof include hollow sealing, solid sealing, and membrane sealing. Hereinafter, hollow sealing, solid sealing, and membrane sealing will be described.

(1) Hollow sealing In the case of hollow sealing, a light-transmitting sealing substrate is disposed on the back electrode layer, and a light-transmitting adhesive layer is formed on the outer periphery of the supporting substrate or the sealing substrate. The substrate and the sealing substrate are bonded to each other through an adhesive layer.

(Sealing substrate)
In the present invention, when a plurality of organic EL panels are arranged so as to partially overlap each other, among the organic EL panels that partially overlap each other, sealing one organic EL panel located on the light emitting surface side Since the substrate overlaps the light emitting region of another organic EL panel, the sealing substrate has light transmittance. The total light transmittance of the sealing substrate can be the same as the total light transmittance of the support substrate.
In addition, when removing the back electrode layer, the transparent electrode layer, the insulating layer, etc. of the laser light irradiated portion by irradiating laser light from the sealing substrate side, the sealing substrate shall transmit laser light. Is preferred.

Since the kind of the sealing substrate can be the same as that of the support substrate, description thereof is omitted here.
Further, the thickness and the like of the sealing substrate can be the same as those of the support substrate, and thus description thereof is omitted here.
The shape of the sealing substrate is appropriately selected according to the type of the sealing substrate, and examples thereof include a flat plate shape and a cap shape.

(Adhesive layer)
In the present invention, when a plurality of organic EL panels are arranged so as to partially overlap each other, among the organic EL panels that partially overlap each other, the adhesive layer of one organic EL panel located on the light emitting surface side Since it overlaps with the light emitting region of another organic EL panel, the adhesive layer has light transmittance. The total light transmittance of the adhesive layer can be the same as the total light transmittance of the support substrate.

As an adhesive used for the adhesive layer, an adhesive generally used for an organic EL panel can be used. Among these, the adhesive is preferably a curable adhesive. This is because the adhesion between the support substrate and the sealing substrate is strengthened, and entry of moisture, oxygen, and the like can be effectively prevented.
Examples of the curable adhesive include a thermosetting adhesive and a photocurable adhesive. Specific examples include polyimide resins, silicone resins, epoxy resins, acrylic resins, and the like.

  As a method for forming the adhesive layer, a general method for forming an adhesive layer in an organic EL panel can be employed.

(Getter layer)
In the space between the support substrate and the sealing substrate, a getter layer that absorbs moisture is preferably disposed. As the getter layer, a general getter layer used for an organic EL panel can be applied.

(Other configurations)
When sealing the organic EL element, a thin film is inserted between the support substrate on which the organic EL element is formed and the sealing substrate on which the adhesive layer is formed by a solid sealing method described later. Can be secured. In this case, similarly to the solid sealing described later, the organic EL panel can be thinned, and a part of the organic EL panel overlaps with each other when a plurality of organic EL panels are arranged so as to overlap each other. The step can be reduced, and the seam between the organic EL panels can be made less conspicuous to improve the visibility.
The thin film may have the function of the getter layer.

(2) Solid sealing In the case of solid sealing, a light-transmitting adhesive layer is formed on a support substrate so as to cover an organic EL element having a transparent electrode layer, an organic EL layer, and a back electrode layer. A sealing substrate is disposed on the support substrate, and the support substrate and the sealing substrate are bonded to each other through an adhesive layer.
In the case of solid sealing, it is possible to reduce the thickness of the organic EL panel, and when a plurality of organic EL panels are arranged so as to partially overlap each other, a step difference in a portion where the organic EL panels partially overlap each other is reduced. It is possible to improve visibility by making the joint between the organic EL panels less noticeable.

(Sealing substrate)
As described in the section of the hollow sealing, the sealing substrate has light transmittance. The total light transmittance of the sealing substrate can be the same as the total light transmittance of the support substrate.
In addition, when removing the back electrode layer, the transparent electrode layer, the insulating layer, etc. of the laser light irradiated portion by irradiating laser light from the sealing substrate side, the sealing substrate shall transmit laser light. Is preferred.

Since the kind of the sealing substrate can be the same as that of the support substrate, description thereof is omitted here. Among these, flexible materials such as resin films and thin glass are preferably used.
Further, the thickness and the like of the sealing substrate can be the same as those of the support substrate, and thus description thereof is omitted here.

(Adhesive layer)
Since the adhesive layer can be the same as the adhesive layer in the case of the hollow sealing, the description here is omitted.

(3) Film sealing In the case of film sealing, a light-transmitting sealing film is formed on a support substrate so as to cover an organic EL element having a transparent electrode layer, an organic EL layer, and a back electrode layer.
In the case of film sealing, the organic EL panel can be thinned as in the case of solid sealing, and when a plurality of organic EL panels are arranged so that some of them overlap each other, some of the organic EL panels overlap each other. The level difference in the portion can be reduced, and the seam between the organic EL panels can be made less conspicuous to improve the visibility.

(Sealing film)
In the present invention, when a plurality of organic EL panels are arranged so as to partially overlap each other, among the organic EL panels that partially overlap each other, sealing one organic EL panel located on the light emitting surface side Since the film overlaps the light emitting region of another organic EL panel, the sealing film has light transmittance. The total light transmittance of the sealing film can be the same as the total light transmittance of the support substrate.
In addition, when removing the back electrode layer, transparent electrode layer, insulating layer, etc. of the laser light irradiated portion by irradiating laser light from the sealing film side, the sealing film must transmit laser light. Is preferred.

  As the sealing film, a sealing film generally used for an organic EL panel can be applied, and examples thereof include an inorganic layer such as a silicon oxide film, a silicon nitride oxide film, and a silicon nitride film, and an organic layer. . These films may be formed by one kind alone, or two or more kinds may be laminated.

  As a method for forming the sealing film, a general method for forming a sealing film in an organic EL panel can be employed.

9. Organic EL Panel The thickness of the organic EL panel of the present invention is preferably 300 μm or less, more preferably 250 μm or less, and particularly preferably 200 μm or less. If the thickness of the organic EL panel is within the above range, the step in the portion where the organic EL panels partially overlap each other can be reduced when a plurality of organic EL panels are disposed so as to partially overlap each other. This is because the visibility can be improved by making the joint between the organic EL panels less noticeable. The lower the thickness of the organic EL panel, the better. The lower limit of the thickness of the organic EL panel is not particularly limited, but is about 50 μm in consideration of the thickness of each layer.

  In addition, since the manufacturing method of an organic EL panel is described in detail in the section of “C. Manufacturing method of organic EL panel” described later, description thereof is omitted here.

B. Organic EL device The organic EL device of the present invention is an organic EL device in which a plurality of the above-mentioned organic EL panels are arranged so that a part of the back electrode layers overlap each other and the light emitting regions do not overlap each other, Among the organic EL panels in which a part of the back electrode layer overlaps with each other, the one organic EL panel located on the light emitting surface side has the light emission in the vicinity of the part in which the back electrode layer partially overlaps with each other. It has a back electrode layer removal part in which the back electrode layer is not formed so that the back electrode layer of one organic EL panel located on the surface side does not overlap the light emitting region of another organic EL panel. It is a feature.

According to the present invention, as described in the above section “A. Organic EL panel”, among the organic EL panels in which the back electrode layers partially overlap each other, one organic EL panel located on the light emitting surface side is By having the predetermined back electrode layer removal portion, the joint between the organic EL panels can be made inconspicuous, and the visibility can be improved.
In addition, since the back electrode layer removal portion is formed, the seam between the organic EL panels can be made inconspicuous, so the non-display area on the outer periphery of the organic EL panel can be arbitrarily set, and the organic EL panel It is possible to secure a sufficient area for sealing the element. This is particularly useful in the case of a high-definition pixel array with a small pixel interval.

  The organic EL panel is described in detail in the above section “A. Organic EL panel”, and the description thereof is omitted here. Hereinafter, another configuration of the organic EL device of the present invention will be described.

1. Arrangement of organic EL panel In the present invention, as the arrangement of the organic EL panel, the organic EL panel is such that part of the back electrode layer of the organic EL panel overlaps with each other and the light emitting area of the organic EL panel does not overlap with each other. As long as a plurality of organic EL panels 1A and 1B overlap each other as shown in FIGS. 2A and 2B and FIGS. 3A and 3B, The back electrode layer 7 having light impermeability of one organic EL panel 1A located on the light emission surface side and the sub-pixels R, G, and B (light emitting regions) of the other organic EL panel 1B are not overlapped. Organic EL panels 1A and 1B are arranged. Further, usually, as shown in FIGS. 2A and 2B and FIGS. 3A and 3B, the organic EL panels 1A and 1B are located on the light emitting surface side in a portion where the organic EL panels 1A and 1B overlap each other. The distances y1 and y2 between the outermost peripheral pixel P of one organic EL panel 1A and the outermost peripheral pixel P of another organic EL panel 1B and the pixel intervals x1 and x2 of the organic EL panels 1A and 1B are substantially the same. The organic EL panels 1A and 1B are arranged so as to be.

  In the part where the organic EL panels partially overlap each other, the distance between the outermost peripheral pixel of one organic EL panel and the outermost peripheral pixel of the other organic EL panel located on the light emitting surface side and the pixel interval are approximately “Same” means that when the pixel interval is 1, the distance between the outermost peripheral pixel of one organic EL panel and the outermost peripheral pixel of another organic EL panel located on the light emitting surface side is 0.7 to It is within the range of 1.3.

  An example of the arrangement of the organic EL panel will be described. As illustrated in FIG. 9A, two panel sides 10a and 10b on which the transparent electrode layer extraction electrode 21 and the back electrode layer extraction electrode 22 are not formed are adjacent to each other. When the back electrode layer removal portions 11a to 11d are formed on the outer edge of the back electrode layer 7 near 10b, one of the organic EL panels 1 adjacent in the left-right direction as illustrated in FIG. 9B. The panel side 10a of the organic EL panel 1 overlaps the upper side of the panel side 10d of the other organic EL panel 1, and the panel side 10b of one organic EL panel 1 among the organic EL panels adjacent in the vertical direction is the other organic EL panel. Among the organic EL panels 1 that overlap the upper side of the panel side 10c of the panel 1 and are adjacent to each other in the diagonally upper left and lower diagonal directions, the corners of the panel sides 10a and 10b of one organic EL panel 1 are the other. Among the organic EL panels 1 that overlap the upper corners of the panel sides 10c and 10d of the EL panel 1 and are adjacent in the diagonally upper right and lower left directions, the corners of the panel sides 10b and 10d of one organic EL panel 1 are the other organic A plurality of organic EL panels 1 can be arranged so as to overlap the corners of the panel sides 10a and 10c of the EL panel 1. In the case of such an organic EL panel arrangement, any direction of up, down, left, right, diagonally up right, diagonally down right, diagonally up left, diagonally down left is made without making the seam between the organic EL panels conspicuous In addition, a plurality of organic EL panels can be arranged, and the size can be easily increased.

  The number of organic EL panels may be two or more, and is not particularly limited. The organic EL device of the present invention may be one in which several hundred organic EL panels are arranged, for example.

2. Resin In the present invention, as illustrated in FIG. 13, a front substrate 31 having optical transparency is disposed on the light emitting surface side of the plurality of organic EL panels 1, and the plurality of organic EL panels 1 and the front substrate 31 are disposed. A resin 32 having optical transparency may be filled in between. By setting it as such a structure, the light-projection surface of the organic electroluminescent apparatus 20 can be planarized, the seam of the organic electroluminescent panels 1 can be made hard to see, and visibility can further be improved.

  The refractive index of the resin and the refractive index of the support substrate of the organic EL panel are preferably substantially the same. That the refractive index of the resin and the refractive index of the support substrate of the organic EL panel are substantially the same means that the difference between the refractive index of the resin and the refractive index of the support substrate of the organic EL panel is 0.15 or less. It is preferably 0.1 or less, and more preferably 0.05 or less.

  The resin has optical transparency. The total light transmittance of the resin can be the same as the total light transmittance of the support substrate.

  Such a resin is appropriately selected depending on the type of the support substrate, and examples thereof include curable resins such as a photo-curable resin and a thermosetting resin. Specifically, the epoxy resin contains a benzene ring. A photocurable resin or a thermosetting resin obtained by combining a high refractive index resin and a low refractive index resin typified by an alicyclic epoxy resin can be used.

  As a method of filling the resin between the plurality of organic EL panels and the front substrate, for example, a method of arranging the resin on the front substrate and superimposing the front substrate and the plurality of organic EL panels through the resin. Can be used. When a curable resin is used, the curable resin is cured after the front substrate and the plurality of organic EL panels are overlapped via the curable resin.

3. Front Substrate In the present invention, as described above, as illustrated in FIG. 13, the front substrate 31 having optical transparency is arranged on the light emitting surface side of the plurality of organic EL panels 1, and the plurality of organic EL A resin 32 having optical transparency may be filled between the panel 1 and the front substrate 31.

  The refractive index of the front substrate and the refractive index of the resin are preferably substantially the same. The fact that the refractive index of the front substrate and the refractive index of the resin are substantially the same means that the difference between the refractive index of the front substrate and the refractive index of the resin is 0.15 or less, preferably 0.1 or less. More preferably, it is 0.05 or less.

  The front substrate is light transmissive. The total light transmittance of the front substrate can be the same as the total light transmittance of the support substrate.

  Such a front substrate is appropriately selected according to the type of the support substrate, and the same substrate as the support substrate can be used.

4). Color filter layer In the present invention, a color filter layer may be formed outside the front substrate. This is because the color purity can be increased.
The color filter layer is not particularly limited as long as it has a colored layer, and may have a light shielding part as necessary, and a general color filter can be used.

C. Manufacturing method of organic EL panel The manufacturing method of the organic EL panel of the present invention includes a light-transmitting support substrate, a transparent electrode layer formed on the support substrate, and a light emitting layer formed on the transparent electrode layer. And an organic EL panel formed on the organic EL layer and having a light-opaque back electrode layer, and the other side of the organic EL panel on the back electrode layer side. When the organic EL panel is arranged so that a part of the back electrode layer of the organic EL panel and a part of the back electrode layer of the other organic EL panel overlap each other, a part of the back electrode layer is In order to prevent the back electrode layer of the organic EL panel and the light emitting area of the other organic EL panel from overlapping each other in the vicinity of the overlapping portion, a part of the outer edge of the back electrode layer in the vicinity of at least one panel side Back to remove It has the surface electrode layer removal process.

The manufacturing method of the organic EL panel of the present invention will be described with reference to the drawings.
14 (a) to 14 (b) and FIGS. 15 (a) to 15 (b) are process diagrams showing an example of the method for producing the organic EL panel of the present invention, and an example in which the organic EL panel is a display panel. It is. 14A is a cross-sectional view taken along line GG in FIG. 16, and FIG. 15A is a cross-sectional view taken along line HH in FIG. FIG. 16 is a plan view from the support substrate 2 side of FIGS. 14A and 15A, and configurations other than the support substrate 2, the light emitting layer 6, and the back electrode layer 7 are omitted. 14B is a cross-sectional view taken along line AA in FIG. 1C, and FIG. 15B is a cross-sectional view taken along line BB in FIG. FIG.1 (c) is a top view from the support substrate 2 side of Fig.14 (a) and FIG.15 (a), and structures other than the support substrate 2, the light emitting layer 6, and the back surface electrode layer 7 are abbreviate | omitted. .
First, as shown in FIGS. 14A, 15A, and 16, an organic EL panel 1X is manufactured. The organic EL panel 1X covers the support substrate 2, the transparent electrode layer 3 formed in a stripe shape on the support substrate 2, and the end of the transparent electrode layer 3, and includes subpixels R, G, and B. An insulating layer 4 formed so as to demarcate, a partition wall 5 formed in a stripe shape on the insulating layer 4 so as to be orthogonal to a stripe pattern of the transparent electrode layer 3, and formed on the transparent electrode layer 3 and the partition wall 5 The light emitting layer 6 (red light emitting layer 6R, green light emitting layer 6G, blue light emitting layer 6B), a back electrode layer 7 formed on the light emitting layer 6, and a sealing substrate 9 are provided. The support substrate 2 and the sealing substrate 9 are bonded together via the adhesive layer 8 and have a hollow sealing structure. The support substrate 2, the transparent electrode layer 3, the insulating layer 4, the partition wall 5, the adhesive layer 8, and the sealing substrate 9 are all light transmissive. On the other hand, the back electrode layer 7 is light-impermeable. In the organic EL panel 1X, one sub-pixel (sub-pixel) R, G, and B constitutes one pixel (pixel) P. The organic EL panel 1 is a bottom emission type in which light L is emitted from the support substrate 2 side.
Next, as shown in FIGS. 14A to 14B and FIGS. 15A to 15B, the organic EL panel 1X is supported on a part of the outer edge of the back electrode layer 7 near the panel sides 10a and 10b. Laser light 51 is irradiated from the substrate 2 side, and the back electrode layer 7, the insulating layer 4, and the partition walls 5 at the laser light irradiated portion are removed (back electrode layer removing step). Thereby, as shown in FIG.14 (b), FIG.15 (b), and FIG.1 (c), the back surface electrode layer removal parts 11a, 11b, and 11c are formed.

According to the present invention, when a plurality of organic EL panels are arranged as described in the above section “A. Organic EL panel” by having a back electrode layer removing step, the seams between the organic EL panels are connected. It can be made inconspicuous and the visibility can be improved.
In addition, since the back electrode layer removing step can make the seam between the organic EL panels inconspicuous, the non-display area on the outer periphery of the organic EL panel can be arbitrarily set, and the sealing of the organic EL element can be performed. It is possible to secure a sufficient area for stopping. This is particularly useful in the case of a high-definition pixel array with a small pixel interval.
Therefore, it is possible to obtain an organic EL panel that is excellent in visibility and can constitute a highly reliable organic EL device.

  Hereinafter, each process in the manufacturing method of the organic electroluminescent panel of this invention is demonstrated.

1. Back Electrode Layer Removal Step In the back electrode layer removal step of the present invention, another organic EL panel is placed on the back electrode layer side of the organic EL panel of the present invention and a part of the back electrode layer of the organic EL panel of the present invention and other organic When the back electrode layer of the EL panel is arranged so as to overlap each other, the back electrode layer of the organic EL panel of the present invention and another organic EL panel in the vicinity of the part where the back electrode layer partially overlaps each other This is a step of removing a part of the outer edge of the back electrode layer in the vicinity of at least one panel side so as not to overlap the light emitting region.

  The method for removing a part of the outer edge of the back electrode layer in the vicinity of at least one panel side is not particularly limited as long as it can remove the back electrode layer. Is preferably used. This is because a minute region can be processed. Moreover, it is because only a predetermined layer inside the organic EL element can be removed without damaging the support substrate, the sealing substrate, or the sealing film.

  When employing the method of irradiating laser light, in the back electrode layer removal step, it is preferable to remove the back electrode layer in the laser light irradiated portion and simultaneously remove the transparent electrode layer in the laser light irradiated portion. When the plurality of organic EL panels are arranged so as to partially overlap each other by removing the transparent electrode layer in the laser light irradiation portion at the same time, the luminance due to the transparent electrode layer in the portion where the organic EL panels partially overlap each other This is because it is possible to suppress the decrease in brightness, reduce the luminance unevenness, and make the joint between the organic EL panels more inconspicuous.

  In the case of adopting a method of irradiating laser light, in the back electrode layer removing step, it is preferable to remove the back electrode layer in the laser light irradiated portion and simultaneously remove the insulating layer in the laser light irradiated portion. By simultaneously removing the insulating layer in the laser light irradiation portion, when a plurality of organic EL panels are arranged so that they partially overlap each other, the luminance is reduced due to the insulating layer in the portion where the organic EL panels partially overlap each other This is because it is possible to suppress the luminance unevenness and make the joint between the organic EL panels more inconspicuous.

  Furthermore, when the method of irradiating laser light is employed, in the back electrode layer removal step, it is preferable to remove the back electrode layer in the laser light irradiated portion and simultaneously remove the partition wall in the laser light irradiated portion. By simultaneously removing the partition walls of the laser light irradiated part, when a plurality of organic EL panels are arranged so that they partially overlap each other, the decrease in luminance due to the partition walls in the part where the organic EL panels partially overlap each other is suppressed. This is because luminance unevenness can be reduced and the seams between the organic EL panels can be made more inconspicuous.

  Moreover, when employ | adopting the method of irradiating a laser beam, in a back surface electrode layer removal process, it is preferable to remove the organic EL layer of a laser beam irradiation part simultaneously with the removal of the back surface electrode layer of a laser beam irradiation part. When the plurality of organic EL panels are arranged so as to partially overlap each other by removing the organic EL layer in the laser light irradiation portion at the same time, the luminance due to the organic EL layer in the portion where the organic EL panels partially overlap each other This is because it is possible to suppress the decrease in brightness, reduce the luminance unevenness, and make the joint between the organic EL panels more inconspicuous.

  The laser beam used in the present invention is not particularly limited as long as the back electrode layer can be removed. However, when the transparent electrode layer or the like in the laser light irradiation portion is removed at the same time, the transparent electrode layer or the like is also removed. Preferably it is possible. As such laser light, laser light generally used for laser repair of organic EL panels can be used. For example, YAG laser, Ar ion laser, He—Ne laser, carbon dioxide laser, excimer laser, A semiconductor laser is exemplified.

  The wavelength of the laser beam is not particularly limited as long as it is a wavelength that can be absorbed by the back electrode layer. A wavelength that is absorbed is preferred. The wavelength of the laser light is appropriately selected according to the type of the back electrode layer, the type of the transparent electrode layer, the layer configuration of the organic EL panel, and the like.

  The irradiation direction of the laser beam is not particularly limited as long as the back electrode layer can be irradiated with the laser beam. The laser beam may be irradiated from the support substrate side, and the back electrode layer side (sealing substrate or Laser light may be irradiated from the sealing film side), which is appropriately selected according to the layer structure of the organic EL panel.

  The irradiation condition of the laser beam is appropriately selected according to the type of the back electrode layer, the type of the transparent electrode layer, the layer configuration of the organic EL panel, and the like.

  The back electrode layer removing step may be performed before the organic EL element is sealed, or may be performed after the organic EL element is sealed. When the back electrode layer removing step is performed before sealing the organic EL element, it is not necessary to consider the absorption of the laser light of the support substrate, the sealing substrate, or the sealing film, and there is an advantage that there are wide choices of laser light. Have. On the other hand, when the back electrode layer removing step is performed after sealing the organic EL element, there is no need to irradiate laser light in a reduced pressure atmosphere, and there is an advantage that the equipment cost can be reduced.

2. Other Steps In the present invention, the steps for forming each component of the organic EL panel are usually performed. The method for forming each component of the organic EL panel is described in the above section “A. Organic EL panel”, and thus the description thereof is omitted here.

D. Manufacturing method of organic EL device In the manufacturing method of the organic EL device of the present invention, a plurality of organic EL panels described above are arranged so that the back electrode layers partially overlap each other and the light emitting regions do not overlap each other. A method for manufacturing an EL device, wherein the back electrode layer of one of the organic EL panels located on the light emitting surface side among the organic EL panels in which a part of the back electrode layers overlap each other, A back electrode layer removing step for removing a portion overlapping with the light emitting region of the EL panel is provided.

The manufacturing method of the organic EL device of the present invention will be described with reference to the drawings.
FIGS. 17A to 17B are process diagrams showing an example of a method for manufacturing an organic EL device according to the present invention, which is an example when the organic EL device is a display device. FIG. 17B is a cross-sectional view taken along the line CC of FIG. FIG. 2B is a plan view from the support substrate 2 side of FIG. 17B, and the configuration other than the support substrate 2, the light emitting layer 6 and the back electrode layer 7 is omitted.
First, as shown in FIG. 17A, an organic EL device 20X is manufactured. The organic EL device 20X is obtained by replacing the organic EL panel 1X shown in FIG. 14A, FIG. 15A, and FIG. A plurality of subpixels R, G, and B (light emitting regions) are arranged so as to overlap each other and not overlap each other.
Next, as shown in FIGS. 17A to 17B, the sub-pixels R, G, and other sub-pixels of the other organic EL panel 1X of the back electrode layer 7 of the one organic EL panel 1X located on the light emission surface side are illustrated. The portion overlapping with B (light emitting region) is irradiated with the laser beam 51, and the back electrode layer 7 and the insulating layer 4 in the laser beam irradiated portion are removed (back electrode layer removing step). Thereby, as shown in FIGS. 17B and 2B, the back electrode layer removal portion 11a is formed.

According to the present invention, by having the back electrode layer removing step, the seam between the organic EL panels can be made inconspicuous and the visibility can be improved as described in the above section “A. Organic EL panel”. It becomes possible to do.
In addition, since the back electrode layer removing step can make the seam between the organic EL panels inconspicuous, the non-display area on the outer periphery of the organic EL panel can be arbitrarily set, and the sealing of the organic EL element can be performed. It is possible to secure a sufficient area for stopping. This is particularly useful in the case of a high-definition pixel array with a small pixel interval.
Therefore, it is possible to obtain an organic EL device with excellent visibility and high reliability.

  Hereinafter, each process in the manufacturing method of the organic EL device of the present invention will be described.

1. Back Electrode Layer Removal Step The back electrode layer removal step in the present invention is the other of the back electrode layers of one organic EL panel located on the light emitting surface side among the organic EL panels in which the back electrode layers partially overlap each other. This is a step of removing a portion overlapping the light emitting region of the organic EL panel.

  As a method of removing a portion of the back electrode layer of one organic EL panel located on the light emitting surface side that overlaps the light emitting region of another organic EL panel from among the organic EL panels in which part of the back electrode layer overlaps each other The method is not particularly limited as long as it can remove the back electrode layer, but among them, a method of irradiating a laser beam is preferably used. This is because a minute region can be processed. Moreover, it is because only a predetermined layer inside the organic EL panel can be removed without damaging the support substrate, the sealing substrate, or the sealing film.

  The back electrode layer removing step may be performed before arranging the plurality of organic EL panels or after arranging the plurality of organic EL panels. When the back electrode layer removing step is performed before arranging a plurality of organic EL panels, the other organic EL panel arranged on the back electrode layer side of one organic EL panel for removing a part of the back electrode layer is removed. This has the advantage that the light emitting region can be prevented from being damaged by the laser beam. On the other hand, when the back electrode layer removing step is performed after arranging a plurality of organic EL panels, there is an advantage that alignment when arranging a plurality of organic EL panels is easy.

  The direction of laser light irradiation is particularly limited as long as the back electrode layer of one organic EL panel located on the light emitting surface side can be irradiated with laser light among the organic EL panels in which part of the back electrode layers overlap each other. Instead, it is appropriately selected depending on whether the back electrode layer removing step is performed before the arrangement of the plurality of organic EL panels or after the arrangement of the plurality of organic EL panels. When the back electrode layer removing step is performed before arranging a plurality of organic EL panels, the laser beam may be irradiated from the support substrate side, or the laser beam may be irradiated from the back electrode layer side (sealing substrate or sealing film side). It may be irradiated with light and is appropriately selected according to the layer configuration of the organic EL panel. On the other hand, when the back electrode layer removing step is performed after arranging the plurality of organic EL panels, the laser beam is irradiated from the support substrate side.

  The method of irradiating the laser beam is the same as that described in the above section “C. Manufacturing method of organic EL panel”, and the description thereof is omitted here.

2. Other Steps In the present invention, usually, a step of producing a plurality of organic EL panels and a step of arranging a plurality of organic EL panels are performed. In addition, about the method of forming each structure of an organic electroluminescent panel, it described in the term of the said "A. organic EL panel", and about the arrangement | positioning of the organic electroluminescent panel, it described in the term of the said "B. organic EL apparatus". Therefore, explanation here is omitted.

  The present invention is not limited to the above embodiment. The above-described embodiment is an exemplification, and the present invention has substantially the same configuration as the technical idea described in the claims of the present invention, and any device that exhibits the same function and effect is the present invention. It is included in the technical scope of the invention.

Hereinafter, the present invention will be specifically described with reference to examples.
[Example 1]
(Formation of transparent electrode layer)
First, an indium tin oxide (ITO) electrode film having a thickness of 200 nm is formed on a glass substrate (thickness: 0.1 mm) by ion plating, a photosensitive resist is applied on the ITO electrode film, and mask exposure is performed. Then, development and etching of the ITO electrode film were performed to form 450 transparent electrode layers having a width of 124 μm at a pitch of 154 μm.

(Formation of insulating layer)
Next, the glass substrate on which the transparent electrode layer is formed is subjected to cleaning treatment and ultraviolet plasma cleaning, and then a positive photosensitive resist mainly composed of a polyimide precursor is applied by a spin coating method, and photolithography is performed. The insulating layer (thickness) is patterned so that light emitting regions (openings) of 100 μm × 408 μm exist on each transparent electrode layer at a pitch of 154 μm in the direction orthogonal to the stripe of the transparent electrode layer and a pitch of 462 μm in the parallel direction. 1.5 μm) was formed. The pixel interval (x1, x2) defined by the insulating layer was 54 μm.

(Formation of partition walls)
Next, the glass substrate on which the insulating layer is formed is subjected to cleaning treatment and ultraviolet plasma cleaning, and then a negative photosensitive resist composed of a novolac resin, a phenol resin, and a melamine resin is applied by a spin coat method. Patterning was performed by a lithography process, and a partition wall having a stripe shape and a reverse taper shape was formed on the insulating layer so as to be orthogonal to the stripe of the transparent electrode layer. The partition wall had a width of 20 μm, a height of 4 μm, and an inverse taper angle of 45 °.

(Formation of hole transport layer)
Metal mask having an opening of 80 mm × 80 mm made of N, N′-diphenyl-N, N′-bis (3methylphenyl) -1,1′-biphenyl-4,4′-diamine (TPD) by vacuum deposition Was used for vapor deposition (deposition rate = 0.1 nm / second). As a result, an 80 mm × 80 mm hole transport layer (thickness: 80 nm) made of TPD was formed on the transparent electrode layer.

(Formation of light emitting layer)
Using a metal mask in which a large number of openings of 120 μm × 428 μm are formed in a matrix at a 462 μm pitch in a mixed layer of a host material and a guest material by a vacuum evaporation method, the center of the opening is located at the center of the subpixel. Vapor deposition was performed (deposition rate = 0.1 nm / second). As the guest material, red light emission (R), green light emission (G), and blue light emission (B) materials were used, respectively, to form pixels composed of RGB sub-pixels. This formed each light emitting layer (thickness 40 nm) which consists of a mixed layer of host material and guest material on a positive hole transport layer.

(Formation of electron transport layer)
Tris (8-quinolinolato) aluminum complex (Alq ₃ ) was deposited by a vacuum deposition method in the same manner as in the formation of the hole transport layer (vapor deposition rate = 0.1 nm / second). Thereby, an 80 mm × 80 mm electron transport layer (thickness 20 nm) made of Alq ₃ was formed on each light emitting layer.

(Formation of electron injection layer)
Lithium fluoride was vapor-deposited by vapor deposition (vapor deposition rate = 0.1 nm / second) in the same manner as in the formation of the hole transport layer. Thereby, an electron injection layer (thickness 2 nm) of 90 mm × 80 mm made of lithium fluoride was formed on the electron transport layer.

(Formation of back electrode layer)
Next, the metal mask used for forming the electron injection layer was used as it was, and aluminum was deposited by vapor deposition (deposition rate = 0.4 nm / second). As a result, a 90 mm × 80 mm back electrode layer (thickness 300 nm) made of aluminum was formed on the electron injection layer.
Next, the back electrode layer was removed by laser light irradiation so that back electrode layer removal portions 11a to 11c as shown in FIG. The length b1 of the back electrode layer removing portion 11a in the direction parallel to the panel side 10a is 418 μm, the distance z1 from the end of the back electrode layer removing portion 11a to the end of the outermost pixel P is 30 μm, and the back electrode The length b2 of the layer removal portion 11b in the direction parallel to the panel side 10b was 110 μm, and the distance z2 from the end of the back electrode layer removal portion 11b to the end of the outermost pixel P was 30 μm. Further, the back electrode layer removal portion 11c has a length in a direction parallel to the panel side 10a of the back electrode layer removal portion 11c that matches the width of the back electrode layer removal portion 11b, and the panel side 10b of the back electrode layer removal portion 11c. The length in the direction parallel to the width of the back electrode layer removal portion 11a is made to match the width of the back electrode layer removal portion 11a.

(Sealing)
Finally, a 100 mm × 100 mm sealing plate was placed on the surface side on which the back electrode layer was formed so as to cover the organic EL layer and the back electrode layer, and bonded together via an ultraviolet curable adhesive. As a result, an organic EL panel in which extraction electrodes were formed on two sides and a back electrode layer removal portion was formed on the other two sides was obtained.

(Evaluation)
By overlapping the organic EL panels so as to hide the extraction electrodes on the two sides of the organic EL panels, it becomes possible to make the joints between the organic EL panels less noticeable.

DESCRIPTION OF SYMBOLS 1, 1A, 1B ... Organic EL panel 2 ... Support substrate 3 ... Transparent electrode layer 4 ... Insulating layer 5 ... Partition 6 ... Light emitting layer 6R ... Red light emitting layer 6G ... Green light emitting layer 6B ... Blue light emitting layer 7 ... Back surface electrode layer 8 ... Adhesive layer 9 ... Sealing substrate 10a, 10b, 10c, 10d ... Panel sides 11a, 11b, 11c, 11d ... Back electrode layer removal part 13 ... Non-display area 16 ... Light emitting area 20 ... Organic EL device 31 ... Front substrate 32 ... Resin 51 ... Laser light L ... Light R, G, B ... Sub-pixel
P ... Pixel

Claims (13)

A support substrate having optical transparency;
A transparent electrode layer formed on the support substrate;
An organic electroluminescence layer formed on the transparent electrode layer and including a light emitting layer;
An organic electroluminescence element formed on the organic electroluminescence layer and having a light-opaque back electrode layer, and having the transparent electrode layer, the organic electroluminescence layer, and the back electrode layer sealed. An organic electroluminescence panel,
Another organic electroluminescence panel is placed on the back electrode layer side of the organic electroluminescence panel, and a part of the back electrode layer of the organic electroluminescence panel and a part of the back electrode layer of the other organic electroluminescence panel are mutually When arranged so as to overlap, the back electrode layer of the organic electroluminescence panel and the light emitting region of the other organic electroluminescence panel do not overlap in the vicinity of the portion where the back electrode layers partially overlap each other An organic electroluminescence panel comprising a back electrode layer removing portion on which the back electrode layer is not formed at the outer edge of the back electrode layer in the vicinity of at least one panel side.   The organic electroluminescence panel according to claim 1, wherein the transparent electrode layer is not formed in the back electrode layer removal portion.   The insulating layer is formed on the support substrate on which the transparent electrode layer is formed, and the insulating layer is not formed on the back electrode layer removing portion. The organic electroluminescence panel described in 1.   Of the layers constituting the organic electroluminescence layer, at least one constituent layer is formed on one surface on the support substrate on which the transparent electrode layer is formed, and the back electrode layer removing portion includes the constituent layer. The organic electroluminescence panel according to claim 1, wherein the organic electroluminescence panel is not formed.   The thickness of the said organic electroluminescent panel is 300 micrometers or less, The organic electroluminescent panel in any one of Claim 1 to 4 characterized by the above-mentioned.   The extraction electrode for the transparent electrode layer connected to the transparent electrode layer is formed on the support substrate in the vicinity of one panel side, and connected to the back electrode layer on the support substrate in the vicinity of the other panel side An extraction electrode for the back electrode layer is formed, and the back electrode layer is formed on the outer edge of the back electrode layer in the vicinity of two panel sides where the extraction electrode for the transparent electrode layer and the extraction electrode for the back electrode layer are not formed. The organic electroluminescence panel according to any one of claims 1 to 5, wherein a removal portion is formed. An organic electroluminescence panel according to any one of claims 1 to 6, wherein a plurality of organic electroluminescence devices are arranged such that a part of the back electrode layers overlap each other and the light emitting regions do not overlap each other. There,
Among the organic electroluminescence panels in which a part of the back electrode layer overlaps with each other, the one organic electroluminescence panel located on the light emission surface side is in the vicinity of a part in which the back electrode layer partially overlaps with each other, The back electrode layer removal portion in which the back electrode layer is not formed so that the back electrode layer of one organic electroluminescence panel located on the light emitting surface side does not overlap the light emitting region of the other organic electroluminescence panel An organic electroluminescence device comprising:   A light-transmitting front substrate is disposed on the light emission surface side of the plurality of organic electroluminescence panels, and a light-transmitting resin is filled between the plurality of organic electroluminescence panels and the front substrate. 8. The organic electroluminescence device according to claim 7, wherein the supporting substrate of the organic electroluminescence panel, the front substrate, and the resin have substantially the same refractive index.   The organic electroluminescence device according to claim 8, wherein a color filter layer is formed outside the front substrate. A light-transmitting support substrate, a transparent electrode layer formed on the support substrate, an organic electroluminescence layer formed on the transparent electrode layer and including a light emitting layer, and formed on the organic electroluminescence layer A method for producing an organic electroluminescence panel having a back electrode layer having light impermeability,
Another organic electroluminescence panel is placed on the back electrode layer side of the organic electroluminescence panel, and a part of the back electrode layer of the organic electroluminescence panel and a part of the back electrode layer of the other organic electroluminescence panel are mutually When arranged so as to overlap, the back electrode layer of the organic electroluminescence panel and the light emitting region of the other organic electroluminescence panel do not overlap in the vicinity of the portion where the back electrode layers partially overlap each other A method for producing an organic electroluminescence panel, comprising a back electrode layer removing step of removing a part of the outer edge of the back electrode layer in the vicinity of at least one panel side.   The method of manufacturing an organic electroluminescence panel according to claim 10, wherein, in the back electrode layer removing step, the back electrode layer is removed by irradiating the back electrode layer with laser light.   12. The method of manufacturing an organic electroluminescence panel according to claim 11, wherein the transparent electrode layer in the laser light irradiation portion is simultaneously removed in the back electrode layer removing step.   12. The insulating layer is formed on the support substrate on which the transparent electrode layer is formed, and the insulating layer in the laser light irradiation portion is simultaneously removed in the back electrode layer removing step. Or the manufacturing method of the organic electroluminescent panel of Claim 12.

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