Light-emitting element including a charge injection transport layer that includes a dissolvable metal compound, and display device and method for manufacturing thereof

• US 8,890,174 B2
• Filed: 08/09/2011
• Issued: 11/18/2014
• Est. Priority Date: 02/10/2009
• Status: Active Grant

• Current Assignee: JDI Design and Development GK
• Original Assignee: Panasonic Corporation (Panasonic Holdings Corporation)
• Inventors: Harada, Kenji, Takeuchi, Takayuki, Nishiyama, Seiji, Komatsu, Takahiro
• Primary Examiner(s): Toledo, Fernando L
• Assistant Examiner(s): Bradford, Peter
• Application Number:
  US13/205,778
• Publication Number:
  US 20110291087A1
• Time in Patent Office: 1,197 Days
• Field of Search: 257/E51.022, 257/40, 257/91, 257/79, 257/E51.019, 257/E27.119, 257/E51.018, 438/46, 438/99
• US Class Current: 257/79
• CPC Class Codes: H10K 50/14 Carrier transporting layers
• CPC Class Codes: H10K 59/122 Pixel-defining structures or layers, e.g. banks
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 71/135 using ink-jet printing
• CPC Class Codes: H10K 71/233 by photolithographic etching

Abstract

A light emitter and a method of manufacturing a light emitter. The light emitter includes a first electrode, a charge injection transport layer, a light-emitting layer, and a second electrode that are layered in this order. At least the light-emitting layer is defined by a bank that has at least one liquid-repellent surface. The charge injection transport layer is principally composed of a metal compound that is more liquid-philic than the surface of the bank. The charge injection transport layer includes a recessed structure so that in a region defined by the bank, the charge injection transport layer is lower than a bottom surface of the bank.

Claims

1. A light emitter, comprising:

a first electrode;

a charge injection transport layer;

a light-emitting layer; and

a second electrode, said first electrode, said charge injection transport layer, and said second electrode being layered in this order, at least said light-emitting layer being defined by a bank,

wherein said charge injection transport layer includes;

a metal compound that is dissolvable by a predetermined solvent; and

a recessed portion where said metal compound has been dissolved by the predetermined solvent,

said recessed portion of said charge injection transport layer including;

an inner bottom surface that is in contact with a bottom surface of said light-emitting layer; and

an inner side surface that is continuous with said inner bottom surface and in contact at least with a portion of a side surface of said light-emitting layer.

2. The light emitter of claim 1, wherein said charge injection transport layer is liquid-philic and said bank is liquid-repellent with respect to an ink composition containing an organic EL material from which said light-emitting layer is formed.

3. The light emitter of claim 1, wherein the predetermined solvent is at least one of a developing solution for removing a part of a resist film used to form said bank and a cleaning fluid for cleaning residuals of the resist film remaining after formation of said bank.

4. The light emitter of claim 1, wherein said charge injection transport layer comprises a hole-injection layer including a metal oxide.

5. The light emitter of claim 4, wherein said metal oxide comprises an oxide of one of tungsten and molybdenum.

6. The light emitter of claim 1, wherein said recessed portion has an average depth of 5 nm to 100 nm.

7. The light emitter of claim 1, wherein said light-emitting layer has an average film thickness that is smaller than an average depth of said recessed portion.

8. The light emitter of claim 1, wherein said inner bottom surface of said recessed portion of said charge injection transport layer is substantially parallel with a bottom surface of said first electrode.

9. The light emitter of claim 1, wherein a depth of said recessed portion of said charge injection transport layer is greatest about a middle of said inner bottom surface of said recessed portion.

10. The light emitter of claim 1, wherein a depth of said recessed portion is predetermined in accordance with a melting speed of said metal compound with respect to the predetermined solvent, the melting speed being based on a temperature of the predetermined solvent.

11. A light emitter, comprising:

a first electrode;

a charge injection transport layer;

an intermediate layer;

a light-emitting layer; and

a second electrode, said first electrode, said charge injection transport layer, said intermediate layer, said light-emitting layer, and said second electrode being layered in this order, at least said light-emitting layer being defined by a bank,

wherein said charge injection transport layer is formed of a metal compound that is dissolvable by a predetermined solvent, said charge injection transport layer including a recessed portion in which said metal compound has been dissolved by the predetermined solvent,

said recessed portion of said charge injection transport layer including an inner bottom surface that is in contact with a bottom surface of said intermediate layer, an inner side surface of said recessed portion being continuous with said inner bottom surface and in contact at least with a portion of a side surface of said intermediate layer.

12. The light emitter of claim 11, wherein said intermediate layer is liquid-philic with respect to an ink composition containing an organic EL material from which said light-emitting layer is formed.

13. The light emitter of claim 11, wherein said light-emitting layer is in contact with said intermediate layer.

14. The light emitter of claim 11, wherein said intermediate layer has an average film thickness that is smaller than an average depth of said recessed portion.

15. The light emitter of claim 11, wherein a depth of said recessed portion is predetermined in accordance with a melting speed of said metal compound with respect to the predetermined solvent, the melting speed being based on a temperature of the predetermined solvent.

16. A light emitter, comprising:

a first electrode;

a charge injection transport layer;

a light-emitting layer; and

a second electrode, said first electrode, said charge injection transport layer, said light-emitting layer and said second electrode being layered in this order, at least said light-emitting layer being defined by a bank,

wherein said charge injection transport layer has a recessed structure including a recessed portion,

said recessed portion of said charge injection transport layer including an inner bottom surface and an inner side surface being continuous with said inner bottom surface, and

an ink material-containing layer is accumulated in said recessed portion and is in contact with said inner bottom surface and said inner side surface.

17. The light emitter of claim 16, wherein said ink material-containing layer is said light-emitting layer.

18. The light emitter of claim 16, wherein said charge injection transport layer is liquid-philic and said bank is liquid-repellent with respect to said ink material-containing layer.

19. The light emitter of claim 16,

wherein said metal compound includes a melting speed with respect to the predetermined solvent which is dependent on a temperature of the predetermined solvent, and

a depth of said recessed portion is predetermined in accordance with the temperature of the predetermined solvent.