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  Method for manufacturing organic el device, organic el device, and electronic apparatusUSPTO Application #: 20050253131Title: Method for manufacturing organic el device, organic el device, and electronic apparatus Abstract: The present invention provides reduced production cost in a method for manufacturing an organic EL device including a step of forming a light-emitting layer having a predetermined pattern by an ink-jet method. The method achieves this objective by not forming a bank which surrounds an area in a substrate surface other than an area at which a light-emitting layer is formed. A solution-repellent treatment is performed so that a droplet of a liquid containing a light-emitting material has a contact angle of 15° to 90° with respect to the substrate surface immediately before formation of the light-emitting layer. Accordingly, a fluorine containing layer (a layer composed of a material containing fluorine) is formed. Between a step of forming the light-emitting layer and a step of forming a cathode, a step of forming a hole blocking layer over the entire surface of the substrate is performed. (end of abstract)
Agent: Oliff & Berridge, PLC - Alexandria, VA, US Inventor: Hidekazu Kobayashi USPTO Applicaton #: 20050253131 - Class: 257013000 (USPTO) Related Patent Categories: Active Solid-state Devices (e.g., Transistors, Solid-state Diodes), Thin Active Physical Layer Which Is (1) An Active Potential Well Layer Thin Enough To Establish Discrete Quantum Energy Levels Or (2) An Active Barrier Layer Thin Enough To Permit Quantum Mechanical Tunneling Or (3) An Active Layer Thin Enough To Permit Carrier Transmission With Substantially No Scattering (e.g., Superlattice Quantum Well, Or Ballistic Transport Device), Heterojunction, Incoherent Light Emitter The Patent Description & Claims data below is from USPTO Patent Application 20050253131. Brief Patent Description - Full Patent Description - Patent Application Claims
CROSS-REFERENCE TO RELATED APPLICATION [0001] This is a Division of Application Ser. No. 09/925,320 filed Aug. 10, 2001. The entire disclosure of the prior application is hereby incorporated by reference herein in its entirety. BACKGROUND OF THE INVENTION [0002] 1. Field of Invention [0003] The present invention relates to methods for manufacturing organic EL (electroluminescence) devices. The organic EL devices can be used, for example, as displays of a television and a computer, and light sources, such as a backlight of a liquid crystal display. [0004] 2. Description of Related Art [0005] Recently, as a self-luminous display used in place of a liquid crystal display, organic EL devices (light-emitting devices having a structure in which an organic light-emitting layer is provided between an anode and a cathode) have rapidly been developed. As a material for the light-emitting layer used for an organic EL device, there are organic materials with low molecular weight such as an aluminum quinolinol complex (Alq3), and organic materials with large molecular weight such as polyparaphenylene vinylene (PPV). A light-emitting layer composed of an organic material with low molecular weight can be formed by a deposition method as disclosed in, for example, Appl. Phys. Lett. 51(12), Sep. 21, 1987, p. 913. A light-emitting layer composed of an organic material with large molecular weight is formed by a coating method as disclosed in, for example, Appl. Phys. Lett. 71(1), Jul. 7, 1997, p. 34. [0006] For example, in an organic EL device for use in a display, it can be necessary to arrange a light-emitting layer at a position on a substrate corresponding to each pixel. In addition, in the cases of a color display and a white light source, it can be necessary to arrange each of light-emitting layers having three primary colors at each corresponding position on a substrate. Accordingly, when the arrangement of light-emitting layers can be performed by an ink-jet method, coating and patterning can be simultaneously performed, and hence, patterning with high accuracy can be performed in a short period of time. In addition, since a material used in this method can be minimized, the material can be efficiently used, and reduction in production cost can be effectively achieved. [0007] Previously, when light-emitting layers are formed into a predetermined pattern by an ink-jet method, banks composed of an insulating layer can be formed, and the light-emitting layers are formed in areas surrounded thereby. Whether or not anodes are patterned corresponding to the light-emitting area, the formation of the insulating layers as described above can be performed. SUMMARY OF THE INVENTION [0008] The present invention provides a method for manufacturing an organic EL device in which at least a first electrode layer, a light-emitting layer, and a second electrode layer are sequentially formed above a substrate, and the light-emitting layer can be formed by supplying a liquid containing a light-emitting material in a light-emitting area above the substrate surface. The method for manufacturing the organic EL device includes forming no bank which surrounds an area above the substrate surface other than an area at which the light-emitting layer is formed, performing a solution-repellent treatment so that a droplet of the liquid has a contact angle in the range of 15.degree. to 90.degree. with respect to the substrate surface immediately before the formation of the light-emitting layer, and supplying the liquid to a predetermined position above the substrate surface to which the solution-repellent treatment is applied. [0009] The present invention provides an organic EL device that can include a plurality of light-emitting areas above a substrate, each having a light-emitting layer provided between a first electrode layer and a second electrode layer opposing thereto, and a hole blocking layer, which allows electrons but not holes to pass therethrough, in the light-emitting areas and therebetween. [0010] In addition, the present invention provides a method for manufacturing an organic EL device that can include a plurality of light-emitting areas above a substrate. The method for manufacturing the organic EL device can include a step of forming first electrode layers by patterning in areas above the substrate at which the light-emitting areas are to be formed, a step of forming a hole injection/transport layer above the first electrode layers and between the first electrode layers, a step of forming a light-emitting layer above the hole injection/transport layer in the areas at which the light-emitting areas are to be formed, a step of forming a hole blocking layer, which allows electrons but not holes to pass therethrough, in the light-emitting areas and therebetween including areas above the light-emitting layers, and a step of forming a second electrode layer above the hole blocking layer. [0011] In addition, the present invention provides an electronic apparatus provided with an organic EL device. The organic EL device mentioned above includes a plurality of light-emitting areas above a substrate, each having a light-emitting layer provided between a first electrode layer and a second electrode layer opposing thereto, and in the light-emitting areas and therebetween, a hole injection/transport layer and a hole blocking layer which allows electrons but not holes to pass therethrough. BRIEF DESCRIPTION OF THE DRAWINGS [0012] The invention will be described with reference to the accompanying drawings, in which like elements are referenced to with like numerals, and in which: [0013] FIG. 1 illustrates manufacturing steps in a method for manufacturing an organic EL device according to a first embodiment of the present invention; [0014] FIG. 2 is a cross-sectional view showing an organic EL device formed by the method according to the first embodiment and to a third embodiment; [0015] FIG. 3 is a graph showing the results obtained by measuring luminous characteristics and current characteristics at a position corresponding to a light-emitting layer of the organic EL device formed by the method according to the first embodiment; [0016] FIG. 4 is a graph showing the results obtained by measuring current properties at a position (non light-emitting area) between adjacent light-emitting layers of an organic EL device curve A shows the results of the organic EL device formed by the method according to the first embodiment, curve B shows the results of the device when a fluorine containing layer is not formed in the non light-emitting area, curve C shows the results when a lithium fluoride thin-film is not formed in the non light-emitting area, and curve D shows the results when both the fluorine containing layer and the lithium fluoride thin-film are not formed in the non light-emitting area; [0017] FIG. 5 is a cross-sectional view showing an organic EL device formed by a method according to a second embodiment; [0018] FIG. 6 is a perspective view showing an organic EL device formed by a method according to a fourth embodiment; [0019] FIG. 7 is a perspective view showing the structure of a personal computer corresponding to an example of an electronic apparatus to which the organic EL device of the present invention is applied; [0020] FIG. 8 is a perspective view showing the structure of a mobile phone corresponding to an example of an electronic apparatus to which the organic EL device of the present invention is applied; and Continue reading... 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