Organic EL device and method for manufacturing organic EL device

• US 9,219,101 B2
• Filed: 08/19/2014
• Issued: 12/22/2015
• Est. Priority Date: 02/20/2012
• Status: Active Grant

• Current Assignee: Kaneka Corporation
• Original Assignee: Kaneka Corporation
• Inventors: Hayashi, Katsuhiko
• Primary Examiner(s): MOORE, WHITNEY
• Application Number:
  US14/463,514
• Publication Number:
  US 20140353657A1
• Time in Patent Office: 490 Days
• US Class Current: 1/1
• CPC Class Codes: H05B 45/60 Circuit arrangements for operating LEDs comprising organic material, e.g. for operating organic light-emitting diodes [OLED] or polymer light-emitting diodes [PLED]
• CPC Class Codes: H10K 50/805 Electrodes
• CPC Class Codes: H10K 50/813 characterised by their shape
• CPC Class Codes: H10K 50/822 characterised by their shape
• CPC Class Codes: H10K 59/10 OLED displays
• CPC Class Codes: H10K 59/86 Series electrical configurations of multiple OLEDs
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 71/841 Applying alternating current [AC] during manufacturing or treatment
• CPC Class Codes: Y02B 20/30 Semiconductor lamps, e.g. solid state lamps [SSL] light emitting diodes [LED] or organic LED [OLED]

Abstract

The present invention aims at developing an organic EL device having a structure for power supply to a new organic EL element. The device is formed of unit organic EL elements planarly distributed on a substrate having a planar expanse and includes organic EL element columns and organic EL element rows. The organic EL element columns and the organic EL element rows each have a conductive path in which electric current passes in its longitudinal direction. The organic EL element columns and the organic EL element rows have different longitudinal directions so that their conductive paths cross with each other at a part where the organic EL element columns and the organic EL element rows cross with each other.

Claims

1. An organic EL device comprising a substrate having a planar expanse and unit organic EL elements planarly distributed on the substrate,

the unit organic EL elements each mainly consisting of at least two electrode layers and an organic light-emitting layer sandwiched between the electrode layers,

the device having a plurality of organic EL element belts each formed of a plurality of the unit organic EL elements electrically connected in series so as to extend in a strip-like shape,

each of the organic EL element belts having in its longitudinal direction a conductive path through which electric current passes,

the organic EL element belts extending in different longitudinal directions and crossing with each other, forming a crossing part, so that the conductive paths cross with each other within the organic EL element belts and within the crossing part,

the organic EL element belts crossing with each other in a grid pattern,

the organic El device having a non-light emitting region surrounded by the organic EL element belts,

the organic EL element belts each being formed of a stack of a substrate-side electrode layer, a functional layer, and a rear face-side electrode layer, and

the substrate-side electrode layer having at least one groove dividing the layer,

wherein the groove is formed over the non-light emitting region and a region where the organic EL element belt is located.

2. An organic EL device comprising a substrate having a planar expanse and unit organic EL elements planarly distributed on the substrate,

the unit organic EL elements each mainly consisting of at least two electrode layers and an organic light-emitting layer sandwiched between the electrode layers,

the device having a plurality of organic EL element belts each formed of a plurality of the unit organic EL elements electrically connected in series so as to extend in a strip-like shape,

each of the organic EL element belts having in its longitudinal direction a conductive path through which electric current passes, and

the organic EL element belts extending in different longitudinal directions and crossing with each other, forming a crossing part, so that the conductive paths cross with each other within the organic EL element belts and within the crossing part,

wherein the organic EL element belts comprise at least one organic EL element column extending in one direction and at least one organic EL element row extending in a direction crossing with the organic EL element column,

the unit organic EL elements making up the organic EL element column each being formed of a stack of the two electrode layers and a column-type functional layer between the two electrode layers,

the unit organic EL elements making up the organic EL element row each being formed of a stack of the two electrode layers and a row-type functional layer between the two electrode layers, and

the crossing part including both the column-type functional layer and the row-type functional layer stacked between the two electrode layers.

3. An organic EL device comprising a substrate having a planar expanse and unit organic EL elements planarly distributed on the substrate,

the unit organic EL elements each mainly consisting of at least two electrode layers and an organic light-emitting layer sandwiched between the electrode layers,

the device having a plurality of organic EL element belts each formed of a plurality of the unit organic EL elements electrically connected in series so as to extend in a strip-like shape,

each of the organic EL element belts having in its longitudinal direction a conductive path through which electric current passes, and

the organic EL element belts extending in different longitudinal directions and crossing with each other, forming a crossing part, so that the conductive paths cross with each other within the organic EL element belts and within the crossing part,

wherein the organic EL element belts comprise at least one organic EL element column extending in one direction and at least one organic EL element row extending in a direction crossing with the organic EL element column,

wherein the electrode layers include a first electrode layer, a second electrode layer, and a third electrode layer,

the unit organic EL elements making up the organic EL element column each being formed of a stack of the first electrode layer, the second electrode layer, and a column-type functional layer between the first and the second electrode layers,

the unit organic EL elements making up the organic EL element row each being formed of a stack of the first electrode layer, the third electrode layer, and a row-type functional layer between the first and the third electrode layers, and

the crossing part including the first electrode layer, the second electrode layer, and the third electrode layer and further including the column-type functional layer and the row-type functional layer either between the first electrode layer and the second electrode layer or between the first electrode layer and the third electrode layer.

4. An organic EL device comprising a substrate having a planar expanse and unit organic EL elements planarly distributed on the substrate,

the unit organic EL elements each mainly consisting of at least two electrode layers and an organic light-emitting layer sandwiched between the electrode layers,

the device having a plurality of organic EL element belts each formed of a plurality of the unit organic EL elements electrically connected in series so as to extend in a strip-like shape,

each of the organic EL element belts having in its longitudinal direction a conductive path through which electric current passes,

the organic EL element belts extending in different longitudinal directions and crossing with each other, forming a crossing part, so that the conductive paths cross with each other within the organic EL element belts and within the crossing part,

the unit organic EL elements each having a pn junction, and

the organic EL element belts each being formed of a serial connection of the pn junctions of the unit organic EL elements belonging to the belt,

wherein the organic EL element belts each have a p-side power supply part and an n-side power supply part, and

the p-side power supply part and the n-side power supply part of the organic EL element belts being connected to an AC power source in parallel.

5. An organic EL device comprising a substrate having a planar expanse and unit organic EL elements planarly distributed on the substrate,

the unit organic EL elements each mainly consisting of at least two electrode layers and an organic light-emitting layer sandwiched between the electrode layers,

the device having a plurality of organic EL element belts each formed of a plurality of the unit organic EL elements electrically connected in series so as to extend in a strip-like shape,

each of the organic EL element belts having in its longitudinal direction a conductive path through which electric current passes, and

the organic EL element belts extending in different longitudinal directions and crossing with each other, forming a crossing part, so that the conductive paths cross with each other within the organic EL element belts and within the crossing part,

wherein the organic EL element belts comprise:

(1) a plurality of organic EL element columns each extending in one direction and having a first end at one side and a second end at the other side and (2) a plurality of organic EL element rows each extending in a direction crossing with the organic EL element column and having a third end at one side and a fourth end at the other side,

the unit organic EL elements each having a pn junction with a p-side and an n-side,

the first ends being in electrical contact with a p-side of the unit organic EL elements and the second ends being in electrical contact with the n-side,

the third ends being in electrical contact with the p-side of the unit organic EL elements and the fourth ends being in electrical contact with the n-side, and

the first ends of the organic EL element columns in electrical contact with the p-side and the fourth ends of the organic EL element rows in electrical contact with the n-side being in electrical contact with each other.

6. An organic EL device comprising a substrate having a planar expanse and unit organic EL elements planarly distributed on the substrate,

the unit organic EL elements each mainly consisting of at least two electrode layers and an organic light-emitting layer sandwiched between the electrode layers,

the device having a plurality of organic EL element belts each formed of a plurality of the unit organic EL elements electrically connected in series so as to extend in a strip-like shape,

each of the organic EL element belts having in its longitudinal direction a conductive path through which electric current passes, and

the organic EL element belts extending in different longitudinal directions and crossing with each other, forming a crossing part, so that the conductive paths cross with each other within the organic EL element belts and within the crossing part,

wherein the substrate has a periphery,

wherein the device has a plurality of extraction regions formed along the periphery of the substrate,

the extraction regions each including one electrode layer and being in electrical contact with the organic EL element belts, and

the device further comprising a power supply electrode attached over a plurality of the extraction regions.

7. An organic EL device comprising a substrate having a planar expanse and unit organic EL elements planarly distributed on the substrate,

the unit organic EL elements each mainly consisting of at least two electrode layers and an organic light-emitting layer sandwiched between the electrode layers,

the device having a plurality of organic EL element belts each formed of a plurality of the unit organic EL elements electrically connected in series so as to extend in a strip-like shape,

each of the organic EL element belts having in its longitudinal direction a conductive path through which electric current passes,

the organic EL element belts extending in different longitudinal directions and crossing with each other, forming a crossing part, so that the conductive paths cross with each other within the organic EL element belts and within the crossing part,

the unit organic EL elements each being formed of a stack of a substrate-side electrode layer, the organic light-emitting layer, and a rear face-side electrode layer in order in a stacking direction from a side of the substrate,

the device further comprising (1) a dielectric layer having dielectricity stacked on an upper side of the rear face-side electrode layer in the stacking direction and (2) a dielectric electrode layer stacked on an upper side of the dielectric layer in the stacking direction and on a projected plane in a member thickness direction of the crossing part of the organic EL element belts, and

the dielectric electrode layer being electrically connected to the substrate-side electrode layer.

8. The organic EL device as defined in claim 7,

wherein the organic EL element belts comprise at least one organic EL element column extending in one direction and at least one organic EL element row extending in a direction crossing with the organic EL element column,

the dielectric electrode layer comprising one electrically connected to the substrate-side electrode layer of the organic EL element column and one electrically connected to the substrate-side electrode layer of the organic EL element row.

9. A method for manufacturing an organic EL device comprising a substrate having a planar expanse and unit organic EL elements planarly distributed on the substrate,

the unit organic EL elements each mainly consisting of at least two electrode layers and an organic light-emitting layer sandwiched between the electrode layers,

the device having a plurality of organic EL element belts each formed of a plurality of the unit organic EL elements electrically connected in series so as to extend in a strip-like shape,

each of the organic EL element belts each having in its longitudinal direction a conductive path through which electric current passes, and

the organic EL element belts extending in different longitudinal directions and crossing with each other, forming a crossing part, so that the conductive paths cross with each other within the organic EL element belts and within the crossing part,

the method comprising the steps of:

a first electrode layer forming process of forming a first electrode layer on the substrate,

a first electrode layer separation process of forming a first electrode layer separation groove by laser-scribing the first electrode layer,

a preceding functional layer forming process of forming a first functional layer including a hole injection layer, a hole transport layer, a light-emitting layer, an electron transport layer, and an electron injection layer sequentially at a certain position,

a succeeding functional layer forming process of forming a second functional layer including a hole injection layer, a hole transport layer, a light-emitting layer, an electron transport layer, and an electron injection layer sequentially over a part overlapping the first functional layer and a part without overlapping the first functional layer,

an electrode connection groove forming process of forming an electrode connection groove by laser scribing,

a second electrode layer forming process of forming an electrode layer so as to overlap one of the first functional layer and the second functional layer,

a third electrode layer forming process of forming an electrode layer so as to overlap the other of the first functional layer and the second functional layer, and

a unit organic EL element separation groove forming process of forming a unit organic EL element separation groove by laser scribing.

10. The method as defined in claim 9 further comprising the steps of:

an insulation layer forming process of forming an insulation layer,

an insulation groove forming process of forming an opening reaching the first electrode layer by laser-scribing the insulation layer, and

a dielectric electrode layer forming process of forming a dielectric electrode layer.