Patent Application
20160190453
The present disclosure relates to an element manufacturing method and element manufacturing apparatus for manufacturing elements such as organic semiconductor elements.
Manufacturing processes for such elements as an organic semiconductor element and inorganic semiconductor element are commonly performed under a vacuum environment to prevent impurities from entering the element. For example, sputtering, vapor deposition, or other techniques designed to form films under the vacuum environment are used to form cathodic electrodes, anodic electrodes, and semiconductor layers on a substrate. An internal region of an element manufacturing apparatus is deaerated over a predetermined time using a vacuum pump and other means to realize the vacuum environment.
In the manufacturing processes for the above elements, various steps are executed in addition to a film deposition step. These steps include ones that are traditionally executed under atmospheric pressure. To realize the vacuum environment, on the other hand, the predetermined time is needed as discussed above. Accordingly, when in addition to the film deposition step executed under the vacuum environment the steps executed under atmospheric pressure are further included in the manufacturing processes for such an element, a great deal of time is needed for deaerating the inside of the element manufacturing apparatus or replacing an internal environment of the element manufacturing apparatus with atmospheric air. In light of this factor, it is desirable that the element manufacturing steps be executed under an environment whose pressure is lower than atmospheric pressure. This enables reduction in the time and costs needed to obtain one element.
Examples of steps other than film deposition include the step of removing an organic semiconductor layer positioned on an auxiliary electrode. Patent Document 1, for example, describes such a step. When an electrode disposed on the organic semiconductor layer is a common electrode of a thin-film form, the auxiliary electrode is disposed to suppress a location-by-location difference in magnitude of a voltage drop developed across the common electrode. That is to say, connecting the common electrode to the auxiliary electrode at various locations allows the voltage drop across the common electrode to be reduced. Meanwhile, since the organic semiconductor layer is in general provided over an entire region of the substrate, the above-discussed removal step for removing the organic semiconductor layer on the auxiliary electrode needs to be executed to connect the common electrode to the auxiliary electrode.
A known method for removing an organic semiconductor layer present on an auxiliary electrode is by irradiating the organic semiconductor layer with light such as laser light. In this case, the organic semiconductor material constituting the organic semiconductor layer will fly apart during the removal of the organic semiconductor layer by ablation. To prevent contamination with the organic semiconductor material that has flown apart, therefore, it is preferable that the substrate be covered with some appropriate kind of material. Patent Document 1, for example, proposes a method in which first a counter substrate is overlaid upon the substrate under a vacuum environment to constitute an overlay substrate, next while a space between the counter substrate and the substrate is being maintained under the vacuum atmosphere, the overlay substrate is taken out from the vacuum environment into the atmospheric air, and after this operation, the organic semiconductor layer is irradiated with laser light. Based on a differential pressure between the vacuum atmosphere and the atmospheric air, this method enables the counter substrate to be brought into strong and close contact with the substrate, thereby enabling reliable prevention of contamination with the organic semiconductor material that has flown apart.
The step of irradiating organic semiconductor layers with laser light is commonly performed in order upon each of the organic semiconductor layers formed on the plurality of auxiliary electrodes on the substrate. For example, the organic semiconductor layers on the plurality of auxiliary electrodes are sequentially irradiated with the laser light while one of the optical system, which directs the laser light toward the substrate and guides the laser light to the substrate, and the substrate, is being moved relative to the other. Accordingly, there is no need to cover the substrate over its entire region with the counter substrate for the purpose of preventing the organic semiconductor material from flying apart, and a section of the substrate that is to be irradiated with the laser light needs only to be covered with at least the counter substrate. Meanwhile, as in the invention described in Patent Document 1, when the differential pressure between a vacuum atmosphere and the air is used, the substrate is covered over the entire region with the counter substrate. This leads the apparatus configuration to one that is more complex than actually required. In addition, in the invention described in Patent Document 1, a great deal of time is needed for deaerating the inside of the element manufacturing apparatus or replacing an internal environment of the element manufacturing apparatus with atmospheric air.
An embodiment of the present invention has been made with the above in mind, and an object of the invention is to provide an element manufacturing method and element manufacturing apparatus adapted for efficiently covering the section of a substrate that is to be irradiated with laser light.
An embodiment of the present invention is an element manufacturing method for forming an element on a substrate, the method including the step of providing an intermediate product that includes the substrate and a plurality of protrusions each disposed on the substrate, the step of providing a lid member having a first surface, the lid member being provided so that the first surface faces toward the protrusions of the intermediate product, and the step of pressing the lid member to bring a part of the first surface thereof into close contact with a part of the intermediate product, wherein, in the lid member pressing step, on the first surface of the lid member, a shape protrudingly curved toward the intermediate product is formed and a section of the lid member that includes the curved shape is brought into close contact with a part of the intermediate product.
In the element manufacturing method according to an embodiment of the present invention, in addition to the first surface, the lid member may include a second surface that lies on a side opposite to the first surface. In this case, in the lid member pressing step, part of the second surface of the lid member may be pressed toward the intermediate product by use of a lid member pressing mechanism to bring a part of the first surface of the lid member into close contact with a part of the intermediate product.
In the element manufacturing method according to an embodiment of the present invention, the lid member pressing mechanism may include a roller that rotates around a rotational axis of the roller. In this case, in the lid member pressing step, the roller may press part of the second surface of the lid member toward the intermediate product, whereby a shape curved along an outer circumferential surface of the roller may be formed on a region of the first surface of the lid member that corresponds to the second surface thereof.
In the element manufacturing method according to an embodiment of the present invention, the lid member pressing mechanism may include a pressurizing film of a long-size shape that is transported while being retained to form a shape protrudingly curved toward the lid member. In this case, in the lid member pressing step, the curved section of the pressurizing film may press part of the second surface of the lid member toward the intermediate product, whereby a shape curved along the curved section of the pressurizing film may be formed on the first surface of the lid member that corresponds to the second surface thereof.
The element manufacturing method according to an embodiment of the present invention may further include an irradiation step to emit light toward a section of the lid member that is formed with the curved shape. In this case, in the irradiation step, the light may pass through the section of the lid member that is formed with the curved shape, and reach the intermediate product. In addition, in the irradiation step, the light may be emitted from a direction of the substrate within the intermediate product, toward the lid member in close contact with the intermediate product.
The element manufacturing method according to an embodiment of the present invention may further include an irradiation step to emit light toward a section of the lid member that is formed with the curved shape, and in the irradiation step, the light may be guided by an optical system fixed with respect to the rotation of the roller, pass through the lid member, and reach the intermediate product.
In this case, the roller may include a main body constructed of a light-transmissive material to transmit light, the main body constituting the outer circumferential surface of the roller, and in the irradiation step, after the light has passed through an internal space of the roller, the light may pass through the main body of the roller and the lid member and reach the intermediate product. In addition, a mask with a plurality of openings may be disposed in the internal space of the roller, and in the irradiation step, after the light has passed through the openings of the mask, the light may pass through the main body of the roller and the lid member and reach the intermediate product.
Furthermore, the roller may include a main body internally formed with a space, the main body constituting the outer circumferential surface of the roller, a plurality of through-holes each extending from the outer circumferential surface to the internal space may be formed on the main body, and in the irradiation step, after the light has passed through the through-holes of the main body, the light may pass through the lid member and reach the intermediate product.
In the element manufacturing method according to an embodiment of the present invention, the element may include the substrate, a plurality of first electrodes each disposed on the substrate, auxiliary electrodes each disposed between any two of the first electrodes, the protrusions also each disposed between any two of the first electrodes, an organic semiconductor layer disposed on the first electrodes, and a second electrode disposed on the organic semiconductor layer and the auxiliary electrodes, the intermediate product may include the substrate, the first electrodes disposed on the substrate, the auxiliary electrodes and protrusions each disposed between any two of the first electrodes, and the organic semiconductor layer disposed on the first electrodes and the auxiliary electrodes, and the organic semiconductor layer disposed on one of the auxiliary electrodes may be removed while the section of the lid member that is formed with the curved shape is in close contact with a part of the intermediate product.
An embodiment of the present invention is an element manufacturing apparatus for forming an element on a substrate, the apparatus including a transport mechanism for transporting an intermediate product including the substrate and a plurality of protrusions each disposed on the substrate, a lid member supply mechanism for supplying a lid member having a first surface, the mechanism supplying the lid member so that the first surface faces the protrusions of the intermediate product, and a lid member pressing mechanism for bringing a part of the first surface of the lid member into close contact with a part of the intermediate product, wherein, on the first surface of the lid member that is being pressed by the lid member pressing mechanism, a shape protrudingly curved toward the intermediate product is formed and a section of the lid member that includes the curved shape is brought into close contact with a part of the intermediate product.
In the element manufacturing apparatus according to an embodiment of the present invention, in addition to the first surface, the lid member may include a second surface that lies on a side opposite to the first surface. In this case, the lid member pressing mechanism may press a part of the second surface of the lid member toward the intermediate product, whereby part of the first surface of the lid member may come into close contact with a part of the intermediate product.
In the element manufacturing apparatus according to an embodiment of the present invention, the lid member pressing mechanism may include a roller that rotates around a rotational axis of the roller. In this case, a shape curved along an outer circumferential surface of the roller may be formed on the first surface of the lid member that corresponds to the second surface thereof that is being pressed by the roller.
In the element manufacturing apparatus according to an embodiment of the present invention, the lid member pressing mechanism may include a pressurizing film of a long-size shape that is transported while being retained to form a shape protrudingly curved toward the lid member. In this case, the curved section of the pressurizing film may press part of the second surface of the lid member toward the intermediate product, whereby a shape curved along the curved section of the pressurizing film may be formed on the first surface of the lid member that corresponds to the second surface thereof.
The element manufacturing apparatus according to an embodiment of the present invention may further include an irradiation mechanism for emitting light toward a section of the lid member that is formed with the curved shape. In this case, the light may pass through the section of the lid member that is formed with the curved shape, and reach the intermediate product. In addition, the light may be emitted from a direction of the substrate within the intermediate product, toward the lid member in close contact with the intermediate product.
The element manufacturing apparatus according to an embodiment of the present invention may further include an irradiation mechanism for emitting light toward a section of the lid member that is formed with the curved shape, wherein the irradiation mechanism may include an optical system that guides the light so that the light will pass through the lid member and reach the intermediate product, and wherein the optical system may be fixed with respect to the rotation of the roller. In this case, the roller may include a main body constructed of a light-transmissive material to transmit light and internally formed with a space, the main body constituting the outer circumferential surface of the roller, and the irradiation mechanism may be configured so that the light, after passing through an internal space of the roller, passes through the main body and the lid member and reaches the intermediate product. In addition, a mask with a plurality of openings may be disposed in the internal space of the roller, and the irradiation mechanism may be configured so that the light, after passing through the openings of the mask, passes through the main body and the lid member and reaches the intermediate product.
Furthermore, the roller may include a main body internally formed with a space, the main body constituting the outer circumferential surface of the roller, a plurality of through-holes each extending from the outer circumferential surface to the internal space may be formed on the main body, and the irradiation mechanism may be configured so that the light, after passing through the through-holes of the main body, passes through the lid member and reaches the intermediate product.
In the element manufacturing apparatus according to an embodiment of the present invention, the roller may include a first roller and a second roller, both lined up spacedly in the second direction. In this case, the first roller and the second roller may act together to press the second surface of the lid member, whereby a section of the lid member that is positioned between the first roller and the second roller may have a shape curved along an outer circumferential surface of the first roller and an outer circumferential surface of the second roller.
According to the embodiment of the present invention, a substrate can be efficiently covered using an apparatus of a simplified configuration.
Hereunder, embodiments of the present invention will be described with reference to
A layer configuration of an organic semiconductor element 40 according to an embodiment of the present invention will be first described with reference to
As shown in
The organic semiconductor layers 45 each include at least a light-emitting layer that emits light by recombinations of electrons and holes in organic compounds. Each organic semiconductor layer 45 may further include a hole injection layer, a hole transport layer, an electron transport layer or an electron injection layer, and other layers generally provided in an organic EL element. Constituent elements of the organic semiconductor layer can be known ones, for example the elements described in JP2011-9498A.
One first electrode 42 is disposed for each of the organic semiconductor layers 45. The first electrode 42 also functions as a reflecting electrode to reflect the light that has been generated from the organic semiconductor layer 45. Examples of a material constituting the first electrode 42 can include aluminum, chromium, titanium, iron, cobalt, nickel, molybdenum, copper, tantalum, tungsten, platinum, gold, silver, and other metallic elements, whether they be present independently or in combination as an alloy.
The second electrode 46 functions as a common electrode with respect to the plurality of organic semiconductor layers 45. In addition, the second electrode 46 is configured to transmit the light that has been generated from the organic semiconductor layers 45. Examples of a material constituting the second electrode 46 can include a metallic film that has been thinned to such an extent that it can transmit the light, and an oxide conductive material such as indium tin oxide (ITO).
The auxiliary electrodes 43 are provided to suppress variations in voltage drop due to differences in distances from a power supply (not shown) to individual organic semiconductor layers, and thus to suppress a variation in luminance of a display device which uses the organic EL element. As shown in
The protrusions 44 are constructed of a material having an electrical insulating property. In the example of
As shown in
Next, construction of the organic semiconductor element 40 when viewed from the normal-line direction of the substrate 41 is described below. The description focuses particularly upon layout of the auxiliary electrodes 43, protrusions 44, and organic semiconductor layers 45 of the organic semiconductor element 40.
As shown in
As long as the voltage drop can be appropriately reduced, the auxiliary electrode 43 does not need to be connected to the second electrode 46 over an entire region of the auxiliary electrode 43. That is to say, not all of the organic semiconductor layer 45 on the auxiliary electrode 43 requires removal in the removal step detailed later herein. As shown in
Furthermore, the layout of the auxiliary electrodes 43 is not limited as long as the voltage drop across the second electrode 46 can be appropriately reduced. For example, as shown in
Moreover, layout of positions in which the auxiliary electrodes 43 and the second electrode 46 are connected is not limited as long as the voltage drop across the second electrode 46 can be appropriately reduced. In
In
Next, a description will be given of an element manufacturing apparatus 10 and an element manufacturing method according to the embodiment, both intended to form the organic semiconductor element 40 on the substrate 41. As long as impurities can be sufficiently prevented from entering the organic semiconductor element 40, although an environment in which the element manufacturing method is implemented is not limited, the element manufacturing method itself is implemented, for example, partially under a vacuum environment. For example, as long as the environment has a pressure lower than atmospheric pressure, although the more specific pressure in the vacuum environment is not limited, the element manufacturing apparatus 10 has an internal pressure of, for example, 1.0×104 Pa or less.
The element manufacturing apparatus 10 further includes an intermediate product processing device 15 that performs predetermined processing while a lid member described later herein is in close contact with part of the intermediate product 50. Here, a description will be given below of an example in which the intermediate product processing device 15 in the present embodiment is configured as a removal device for removing the organic semiconductor layer 45 disposed on the auxiliary electrode 43. The intermediate product processing device 15 includes a stage 18, a lid member supply mechanism 20, a lid member pressing mechanism 30, and an irradiation mechanism 25. Constituent elements of the intermediate product processing device 15 will be described later herein. The lid member 21 or the element manufacturing apparatus 10 further includes a second electrode forming device 16 that forms a second electrode 46 on the auxiliary electrode 43 and organic semiconductor layer 45 after the organic semiconductor layer 45 on the auxiliary electrode 43 has been removed.
As shown in
The method of manufacturing the organic semiconductor element 40 using the element manufacturing apparatus 10 will be described below with reference to
Next as shown in
Next, a lid member 21 is provided and then as shown in
Next, as shown in
The method of bringing the lid member 21 into close contact with part of the intermediate product 50 and removing the organic semiconductor layer 45 on the auxiliary electrode 43 has been described with reference to
As shown in
The stage 18 has a mounting surface 18a for supporting the intermediate product 50, and the mounting surface 18a has an expanse that is parallel to the first direction D1 and the second direction D2. In addition, the stage 18 is configured to be movable in a moving direction T1 of the stage that is parallel to the first direction D1. The intermediate product 50 is mounted on the stage 18 so that the plurality of protrusions 44 line up on the substrate 41, in the first direction D1. Accordingly, as will be described later herein, either the protrusions 44 of the intermediate product 50 that are lined up in the first direction D1, or peripheral sections of the protrusions 44 can be sequentially irradiated with light by repeating movement of the stage 18 in the moving direction T1 thereof and irradiating the intermediate product 50 with light from the irradiation mechanism 25. The protrusions 44 of the intermediate product 50 mounted on the stage 18 extend in the third direction D3 that is orthogonal to the first direction D1 and the second direction D2.
As shown in
At least one of polyethylene terephthalate (PET), cycloolefin polymer (COP), polypropylene (PP), polyethylene (PE), polycarbonate (PC), a glass film, and other materials having a property to transmit light is used as a material for the lid member 21 to allow light such as laser light to pass through.
The roller 31 of the lid member pressing mechanism 30 is constructed to rotate in synchronization with the movement of the stage 18. In other words, after the lid member 21 has been wound around the roller 31, the roller 31 transports the lid member to ensure matching between a moving speed of the stage 18 and a transport speed of the lid member 21. The roller 31 includes a cylindrical main body 32 and a drive for rotating the main body 32 while supporting it at a predetermined position. The main body 32 refers to a section constituting an outer circumferential surface of the roller 31, that is, a surface that comes into contact with the lid member 21. The outer circumferential surface of the roller 31 and that of the main body 32 are therefore synonymous.
A more specific configuration of the drive for rotating the main body 32 is not limited as long as an optical path for emitting light toward the intermediate product 50 is not obstructed.
The main body 32 in the present embodiment is constructed of the light-transmissive materials that transmit light, such as glass. In addition, a space 32b is formed inside the main body 32. For example, the space 32 is configured to allow the main body 32 to penetrate the roller 31, in an axial direction of the roller. Disposing the space 32b allows an optical system 27 (and the like) of the irradiation mechanism 25 to be placed inside the roller 31, as will be described later herein.
As shown in
The optical system 27 is fixed with respect to the movement of the stage 18 and the rotation of the roller 31. That is to say, the optical system 27 is disposed independently of the stage 18 and the roller 31. For example, the optical system 27 is configured so that the traveling direction of the light L2 generated by the optical system 27 will remain unchanged even after the stage 18 has moved or the roller 31 has rotated. Meanwhile, as described above, the stage 18 can be moved in the first direction D1 and the protrusions 44 of the intermediate product 50 are lined up in the first direction D1. Even when the optical system 27 is at rest, therefore, the protrusions 44 or the peripheral sections of the protrusions 44 can be sequentially irradiated with the light. In addition, because of no need to move the optical system 27 in the first direction D1, no misalignment of an aiming line of the optical system 27 occurs during necessary steps. This means that light irradiation can be executed with high positional accuracy relative to irradiating a plurality of sections of the intermediate product 50 with light while moving the light source 26 and/or the optical system 27.
As indicated by a dotted line with arrow M in
In the case where the intermediate product 50 can be irradiated with the light at that given position in the second direction, sections of the intermediate product 50 that are to be irradiated with the light do not need to line up in the first direction orthogonal to the second direction. Therefore, although this is not shown, the protrusions 44 of the intermediate product 50 do not need to line up in the first direction D1.
Next, a method of removing the organic semiconductor layer 45 on an auxiliary electrode 43 using the intermediate product processing device 15 will be described with reference to
First the lid member 21 having the first surface 21a is set in place so that the first surface 21a faces the protrusions 44 of the intermediate product 50. A lid member supply step is executed to supply the lid member 21 between the main body 32 of the roller 31 and the intermediate product 50 by use of, for example, the lid member supply mechanism 20 so that the first surface 21a faces the stage 18. Next, a lid member pressing step is executed to press a part of the lid member 21 toward the stage 18 by use of the roller 31 of the lid member pressing mechanism 30. Thus, part of the first surface 21a of the lid member 21 comes into firm contact with a part of the intermediate product 50. More specifically, as shown in
The lid member pressing step is followed by an irradiation step, in which step the section of the intermediate product 50 that is in close contact with the lid member 21 is irradiated with light via the lid member 21. Conceptually, the “section of the intermediate product 50 that is in close contact with the lid member 21” encompasses not only the protrusions 44 that are in direct contact with the first surface 21a of the lid member 21, but also sections surrounded by the protrusions 44 that are in direct contact with the first surface 21a of the lid member 21. Not all of the section of the intermediate product 50 that is in close contact with the lid member 21 requires light irradiation. In the present embodiment, only the section of the intermediate product 50 that is in close contact with the lid member 21 and is provided with the organic semiconductor layer 45 to be removed is irradiated with the light.
Here in accordance with the present embodiment, as described above, the curved section 21c is formed on the first surface 21a of the lid member 21 and then used to bring the lid member 21 into close contact with the intermediate product 50. This allows the first surface 21a of the lid member 21 to be pressed firmly, without a clearance, against the section of the intermediate product 50 that is provided with the protrusions 44. Accordingly the organic semiconductor material that has flown apart from the surface of the auxiliary electrode 43 can be more reliably prevented from contaminating the organic semiconductor layer 45 on the auxiliary electrode 43, and an ambient environment.
In this manner, a simplified constituent element of the roller 31 can be used to cover part of the intermediate product 50 efficiently with the lid member 21. For this reason, the organic semiconductor element 40 having high quality can be manufactured at a low cost.
Once the organic semiconductor layer 45 on the auxiliary electrode 43 has been removed, the light from the irradiation mechanism 25 is shut down. That is to say, the irradiation of the intermediate product 50 with the light is stopped.
An example in which, at sections of the lid member 21 that do not transmit the light L2, a clearance is formed partially between the main body 32 of the roller 31 and the second surface 21b of the lid member 21, is shown in
Next, the stage 18 is moved in the moving direction T1 of the stage and the rid material 21 is moved in the rotational direction R of the main body 32 of the roller 31. After this, when the next organic semiconductor layer 45 to be removed from the surface of the auxiliary electrode 43 reaches the optical path of the light L2 that extends from the optical system 27 to the intermediate product 50, the irradiation mechanism 25 emits light once again. The organic semiconductor layer 45 on the auxiliary electrode 43 is then irradiated with the light L2 from the irradiation mechanism 25 once again, whereby the organic semiconductor layer 45 is removed. In this manner, the organic semiconductor layers 45 on the auxiliary electrodes 43 lined up in the first direction D1 parallel to the moving direction T1 of the stage can be removed in order. The organic semiconductor layers 45 on the auxiliary electrodes 43 are usually arranged at equal intervals above the substrate 41. The organic semiconductor layers 45 on the auxiliary electrodes 43 may therefore be irradiated with the light in order by turning on and off the light source 26 of the irradiation mechanism 25 at fixed periods that allow for intervals of the auxiliary electrodes 43 and the moving speed of the stage 18.
As can be seen from the above, when the stage 18 moves and the main body 32 rotates, the optical system 27 of the irradiation mechanism 25 remains at rest. For this reason, in the present embodiment, the intermediate product 50 can be light-irradiated with high positional accuracy, which in turn allows accurate removal of the organic semiconductor layer 45 from the surface of the auxiliary electrode 43.
In addition, in accordance with the present embodiment, the lid member 21 supplied on a roll-to-roll basis can be used to cover the intermediate product 50 placed on the moving stage 18. Accordingly the step of removing the organic semiconductor layer 45 on the surface of the auxiliary electrode 43 can be executed for a plurality of intermediate products 50 by use of one roll unit having one lid member 21 wound around it. A device or step for cutting the lid member 21 for each intermediate product 50 is therefore unnecessary, for which reason the apparatus configuration and the steps can be simplified. Occurrence of a gas due to the cutting of the lid member 21 and resulting contamination of the intermediate product 50 can also be prevented.
After the above removal, the mirror 27a may be moved along the rotational axis of the roller 31 to remove the organic semiconductor layers 45 on the plurality of auxiliary electrodes 43 positioned on a new line different from that of the first direction D1 in which the organic semiconductor layer 45 has existed until removed in the removal step. After the mirror 27a has been moved, the organic semiconductor layers 45 on the plurality of auxiliary electrodes 43 positioned on the new line can be removed by executing the above step once again while moving the stage 18.
Various changes may be made to the embodiments described above. Modifications will be described with reference being made to part of the accompanying drawings. In the following description and the drawings used therein, the same reference numbers as those which have been used to denote the corresponding elements/sections in the above embodiments will be used for the elements/sections that can be configured similarly to those of the embodiments, and overlapped description will be omitted. In addition, where the operational effects obtained in the embodiments can also be obviously obtained in the modifications, description of these effects may be omitted.
The examples where the first electrodes 42 and the auxiliary electrodes 43 are formed on the substrate 41 earlier than the protrusions 44 have been shown and described in the embodiments described above. These examples, however, are not restrictive and in a modification, the protrusions 44 may be formed on the substrate 41 earlier than the first electrodes 42 and the auxiliary electrodes 43. The close-fitting step and removal step in any one of the embodiments described above can be used in such a modification as well. This modification will be described below with reference to
First as shown in
After the formation of the electrodes 42 and 43, as shown in
Next as shown in section
In the embodiment shown in
After the above pressing operation, the organic semiconductor layer 45 on the auxiliary electrode 43 positioned on a protrusion 44 is irradiated with the light L2, whereby as shown in
After the above removal, as shown in
A Modification in which the Intermediate Product Processing Device is Configured as an Exposure Device
The examples where the intermediate product processing device 15 is configured as the removal device to remove part of the organic semiconductor layers 45 on the auxiliary electrodes 43 have been shown and described in the above embodiments and in a modification. Applications of the intermediate product processing device 15, however, are not limited to the examples. For example, although this is not shown, the intermediate product processing device 15 may be used as an exposure device that executes an exposure step in which it irradiates a desired layer of the intermediate product 50 with exposure light L2 while the lid member 21 is in close contact with the intermediate product 50.
A Modification in which the Intermediate Product Processing Device is Configured as a Vapor Deposition Device
In an alternative modification, as shown in
In the present modification, as shown in
The evaporation of the vapor deposition material 48 by heating is not limited to the method described above. For example, the vapor deposition material 48 may be heated by forming an infrared-light absorbing metallic thin film between the first surface 21a of the lid member 21 and the organic semiconductor layer 45 and emitting light toward the metallic thin film for heating. In this case, although substantially no light is directly applied to the vapor deposition material 48 provided on the first surface 21a of the lid member 21, the vapor deposition material 48 can be evaporated since it can be heated indirectly via the metallic thin film. Whether the vapor deposition material 48 is directly irradiated with the light or heated indirectly via the metallic thin film, it is common in that the light is emitted toward the section of the lid member 21 that is formed with the curved shape.
If the metallic thin film is formed from a magnetic material, for tighter contact between the lid member 21 and the intermediate product 50, magnetic fields may be generated around the lid member 21 or a magnetic body may be placed at an opposite side of the intermediate product 50 with respect to the lid member 21, thereby to generate a magnetic force that draws the lid member 21 toward the intermediate product 50.
The examples where the mirror 27a of the optical system is constructed to be movable along the rotational axis of the roller 31, in the internal space 32b of the main body 32 of the roller 31, have been shown and described in the above embodiments and modifications. These examples, however, are not intended to limit a more specific configuration of the optical system 27 for emitting light toward the plurality of sections/elements positioned on a plurality of lines represented along the second direction D2. For example as shown in
The light L2 that has been guided to the mask 28 first passes through the openings 28a of the mask 28, then passes through the main body 32 of the roller 31 and the lid member 21, and reaches the intermediate product 50. Accordingly the plurality of sections of the intermediate product 50 that are lined up in the second direction D2 can be simultaneously irradiated with the light L2. Therefore, the plurality of sections lined up in the second direction D2 can be irradiated with the light at the same time without moving the mirror 27a as in the above-described case. Hence the time required for the step can be reduced. In addition, irradiation with the light can be executed with higher positional accuracy since the mirror 27a is free from optical misalignment due to the movement of the mirror 27a.
The examples where the main body 32 of the roller 31 is formed from a light-transmissive material that transmits light have also been shown and described in the above embodiments and modifications. The roller main body 32, however, does not have its configuration limited as long as the light L2 can pass through the curved section 21c of the lid member 21 and reach the intermediate product 50. For example as shown in
If or when the through-holes 32c are formed on the main body 32 of the roller 31 as in the present modification, the material constituting the main body 32 can be not only a light-transmissive material that transmits light, but also such a metallic material as a material not allowing light to pass through. In accordance with the present modification, therefore, the material constituting the main body 32 can be selected easily. For example, the material of the main body 32 can be selected considering workability and availability, whereby the roller 31 can be improved in characteristics and a cost requirement of the roller 31 can be lowered.
In addition, in the present modification, even when as denoted by a dotted line in
The examples where the lid member 21 is in contact over its entire lateral region with the roller 31 have been shown and described in the above embodiments and modifications. A more specific configuration of the roller 31, however, is not limited as long as the shape curved along the outer circumferential surface 32a of the roller main body 32 can be imparted to the first surface 21a of the lid member 21. For example as shown in
In the present modification, a section of the lid member 21 that lies between the first roller 33 and the second roller 34 is out of contact with outer circumferential surfaces of the rollers 33 and 34. Even in this case, if the lid member 21 has predetermined rigidity, a shape curved along the outer circumferential surfaces of the rollers 33 and 34 is formed on a region of the first surface 21a of the lid member 21 that corresponds to the second surface 21b directly pressed by the rollers 33, 34. More specifically in the present modification, as shown in
In addition, in accordance with the present modification, the optical system 27 for guiding light to the intermediate product 50 via the curved section 21c of the lid member 21 can be disposed in the interspace between the first roller 33 and the second roller 34 or in a peripheral space therebetween. Accordingly the space for disposing the optical system does not need to be formed internally to the first roller 33 or the second roller 34. Furthermore, the flexibility of layout of the optical system 27 is enhanced relative to that obtained when the optical system 27 is disposed in an internal space of the rollers. Therefore, the light can be guided to the intermediate product 50 more easily and with higher accuracy.
The examples where the lid member pressing mechanism 30 for bringing part of the first surface 21a of the lid member 21 into close contact with part of the intermediate product 50 includes the roller 31 that presses part of the second surface 21b of the lid member 21 toward the intermediate product 50 have been shown and described in the above embodiments and modifications. A more specific configuration of the lid member pressing mechanism 3, however, is not limited as long as the shape protrudingly curved toward the intermediate product 50 is formed at least partially on the first surface 21a of the lid member 21 and the section of the lid member 21 that includes the curved shape is brought into close contact with a part of the intermediate product 50.
For example as shown in
In addition, in the present modification, as in the above-described embodiments, the pressurizing film 35 being transported can be used to configure the lid member pressing mechanism 30 and thus to bring the lid member 21 being transported at a synchronous speed, and the intermediate product 50 into close contact with one another to cover the intermediate product 50. Accordingly, various steps such as the irradiation step can be executed for the lid member 21 being transported and for the intermediate product 50. The organic semiconductor element 40 having high quality can therefore be efficiently manufactured at a low cost.
The material constituting the pressurizing film 35, and thickness, layer configuration, and other factors of the pressurizing film 35 are selected for an appropriate configuration of the curved section 35c. For example, a material having a coefficient of elasticity that is higher than that of the material constituting the lid member 21 is used as the material constituting the pressurizing film 35. In addition, the thickness of the pressurizing film 35 may be increased above that of the lid member 21 so that the curved section 35c is appropriately formed on the pressurizing film 35, between the paired guide rollers 35r. Alternatively a plurality of films may be stacked upon each other to form the pressurizing film 35. For example, the pressurizing film 35 may include one pair of films and an interference layer provided between the paired films. The paired films can be, for example, one pair of PET films each ranging from 100 to 500 μm in thickness. The interference layer may be formed using a light-transmissive material of a gel form. A light-transmissive optical pressure-sensitive adhesive, so-called an optical clear adhesive (OCA), can be used as the material for the interference layer.
In the present modification, the organic semiconductor material that has flown apart from an auxiliary electrode 43 of the intermediate product 50 sticks to the first surface 21a of the lid member 21. To manufacture the organic semiconductor element 40 having high quality, therefore, it is preferable that the lid member 21 with the organic semiconductor material sticking thereto be discarded without being reused during the manufacture of the organic semiconductor element 40. The organic semiconductor material, however, does not stick to the pressurizing film 35. In addition, as shown in
The examples where the lid member 21 including the first surface 21a and the second surface 21b is used as a member for covering the intermediate product 50 have been shown and described in the above embodiments and modifications. A more specific configuration of the lid member 21, however, is not limited as long as the intermediate product 50 can be appropriately covered using the curved shape. For example as shown in
A cleaning mechanism 36 for cleaning the organic semiconductor layer 45 that has been formed on the surface of the roller 31 may be disposed as shown in
While this is not shown, the roller 31 in the present modification may be one configured by winding a film. In this case, even if the surface of the roller 31 becomes contaminated with the organic semiconductor layer 45, the surface of the roller 31 can always be kept clean by unwinding the film having the organic semiconductor layer 45 sticking thereto, and removing this film. The cleaning mechanism 36 for cleaning the surface of the roller 31, therefore, becomes unnecessary.
The examples where the light L2 is emitted from a direction of the lid member 21, toward the organic semiconductor layer 45 provided on the auxiliary electrode 43, have been shown and described in the above embodiments and modifications. The direction in which the light L2 is emitted, however, is not limited as long as the organic semiconductor layer 45 can be appropriately heated. For example as shown in
The examples where, when the plurality of intermediate products 50 lined up in the first direction D1 are irradiated with the light L2 in order, the stage 18 moves in the moving direction T1 of the stage and the optical system 27 of the irradiation mechanism 25 remains at rest, have been shown and described in the above embodiments and modifications. The present invention, however, is not limited to these examples and when the plurality of intermediate products 50 lined up in the first direction D1 are irradiated with the light L2 in order, the stage 18 may remain at rest and the optical system 27 may move in the first direction D1.
The example where the stage 18 is used as a mechanism for transporting the intermediate product 50 has been shown and described in the above embodiments and modifications. However, this example is not intended to limit applications of the present invention and although this is not shown, the intermediate product 50 may be supplied and transported in roll-to-roll form. That is to say, the substrate 41 of the intermediate product 50 may extend in long-size form and the first electrodes 42, auxiliary electrodes 43, protrusions 44, organic semiconductor layers 45, second electrode 46, and the like of the intermediate product 50 may be formed on the substrate 41 that extends in the long-size form. In this case, the mechanism for transporting the intermediate product 50 in the direction T1 can be a general transport mechanism used in the roll-to-roll form.
The example where the organic semiconductor element 40 is an organic EL element has been shown and described in the above embodiments and modifications. However, this does not limit a type of the organic semiconductor element manufactured using the above-described element manufacturing apparatus 10 and element manufacturing method. For example, various organic semiconductor elements such as organic transistor devices and organic solar-cell devices can be manufactured using the element manufacturing apparatus 10 and the element manufacturing method. The organic semiconductor layers and other constituent elements used in organic transistor devices can be known ones, for example, those described in JP2009-87996A. In addition, the organic semiconductor layers and other elements used in an organic solar cell device can be known ones, for example, those described in JP2011-151195A. In addition, the element manufacturing apparatus 10 and the element manufacturing method may be applied to manufacturing inorganic semiconductor elements as well as to organic semiconductor elements.
The example where the constituent elements of the intermediate product processing device 15 are arranged inside the chamber maintained in a vacuum atmosphere has been shown and described in the above embodiments and modifications. That is to say, the example where the step of irradiating the intermediate product 50 with light by use of the intermediate product processing device 15 is executed under a vacuum environment has been shown and described. The example, however, is not intended to limit applications of the present invention, and the step of irradiating the intermediate product 50 with light by use of the intermediate product processing device 15 may be executed under a non-vacuum environment such as an atmospheric pressure environment.
While several modifications of the embodiments have been described, naturally these modifications may also be applied in combination as appropriate.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2013-159456 | Jul 2013 | JP | national |
| Filing Document | Filing Date | Country | Kind |
|---|---|---|---|
| PCT/JP2014/070235 | 7/31/2014 | WO | 00 |
