WO2014147789A1 - Organic electroluminescence device, organic electroluminescence device manufacturing method, and film forming method - Google Patents
Organic electroluminescence device, organic electroluminescence device manufacturing method, and film forming method Download PDFInfo
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- the present invention relates to an organic electroluminescent device in which a silicon nitride film is formed as a passivation layer, a method for manufacturing the organic electroluminescent device, and a film forming method.
- organic EL display devices using organic electroluminescence (organic EL) elements have attracted attention as a technology for liquid crystal display devices.
- organic EL display device oxidation at the interface with an organic layer or an electrode in contact with the organic layer leads to serious deterioration in display performance.
- a sealing method is used in which the periphery of a glass plate to which a glass frit used as a sealing material or a seal-type hygroscopic agent is attached is adhered with a resin.
- the characteristics required for the passivation layer include that it can be formed at a temperature lower than the glass transition temperature (Tg) of the organic layer, and that it has high light transmissibility that is compatible with the top emission method.
- Tg glass transition temperature
- SiN silicon nitride
- the SiN film When the SiN film is formed as a passivation layer on the organic EL element by a chemical vapor deposition (CVD) method or the like, fine pores are generated due to the defect growth of the SiN film. And the phenomenon considered that a water
- CVD chemical vapor deposition
- the barrier property is remarkably improved as compared with a SiN film having the same total film thickness. This is because the intermediate layer functions as a defect separation layer and a particle embedding layer.
- the polymer organic thin film is basically formed by vapor deposition, it is a disadvantageous process for manufacturing an organic EL display device and the like in that a uniform film is formed over a large area.
- the present invention provides an organic EL device, a method for manufacturing the organic EL device, and a film forming method that can suppress deterioration in quality due to moisture permeation into the interior.
- an organic electroluminescent device is formed by forming a laminate including an amorphous silicon nitride film and a plasma polymerized film on an organic EL element including an organic layer by surface wave excitation plasma chemical vapor deposition.
- a method for manufacturing a sense device is provided.
- a film forming method using a surface wave excited plasma chemical vapor deposition apparatus wherein (a) silane gas and ammonia gas are used as film forming gases at a film forming temperature of 120 ° C. or less. And b) forming an amorphous silicon nitride film on the substrate; and (b) amorphous silicon oxycarbide using a hexamethyldisiloxane gas and an oxygen gas as a deposition gas at a deposition temperature of 120 ° C. or lower. Forming a film on the amorphous silicon nitride film.
- an organic electroluminescence device includes an amorphous silicon nitride film and a laminate including a plasma polymerized film, and the laminate is formed by surface wave excitation plasma chemical vapor deposition.
- an organic EL device it is possible to provide an organic EL device, a method for manufacturing the organic EL device, and a film forming method that can suppress deterioration in quality due to moisture permeation into the interior.
- the organic EL device 1 includes a lower substrate 10, and a lower electrode 21, an organic layer 22, and an upper electrode 23 that are disposed on the lower substrate 10.
- An organic EL element 20, a stacked body 30 disposed on the organic EL element 20, a filler 40 disposed on the stacked body 30, and a sealing material 50 disposed on the filler 40 are provided.
- the strength of the organic EL device 1 can be maintained by filling the space between the organic EL element 20 and the sealing material 50 with the filler 40. Further, a resin film 70 is disposed between the lower substrate 10 and the sealing material 50 so as to surround the periphery of the organic EL element 20, the stacked body 30, and the filler 40. By bonding the lower substrate 10 and the sealing material 50 with the resin film 70, deterioration or oxidation of the organic layer 22 can be suppressed.
- the laminated body 30 is formed by a surface wave excitation plasma chemical vapor deposition method, which will be described in detail later.
- the stacked body 30 includes an amorphous silicon nitride (SiN) film and a plasma polymerization film.
- SiN amorphous silicon nitride
- the stacked body 30 includes a first amorphous SiN film 31 disposed on the organic EL element 20 and a plasma polymerization film 32 disposed on the first amorphous SiN film 31. And a second amorphous SiN film 33 disposed on the plasma polymerization film 32.
- the plasma polymerized film 32 for example, an amorphous silicon oxycarbide (SiOC) film or the like can be adopted.
- the first amorphous SiN film 31 and the second amorphous SiN film 33 function as a passivation layer disposed so that the organic EL element 20 and the filler 40 are not in direct contact with each other. Further, the plasma polymerization film 32 which is an intermediate layer of the passivation layer functions as a defect separation layer. That is, the plasma polymerized film 32 prevents pores from continuing between the first amorphous SiN film 31 and the second amorphous SiN film 33. Thereby, it is suppressed that the water
- the organic EL element 20 is disposed on the lower electrode 21 so as to be surrounded by the insulating separation film 60. Light emission occurs in the light emitting region where the lower electrode 21, the organic layer 22, and the upper electrode 23 are stacked. Therefore, a plurality of light emitting elements can be arranged on one lower substrate 10 by forming a plurality of organic EL elements 20 electrically insulated by the separation film 60. In order to supply power to the organic EL element 20, the lower electrode 21 extends to the outside of the resin film 70.
- the organic layer 22 is electrically connected to the lower electrode 21 and the upper electrode 23.
- the current flowing between the lower electrode 21 and the upper electrode 23 is controlled by a control circuit (not shown) arranged around the organic EL element 20 or in the lower substrate 10, so that each region of the organic layer 22 is controlled. Light emission is controlled.
- light is generated in the organic layer 22 by applying an electric field to the organic layer 22 using the lower electrode 21 in contact with the organic layer 22 as a metal cathode electrode and the upper electrode 23 as a transparent anode electrode. Specifically, holes are supplied from the upper electrode 23 to the organic layer 22, and electrons are supplied from the lower electrode 21 to the organic layer 22. Then, light generated by recombination of holes and electrons is emitted from the organic layer 22, passes through the upper electrode 23, the laminate 30, the filler 40 and the sealing material 50, and is output to the outside of the organic EL device 1. Light L is output.
- a light-transmitting material such as a glass plate is used for the sealing material 50, and a transparent filler is used for the filler 40.
- a transparent filler is used for the filler 40.
- it can suppress that a water
- the upper electrode 23 which is a transparent electrode includes an indium tin oxide (ITO) film, an indium oxide / zinc oxide (IZO) film, a zinc oxide (ZnO) film, an aluminum (Al) -doped titanium oxide (TiO 2 ) film, an oxide A tin (SnO 2 ) film or the like can be used.
- ITO indium tin oxide
- IZO indium oxide / zinc oxide
- ZnO zinc oxide
- Al aluminum
- Al aluminum -doped titanium oxide
- SiO 2 oxide A tin
- SnO 2 oxide A tin
- the organic layer 22 can employ a structure in which a hole transport layer, an electron transport layer, or the like made of an organic compound or the like is laminated.
- a diphenylnaphthyldiamine (NPD) film or the like can be used for the hole transport layer
- a quinolinol aluminum complex (Alq 3 ) film or the like can be used for the electron transport layer.
- the organic layer 22 may have a structure including a light emitting layer disposed between the hole transport layer and the electron transport layer.
- a glass substrate or the like can be used for the lower substrate 10.
- Polyimide or the like can be used for the separation membrane 60. Since the polyimide passes moisture, the separation membrane 60 is covered with the laminate 30. Further, a filler 40 that retains moisture is applied to the outside of the laminate 30.
- a plasma polymerization film 32 such as an amorphous SiOC film formed by surface wave excitation plasma chemical vapor deposition is provided in the middle of a passivation layer made of an amorphous SiN film.
- a plasma polymerization film 32 such as an amorphous SiOC film formed by surface wave excitation plasma chemical vapor deposition is provided in the middle of a passivation layer made of an amorphous SiN film.
- a passivation layer made of an amorphous SiN film.
- defect separation layers According to the surface wave excitation plasma chemical vapor deposition method, it is easy to form a uniform film over a large area. For this reason, even if the organic EL device 1 has a large area, it is possible to easily prevent moisture from the outside from reaching the organic EL element 20 through the pores generated in the passivation layer.
- the nitride film deposited by the plasma CVD method is basically amorphous.
- a surface wave excitation plasma CVD device 110 as shown in FIG. 3 can be used.
- the surface wave excitation plasma CVD apparatus 110 includes a waveguide 112 into which a microwave 111 is introduced, a chamber 114 in which the substrate 100 is stored, a stage 115 on which the substrate 100 to be processed is mounted, and a substrate in the chamber 114. 100, a dielectric 116 disposed opposite to 100, a discharge gas introduction port 117 for introducing a discharge gas into the chamber 114, a film formation gas introduction port 118 for introducing a film formation gas into the chamber 114, and a chamber 114 And an exhaust port 119 for exhausting the gas.
- the laminated body 30 of the organic EL apparatus 1 is manufactured using the surface wave excitation plasma CVD apparatus 110 shown in FIG. 3 is demonstrated.
- the film-forming process by the surface wave excitation plasma CVD apparatus 110 is performed as follows.
- the microwave 111 output from a microwave power source (not shown) and introduced into the waveguide 112 reaches the dielectric 116 via the slot antenna 113 formed in the waveguide 112.
- the arrow described in FIG. 3 has shown the moving direction of the microwave.
- a discharge gas such as argon (Ar) gas is introduced into the chamber 114 from the discharge gas introduction port 117.
- the argon plasma 120 is excited in the chamber 114 by the energy of the microwave 111 introduced into the chamber 114 via the dielectric 116.
- the plasma 120 behaves like a metal, and the microwave 111 does not propagate in the plasma 120 and does not propagate.
- 116 extends laterally along 116. That is, when the electron density of the plasma 120 exceeds the critical density of surface wave generation, the microwave 111 becomes a surface wave and propagates along the boundary surface between the plasma 120 and the dielectric 116. This state is called “surface wave plasma mode”.
- the film forming process using the surface wave excitation plasma CVD apparatus 110 in the present embodiment is mainly performed under conditions of the surface wave plasma mode.
- the manufacturing method of the organic EL device 1 shown in FIG. 1 will be described.
- the manufacturing method of the organic EL device 1 described below is an example, and it is needless to say that it can be realized by various other manufacturing methods including this modification.
- the organic EL element 20 is formed on the lower substrate 10 by a known method or the like.
- the lower electrode film is formed on the lower substrate 10 by vapor deposition or the like.
- the lower electrode film is patterned by a lift-off method or an etching method using a photolithography technique to form a lower electrode 21 as shown in FIG.
- a separation film 60 having an opening as shown in FIG. 5 is formed on the lower substrate 10 and the lower electrode 21 using a vapor deposition mask.
- the organic layer 22 is formed on the lower electrode 21 so as to fill the opening of the separation membrane 60. Thereafter, an upper electrode film is formed on the organic layer 22.
- the upper electrode film is patterned into a desired pattern by an etching method using a photolithography technique or the like to form the upper electrode 23.
- the organic EL element 20 is formed on the lower substrate 10.
- the laminate 30 shown in FIG. 2 is formed on the organic EL element 20 as follows.
- an amorphous SiOC film is formed as the plasma polymerization film 32.
- the first amorphous SiN film 31 and the second amorphous SiN film 33 Ar gas as a discharge gas is introduced into the chamber 114 from the discharge gas inlet 117, and silane gas and ammonia are used as the film forming gas.
- a gas is introduced into the chamber 114 from the deposition gas inlet 118.
- the film formation conditions are, for example, that the flow rate of silane gas is 70 sccm, the flow rate of ammonia gas is 500 sccm, the flow rate of argon gas is 350 sccm, and the pressure in the chamber 114 during film formation is 10 Pa.
- vaporized hexamethyldisiloxane and oxygen (O 2 ) gas are introduced into the chamber 114 from the film forming gas inlet 118.
- the film forming conditions for example, the flow rate of hexamethyldisiloxane is 200 sccm, the flow rate of O 2 gas is 400 sccm, and the pressure in the chamber 114 during film formation is 5 Pa.
- the distance between the plasma and the substrate is 200 mm, and the microwave power density is 1.57 W / cm 2 .
- the substrate surface temperature rises to 80 ° C. and stabilizes.
- the temperature of the stacked body 30 during film formation is maintained at a temperature lower than the glass transition temperature of the organic layer 22.
- the film forming temperature is set to 120 ° C. or lower.
- the distance between the substrate 100 and the dielectric 116 is preferably about 150 mm to 250 mm.
- the distance between the substrate 100 and the dielectric 116 is constant, the barrier property of the formed SiN film is improved. The inventors have confirmed that the above effect can be obtained when the distance between the substrate 100 and the dielectric 116 is 150 mm to 250 mm.
- the lower substrate 10 on which the organic EL element 20 is formed is reciprocated below the dielectric 116 while being reciprocated on the organic EL element 20.
- the stacked body 30 may be formed.
- the film thicknesses of the first amorphous SiN film 31, the plasma polymerized film 32, and the second amorphous SiN film 33 are formed by a moving film forming method in which the lower substrate 10 is reciprocated in parallel with the main surface, which is the film forming surface.
- the distribution can be made uniform.
- the filler 40 is formed on the laminated body 30. Then, by bonding the lower substrate 10 and the sealing material 50 with the resin film 70, the organic EL device 1 shown in FIG. 1 is completed.
- the first amorphous SiN film 31, the plasma polymerization film 32, and the second amorphous SiN film 33 are formed on the same surface. It can be formed continuously using the wave excitation plasma CVD apparatus 110. Thereby, increase in the manufacturing time of the organic EL device 1 can be suppressed.
- Samples S1 to S5 having different structures of the laminate 30 are manufactured by the film forming method using the surface wave excitation plasma CVD apparatus 110 described above, and the samples S1 to S5 are placed in a constant temperature and humidity chamber of 85 ° C. and 85% RH. An acceleration test for storing sample S5 was performed. Samples S1 to S5 have a structure in which the filler 40 is formed on the laminate 30 formed on the organic EL element 20, and the outer periphery of the glass plate of the sealing material 50 is adhered and sealed with resin.
- Sample S1 SiN film with a thickness of 200 nm
- Sample S2 SiN film with a thickness of 400 nm
- Sample S3 SiN film with a thickness of 1 ⁇ m
- Sample S4 SiN film with a thickness of 100 nm / SiOC film with a thickness of 3 ⁇ m / SiN film with a thickness of 100 nm
- Sample S5 SiN film with a thickness of 200 nm / SiOC film with a thickness of 3 ⁇ m / SiN film with a thickness of 200 nm That is, samples S1 to S3 have a single layer of SiN film, and samples S4 to S5 have hexamethyldisiloxane.
- a laminate 30 having a three-layer structure in which an SiOC film as a raw material is an intermediate layer is an intermediate layer.
- the total film thickness of the SiN film is the same between sample S1 and sample S4. Further, the total film thickness of the SiN film is the same between the sample S2 and the sample S5.
- SiN films are formed in various film thicknesses, and in the case of samples S4 to S5, SiN films, SiOC films, SiN films are formed. Were sequentially formed to form a laminate 30.
- FIG. 8 shows the result of the acceleration test performed on samples S1 to S5.
- the acceleration test the ratio of lighting elements that maintain lighting even after a certain period of time was investigated.
- the number of lighting elements in the sample S4 is maintained even after 600 hours as in the sample S3. Since the total film thickness of the SiN film in sample S4 is 200 nm, which is the same as that in sample S1, it was confirmed that the effect of defect separation by the intermediate layer appeared. In the sample S5 in which the total film thickness of the SiN film is 400 nm, which is the same as the sample S2, the ratio of the lighting elements is higher than that in the sample S4.
- the refractive index of the plasma polymerization film 32 formed by this embodiment is about 1.5, and the light transmittance is high. For this reason, the organic EL device 1 can sufficiently cope with a top emission method of outputting light from the sealing material 50 side to the outside.
- the stacked body 30 including the amorphous SiN film and the plasma polymerization film is formed by the surface wave excitation plasma chemical vapor deposition method. It is formed on the organic EL element 20. As a result, it is possible to provide the organic EL device 1 that can suppress deterioration in quality due to moisture permeation into the interior.
- the intermediate layer of the passivation layer made of the SiN film as a plasma polymerized film whose growth rate is about 20 times faster than that of the SiN film, an increase in manufacturing time can be suppressed as compared to manufacturing the SiN film thicker.
- the bottom substrate 10 may be a transparent substrate
- the lower electrode 21 may be a transparent electrode, so that the organic EL device 1 may employ a bottom emission method that emits light from the lower substrate 10 side.
- the present invention can be used for the purpose of suppressing moisture permeation through the passivation film.
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Abstract
Description
本発明は、パッシベーション層として窒化シリコン膜が形成される有機エレクトロルミネセンス装置、有機エレクトロルミネセンス装置の製造方法及び成膜方法に関する。 The present invention relates to an organic electroluminescent device in which a silicon nitride film is formed as a passivation layer, a method for manufacturing the organic electroluminescent device, and a film forming method.
近年、液晶表示装置の技術として、有機エレクトロルミネセンス(有機EL)素子を用いた有機EL表示装置が注目されている。有機EL表示装置では、有機層や有機層に接する電極との界面での酸化が表示性能の深刻な劣化につながる。このため、封止材として使用するガラスフリットやシールタイプの吸湿剤を貼り付けたガラス板の周囲を、樹脂で接着する封止方法が用いられている。 In recent years, organic EL display devices using organic electroluminescence (organic EL) elements have attracted attention as a technology for liquid crystal display devices. In an organic EL display device, oxidation at the interface with an organic layer or an electrode in contact with the organic layer leads to serious deterioration in display performance. For this reason, a sealing method is used in which the periphery of a glass plate to which a glass frit used as a sealing material or a seal-type hygroscopic agent is attached is adhered with a resin.
更に、有機EL表示装置の大型化が進んでいることから、有機EL素子と封止ガラス間の空間を熱硬化型の透明充填材やデシカント(吸湿材)などで充填する構造が開発されている。これは、充填材で有機EL素子と封止ガラス間の空間を埋めることにより、有機EL表示装置の強度を保つためである(例えば特許文献1参照。)。 Furthermore, since the size of the organic EL display device is increasing, a structure in which the space between the organic EL element and the sealing glass is filled with a thermosetting transparent filler or a desiccant (hygroscopic material) has been developed. . This is to maintain the strength of the organic EL display device by filling the space between the organic EL element and the sealing glass with a filler (see, for example, Patent Document 1).
しかしながら、上記のような構造においては、充填材と直接接触することによる有機層や電極の劣化が懸念される。このため、有機層及び電極と充填材との間にパッシベーション層を配置して有機EL素子の劣化を抑制することが必要になる。 However, in the structure as described above, there is a concern about deterioration of the organic layer and the electrode due to direct contact with the filler. For this reason, it is necessary to arrange a passivation layer between the organic layer and the electrode and the filler to suppress deterioration of the organic EL element.
パッシベーション層に求められる特性としては、有機層のガラス転移温度(Tg)よりも低温で形成可能であること、トップエミッション方式にも対応可能な高光透過性を有することなどが挙げられる。例えば、窒化シリコン(SiN)膜をパッシベーション層として採用可能である。 The characteristics required for the passivation layer include that it can be formed at a temperature lower than the glass transition temperature (Tg) of the organic layer, and that it has high light transmissibility that is compatible with the top emission method. For example, a silicon nitride (SiN) film can be used as the passivation layer.
SiN膜を上記のパッシベーション層として有機EL素子上に化学気相成長(CVD)法などにより成膜した場合、SiN膜の欠陥成長に起因する微細な細孔が生じる。そして、この細孔を通じて水分が透過すると考えられる現象が見られる。SiN膜上に透明充填材や吸湿材が塗布される構造においても、塗布された材料そのものによって、あるいは、塗布された材料を水分が透過することによって有機EL素子の電極や有機層へのダメージが生じるという同様の問題が予想される。 When the SiN film is formed as a passivation layer on the organic EL element by a chemical vapor deposition (CVD) method or the like, fine pores are generated due to the defect growth of the SiN film. And the phenomenon considered that a water | moisture content permeate | transmits through this pore is seen. Even in a structure in which a transparent filler or a hygroscopic material is applied on the SiN film, damage to the electrodes and organic layers of the organic EL element is caused by the applied material itself or by moisture passing through the applied material. A similar problem is expected to arise.
このため、SiN膜の膜厚を厚くする方法が考えられるが、膜厚を厚くすることにより成膜工程の時間が増大する。その結果、スループットが低下し、製造コストが増大する。また、SiN膜の膜厚を十分に厚くしても、水分に対するバリア性は必ずしも膜厚に比例して改善されず、格段の効果を期待できない。 For this reason, a method of increasing the film thickness of the SiN film can be considered, but increasing the film thickness increases the time of the film forming process. As a result, the throughput decreases and the manufacturing cost increases. Moreover, even if the film thickness of the SiN film is sufficiently increased, the barrier property against moisture is not necessarily improved in proportion to the film thickness, and a remarkable effect cannot be expected.
ここで、SiN膜間に高分子有機薄膜を中間層として設けた場合に、トータル膜厚が同じSiN膜よりもバリア性が格段に向上することが確認されている。これは、中間層が欠陥分離層及びパーティクル埋め込み層として機能するためである。しかしながら、高分子有機薄膜は基本的に蒸着法により成膜されるため、大面積に一様な膜を形成するという点において、有機EL表示装置などの製造には不利なプロセスである。 Here, it has been confirmed that when a polymer organic thin film is provided as an intermediate layer between SiN films, the barrier property is remarkably improved as compared with a SiN film having the same total film thickness. This is because the intermediate layer functions as a defect separation layer and a particle embedding layer. However, since the polymer organic thin film is basically formed by vapor deposition, it is a disadvantageous process for manufacturing an organic EL display device and the like in that a uniform film is formed over a large area.
上記問題点に鑑み、本発明は、内部への水分の透過に起因する品質の劣化を抑制できる有機EL装置、有機EL装置の製造方法及び成膜方法を提供する。 In view of the above problems, the present invention provides an organic EL device, a method for manufacturing the organic EL device, and a film forming method that can suppress deterioration in quality due to moisture permeation into the interior.
本発明の一態様によれば、非晶質窒化珪素膜とプラズマ重合膜を含む積層体を、表面波励起プラズマ化学気相成長法によって、有機層を含む有機EL素子上に形成する有機エレクトロルミネセンス装置の製造方法が提供される。 According to one aspect of the present invention, an organic electroluminescent device is formed by forming a laminate including an amorphous silicon nitride film and a plasma polymerized film on an organic EL element including an organic layer by surface wave excitation plasma chemical vapor deposition. A method for manufacturing a sense device is provided.
本発明の他の態様によれば、表面波励起プラズマ化学気相成長装置を用いた成膜方法であって、(イ)120℃以下の成膜温度で、成膜ガスとしてシランガス及びアンモニアガスを用いて非晶質窒化珪素膜を基板上に形成するステップと、(ロ)120℃以下の成膜温度で、成膜ガスとしてヘキサメチルジシロキサンガス及び酸素ガスを用いて非晶質酸化炭化珪素膜を非晶質窒化珪素膜上に形成するステップとを含む成膜方法が提供される。 According to another aspect of the present invention, there is provided a film forming method using a surface wave excited plasma chemical vapor deposition apparatus, wherein (a) silane gas and ammonia gas are used as film forming gases at a film forming temperature of 120 ° C. or less. And b) forming an amorphous silicon nitride film on the substrate; and (b) amorphous silicon oxycarbide using a hexamethyldisiloxane gas and an oxygen gas as a deposition gas at a deposition temperature of 120 ° C. or lower. Forming a film on the amorphous silicon nitride film.
本発明の更に他の態様によれば、(イ)下部基板と、(ロ)有機層を含み、下部基板上に配置された有機EL素子と、(ハ)有機EL素子上に配置された、非晶質窒化珪素膜とプラズマ重合膜を含む積層体とを備え、積層体が表面波励起プラズマ化学気相成長法によって形成された有機エレクトロルミネセンス装置が提供される。 According to still another aspect of the present invention, (a) a lower substrate, (b) an organic EL element that includes an organic layer and is disposed on the lower substrate, and (c) is disposed on the organic EL element. An organic electroluminescence device is provided that includes an amorphous silicon nitride film and a laminate including a plasma polymerized film, and the laminate is formed by surface wave excitation plasma chemical vapor deposition.
本発明によれば、内部への水分の透過に起因する品質の劣化を抑制できる有機EL装置、有機EL装置の製造方法及び成膜方法を提供できる。 According to the present invention, it is possible to provide an organic EL device, a method for manufacturing the organic EL device, and a film forming method that can suppress deterioration in quality due to moisture permeation into the interior.
図面を参照して、本発明の実施形態を説明する。以下の図面の記載において、同一又は類似の部分には同一又は類似の符号を付している。ただし、図面は模式的なものであり、厚みと平面寸法との関係、各層の厚みの比率等は現実のものとは異なることに留意すべきである。したがって、具体的な厚みや寸法は以下の説明を参酌して判断すべきものである。又、図面相互間においても互いの寸法の関係や比率が異なる部分が含まれていることはもちろんである。 Embodiments of the present invention will be described with reference to the drawings. In the following description of the drawings, the same or similar parts are denoted by the same or similar reference numerals. However, it should be noted that the drawings are schematic, and the relationship between the thickness and the planar dimensions, the ratio of the thickness of each layer, and the like are different from the actual ones. Therefore, specific thicknesses and dimensions should be determined in consideration of the following description. Moreover, it is a matter of course that portions having different dimensional relationships and ratios are included between the drawings.
又、以下に示す実施形態は、この発明の技術的思想を具体化するための装置や方法を例示するものであって、この発明の実施形態は、構成部品の材質、形状、構造、配置などを下記のものに特定するものでない。この発明の実施形態は、請求の範囲において、種々の変更を加えることができる。 Further, the embodiments described below exemplify apparatuses and methods for embodying the technical idea of the present invention, and the embodiments of the present invention include the material, shape, structure, arrangement, etc. of components. Is not specified as follows. The embodiment of the present invention can be variously modified within the scope of the claims.
本発明の実施形態に係る有機EL装置1は、図1に示すように、下部基板10と、下部基板10上に配置された、下部電極21、有機層22及び上部電極23が順に積層された有機EL素子20と、有機EL素子20上に配置された積層体30と、積層体30上に配置された充填材40と、充填材40上に配置された封止材50とを備える。
As shown in FIG. 1, the
有機EL素子20と封止材50間の空間を充填材40で充填することによって、有機EL装置1の強度を保つことができる。また、有機EL素子20、積層体30及び充填材40の周囲を囲むように、下部基板10と封止材50間に樹脂膜70が配置されている。樹脂膜70によって下部基板10と封止材50とを接着することにより、有機層22の劣化や酸化などを抑制できる。
The strength of the
積層体30は、詳細は後述するが、表面波励起プラズマ化学気相成長法によって形成される。積層体30は、非晶質窒化珪素(SiN)膜及びプラズマ重合膜を含む。積層体30は、図2に示すように、有機EL素子20上に配置された第1の非晶質SiN膜31と、第1の非晶質SiN膜31上に配置されたプラズマ重合膜32と、プラズマ重合膜32上に配置された第2の非晶質SiN膜33とを備える。プラズマ重合膜32には、例えば非晶質酸化炭化珪素(SiOC)膜などを採用可能である。
The laminated
第1の非晶質SiN膜31及び第2の非晶質SiN膜33は、有機EL素子20と充填材40とが直接に接触しないように配置されたパッシベーション層として機能する。また、パッシベーション層の中間層であるプラズマ重合膜32は、欠陥分離層として機能する。即ち、プラズマ重合膜32によって、第1の非晶質SiN膜31と第2の非晶質SiN膜33間で細孔が連続することが防止される。これにより、パッシベーション層に生じる細孔を通じて外部からの水分が有機EL素子20に達することが抑制される。
The first
なお、絶縁性の分離膜60に周囲を囲まれて、有機EL素子20は下部電極21上に配置されている。下部電極21、有機層22及び上部電極23が積層された発光領域で発光が生じる。したがって、分離膜60により電気的に絶縁された複数の有機EL素子20を形成することにより、1つの下部基板10上に複数の発光素子を配置できる。なお、有機EL素子20に給電するために、下部電極21は樹脂膜70の外側まで延伸している。
The
有機層22は、下部電極21及び上部電極23と電気的に接続されている。例えば、有機EL素子20の周囲や下部基板10内に配置された制御回路(図示せず)によって下部電極21と上部電極23間に流れる電流を制御することにより、有機層22の各領域での発光が制御される。
The
例えば有機層22に接する下部電極21を金属カソード電極とし、上部電極23を透明アノード電極として有機層22に電界を印加することで、有機層22で光が発生する。具体的には、上部電極23から有機層22に正孔が供給され、下部電極21から有機層22に電子が供給される。そして、正孔と電子の再結合により発生した光が有機層22から放出され、上部電極23、積層体30、充填材40及び封止材50を透過して、有機EL装置1の外部に出力光Lが出力される。
For example, light is generated in the
したがって、封止材50には、ガラス板などの光透過性の材料が使用され、充填材40には透明充填材が使用される。なお、充填材40に吸湿材を使用することにより、水分が外部から有機EL素子20に達することを抑制することができる。
Therefore, a light-transmitting material such as a glass plate is used for the sealing
透明電極である上部電極23には、酸化インジウムスズ(ITO)膜、酸化インジウム・酸化亜鉛(IZO)膜、酸化亜鉛(ZnO)膜、アルミニウム(Al)ドープの酸化チタン(TiO2)膜、酸化スズ(SnO2)膜等が採用可能である。下部電極21には、アルミニウム(Al)膜、マグネシウム(Mg)-Ag合金膜等が使用可能である。
The
有機層22は、有機化合物等からなる正孔輸送層や電子輸送層等が積層された構造を採用可能である。例えば、正孔輸送層にジフェニルナフチルジアミン(NPD)膜等が使用可能であり、電子輸送層にキノリノールアルミ錯体(Alq3)膜等が使用可能である。なお、有機層22が、正孔輸送層と電子輸送層の間に配置された発光層を備える構造であってもよい。
The
下部基板10には、ガラス基板などを採用可能である。分離膜60に、ポリミドなどを使用可能である。ポリミドは水分を通すため、分離膜60は積層体30によって周囲を覆われている。更に、水分を保持する充填材40が、積層体30の外側に塗布されている。
A glass substrate or the like can be used for the
既に述べたように、有機EL素子20と充填材40間のパッシベーション層としてSiN膜を使用した場合には、SiN膜に発生する細孔を通じて外部から水分が有機EL素子20に達するという問題がある。また、欠陥分離層として使用可能な高分子有機薄膜は、従来成膜法である蒸着法では大面積に一様な膜を成膜することが困難である。
As already described, when a SiN film is used as a passivation layer between the
しかし、図1に示した有機EL装置1では、表面波励起プラズマ化学気相成長法によって形成された非晶質SiOC膜などのプラズマ重合膜32が、非晶質SiN膜からなるパッシベーション層の中間に、欠陥分離層として配置されている。表面波励起プラズマ化学気相成長法によれば、大面積に一様な膜を成膜することが容易である。このため、有機EL装置1が大面積であっても、パッシベーション層に生じる細孔を通じて外部からの水分が有機EL素子20に達することを容易に防止できる。
However, in the
プラズマCVD法により堆積される窒化膜は、基本的に非晶質である。図1に示した有機EL装置1の製造には、例えば、図3に示すような表面波励起プラズマCVD装置110を使用可能である。
The nitride film deposited by the plasma CVD method is basically amorphous. For manufacturing the
表面波励起プラズマCVD装置110は、マイクロ波111が導入される導波管112と、基板100が格納されるチャンバー114と、処理対象の基板100が搭載されるステージ115と、チャンバー114内で基板100と対向して配置される誘電体116と、チャンバー114内に放電ガスを導入する放電ガス導入口117と、チャンバー114内に成膜ガスを導入する成膜ガス導入口118と、チャンバー114内のガスを排気する排気口119とを備える。
The surface wave excitation
以下では、図3に示した表面波励起プラズマCVD装置110を用いて有機EL装置1の積層体30を製造する場合について説明する。なお、表面波励起プラズマCVD装置110による成膜処理は以下のように行われる。
Below, the case where the
図示を省略したマイクロ波電源から出力されて導波管112に導入されたマイクロ波111は、導波管112に形成されたスロットアンテナ113を介して誘電体116に達する。なお、図3中に記載した矢印はマイクロ波の移動方向を示している。
The
一方、放電ガス導入口117から放電ガス、例えばアルゴン(Ar)ガスがチャンバー114内に導入される。そして、誘電体116を介してチャンバー114内に導入されたマイクロ波111のエネルギーによって、チャンバー114内にアルゴンのプラズマ120が励起される。このとき、プラズマ120中の電子密度が7.45×1010個/cm-3以上の条件では、プラズマ120は金属的なふるまいをし、マイクロ波111はプラズマ120中を伝搬せずに誘電体116に沿って横方向に広がる。つまり、プラズマ120の電子密度が表面波発生の臨界密度を越えると、マイクロ波111は表面波となってプラズマ120と誘電体116との境界面に沿って伝搬する。この状態は「表面波プラズマモード」と呼ばれる。本実施形態における表面波励起プラズマCVD装置110を用いた成膜処理は、主に表面波プラズマモードの条件で行う。
On the other hand, a discharge gas such as argon (Ar) gas is introduced into the
以下に、図1に示した有機EL装置1の製造方法を説明する。なお、以下に述べる有機EL装置1の製造方法は一例であり、この変形例を含めて、これ以外の種々の製造方法により実現可能であることは勿論である。
Hereinafter, a method for manufacturing the
公知の方法などにより、下部基板10上に有機EL素子20を形成する。例えば、蒸着法等により下部電極膜を下部基板10上に形成する。この下部電極膜を、フォトリソグラフィ技術を用いたリフトオフ法或いはエッチング法等によりパターニングして、図4に示すように、下部電極21を形成する。
The
次いで、下部基板10及び下部電極21上に、図5に示すような開口部を有する分離膜60を、蒸着マスクを用いて形成する。
Next, a
そして、分離膜60の開口部を埋め込むようにして、有機層22を下部電極21上に形成する。その後、上部電極膜を有機層22上に形成する。フォトリソグラフィ技術を用いたエッチング法等により所望のパターンに上部電極膜をパターニングして、上部電極23を形成する。以上により、図6に示すように、下部基板10に有機EL素子20が形成される。
Then, the
次に、図3に示した表面波励起プラズマCVD装置110を用いて、以下のようにして図2に示した積層体30を有機EL素子20上に形成する。なお、以下ではプラズマ重合膜32として非晶質SiOC膜を形成する。
Next, using the surface wave excitation
第1の非晶質SiN膜31及び第2の非晶質SiN膜33の形成においては、放電ガスとしてArガスを放電ガス導入口117からチャンバー114内に導入し、成膜ガスとしてシランガスとアンモニアガスを成膜ガス導入口118からチャンバー114に導入する。成膜条件は、例えば、シランガスの流量を70sccm、アンモニアガスの流量を500sccm、アルゴンガスの流量を350sccmとし、成膜中のチャンバー114内の圧力を10Paとする。
In the formation of the first
非晶質SiOC膜の形成においては、気化したヘキサメチルジシロキサンと酸素(O2)ガスを成膜ガス導入口118からチャンバー114に導入する。成膜条件は、例えば、ヘキサメチルジシロキサンの流量を200sccm、O2ガスの流量を400sccmとし、成膜中のチャンバー114内の圧力を5Paとする。
In forming the amorphous SiOC film, vaporized hexamethyldisiloxane and oxygen (O 2 ) gas are introduced into the
いずれの成膜においても、プラズマと基板間の距離は200mm、マイクロ波出力密度は1.57W/cm2とする。この条件でステージ冷却が無い場合、基板表面温度は80℃まで上昇して安定する。 In any film formation, the distance between the plasma and the substrate is 200 mm, and the microwave power density is 1.57 W / cm 2 . When there is no stage cooling under these conditions, the substrate surface temperature rises to 80 ° C. and stabilizes.
なお、表面波励起プラズマCVD装置110による成膜処理では、成膜中の積層体30の温度が有機層22のガラス転移温度よりも低い温度に維持される。例えば、成膜温度を120℃以下とする。
In the film forming process by the surface wave excitation
また、表面波励起プラズマCVD装置110による成膜処理では、基板100と誘電体116との距離が150mm~250mm程度であることが好ましい。基板100と誘電体116との距離が一定程度である場合に、成膜されるSiN膜のバリア性が向上する。発明者らは、基板100と誘電体116との距離が150mm~250mmである場合に上記効果を得られることを確認した。
Further, in the film forming process by the surface wave excitation
なお、積層体30を構成する各膜の膜厚分布の均一化のために、有機EL素子20が形成された下部基板10を誘電体116の下方で往復運動させながら、有機EL素子20上に積層体30を形成してもよい。下部基板10を成膜面である主面と平行に往復運動させる移動成膜法により、第1の非晶質SiN膜31、プラズマ重合膜32及び第2の非晶質SiN膜33の膜厚分布を均一にすることができる。
Note that, in order to make the film thickness distribution of each film constituting the stacked
図7に示すように積層体30をパターニングした後、積層体30上に充填材40を形成する。そして、下部基板10と封止材50を樹脂膜70で接着することにより、図1に示した有機EL装置1が完成する。
As shown in FIG. 7, after patterning the
上記のように表面波励起プラズマCVD法を用いて積層体30を形成することにより、第1の非晶質SiN膜31、プラズマ重合膜32及び第2の非晶質SiN膜33を同一の表面波励起プラズマCVD装置110を用いて連続的に形成することができる。これにより、有機EL装置1の製造時間の増大を抑制することができる。
By forming the laminate 30 using the surface wave excitation plasma CVD method as described above, the first
以上に説明した表面波励起プラズマCVD装置110を用いた成膜方法によって積層体30の構造が異なる以下のサンプルS1~サンプルS5を製造し、85℃85%RHの恒温恒湿槽にサンプルS1~サンプルS5を保管する加速試験を行った。サンプルS1~サンプルS5は、有機EL素子20上に形成した積層体30上に充填材40を形成し、封止材50のガラス板外周を樹脂で接着して封止した構造である。サンプルS1~サンプルS5の積層体30の構造は以下の通りである:
サンプルS1:厚さ200nmのSiN膜
サンプルS2:厚さ400nmのSiN膜
サンプルS3:厚さ1μmのSiN膜
サンプルS4:厚さ100nmのSiN膜/厚さ3μmのSiOC膜/厚さ100nmのSiN膜
サンプルS5:厚さ200nmのSiN膜/厚さ3μmのSiOC膜/厚さ200nmのSiN膜
即ち、サンプルS1~サンプルS3はSiN膜の単層を有し、サンプルS4~サンプルS5はヘキサメチルジシロキサンと原料とするSiOC膜を中間層とする3層構造の積層体30を有する。サンプルS1とサンプルS4とで、SiN膜のトータルの膜厚は同一である。また、サンプルS2とサンプルS5とで、SiN膜のトータルの膜厚は同一である。
The following samples S1 to S5 having different structures of the laminate 30 are manufactured by the film forming method using the surface wave excitation
Sample S1: SiN film with a thickness of 200 nm Sample S2: SiN film with a thickness of 400 nm Sample S3: SiN film with a thickness of 1 μm Sample S4: SiN film with a thickness of 100 nm / SiOC film with a thickness of 3 μm / SiN film with a thickness of 100 nm Sample S5: SiN film with a thickness of 200 nm / SiOC film with a thickness of 3 μm / SiN film with a thickness of 200 nm That is, samples S1 to S3 have a single layer of SiN film, and samples S4 to S5 have hexamethyldisiloxane. And a laminate 30 having a three-layer structure in which an SiOC film as a raw material is an intermediate layer. The total film thickness of the SiN film is the same between sample S1 and sample S4. Further, the total film thickness of the SiN film is the same between the sample S2 and the sample S5.
図3に示した表面波励起プラズマCVD装置110を用いて、サンプルS1~サンプルS3の場合はSiN膜を各膜厚で形成し、サンプルS4~サンプルS5の場合はSiN膜、SiOC膜、SiN膜を順次成膜して積層体30を形成した。
Using the surface wave excitation
サンプルS1~サンプルS5について上記の加速試験を行った結果を図8に示す。なお、加速試験では、一定時間経過後も点灯を維持する点灯素子の割合を調査した。 FIG. 8 shows the result of the acceleration test performed on samples S1 to S5. In the acceleration test, the ratio of lighting elements that maintain lighting even after a certain period of time was investigated.
積層体30がSiN膜の単層であり、且つSiN膜の膜厚が比較的薄いサンプルS1~サンプルS2では、400時間前後で点灯素子数が零となった。また、SiN膜を厚くしたサンプルS3では、600時間後の点灯素子数は40%程度である。
In Sample S1 to Sample S2 in which the
一方、SiOC膜からなる中間層を有する3層構造の積層体30を採用した場合は、サンプルS4がサンプルS3と同程度の点灯素子数を600時間後も維持している。サンプルS4におけるSiN膜のトータル膜厚はサンプルS1と同じ200nmであるため、中間層による欠陥分離の効果が表れていることが確認された。SiN膜のトータル膜厚がサンプルS2と同じ400nmであるサンプルS5では、点灯素子の割合がサンプルS4よりも更に高い。 On the other hand, when the laminate 30 having a three-layer structure having an intermediate layer made of a SiOC film is employed, the number of lighting elements in the sample S4 is maintained even after 600 hours as in the sample S3. Since the total film thickness of the SiN film in sample S4 is 200 nm, which is the same as that in sample S1, it was confirmed that the effect of defect separation by the intermediate layer appeared. In the sample S5 in which the total film thickness of the SiN film is 400 nm, which is the same as the sample S2, the ratio of the lighting elements is higher than that in the sample S4.
なお、本実施形態によって形成されるプラズマ重合膜32の屈折率は1.5程度あり、且つ光透過率も高い。このため、有機EL装置1は、封止材50側から外部に光を出力するトップエミッション方式にも十分に対応可能である。
In addition, the refractive index of the
以上に説明したように、本発明の実施形態に係る有機EL装置1の製造方法によれば、非晶質SiN膜及びプラズマ重合膜を含む積層体30が表面波励起プラズマ化学気相成長法によって有機EL素子20上に形成される。その結果、内部への水分の透過に起因する品質の劣化を抑制できる有機EL装置1を提供することができる。
As described above, according to the method for manufacturing the
また、SiN膜からなるパッシベーション層の中間層をSiN膜よりも成長レートが20倍程度速いプラズマ重合膜とすることにより、SiN膜を厚く製造することに比べて、製造時間の増大を抑制できる。 Further, by forming the intermediate layer of the passivation layer made of the SiN film as a plasma polymerized film whose growth rate is about 20 times faster than that of the SiN film, an increase in manufacturing time can be suppressed as compared to manufacturing the SiN film thicker.
(その他の実施形態)
上記のように、本発明は実施形態によって記載したが、この開示の一部をなす論述及び図面はこの発明を限定するものであると理解すべきではない。この開示から当業者には様々な代替実施形態、実施例及び運用技術が明らかとなろう。
(Other embodiments)
As mentioned above, although this invention was described by embodiment, it should not be understood that the description and drawing which form a part of this indication limit this invention. From this disclosure, various alternative embodiments, examples and operational techniques will be apparent to those skilled in the art.
上記では、プラズマ重合膜32としてSiOC膜を有する積層体30を形成する場合を説明したが、SiOC膜以外のプラズマ重合膜をパッシベーション層の中間層に使用してもよい。また、下部基板10を透明基板とし、下部電極21を透明電極とすることにより、有機EL装置1に下部基板10側から光を放出するボトムエミッション方式を採用してもよい。
In the above description, the case where the
このように、本発明はここでは記載していない様々な実施形態等を含むことは勿論である。したがって、本発明の技術的範囲は上記の説明から妥当な請求の範囲に係る発明特定事項によってのみ定められるものである。 Thus, it goes without saying that the present invention includes various embodiments that are not described herein. Therefore, the technical scope of the present invention is defined only by the invention specifying matters according to the scope of claims reasonable from the above description.
本発明は、パッシベーション膜での水分の透過を抑制する用途に利用可能である。 The present invention can be used for the purpose of suppressing moisture permeation through the passivation film.
Claims (15)
前記有機EL素子上に第1の前記非晶質窒化珪素膜を形成するステップと、
前記第1の非晶質窒化珪素膜上に前記プラズマ重合膜を形成するステップと、
前記プラズマ重合膜上に第2の前記非晶質窒化珪素膜を形成するステップと
を含むことを特徴とする請求項1に記載の有機エレクトロルミネセンス装置の製造方法。 Forming the laminate comprises:
Forming the first amorphous silicon nitride film on the organic EL element;
Forming the plasma polymerized film on the first amorphous silicon nitride film;
The method of manufacturing an organic electroluminescence device according to claim 1, further comprising: forming a second amorphous silicon nitride film on the plasma polymerization film.
前記プラズマ重合膜が非晶質酸化炭化珪素膜であり、該非晶質酸化炭化珪素膜を、成膜ガスとしてヘキサメチルジシロキサンガス及び酸素ガスを用いて前記有機層のガラス転移温度よりも低い温度で形成する
ことを特徴とする請求項1に記載の有機エレクトロルミネセンス装置の製造方法。 Forming the amorphous silicon nitride film at a temperature lower than the glass transition temperature of the organic layer using a silane gas and an ammonia gas as a deposition gas;
The plasma polymerized film is an amorphous silicon oxycarbide film, and the amorphous silicon oxycarbide film is formed at a temperature lower than the glass transition temperature of the organic layer using hexamethyldisiloxane gas and oxygen gas as a film forming gas. The method for producing an organic electroluminescent device according to claim 1, wherein:
前記充填材上に封止材を形成するステップと、
前記有機EL素子、前記積層体及び前記充填材の周囲を囲むように、前記有機EL素子が配置された下部基板と前記封止材間に樹脂膜を形成するステップと
を更に含むことを特徴とする請求項1に記載の有機エレクトロルミネセンス装置の製造方法。 Forming a filler on the laminate;
Forming a sealing material on the filler;
Forming a resin film between the lower substrate on which the organic EL element is disposed and the sealing material so as to surround the organic EL element, the laminate, and the filler. The manufacturing method of the organic electroluminescent apparatus of Claim 1.
200℃以下の成膜温度で、成膜ガスとしてシランガス及びアンモニアガスを用いて非晶質窒化珪素膜を基板上に形成するステップと、
200℃以下の成膜温度で、成膜ガスとしてヘキサメチルジシロキサンガス及び酸素ガスを用いて非晶質酸化炭化珪素膜を前記非晶質窒化珪素膜上に形成するステップと
を含むことを特徴とする成膜方法。 A film forming method using a surface wave excitation plasma chemical vapor deposition apparatus,
Forming an amorphous silicon nitride film on a substrate using a silane gas and an ammonia gas as a deposition gas at a deposition temperature of 200 ° C. or less;
Forming an amorphous silicon oxycarbide film on the amorphous silicon nitride film using a hexamethyldisiloxane gas and an oxygen gas as a film forming gas at a film forming temperature of 200 ° C. or lower. A film forming method.
前記第1の非晶質窒化珪素膜上に前記プラズマ重合膜を形成するステップと、
前記プラズマ重合膜上に第2の前記非晶質窒化珪素膜を形成するステップと
を含むことを特徴とする請求項7に記載の成膜方法。 Forming a first amorphous silicon nitride film;
Forming the plasma polymerized film on the first amorphous silicon nitride film;
Forming a second amorphous silicon nitride film on the plasma polymerized film.
有機層を含み、前記下部基板上に配置された有機EL素子と、
前記有機EL素子上に配置された、非晶質窒化珪素膜とプラズマ重合膜を含む積層体と、
を備え、前記積層体が表面波励起プラズマ化学気相成長法によって形成されたことを特徴とする有機エレクトロルミネセンス装置。 A lower substrate,
An organic EL element including an organic layer and disposed on the lower substrate;
A laminate including an amorphous silicon nitride film and a plasma polymerized film disposed on the organic EL element;
An organic electroluminescence device, wherein the laminate is formed by surface wave excitation plasma chemical vapor deposition.
前記有機EL素子上に配置された第1の非晶質窒化珪素膜と、
前記第1の非晶質窒化珪素膜上に配置された前記プラズマ重合膜と、
前記プラズマ重合膜上に配置された第2の非晶質窒化珪素膜と
を備えることを特徴とする請求項12に記載の有機エレクトロルミネセンス装置。 The laminate is
A first amorphous silicon nitride film disposed on the organic EL element;
The plasma polymerized film disposed on the first amorphous silicon nitride film;
The organic electroluminescence device according to claim 12, further comprising: a second amorphous silicon nitride film disposed on the plasma polymerization film.
前記充填材上に配置された封止材と、
前記有機EL素子、前記積層体及び前記充填材の周囲を囲むように、前記下部基板と前記封止材間に配置された樹脂膜と
を更に備えることを特徴とする請求項12に記載の有機エレクトロルミネセンス装置。 A filler disposed on the laminate;
A sealing material disposed on the filler;
The organic material according to claim 12, further comprising: a resin film disposed between the lower substrate and the sealing material so as to surround the organic EL element, the stacked body, and the filler. Electroluminescence device.
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