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Process for producing an organic electroluminescent device

Imported: 23 Feb '17 | Published: 22 Oct '02

Yoshio Himeshima, Shigeo Fujimori, Akira Kohama

USPTO - Utility Patents

Abstract

A method for producing an organic electroluminescent device, which is provided with first electrodes formed on a substrate, a thin film layer formed on the first electrode containing at least an emitting layer composed of an organic compound and a plurality of second electrodes formed on the thin film layer, and has a plurality of luminescent regions on said substrate, comprising the steps of forming spacers having a height at least partially exceeding the thickness of said thin film layer on the substrate, and vapor-depositing a deposit for patterning while the shadow mask having reinforcing lines formed across its apertures is kept in contact with said spacers. Highly precise fine patterning can be effected under wide vapor deposition conditions without degrading the properties of organic electroluminescent elements, and high stability can be achieved by a relatively simple process without limiting the structure of the electroluminescent device.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

FIG. 1 is a plan view showing an example of the organic electroluminescent device produced according to the present invention.

FIG. 2 is a sectional view along I-I′ of FIG.

1.

FIG. 3 is a sectional view along II-II′ of FIG.

1.

FIG. 4 is a plan view showing an example of the shadow mask used in the present invention.

FIG. 5 is a sectional view along I-I′ of FIG.

4.

FIG. 6 is a sectional view along I-I′ for illustrating an example of the second electrode patterning method in the present invention.

FIG. 7 is a sectional view along II-II′ for illustrating an example of the second electrode patterning method in the present invention (side view of FIG.

6).

FIG. 8 is a plan view showing an example of the first electrode pattern.

FIG. 9 is a plan view showing an example of the spacers formed in the present invention.

FIG. 10 is a plan view showing another example of the organic electroluminescent device produced according to the present invention.

FIG. 11 is a sectional view along I-I′ of FIG.

10.

FIG. 12 is a sectional view along II-II′ of FIG.

10.

FIG. 13 is a plan view showing a further other example of the organic electroluminescent device produced according to the present invention.

FIG. 14 is a sectional view along I-I′ of FIG.

13.

FIG. 15 is a sectional view along II-II′ of FIG.

13.

FIG. 16 is a sectional view along I-I′ for illustrating a method for forming the hole transport layer.

FIG. 17 is a plan view showing another example of the shadow mask used in the present invention.

FIG. 18 is a sectional view along I-I′ for illustrating an example of the emitting layer patterning method in the present invention.

FIG. 19 is a sectional view along II-II′ for illustrating an example of the emitting layer patterning method in the present invention (side view of FIG.

18).

FIG. 20 is a plan view showing an example of the emitting layer patterned in the present invention.

FIG. 21 is a sectional view along I-I′ for illustrating a method for forming the electron transport layer.

FIG. 22 is a sectional view along I-I′ showing another example of the electron transport layer patterned in the present invention.

FIG. 23 is a sectional view along III-III′ of FIG.

4.

FIG. 24 is a sectional view along III-III′ showing a further other example of the shadow mask used in the present invention.

FIG. 25 is a sectional view along III-III′ showing a still further other example of the shadow mask used in the present invention.

FIG. 26 is a plan view showing a still further other example of the shadow mask used in the present invention.

FIG. 27 is a sectional view along I-I′ showing another example of the second electrode patterning method in the present invention.

FIG. 28 is a sectional view along II-II′ for illustrating another example of the second electrode patterning method in the present invention (side view of FIG.

27).

FIG. 29 is a sectional view along III-III′ showing an example of the shadow mask with cushion portions used in the present invention.

FIG. 30 is a plan view showing the shadow mask for second electrode patterning used in Example 1.

FIG. 31 is a sectional view along I-I′ of FIG.

30.

FIG. 32 is a plan view showing the organic electroluminescent device produced in Example 1.

FIG. 33 is a sectional view along I-I′ of FIG.

32.

FIG. 34 is a sectional view along II-II′ of FIG.

32.

FIG. 35 is a plan view for illustrating the method for producing the shadow mask for emitting layer patterning used in the examples.

FIG. 36 is sectional views for illustrating the method for producing the shadow mask for second electrode patterning used in the examples.

FIG. 37 is a sectional view showing an example of the conventional organic electroluminescent element.

Claims

1. An organic electroluminescent device, comprising a first electrode formed on a substrate, a film layer on the first electrode and a second electrodes formed on the film layer, said film layer comprising a plurality of luminescent regions by vapor-deposition, wherein the film layer comprises at least an emitting layer composed of an organic compound and wherein an electron transport material is deposited on an entire area where the luminescent regions exist to form an electron transport layer.

2. An organic electroluminescent device according to claim 1, wherein the plurality of luminescent regions comprises at least three color luminescent regions.

3. An organic electroluminescent device according to claim 1, wherein the electron transport material has a luminescence energy equivalent to or larger than that of the emitting layer.

4. An organic electroluminescent device, comprising a first electrode formed on a substrate, a film layer on the first electrode, a second electrode formed on the thin film, said film layer comprising a plurality of luminescent regions, and a spacer having a height exceeding a thickness of said film layer, wherein the film layer comprises at least an emitting layer composed of an organic compound and wherein an electron transport material is deposited on an entire area where the luminescent regions exist to form an electron transport layer.

5. The organic electroluminescent device according to claim 1 or 4, wherein the device is an active matrix type device.