WO2025215817A1 - Light-emitting element and method for manufacturing same, display device, nano metal oxide particle group, dispersion liquid for nano metal oxide particles, and method for manufacturing nano metal oxide particles - Google Patents
Light-emitting element and method for manufacturing same, display device, nano metal oxide particle group, dispersion liquid for nano metal oxide particles, and method for manufacturing nano metal oxide particlesInfo
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- WO2025215817A1 WO2025215817A1 PCT/JP2024/014777 JP2024014777W WO2025215817A1 WO 2025215817 A1 WO2025215817 A1 WO 2025215817A1 JP 2024014777 W JP2024014777 W JP 2024014777W WO 2025215817 A1 WO2025215817 A1 WO 2025215817A1
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- metal oxide
- oxide nanoparticles
- light
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- emitting
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- C—CHEMISTRY; METALLURGY
- C01—INORGANIC CHEMISTRY
- C01G—COMPOUNDS CONTAINING METALS NOT COVERED BY SUBCLASSES C01D OR C01F
- C01G9/00—Compounds of zinc
- C01G9/02—Oxides; Hydroxides
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- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/12—Light sources with substantially two-dimensional radiating surfaces
- H05B33/14—Light sources with substantially two-dimensional radiating surfaces characterised by the chemical or physical composition or the arrangement of the electroluminescent material, or by the simultaneous addition of the electroluminescent material in or onto the light source
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/10—OLEDs or polymer light-emitting diodes [PLED]
- H10K50/11—OLEDs or polymer light-emitting diodes [PLED] characterised by the electroluminescent [EL] layers
- H10K50/115—OLEDs or polymer light-emitting diodes [PLED] characterised by the electroluminescent [EL] layers comprising active inorganic nanostructures, e.g. luminescent quantum dots
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K50/00—Organic light-emitting devices
- H10K50/10—OLEDs or polymer light-emitting diodes [PLED]
- H10K50/14—Carrier transporting layers
- H10K50/16—Electron transporting layers
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/10—OLED displays
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K77/00—Constructional details of devices covered by this subclass and not covered by groups H10K10/80, H10K30/80, H10K50/80 or H10K59/80
Definitions
- One aspect of the present disclosure relates to a light-emitting element, a method for manufacturing a light-emitting element, a display device, a group of metal oxide nanoparticles, a dispersion of metal oxide nanoparticles, and a method for manufacturing metal oxide nanoparticles.
- Patent Document 1 describes an OLED or QLED equipped with electronic functional layers, such as an electron transport layer or an electron injection layer, formed solely from zinc oxide nanoparticles or magnesium zinc oxide nanoparticles.
- Zinc oxide nanoparticles or magnesium zinc oxide nanoparticles have relatively large particle size variations, and as a result, electronic functional layers formed solely from zinc oxide nanoparticles or magnesium zinc oxide nanoparticles lack density, resulting in insufficient protection of the light-emitting layer below the electronic functional layer.
- One aspect of the present disclosure aims to provide metal oxide nanoparticles with small particle size and particle size variation, a method for manufacturing metal oxide nanoparticles, a light-emitting element with high luminous efficiency, and a method for manufacturing the same.
- the light-emitting device of the present disclosure has the following features: an anode; a cathode; a light-emitting layer disposed between the anode and the cathode; an electronic functional layer disposed between the cathode and the light-emitting layer;
- the electronic functional layer includes a plurality of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements, or a semi-metallic element, zinc, and oxygen.
- the display device of the present disclosure comprises: A display device comprising a plurality of the light-emitting elements.
- the metal oxide nanoparticles of the present disclosure are made of a group of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements, or a semi-metallic element, zinc, and oxygen.
- the dispersion of metal oxide nanoparticles of the present disclosure has the following features: The metal oxide nanoparticles and a solvent are included.
- the method for producing metal oxide nanoparticles of the present disclosure includes the steps of: a micromixer that mixes and discharges a first precursor of metal oxide nanoparticles that contains a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second precursor of metal oxide nanoparticles that contains a second element that is an element selected from non-metal elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element, a third precursor of metal oxide nanoparticles that contains zinc, and a reactant, all of which are supplied from the outside; a microchannel having a supply end at one end and a discharge end at the other end, the microchannel receiving the fluid discharged from the micromixer from the supply end; and a microreactor that controls the reaction conditions in at least a portion of the microchannel, to produce metal oxide nanoparticles having a core that contains the first element, the second element, zinc,
- the method for manufacturing a light-emitting element includes the steps of: an anode formation step of forming an anode; a cathode forming step of forming a cathode, which is performed after the anode forming step; a light-emitting layer forming step of forming a light-emitting layer, which is carried out between the anode forming step and the cathode forming step; an electronic functional layer forming step of forming an electronic functional layer, which is performed between the light-emitting layer forming step and the cathode forming step; In the electronic functional layer forming step, the electronic functional layer is formed, which contains metal oxide nanoparticles produced by the method for producing metal oxide nanoparticles.
- One aspect of the present disclosure provides metal oxide nanoparticle groups and methods for producing metal oxide nanoparticles with small particle size and particle size variation, as well as light-emitting devices with high luminous efficiency and methods for producing the same.
- FIG. 1 is a plan view showing a schematic configuration of a display device according to a first embodiment.
- 2 is a cross-sectional view showing a schematic configuration of a light-emitting element provided in the display device of the first embodiment shown in FIG. 1.
- FIG. 3A to 3C are diagrams illustrating an example of a method for manufacturing the light-emitting element shown in FIG. 2.
- 3 is a diagram showing a schematic configuration of a reaction apparatus used in a process for producing metal oxide nanoparticles contained in an electronic functional layer provided in the light-emitting element shown in FIG. 2.
- FIG. FIG. 5 is a diagram showing an example of process conditions in a process for producing metal oxide nanoparticles using the reaction apparatus shown in FIG. 4.
- FIG. 5 is a diagram illustrating a process for producing metal oxide nanoparticles using the reaction apparatus shown in FIG. 4.
- FIG. 5 is a diagram illustrating a recovery step of metal oxide nanoparticles that is carried out after producing metal oxide nanoparticles using the reaction apparatus shown in FIG. 4.
- FIG. 3 is a diagram showing the results of FT-IR of metal oxide nanoparticles contained in an electronic functional layer provided in the light-emitting element shown in FIG. 2.
- 3 is a diagram showing the particle size distribution of metal oxide nanoparticles contained in an electronic functional layer provided in the light-emitting element shown in FIG. 2.
- FIG. 10 is a graph showing the relationship between current density and luminance of each of the light-emitting elements of Reference Example 1 and Reference Example 2.
- FIG. 1 is a diagram showing the relationship between current density and luminance of the light-emitting element of Example 1 and the light-emitting element of Comparative Example 1.
- FIG. 1 is a diagram showing the relationship between current density and luminance of the light
- FIG. 1 is a plan view showing a schematic configuration of a display device 1 according to the first embodiment.
- the display device 1 has a frame area NDA and a display area DA.
- the display area DA of the display device 1 has a plurality of pixels PIX, each of which includes a red subpixel RSP, a green subpixel GSP, and a blue subpixel BSP.
- PIX pixels PIX
- an example is described in which one pixel PIX is composed of a red subpixel RSP, a green subpixel GSP, and a blue subpixel BSP, but this is not limiting.
- one pixel PIX may include subpixels of other colors in addition to the red subpixel RSP, green subpixel GSP, and blue subpixel BSP.
- FIG. 2 is a cross-sectional view showing the schematic configuration of the light-emitting element 30 provided in the display device 1 of embodiment 1 shown in FIG. 1.
- the red subpixel RSP provided in the display area DA of the display device 1 includes a red light-emitting element in which the light-emitting layer EM in the light-emitting element 30 shown in FIG. 2 is a red light-emitting layer
- the green subpixel GSP provided in the display area DA of the display device 1 includes a green light-emitting element in which the light-emitting layer EM in the light-emitting element 30 shown in FIG. 2 is a green light-emitting layer
- the blue subpixel BSP provided in the display area DA of the display device 1 includes a blue light-emitting element in which the light-emitting layer EM in the light-emitting element 30 shown in FIG. 2 is a blue light-emitting layer.
- the light-emitting element 30 includes an anode 2, a cathode 5, an emitting layer EM provided between the anode 2 and the cathode 5, an electronic functional layer 4 provided between the cathode 5 and the emitting layer EM, and a hole functional layer 3 provided between the anode 2 and the emitting layer EM.
- the light-emitting element 30 is described as including the hole functional layer 3 as an example, but this is not limiting, and the hole functional layer 3 may be omitted as appropriate.
- the hole functional layer 3 may include at least one of a hole transport layer (HTL) and a hole injection layer (HIL).
- the hole injection layer (HIL) may be formed using, for example, a composite of poly(3,4-ethylenedioxythiophene) (PEDOT) and polystyrene sulfonic acid (PSS) (PEDOT:PSS), NiO particles, MoO3 particles, or the like.
- the hole transport layer can be formed using, for example, poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4′-(N-(4-sec-butylphenyl))diphenylamine)] (TFB), N,N′-bis(4-butylphenyl)-N,N′-bis(phenyl)-benzidine (poly-TPD), polyvinylcarbazole (PVK), 4,4′-bis(carbazol-9-yl)biphenyl (CBP), NiO particles, or the like.
- the electronic functional layer 4 is a single layer that functions as an electron transport layer (ETL), an electron injection layer (EIL), and a hole blocking layer (HBL), but this is not limited to this.
- the electronic functional layer 4 may include two or more layers selected from an electron transport layer (ETL), an electron injection layer (EIL), and a hole blocking layer (HBL).
- the electronic functional layer 4 is provided so as to be in contact with both the cathode 5 and the light-emitting layer EM.
- the electronic functional layer 4 provided between the cathode 5 and the light-emitting layer EM contains a plurality of metal oxide nanoparticles each having a core containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf; a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semi-metallic element; zinc; and oxygen.
- the metal oxide nanoparticles contained in the electronic functional layer 4 are nanoparticles with a core structure consisting only of a core containing the first element, the second element, zinc, and oxygen.
- Core-structured nanoparticles differ from core/shell nanoparticles having a core and a shell with a different composition from the core in that they do not have a shell with a different composition from the core.
- semi-metallic elements include B, Si, Ge, As, Sb, and Te.
- the metal oxide nanoparticles contained in the electronic function layer 4 are nanoparticles with a core structure formed by a competitive reaction between molecules containing the first element, molecules containing the second element, and molecules containing zinc, and composed only of a core containing the first element, the second element, zinc, and oxygen. Therefore, their particle size is unlikely to increase in size, and their particle size and particle size variation are small.
- an electronic function layer 4 containing a plurality of metal oxide nanoparticles with such small particle size and particle size variation, or an electronic function layer 4 composed of a plurality of metal oxide nanoparticles with such small particle size and particle size variation can achieve high density and high resistance to the cathode 5 formation process, such as a vapor deposition process or sputtering process, in the cathode 5 formation process, which is a subsequent process of forming the electronic function layer 4. Therefore, a light-emitting element 30 including the electronic function layer 4 can achieve high luminous efficiency.
- metal oxide nanoparticles contained in the electronic functional layer 4 are nanoparticles with a core structure consisting only of a core of a single composition can be confirmed using, for example, time-of-flight secondary ion mass spectrometry (TOF-SIMS), or by performing elemental analysis while gradually etching the metal oxide nanoparticles from the outside.
- TOF-SIMS time-of-flight secondary ion mass spectrometry
- the second element which is an element or semimetal element selected from the non-metal elements mentioned above excluding hydrogen, oxygen, and Group 18 elements, may be any of B, C, N, F, Si, P, S, Cl, Ge, As, Se, Br, Sb, Te, I, and At, and the second element mentioned above may be any of B, Si, Ge, As, Sb, Te, C, N, P, and S.
- the amount of oxygen element is preferably greater than the amount of the first element, the amount of the second element, and the amount of zinc element, and the amount of the second element and the amount of zinc element are preferably greater than the amount of the first element.
- the metal oxide nanoparticles contained in the electronic function layer 4 are described as an example of nanoparticles with a core structure consisting of only a core of a single composition composed of Mg as the first element, Si as the second element, zinc, and oxygen.
- the metal oxide nanoparticles contained in the electronic function layer 4 in this embodiment contain Zn-O bonds, Mg-O bonds, and Si-O bonds.
- a portion of a cross section cut along the thickness direction of the electronic functional layer 4 contains 10 ⁇ N metal oxide nanoparticles (N is a natural number greater than or equal to 2) containing Mg as the first element and Si, zinc, and oxygen as the second elements.
- N is a natural number greater than or equal to 2
- the particle sizes of the 10 ⁇ N metal oxide nanoparticles are arranged in ascending order, it is preferable that the particle size of the 5 ⁇ Nth metal oxide nanoparticle is 1.8 nm or less, and the difference between the particle size of the 9 ⁇ Nth metal oxide nanoparticle and the particle size of the Nth nanoparticle is 2.1 nm or less.
- the particle sizes of the 10 ⁇ N metal oxide nanoparticles can be measured, for example, using a scanning transmission electron microscope (STEM).
- the particle size of the 5 ⁇ Nth metal oxide nanoparticle means the particle size of the metal oxide nanoparticle that is 50% (median) of the particle sizes of the 10 ⁇ N metal oxide nanoparticles arranged in ascending order.
- the particle size of the 9 ⁇ Nth metal oxide nanoparticle means the particle size of the metal oxide nanoparticle that is 90% of the particle sizes of the 10 ⁇ N metal oxide nanoparticles arranged in ascending order.
- the particle size of the Nth metal oxide nanoparticle means the particle size of the metal oxide nanoparticle that corresponds to 10% of the particle sizes of the 10 x N metal oxide nanoparticles arranged in ascending order.
- the light-emitting layer EM provided in the light-emitting element 30 shown in FIG. 2 is described as an example containing quantum dots (QDs), but this is not limited thereto and the light-emitting layer may also contain an organic light-emitting material.
- the quantum dots (QDs) may have, for example, a core structure, a core/shell structure, a core/shell/shell structure, or a shell structure with a continuously varying core/shell ratio.
- the core portion may be composed of, for example, Si or C in the case of a unicomponent system; for example, CdSe, CdS, CdTe, InP, GaP, InN, ZnSe, ZnS, or ZnTe in the case of a ternary system; for example, CdSeTe, GaInP, or ZnSeTe; and for example, AIGS in the case of a quaternary system.
- the shell portion can be composed of, for example, CdS, CdTe, CdSe, ZnS, ZnSe, ZnTe, etc.
- the shell portion can be composed of, for example, CdSSe, CdTeSe, CdSTe, ZnSSe, ZnSTe, ZnTeSe, AIP, etc.
- the light-emitting element 30 shown in Figure 2 may be either a top-emission type or a bottom-emission type.
- the light-emitting element 30 has a stacked structure in which the cathode 5 is disposed above the anode 2.
- the anode 2 should be formed from an electrode material that reflects visible light
- the cathode 5 should be formed from an electrode material that transmits visible light.
- the anode 2 should be formed from an electrode material that transmits visible light
- the cathode 5 should be formed from an electrode material that reflects visible light.
- the electrode material that reflects visible light is not particularly limited as long as it can reflect visible light and is conductive, but examples include metal materials such as Al, Mg, Li, and Ag, alloys of these metal materials, laminates of these metal materials and transparent metal oxides (e.g., indium tin oxide, indium zinc oxide, indium gallium zinc oxide, etc.), and laminates of these alloys and these transparent metal oxides.
- metal materials such as Al, Mg, Li, and Ag, alloys of these metal materials, laminates of these metal materials and transparent metal oxides (e.g., indium tin oxide, indium zinc oxide, indium gallium zinc oxide, etc.), and laminates of these alloys and these transparent metal oxides.
- electrode materials that transmit visible light are not particularly limited as long as they are transparent to visible light and conductive, but examples include transparent metal oxides (e.g., indium tin oxide, indium zinc oxide, indium gallium zinc oxide, etc.), thin films made of metal materials such as Al or Ag, and nanowires made of metal materials such as Al or Ag.
- transparent metal oxides e.g., indium tin oxide, indium zinc oxide, indium gallium zinc oxide, etc.
- thin films made of metal materials such as Al or Ag
- nanowires made of metal materials such as Al or Ag.
- Figure 3 shows an example of a method for manufacturing the light-emitting element 30 shown in Figure 2.
- anode formation process S1 to form the anode 2
- hole functional layer formation process S2 to form the hole functional layer 3
- light-emitting layer formation process S3 to form the light-emitting layer EM
- electronic functional layer formation process S4 to form the electronic functional layer 4
- cathode formation process S5 to form the cathode 5.
- the electronic functional layer 4 is formed, which includes a plurality of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, which are manufactured by the metal oxide nanoparticle manufacturing method described below; a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semimetallic element; zinc; and oxygen.
- the electronic function layer formation step S4 is performed between the light-emitting layer formation step S3 and the cathode formation step S5, and as shown in FIG. 2, the electronic function layer 4 is provided so as to be in contact with both the cathode 5 and the light-emitting layer EM.
- FIG. 4 is a diagram showing the schematic configuration of a reaction apparatus 10 used in the process of producing metal oxide nanoparticles contained in the electronic function layer 4 of the light-emitting element 30 shown in FIG. 2.
- FIG. 5 is a diagram showing an example of process conditions for the process of producing metal oxide nanoparticles using the reaction apparatus 10 shown in FIG. 4.
- FIG. 6 is a diagram illustrating the process of producing metal oxide nanoparticles using the reaction apparatus 10 shown in FIG. 4.
- FIG. 7 is a diagram illustrating the metal oxide nanoparticle recovery process performed after producing metal oxide nanoparticles using the reaction apparatus 10 shown in FIG. 4.
- FIG. 8 is a diagram showing the results of FT-IR of metal oxide nanoparticles contained in the electronic function layer 4 of the light-emitting element 30 shown in FIG. 2.
- FIG. 9 is a diagram showing the particle size distribution of metal oxide nanoparticles contained in the electronic function layer 4 of the light-emitting element 10 shown in FIG. 2.
- the reaction apparatus includes a micromixer that mixes and discharges a first precursor of metal oxide nanoparticles containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second precursor of metal oxide nanoparticles containing a second element that is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semi-metallic element, a third precursor of metal oxide nanoparticles containing zinc, and a reactant, all supplied from the outside; a microchannel having a supply end on one side and a discharge end on the other side, and into which the fluid discharged from the micromixer is supplied from the supply end; and a microreactor that controls the reaction conditions in at least a portion of the microchannel.
- a micromixer that mixes and discharges a first precursor of metal oxide nanoparticles containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al,
- the reaction apparatus described above is the reaction apparatus 10 shown in FIG. 4, and an example will be given of the production of metal oxide nanoparticles having a core structure consisting only of a core containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element, zinc, and oxygen, but the present invention is not limited to this.
- the reaction apparatus 10 is equipped with a micromixer including a first micromixer 16 including a first supply port Inlet1, a second supply port Inlet2, and a first outlet Outlet1, and a second micromixer 19 including a third supply port Inlet3, a fourth supply port Inlet4, and a second outlet Outlet2, and the fluid discharged from the first outlet Outlet1 is supplied from the third supply port Inlet3, and the fluid discharged from the second outlet Outlet2 is supplied from the supply end of the microchannel 20.
- a micromixer including a first micromixer 16 including a first supply port Inlet1, a second supply port Inlet2, and a first outlet Outlet1, and a second micromixer 19 including a third supply port Inlet3, a fourth supply port Inlet4, and a second outlet Outlet2, and the fluid discharged from the first outlet Outlet1 is supplied from the third supply port Inlet3, and the fluid discharged from the second outlet Outlet2 is supplied from the supply end of the microchannel 20.
- the reaction apparatus 10 further includes a first supply unit 11 configured to supply a first solution containing a first precursor of metal oxide nanoparticles containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a third precursor of metal oxide nanoparticles containing zinc, and a first solvent to one of the first supply port Inlet1, the second supply port Inlet2, and the fourth supply port Inlet4 at a first flow rate; a second supply unit 12 that supplies a second solution containing the reactant and a second solvent at a second flow rate to another one of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4; and a third supply unit 13 that supplies a third solution containing a third solvent and a second precursor of metal oxide nanoparticles containing a second element, the second element being a semi-metallic element or an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements, to yet another one
- the reaction apparatus 10 includes a microchannel 20 having one end as a supply end and the other end as a discharge end, to which a fluid discharged from the second discharge port Outlet 2 of the second micromixer 19 is supplied from the supply end, and a microreactor 21 that controls the reaction conditions in at least a portion of the microchannel 20.
- TMAH.5H 2 O tetramethylammonium hydroxide
- a second precursor of metal oxide nanoparticles containing a second element which is an element selected from nonmetallic elements excluding hydrogen, oxygen, and Group 18 elements, or a semimetallic element, is supplied from a first supply unit 11 to a first supply port Inlet 1 at a first flow rate.
- a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf
- a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semi-metallic element, zinc, and oxygen.
- the reaction apparatus 10 further includes a first supply flow path 14 connecting a first supply port Inlet 1 of the first micromixer 16 to an outlet of the first supply unit 11, a second supply flow path 15 connecting a second supply port Inlet 2 of the first micromixer 16 to an outlet of the second supply unit 12, a third supply flow path 17 connecting a first outlet Outlet 1 of the first micromixer 16 to a third supply port Inlet 3 of the second micromixer 19, a fourth supply flow path 18 connecting a fourth supply port Inlet 4 of the second micromixer 19 to an outlet of the third supply unit 13, and a recovery unit 22 for recovering a fluid discharged from an outlet end of the microchannel 20.
- the first supply flow path 14 and the second supply flow path 15 are preferably the same supply flow path having the same flow path diameter and flow path length, and the third supply flow path 17 and the fourth supply flow path 18 are preferably the same supply flow path having the same flow path diameter and flow path length.
- the reaction apparatus 10 when the outlet of the first supply unit 11 is directly connected to the first supply port Inlet 1 of the first micromixer 16, the reaction apparatus 10 does not need to have the first supply flow path 14, when the outlet of the second supply unit 12 is directly connected to the second supply port Inlet 2 of the first micromixer 16, the reaction apparatus 10 does not need to have the second supply flow path 15, when the outlet of the third supply unit 13 is directly connected to the fourth supply port Inlet 4 of the second micromixer 19, the reaction apparatus 10 does not need to have the fourth supply flow path 18, and when the first outlet Outlet 1 of the first micromixer 16 and the third supply port Inlet 3 of the second micromixer 19 are directly connected, the reaction apparatus 10 does not need to have the third supply flow path 17.
- the reaction apparatus 10 does not need to have the recovery unit 22, and in this case, the user of the reaction apparatus 10 can prepare the recovery unit 22.
- the microreactor 21 that controls the reaction conditions in at least a part of the microchannel 20 controls, for example, the temperature of a part of the microchannel 20 to an optimum temperature for the reaction of the fluid flowing in the microchannel 20 .
- magnesium acetate is used as the first precursor
- TEOS Tetraethyl orthosilicate
- zinc acetate is used as the third precursor.
- the first solution may be supplied from the first supply unit 11 at a first flow rate to one of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4, the second solution may be supplied from the second supply unit 12 at a second flow rate to the other of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4, and the third solution may be supplied from the third supply unit 13 at a third flow rate to the other of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4.
- the reactor 10 includes a T-shaped first micromixer 16 and a T-shaped second micromixer 19 in a planar view.
- the T-shaped first micromixer 16 and the T-shaped second micromixer 19 can realize a flow microreactor-type special reaction field that utilizes turbulence in a planar view.
- the reactor 10 includes a T-shaped first micromixer 16 and a T-shaped second micromixer 19 in a planar view.
- the reactor 10 may include, for example, a V-shaped micromixer in a planar view instead of at least one of the T-shaped first micromixer 16 and the T-shaped second micromixer 19.
- a V-shaped micromixer in a planar view can also realize a flow microreactor-type special reaction field that utilizes turbulence.
- the reaction apparatus 10 may be equipped with, for example, a linear micromixer instead of at least one of the T-shaped first micromixer 16 and the T-shaped second micromixer 19.
- a linear micromixer can realize a special reaction field of the flow microreactor type in which fluids supplied from two supply ports flow in parallel.
- the amounts of zinc acetate and magnesium acetate were adjusted so that the concentration ratio of Mg 2+ to Zn 2+ was 15:85, and the amounts of zinc acetate and magnesium acetate and the amount of dimethyl sulfoxide (DMSO) as the first solvent were adjusted so that the concentration of the first solution was 0.1 M.
- TMAH.5H 2 O tetramethylammonium hydroxide
- ethanol which is the second solvent
- the molar ratio of Mg 2+ and Zn 2+ in the first solution to tetramethylammonium hydroxide (e.g., TMAH.5H 2 O) in the second solution was adjusted to 1:1.3.
- tetraethoxysilane (TEOS (Tetraethyl) tetraethoxysilane
- the flow rates of the first solution, the second solution, and the third solution can be appropriately determined taking into account the amount of metal oxide nanoparticles to be obtained as the final product.
- the flow rates of the first solution were 12.6 mL, the second solution 6.552 mL, and the third solution 16 mL.
- the first supply unit 11 supplied the first solution at a first flow rate, e.g., 9 mL/h
- the second supply unit 12 supplied the second solution at a second flow rate, e.g., 4.68 mL/h
- the third supply unit 13 supplied the third solution at a third flow rate, e.g., 11.5 mL/h.
- the method for producing metal oxide nanoparticles includes, as described above, step S11 of preparing a first solution having a predetermined concentration A (0.1 M in this embodiment), a second solution having a predetermined concentration B (0.25 M in this embodiment), and a third solution having a predetermined concentration C (0.169 M in this embodiment); step S12 of supplying the first solution to the first supply port Inlet 1 of the first micromixer 16 at a predetermined flow rate D (9 ml/h in this embodiment), supplying the second solution to the second supply port Inlet 2 of the first micromixer 16 at a predetermined flow rate E (4.68 ml/h in this embodiment), and supplying the third solution to the fourth supply port Inlet 4 of the second micromixer 19 at a predetermined flow rate F (11.5 ml/h in this embodiment); and step S13 of recovering the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si produced from the discharge end of the microchannel 20.
- step S13 of recovering the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si it is preferable to separately recover the fluid discharged from the discharge end of the microchannel 20 during the initial fixed period and the final fixed period, and to recover only the fluid discharged from the discharge end of the microchannel 20 during an intermediate period other than the above periods as a dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si.
- the method for producing metal oxide nanoparticles preferably further includes step S21 of transferring the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si recovered in step S13 shown in Figure 6 to a centrifuge tube and adding a poor solvent (e.g., ethyl acetate) to precipitate ultranano-sized oxide nanoparticles containing Mg, Zn, and Si, step S22 of separating the solids from the solution by centrifugation, and step S23 of removing the supernatant (e.g., a mixture of the reactants dimethyl sulfoxide (DMSO) and ethanol (EtOH)).
- a poor solvent e.g., ethyl acetate
- the method for producing metal oxide nanoparticles may further include step S24 of removing the solution containing the supernatant and redispersing the solids (ultranano-sized oxide nanoparticles containing Mg, Zn, and Si) in a solvent (e.g., ethanol or butanol) to prepare a redispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si in step S23 shown in FIG. 7 .
- a solvent e.g., ethanol or butanol
- This method allows for the production of a redispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si redispersed in a desired specific solvent. Furthermore, in the step of preparing the redispersion, an organic ligand such as monoethanolamine (MEA) may be added to further improve dispersibility.
- MEA monoethanolamine
- the FT-IR results for the ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si contained in the electronic function layer 4 of the light-emitting element 30 shown in Figure 2 showed absorption at the wavenumbers corresponding to Zn-O bonds, Mg-O bonds, and Si-O bonds, respectively, confirming that the ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si contain Zn-O bonds, Mg-O bonds, and Si-O bonds.
- Figure 9 shows the results of measuring the particle size distribution using a redispersion of metal oxide nanoparticles produced using the reaction apparatus 10 shown in Figure 4, i.e., the ultranano-sized oxide nanoparticles containing Mg, Zn, and Si described above.
- the redispersion here is a solution in which ultranano-sized oxide nanoparticles containing Mg, Zn, and Si are dispersed in ethanol, which is a solvent.
- the particle size of the metal oxide nanoparticles at particle size cumulative 50% (D50) in a redispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si was 1.76 nm, less than 1.80 nm. Furthermore, the difference in particle size between the metal oxide nanoparticles at particle size cumulative 90% (D90) and particle size cumulative 10% (D10) in a redispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si was 2.05 nm, less than 2.10 nm.
- the particle size distribution shown in Figure 9 was measured using DLS (dynamic light scattering) using a Nanotrac wave II manufactured by Microtaract.
- ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si are produced using the reaction apparatus 10 under the conditions shown in Figure 5.
- the particle size of metal oxide nanoparticles at 50% cumulative particle size (D50) is 1.76 nm
- the difference between the particle size of metal oxide nanoparticles at 90% cumulative particle size (D90) and the particle size of metal oxide nanoparticles at 10% cumulative particle size (D10) is 2.05 nm, but this is not limited to this.
- the time that the fluid discharged from the second outlet Outlet 2 of the second micromixer 19 remains in a portion of the microchannel 20 where the reaction conditions are controlled by the microreactor 21 can be adjusted.
- the particle size of the metal oxide nanoparticles at 50% cumulative particle size (D50) in the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si recovered in step S13 shown in Figure 6 was also 1.80 nm or less. Furthermore, the difference in particle size between the metal oxide nanoparticles at 90% cumulative particle size (D90) and the metal oxide nanoparticles at 10% cumulative particle size (D10) in the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si recovered in step S13 shown in Figure 6 was also 2.10 nm or less.
- the ultranano-sized oxide nanoparticles containing Mg, Zn, and Si produced using the reaction apparatus 10 have small particle sizes and particle size variations.
- the ability to produce ultranano-sized oxide nanoparticles containing Mg, Zn, and Si with small particle sizes and particle size variations is believed to be due to the fact that the first solution, second solution, and third solution constantly flow and react to produce oxide nanoparticles with an ultranano-sized core structure containing Mg, Zn, and Si, and the competitive reactions between molecules containing Mg, molecules containing Si, and molecules containing Zn produce oxide nanoparticles with an ultranano-sized core structure containing Mg, Zn, and Si.
- Figure 10 shows the relationship between current density and luminance for the light-emitting element of Reference Example 1 and the light-emitting element of Reference Example 2, i.e., the approximate luminous efficiency. Note that while the results using a red light-emitting element are shown here as an example, similar results can be obtained with green and blue light-emitting elements.
- the light-emitting element (red light-emitting element) of Reference Example 1 shown in Figure 10 is a light-emitting element formed in this order: an anode made of Ag; a hole injection layer made of nickel oxide nanoparticles; a hole transport layer made of poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4'-(N-(4-sec-butylphenyl))diphenylamine)] (TFB); a light-emitting layer containing InP as red-emitting quantum dots; an electron transport layer that is an electronic functional layer made of zinc oxide nanoparticles; and a cathode made of ITO (indium tin oxide).
- ITO indium tin oxide
- the electron transport layer which is an electronic functional layer formed from such zinc oxide nanoparticles and provided in the light-emitting element (red light-emitting element) of Reference Example 1, lacks density and is therefore not highly resistant to the cathode formation process, such as the vapor deposition or sputtering process, that occurs in the cathode formation step, which is a step that follows the electron transport layer formation step.
- the light-emitting element (red light-emitting element) of Reference Example 1 does not achieve satisfactory luminous efficiency.
- the light-emitting element (red light-emitting element) of Reference Example 2 shown in Figure 10 is a light-emitting element in which an anode made of Ag, a hole injection layer made of nickel oxide nanoparticles, a hole transport layer made of poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4'-(N-(4-sec-butylphenyl))diphenylamine)] (TFB) are stacked in this order, a light-emitting layer containing InP as red-emitting quantum dots, an electron transport layer which is an electronic functional layer made of a material that is a mixture of zinc oxide nanoparticles and PVP (polyvinylpyrrolidone), and a cathode made of ITO (indium tin oxide).
- anode made of Ag a hole injection layer made of nickel oxide nanoparticles
- a hole transport layer made of poly[(9,9-d
- each layer was formed to have the same film thickness, and each of the layers other than the electron transport layer, which is the electronic functional layer (anode, hole injection layer, hole transport layer, light-emitting layer containing red-emitting quantum dots, and cathode) was formed using the same material with the same composition.
- the electron transport layer which is the electronic functional layer of Comparative Example 2 and is formed from a material that is a mixture of zinc oxide nanoparticles and PVP (polyvinylpyrrolidone), has slightly improved density compared to the electron transport layer, which is the electronic functional layer of Comparative Example 1.
- a red light-emitting device equipped with the electron transport layer, which is the electronic functional layer of Comparative Example 2 can achieve a slightly improved luminous efficiency.
- an organic-inorganic hybrid electron transport layer such as the electron transport layer, which is the electronic functional layer of Comparative Example 2 and is formed from a material that is a mixture of zinc oxide nanoparticles and PVP (polyvinylpyrrolidone)
- PVP polyvinylpyrrolidone
- Figure 11 shows the relationship between current density and luminance for the light-emitting element of Example 1 and the light-emitting element of Comparative Example 1, i.e., the approximate luminous efficiency. Note that while the results using a blue light-emitting element are shown here as an example, similar results can be obtained with red and green light-emitting elements.
- the light-emitting element (blue light-emitting element) of Comparative Example 1 shown in Figure 11 is a light-emitting element formed in this order: an anode made of Ag; a hole injection layer made of nickel oxide nanoparticles; a hole transport layer made of poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4'-(N-(4-sec-butylphenyl))diphenylamine)] (TFB); a light-emitting layer containing ZnSe as blue-emitting quantum dots; an electron transport layer, which is the electronic functional layer of Comparative Example 2, made of a material mixture of zinc oxide nanoparticles and PVP (polyvinylpyrrolidone); and a cathode made of ITO (indium tin oxide).
- the light-emitting element of Comparative Example 1 blue light-emitting element
- Reference Example 2 red light-emitting element
- the light-emitting element (blue light-emitting element) of Example 1 shown in Figure 11 is a light-emitting element in which an anode made of Ag, a hole injection layer made of nickel oxide nanoparticles, a hole transport layer made of poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4'-(N-(4-sec-butylphenyl))diphenylamine)] (TFB), a light-emitting layer containing ZnSe as blue-emitting quantum dots, an electron transport layer which is electronic functional layer 4 of Example 1 made of oxide nanoparticles with an ultra-nano-sized core structure containing Mg, Zn, and Si as described above, and a cathode made of ITO (indium tin oxide) are stacked in this order.
- anode made of Ag a hole injection layer made of nickel oxide nanoparticles
- a hole transport layer made of poly[(
- each layer was formed to have the same film thickness, and each of the layers other than the electron transport layer, which is the electronic functional layer (anode, hole injection layer, hole transport layer, light-emitting layer containing blue-emitting quantum dots, and cathode) were formed using the same materials with the same composition.
- the electron transport layer which is the electronic functional layer (anode, hole injection layer, hole transport layer, light-emitting layer containing blue-emitting quantum dots, and cathode) were formed using the same materials with the same composition.
- the blue light-emitting device having the electron transport layer as the electronic functional layer 4 of Example 1 achieved a significantly improved and satisfactorily high luminous efficiency compared to the blue light-emitting device having the electron transport layer as the electronic functional layer of Comparative Example 2.
- the ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si contained in the electron transport layer as the electronic functional layer 4 have small particle size and particle size variation, allowing for high density and high resistance to the cathode formation process, such as the vapor deposition process or sputtering process, in the cathode formation step, which is a step subsequent to the step of forming the electron transport layer, and light-emitting devices having the electron transport layer as the electronic functional layer 4 can achieve high luminous efficiency.
- the metal oxide nanoparticle group is composed of a group of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf; a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element; and zinc and oxygen.
- the particle size of the metal oxide nanoparticles at a cumulative 50% (D50) particle size may be 1.80 nm or less, and the difference between the particle size of the metal oxide nanoparticles at a cumulative 90% (D90) particle size and the particle size of the metal oxide nanoparticles at a cumulative 10% (D10) particle size may be 2.10 nm or less.
- the second element may be any of B, Si, Ge, As, Sb, Te, C, N, P, and S. Furthermore, it is preferable that, per unit volume of the metal oxide nanoparticles, the amount of oxygen element is greater than the amount of the first element, the amount of the second element, and the amount of zinc element, and that the amount of the second element and the amount of zinc element are each greater than the amount of the first element.
- the first element may be Mg and the second element may be Si, in which case the metal oxide nanoparticles contain Zn—O bonds, Mg—O bonds, and Si—O bonds.
- the present disclosure can be used in light-emitting devices, methods for manufacturing light-emitting devices, display devices, metal oxide nanoparticle groups, dispersions of metal oxide nanoparticles, and methods for manufacturing metal oxide nanoparticles.
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Abstract
Description
本開示の一態様は、発光素子と、発光素子の製造方法と、表示装置と、金属酸化物ナノ粒子群と、金属酸化物ナノ粒子の分散液と、金属酸化物ナノ粒子の製造方法とに関する。 One aspect of the present disclosure relates to a light-emitting element, a method for manufacturing a light-emitting element, a display device, a group of metal oxide nanoparticles, a dispersion of metal oxide nanoparticles, and a method for manufacturing metal oxide nanoparticles.
近年、発光素子を備えた様々な表示装置が開発されており、特に、OLED(Organic Light Emitting Diode:有機発光ダイオード)または、QLED(Quantum dot Light Emitting Diode:量子ドット発光ダイオード)を備えた表示装置は、低消費電力化、薄型化及び高画質化などを実現できる点から、高い注目を浴びている。 In recent years, a variety of display devices equipped with light-emitting elements have been developed, and display devices equipped with OLEDs (Organic Light Emitting Diodes) or QLEDs (Quantum Dot Light Emitting Diodes) in particular have attracted considerable attention due to their ability to achieve low power consumption, thinness, and high image quality.
特許文献1には、酸化亜鉛のナノ粒子または酸化マグネシウム亜鉛のナノ粒子のみで形成した電子輸送層や電子注入層などの電子機能層を備えたOLEDまたはQLEDについて記載されている。 Patent Document 1 describes an OLED or QLED equipped with electronic functional layers, such as an electron transport layer or an electron injection layer, formed solely from zinc oxide nanoparticles or magnesium zinc oxide nanoparticles.
しかしながら、特許文献1に開示されているように、酸化亜鉛のナノ粒子または酸化マグネシウム亜鉛のナノ粒子のみで形成した電子輸送層や電子注入層などの電子機能層は、電子機能層を形成する工程の後工程であるカソードを形成する工程におけるカソードの成膜プロセス、例えば、蒸着工程またはスパッタリング工程に対する耐性が高くなく、カソードを形成する工程後には、電子機能層の下層である発光層までもダメージを受け、発光効率が著しく低下することが報告されている。酸化亜鉛のナノ粒子または酸化マグネシウム亜鉛のナノ粒子は、その粒径のばらつきが比較的大きく、これが原因で、酸化亜鉛のナノ粒子または酸化マグネシウム亜鉛のナノ粒子のみで形成した電子機能層は緻密性が不足するため、電子機能層の下層である発光層の保護が不十分になってしまう。 However, as disclosed in Patent Document 1, electronic functional layers such as electron transport layers and electron injection layers formed solely from zinc oxide nanoparticles or magnesium zinc oxide nanoparticles do not have high resistance to the cathode formation process, such as the vapor deposition or sputtering process, that occurs in the cathode formation step, which is a subsequent step in forming the electronic functional layer. It has been reported that even the light-emitting layer below the electronic functional layer is damaged after the cathode formation step, resulting in a significant decrease in luminous efficiency. Zinc oxide nanoparticles or magnesium zinc oxide nanoparticles have relatively large particle size variations, and as a result, electronic functional layers formed solely from zinc oxide nanoparticles or magnesium zinc oxide nanoparticles lack density, resulting in insufficient protection of the light-emitting layer below the electronic functional layer.
そこで、酸化亜鉛のナノ粒子または酸化マグネシウム亜鉛のナノ粒子に、バインダーとして機能することが期待できるPVP(ポリビニルピロリドン)などの高分子有機材料を混合した材料を用いて電子輸送層や電子注入層などの電子機能層を形成することが考えられる。しかしながら、酸化亜鉛のナノ粒子または酸化マグネシウム亜鉛のナノ粒子に、高分子有機材料を混合した有機無機ハイブリッド状態の電子機能層は、非常に安定性が悪く、電子機能層を形成する工程において、有機材料と無機材料が相分離してしまうなどの問題があり、酸化亜鉛のナノ粒子または酸化マグネシウム亜鉛のナノ粒子のみで形成した電子機能層に比べると若干の緻密性の改善により若干の発光効率の改善は実現できるが、酸化亜鉛のナノ粒子または酸化マグネシウム亜鉛のナノ粒子が有するそもそもの粒径のばらつきの大きさの影響により、依然として、満足できる程の高い緻密性が得られず、有機無機ハイブリッド状態の電子機能層を備えた発光素子においても満足できる程の高い発光効率が得られないという問題がある。 Therefore, it is conceivable to form electronic functional layers such as electron transport layers and electron injection layers using a material in which zinc oxide nanoparticles or magnesium zinc oxide nanoparticles are mixed with a polymeric organic material such as PVP (polyvinylpyrrolidone), which is expected to function as a binder. However, organic-inorganic hybrid electronic functional layers in which zinc oxide nanoparticles or magnesium zinc oxide nanoparticles are mixed with a polymeric organic material are very unstable, and problems such as phase separation between the organic and inorganic materials occur during the process of forming the electronic functional layer. While slight improvements in density can be achieved compared to electronic functional layers formed only with zinc oxide nanoparticles or magnesium zinc oxide nanoparticles, a satisfactory level of density is still not achieved due to the large variation in particle size inherent in zinc oxide nanoparticles or magnesium zinc oxide nanoparticles. Therefore, there is a problem in that a satisfactory level of luminous efficiency cannot be achieved even in light-emitting devices equipped with an organic-inorganic hybrid electronic functional layer.
本開示の一態様は、粒径及び粒径のばらつきが小さい金属酸化物ナノ粒子群及び金属酸化物ナノ粒子の製造方法と、発光効率が高い発光素子及びその製造方法等を提供することを目的とする。 One aspect of the present disclosure aims to provide metal oxide nanoparticles with small particle size and particle size variation, a method for manufacturing metal oxide nanoparticles, a light-emitting element with high luminous efficiency, and a method for manufacturing the same.
本開示の発光素子は、前記の課題を解決するために、
アノードと、
カソードと、
前記アノードと前記カソードとの間に備えられた発光層と、
前記カソードと前記発光層との間に備えられた電子機能層と、を含み、
前記電子機能層は、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子を複数個含む。
In order to solve the above problems, the light-emitting device of the present disclosure has the following features:
an anode;
a cathode;
a light-emitting layer disposed between the anode and the cathode;
an electronic functional layer disposed between the cathode and the light-emitting layer;
The electronic functional layer includes a plurality of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements, or a semi-metallic element, zinc, and oxygen.
本開示の表示装置は、前記の課題を解決するために、
前記発光素子を複数個含む、表示装置。
In order to solve the above problems, the display device of the present disclosure comprises:
A display device comprising a plurality of the light-emitting elements.
本開示の金属酸化物ナノ粒子群は、前記の課題を解決するために、
Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子の群からなる。
In order to solve the above problems, the metal oxide nanoparticles of the present disclosure are
The nanoparticles are made of a group of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements, or a semi-metallic element, zinc, and oxygen.
本開示の金属酸化物ナノ粒子の分散液は、前記の課題を解決するために、
前記金属酸化物ナノ粒子群と溶媒とを含む。
In order to solve the above problems, the dispersion of metal oxide nanoparticles of the present disclosure has the following features:
The metal oxide nanoparticles and a solvent are included.
本開示の金属酸化物ナノ粒子の製造方法は、前記の課題を解決するために、
外部から供給される、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素を含む金属酸化物ナノ粒子の第1前駆体と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素を含む金属酸化物ナノ粒子の第2前駆体と、亜鉛元素を含む金属酸化物ナノ粒子の第3前駆体と、反応剤とを、混合して排出するマイクロミキサーと、
一方側の端部が供給端部であり、他方側の端部が排出端部であり、前記マイクロミキサーから排出された流体が前記供給端部から供給されるマイクロチャネルと、
前記マイクロチャネルの少なくとも一部の反応条件を制御するマイクロリアクターと、を含む反応装置を用いて、前記第1元素と、前記第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子を製造する。
In order to solve the above-mentioned problems, the method for producing metal oxide nanoparticles of the present disclosure includes the steps of:
a micromixer that mixes and discharges a first precursor of metal oxide nanoparticles that contains a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second precursor of metal oxide nanoparticles that contains a second element that is an element selected from non-metal elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element, a third precursor of metal oxide nanoparticles that contains zinc, and a reactant, all of which are supplied from the outside;
a microchannel having a supply end at one end and a discharge end at the other end, the microchannel receiving the fluid discharged from the micromixer from the supply end;
and a microreactor that controls the reaction conditions in at least a portion of the microchannel, to produce metal oxide nanoparticles having a core that contains the first element, the second element, zinc, and oxygen.
本開示の発光素子の製造方法は、前記の課題を解決するために、
アノードを形成するアノード形成工程と、
前記アノード形成工程よりも後に行われるカソードを形成するカソード形成工程と、
前記アノード形成工程と前記カソード形成工程との間に行われる発光層を形成する発光層形成工程と、
前記発光層形成工程と前記カソード形成工程との間に行われる電子機能層を形成する電子機能層形成工程と、を含み、
前記電子機能層形成工程においては、前記金属酸化物ナノ粒子の製造方法によって製造された金属酸化物ナノ粒子を含む前記電子機能層を形成する。
In order to solve the above-mentioned problems, the method for manufacturing a light-emitting element according to the present disclosure includes the steps of:
an anode formation step of forming an anode;
a cathode forming step of forming a cathode, which is performed after the anode forming step;
a light-emitting layer forming step of forming a light-emitting layer, which is carried out between the anode forming step and the cathode forming step;
an electronic functional layer forming step of forming an electronic functional layer, which is performed between the light-emitting layer forming step and the cathode forming step;
In the electronic functional layer forming step, the electronic functional layer is formed, which contains metal oxide nanoparticles produced by the method for producing metal oxide nanoparticles.
本開示の一態様によれば、粒径及び粒径のばらつきが小さい金属酸化物ナノ粒子群及び金属酸化物ナノ粒子の製造方法と、発光効率が高い発光素子及びその製造方法等を提供できる。 One aspect of the present disclosure provides metal oxide nanoparticle groups and methods for producing metal oxide nanoparticles with small particle size and particle size variation, as well as light-emitting devices with high luminous efficiency and methods for producing the same.
本開示の実施の形態について、図1から図11に基づいて説明すれば、次の通りである。以下、説明の便宜上、特定の実施形態にて説明した構成と同一の機能を有する構成については、同一の符号を付記し、その説明を省略する場合がある。 The following describes an embodiment of the present disclosure with reference to Figures 1 to 11. For ease of explanation, components having the same functions as those described in specific embodiments will be denoted by the same reference numerals, and their description may be omitted.
〔実施形態1〕
図1は、実施形態1の表示装置1の概略的な構成を示す平面図である。
[Embodiment 1]
FIG. 1 is a plan view showing a schematic configuration of a display device 1 according to the first embodiment.
図1に示すように、表示装置1は、額縁領域NDAと、表示領域DAとを備えている。表示装置1の表示領域DAには、複数の画素PIXが備えられており、各画素PIXは、それぞれ、赤色サブ画素RSPと、緑色サブ画素GSPと、青色サブ画素BSPとを含む。本実施形態においては、1画素PIXが、赤色サブ画素RSPと、緑色サブ画素GSPと、青色サブ画素BSPとで構成される場合を一例に挙げて説明するが、これに限定されることはない。例えば、1画素PIXは、赤色サブ画素RSP、緑色サブ画素GSP及び青色サブ画素BSPの他に、さらに他の色のサブ画素を含んでいてもよい。 As shown in FIG. 1, the display device 1 has a frame area NDA and a display area DA. The display area DA of the display device 1 has a plurality of pixels PIX, each of which includes a red subpixel RSP, a green subpixel GSP, and a blue subpixel BSP. In this embodiment, an example is described in which one pixel PIX is composed of a red subpixel RSP, a green subpixel GSP, and a blue subpixel BSP, but this is not limiting. For example, one pixel PIX may include subpixels of other colors in addition to the red subpixel RSP, green subpixel GSP, and blue subpixel BSP.
図2は、図1に示す実施形態1の表示装置1に備えられた発光素子30の概略的な構成を示す断面図である。 FIG. 2 is a cross-sectional view showing the schematic configuration of the light-emitting element 30 provided in the display device 1 of embodiment 1 shown in FIG. 1.
表示装置1の表示領域DAに備えられた赤色サブ画素RSPは図2に示す発光素子30において発光層EMが赤色発光層である赤色発光素子を含み、表示装置1の表示領域DAに備えられた緑色サブ画素GSPは図2に示す発光素子30において発光層EMが緑色発光層である緑色発光素子を含み、表示装置1の表示領域DAに備えられた青色サブ画素BSPは図2に示す発光素子30において発光層EMが青色発光層である青色発光素子を含む。 The red subpixel RSP provided in the display area DA of the display device 1 includes a red light-emitting element in which the light-emitting layer EM in the light-emitting element 30 shown in FIG. 2 is a red light-emitting layer, the green subpixel GSP provided in the display area DA of the display device 1 includes a green light-emitting element in which the light-emitting layer EM in the light-emitting element 30 shown in FIG. 2 is a green light-emitting layer, and the blue subpixel BSP provided in the display area DA of the display device 1 includes a blue light-emitting element in which the light-emitting layer EM in the light-emitting element 30 shown in FIG. 2 is a blue light-emitting layer.
図2に示すように、発光素子30は、アノード2と、カソード5と、アノード2とカソード5との間に備えられた発光層EMと、カソード5と発光層EMとの間に備えられた電子機能層4と、アノード2と発光層EMとの間に備えられた正孔機能層3と、を含む。本実施形態においては、発光素子30が正孔機能層3を備えている場合を一例に挙げて説明するが、これに限定されることはなく、正孔機能層3は適宜省いてもよい。 As shown in FIG. 2, the light-emitting element 30 includes an anode 2, a cathode 5, an emitting layer EM provided between the anode 2 and the cathode 5, an electronic functional layer 4 provided between the cathode 5 and the emitting layer EM, and a hole functional layer 3 provided between the anode 2 and the emitting layer EM. In this embodiment, the light-emitting element 30 is described as including the hole functional layer 3 as an example, but this is not limiting, and the hole functional layer 3 may be omitted as appropriate.
正孔機能層3は、正孔輸送層(HTL)及び正孔注入層(HIL)の少なくとも一方を備えていればよい。正孔注入層(HIL)は、例えば、ポリ(3,4-エチレンジオキシチオフェン)(PEDOT)とポリスチレンスルホン酸(PSS)との複合物(PEDOT:PSS)、NiO粒子、MoO3粒子などを用いて形成することができる。正孔輸送層(HTL)は、例えば、ポリ[(9,9-ジオクチルフルオレニル-2,7-ジイル)-co-(4,4’-(N-(4-sec-ブチルフェニル))ジフェニルアミン)](TFB)、N,N’-ビス(4-ブチルフェニル)-N,N’-ビス(フェニル)-ベンジジン(poly-TPD)またはポリビニルカルバゾール(PVK)、4,4’-ビス(カルバゾール-9-イル)ビフェニル(CBP)、NiO粒子などを用いて形成することができる。 The hole functional layer 3 may include at least one of a hole transport layer (HTL) and a hole injection layer (HIL). The hole injection layer (HIL) may be formed using, for example, a composite of poly(3,4-ethylenedioxythiophene) (PEDOT) and polystyrene sulfonic acid (PSS) (PEDOT:PSS), NiO particles, MoO3 particles, or the like. The hole transport layer (HTL) can be formed using, for example, poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4′-(N-(4-sec-butylphenyl))diphenylamine)] (TFB), N,N′-bis(4-butylphenyl)-N,N′-bis(phenyl)-benzidine (poly-TPD), polyvinylcarbazole (PVK), 4,4′-bis(carbazol-9-yl)biphenyl (CBP), NiO particles, or the like.
本実施形態においては、電子機能層4が、一つの層で、電子輸送層(ETL)、電子注入層(EIL)及び正孔ブロック層(HBL)として機能する場合を一例に挙げて説明するが、これに限定されることはなく、例えば、電子機能層4は、電子輸送層(ETL)、電子注入層(EIL)及び正孔ブロック層(HBL)から選択された2層以上を備えていてもよい。本実施形態においては、図2に示すように、電子機能層4は、カソード5及び発光層EMの両方と接するように設けられている。 In this embodiment, an example will be described in which the electronic functional layer 4 is a single layer that functions as an electron transport layer (ETL), an electron injection layer (EIL), and a hole blocking layer (HBL), but this is not limited to this. For example, the electronic functional layer 4 may include two or more layers selected from an electron transport layer (ETL), an electron injection layer (EIL), and a hole blocking layer (HBL). In this embodiment, as shown in FIG. 2, the electronic functional layer 4 is provided so as to be in contact with both the cathode 5 and the light-emitting layer EM.
図2に示すように、カソード5と発光層EMとの間に備えられた電子機能層4は、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子を複数個含む。すなわち、電子機能層4に含まれる金属酸化物ナノ粒子は、前記第1元素と、前記第2元素と、亜鉛元素と、酸素元素とを含むコアのみで構成されたコア構造のナノ粒子である。コア構造のナノ粒子は、コアとは異なる組成で設けられたシェルを有さない点において、コアとコアの外側にコアとは異なる組成で設けられるシェルとを有するコア/シェル構造のナノ粒子とは異なる。なお、半金属元素とは、例えば、B、Si、Ge、As、Sb及びTeなどを意味する。また、電子機能層4に含まれる金属酸化物ナノ粒子は、前記第1元素を含む分子と、前記第2元素を含む分子と、亜鉛元素を含む分子との競争反応で形成された前記第1元素と、前記第2元素と、亜鉛元素と、酸素元素とを含むコアのみで構成されたコア構造のナノ粒子であるので、粒径がそもそも大きくなりにくく、粒径及び粒径のばらつきが小さい。したがって、このように粒径及び粒径のばらつきが小さい複数個の金属酸化物ナノ粒子を含む電子機能層4または、このように粒径及び粒径のばらつきが小さい複数個の金属酸化物ナノ粒子で構成された電子機能層4は、高い緻密性を実現することができ、電子機能層4を形成する工程の後工程であるカソード5を形成する工程におけるカソード5の成膜プロセス、例えば、蒸着工程またはスパッタリング工程に対する耐性が高く、電子機能層4を備えた発光素子30は、高い発光効率を実現することができる。 As shown in FIG. 2, the electronic functional layer 4 provided between the cathode 5 and the light-emitting layer EM contains a plurality of metal oxide nanoparticles each having a core containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf; a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semi-metallic element; zinc; and oxygen. In other words, the metal oxide nanoparticles contained in the electronic functional layer 4 are nanoparticles with a core structure consisting only of a core containing the first element, the second element, zinc, and oxygen. Core-structured nanoparticles differ from core/shell nanoparticles having a core and a shell with a different composition from the core in that they do not have a shell with a different composition from the core. Examples of semi-metallic elements include B, Si, Ge, As, Sb, and Te. Furthermore, the metal oxide nanoparticles contained in the electronic function layer 4 are nanoparticles with a core structure formed by a competitive reaction between molecules containing the first element, molecules containing the second element, and molecules containing zinc, and composed only of a core containing the first element, the second element, zinc, and oxygen. Therefore, their particle size is unlikely to increase in size, and their particle size and particle size variation are small. Therefore, an electronic function layer 4 containing a plurality of metal oxide nanoparticles with such small particle size and particle size variation, or an electronic function layer 4 composed of a plurality of metal oxide nanoparticles with such small particle size and particle size variation, can achieve high density and high resistance to the cathode 5 formation process, such as a vapor deposition process or sputtering process, in the cathode 5 formation process, which is a subsequent process of forming the electronic function layer 4. Therefore, a light-emitting element 30 including the electronic function layer 4 can achieve high luminous efficiency.
なお、電子機能層4に含まれる金属酸化物ナノ粒子が単一組成のコアのみで構成されたコア構造のナノ粒子であることは、例えば、飛行時間型二次イオン質量分析法(TOF-SIMS)を用いて確認してもよく、金属酸化物ナノ粒子を外側から少しずつエッチングしながら元素分析を行い確認してもよい。 In addition, whether the metal oxide nanoparticles contained in the electronic functional layer 4 are nanoparticles with a core structure consisting only of a core of a single composition can be confirmed using, for example, time-of-flight secondary ion mass spectrometry (TOF-SIMS), or by performing elemental analysis while gradually etching the metal oxide nanoparticles from the outside.
上述した非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素は、B、C、N、F、Si、P、S、Cl、Ge、As、Se、Br、Sb、Te、I及びAtの何れかであってもよく、上述した第2元素は、B、Si、Ge、As、Sb、Te、C、N、P、及びSの何れかであってもよい。 The second element, which is an element or semimetal element selected from the non-metal elements mentioned above excluding hydrogen, oxygen, and Group 18 elements, may be any of B, C, N, F, Si, P, S, Cl, Ge, As, Se, Br, Sb, Te, I, and At, and the second element mentioned above may be any of B, Si, Ge, As, Sb, Te, C, N, P, and S.
電子機能層4に含まれる金属酸化物ナノ粒子の単位体積において、酸素元素の量は、前記第1元素の量、前記第2元素の量及び亜鉛元素の量それぞれよりも多く、前記第2元素の量及び亜鉛元素の量それぞれは、前記第1元素の量よりも多いことが好ましい。 In a unit volume of the metal oxide nanoparticles contained in the electronic functional layer 4, the amount of oxygen element is preferably greater than the amount of the first element, the amount of the second element, and the amount of zinc element, and the amount of the second element and the amount of zinc element are preferably greater than the amount of the first element.
本実施形態においては、電子機能層4に含まれる金属酸化物ナノ粒子が、前記第1元素としてMgと、前記第2元素としてSiと、亜鉛元素と、酸素元素とで構成された単一組成のコアのみで構成されたコア構造のナノ粒子である場合を一例に挙げて説明する。本実施形態における電子機能層4に含まれる金属酸化物ナノ粒子は、Zn-O結合と、Mg-O結合と、Si-O結合とを含む。 In this embodiment, the metal oxide nanoparticles contained in the electronic function layer 4 are described as an example of nanoparticles with a core structure consisting of only a core of a single composition composed of Mg as the first element, Si as the second element, zinc, and oxygen. The metal oxide nanoparticles contained in the electronic function layer 4 in this embodiment contain Zn-O bonds, Mg-O bonds, and Si-O bonds.
電子機能層4の厚さ方向に沿って切断されたある断面の一部は、前記第1元素としてMgと、前記第2元素としてSiと、亜鉛元素と、酸素元素とを含む金属酸化物ナノ粒子を10×N個(Nは2以上の自然数である)含み、前記10×N個の前記金属酸化物ナノ粒子の粒径の値を小さい順に並べた場合、5×N番目の金属酸化物ナノ粒子の粒径は、1.8nm以下であり、9×N番目の金属酸化物ナノ粒子の粒径とN番目の粒径との差は、2.1nm以下であることが好ましい。なお、10×N個の前記金属酸化物ナノ粒子の粒径は、例えば、走査型透過電子顕微鏡(STEM)を用いて測定することができる。5×N番目の金属酸化物ナノ粒子の粒径は、10×N個の前記金属酸化物ナノ粒子の粒径の値を小さい順に並べた場合の50%(中央値)に該当する金属酸化物ナノ粒子の粒径を意味する。9×N番目の金属酸化物ナノ粒子の粒径は、10×N個の前記金属酸化物ナノ粒子の粒径の値を小さい順に並べた場合の90%に該当する金属酸化物ナノ粒子の粒径を意味する。N番目の金属酸化物ナノ粒子の粒径は、10×N個の前記金属酸化物ナノ粒子の粒径の値を小さい順に並べた場合の10%に該当する金属酸化物ナノ粒子の粒径を意味する。 A portion of a cross section cut along the thickness direction of the electronic functional layer 4 contains 10×N metal oxide nanoparticles (N is a natural number greater than or equal to 2) containing Mg as the first element and Si, zinc, and oxygen as the second elements. When the particle sizes of the 10×N metal oxide nanoparticles are arranged in ascending order, it is preferable that the particle size of the 5×Nth metal oxide nanoparticle is 1.8 nm or less, and the difference between the particle size of the 9×Nth metal oxide nanoparticle and the particle size of the Nth nanoparticle is 2.1 nm or less. The particle sizes of the 10×N metal oxide nanoparticles can be measured, for example, using a scanning transmission electron microscope (STEM). The particle size of the 5×Nth metal oxide nanoparticle means the particle size of the metal oxide nanoparticle that is 50% (median) of the particle sizes of the 10×N metal oxide nanoparticles arranged in ascending order. The particle size of the 9×Nth metal oxide nanoparticle means the particle size of the metal oxide nanoparticle that is 90% of the particle sizes of the 10×N metal oxide nanoparticles arranged in ascending order. The particle size of the Nth metal oxide nanoparticle means the particle size of the metal oxide nanoparticle that corresponds to 10% of the particle sizes of the 10 x N metal oxide nanoparticles arranged in ascending order.
本実施形態においては、図2に示す発光素子30に備えられた発光層EMが、例えば、量子ドットQDを含む発光層である場合を一例に挙げて説明するが、これに限定されることはなく、有機発光材料を含む発光層であってもよい。なお、量子ドットQDは、例えば、コア構造、コア/シェル構造、コア/シェル/シェル構造、コア/比率を連続的に変化させたシェル構造を有してもよい。コア部は、一元系の場合、例えば、Si、Cなどで構成することができ、二元系の場合、例えば、CdSe、CdS、CdTe、InP、GaP、InN、ZnSe、ZnS、ZnTeなどで構成することができ、三元系の場合、例えば、CdSeTe、GaInP、ZnSeTeなどで構成することができ、四元系の場合、例えば、AIGSなどで構成することができる。シェル部は、二元系の場合、例えば、CdS、CdTe、CdSe、ZnS、ZnSe、ZnTeなどで構成することができ、三元系の場合、例えば、CdSSe、CdTeSe、CdSTe、ZnSSe、ZnSTe、ZnTeSe、AIPなどで構成することができる。 In this embodiment, the light-emitting layer EM provided in the light-emitting element 30 shown in FIG. 2 is described as an example containing quantum dots (QDs), but this is not limited thereto and the light-emitting layer may also contain an organic light-emitting material. The quantum dots (QDs) may have, for example, a core structure, a core/shell structure, a core/shell/shell structure, or a shell structure with a continuously varying core/shell ratio. The core portion may be composed of, for example, Si or C in the case of a unicomponent system; for example, CdSe, CdS, CdTe, InP, GaP, InN, ZnSe, ZnS, or ZnTe in the case of a ternary system; for example, CdSeTe, GaInP, or ZnSeTe; and for example, AIGS in the case of a quaternary system. In the case of a binary system, the shell portion can be composed of, for example, CdS, CdTe, CdSe, ZnS, ZnSe, ZnTe, etc., and in the case of a ternary system, it can be composed of, for example, CdSSe, CdTeSe, CdSTe, ZnSSe, ZnSTe, ZnTeSe, AIP, etc.
図2に示す発光素子30は、トップエミッション型であっても、ボトムエミッション型であってもよい。発光素子30は、アノード2よりもカソード5が上層として配置された順積構造であるので、トップエミッション型にするためには、アノード2は可視光を反射する電極材料で形成し、カソード5は可視光を透過する電極材料で形成すればよく、ボトムエミッション型にするためには、アノード2は可視光を透過する電極材料で形成し、カソード5は可視光を反射する電極材料で形成すればよい。 The light-emitting element 30 shown in Figure 2 may be either a top-emission type or a bottom-emission type. The light-emitting element 30 has a stacked structure in which the cathode 5 is disposed above the anode 2. To make it a top-emission type, the anode 2 should be formed from an electrode material that reflects visible light, and the cathode 5 should be formed from an electrode material that transmits visible light. To make it a bottom-emission type, the anode 2 should be formed from an electrode material that transmits visible light, and the cathode 5 should be formed from an electrode material that reflects visible light.
可視光を反射する電極材料としては、可視光を反射でき、導電性を有するのであれば、特に限定されないが、例えば、Al、Mg、Li、Agなどの金属材料または、前記金属材料の合金または、前記金属材料と透明金属酸化物(例えば、indium tin oxide、indium zinc oxide、indium gallium zinc oxideなど)との積層体または、前記合金と前記透明金属酸化物との積層体などを挙げることができる。 The electrode material that reflects visible light is not particularly limited as long as it can reflect visible light and is conductive, but examples include metal materials such as Al, Mg, Li, and Ag, alloys of these metal materials, laminates of these metal materials and transparent metal oxides (e.g., indium tin oxide, indium zinc oxide, indium gallium zinc oxide, etc.), and laminates of these alloys and these transparent metal oxides.
一方、可視光を透過する電極材料としては、可視光を透過でき、導電性を有するのであれば、特に限定されないが、例えば、透明金属酸化物(例えば、indium tin oxide、indium zinc oxide、indium gallium zinc oxideなど)または、Al、Agなどの金属材料からなる薄膜または、Al、Agなどの金属材料からなるナノワイア(Nano Wire)などを挙げることができる。 On the other hand, electrode materials that transmit visible light are not particularly limited as long as they are transparent to visible light and conductive, but examples include transparent metal oxides (e.g., indium tin oxide, indium zinc oxide, indium gallium zinc oxide, etc.), thin films made of metal materials such as Al or Ag, and nanowires made of metal materials such as Al or Ag.
図3は、図2に示す発光素子30の製造方法の一例を示す図である。 Figure 3 shows an example of a method for manufacturing the light-emitting element 30 shown in Figure 2.
図2に示す発光素子30は、アノード2よりもカソード5が上層として配置された順積構造であるので、アノード2を形成するアノード形成工程S1と、正孔機能層3を形成する正孔機能層形成工程S2と、発光層EMを形成する発光層形成工程S3と、電子機能層4を形成する電子機能層形成工程S4と、カソード5を形成するカソード形成工程S5とを、この順で行うことで製造することができる。そして、電子機能層形成工程S4においては、後述する金属酸化物ナノ粒子の製造方法によって製造されたMg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子を複数個含む電子機能層4を形成する。本実施形態においては、図3に示すように、発光層形成工程S3とカソード形成工程S5との間には、電子機能層形成工程S4のみが行われ、図2に示すように、電子機能層4は、カソード5及び発光層EMの両方と接するように設けられている。 2 has a sequentially stacked structure in which the cathode 5 is disposed above the anode 2, and can be manufactured by performing the following steps in this order: anode formation process S1 to form the anode 2; hole functional layer formation process S2 to form the hole functional layer 3; light-emitting layer formation process S3 to form the light-emitting layer EM; electronic functional layer formation process S4 to form the electronic functional layer 4; and cathode formation process S5 to form the cathode 5. In the electronic functional layer formation process S4, the electronic functional layer 4 is formed, which includes a plurality of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, which are manufactured by the metal oxide nanoparticle manufacturing method described below; a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semimetallic element; zinc; and oxygen. In this embodiment, as shown in FIG. 3, only the electronic function layer formation step S4 is performed between the light-emitting layer formation step S3 and the cathode formation step S5, and as shown in FIG. 2, the electronic function layer 4 is provided so as to be in contact with both the cathode 5 and the light-emitting layer EM.
図4は、図2に示す発光素子30に備えられた電子機能層4に含まれる金属酸化物ナノ粒子を製造する工程において用いられる反応装置10の概略的な構成を示す図である。図5は、図4に示す反応装置10を用いて金属酸化物ナノ粒子を製造する工程における工程条件の一例を示す図である。図6は、図4に示す反応装置10を用いて金属酸化物ナノ粒子を製造する工程を説明するための図である。図7は、図4に示す反応装置10を用いて金属酸化物ナノ粒子を製造した後に行われる、金属酸化物ナノ粒子の回収工程を説明するための図である。図8は、図2に示す発光素子30に備えられた電子機能層4に含まれる金属酸化物ナノ粒子のFT-IRの結果を示す図である。図9は、図2に示す発光素子10に備えられた電子機能層4に含まれる金属酸化物ナノ粒子の粒度分布を示す図である。 FIG. 4 is a diagram showing the schematic configuration of a reaction apparatus 10 used in the process of producing metal oxide nanoparticles contained in the electronic function layer 4 of the light-emitting element 30 shown in FIG. 2. FIG. 5 is a diagram showing an example of process conditions for the process of producing metal oxide nanoparticles using the reaction apparatus 10 shown in FIG. 4. FIG. 6 is a diagram illustrating the process of producing metal oxide nanoparticles using the reaction apparatus 10 shown in FIG. 4. FIG. 7 is a diagram illustrating the metal oxide nanoparticle recovery process performed after producing metal oxide nanoparticles using the reaction apparatus 10 shown in FIG. 4. FIG. 8 is a diagram showing the results of FT-IR of metal oxide nanoparticles contained in the electronic function layer 4 of the light-emitting element 30 shown in FIG. 2. FIG. 9 is a diagram showing the particle size distribution of metal oxide nanoparticles contained in the electronic function layer 4 of the light-emitting element 10 shown in FIG. 2.
上述したMg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアのみで構成されたコア構造の金属酸化物ナノ粒子は、例えば、マイクロミキサーと、マイクロチャネルと、マイクロリアクターとを含む反応装置を用いて、製造することができる。 Metal oxide nanoparticles having a core structure consisting only of a first element selected from the above-mentioned Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semi-metallic element, zinc, and oxygen can be produced using, for example, a reaction apparatus including a micromixer, a microchannel, and a microreactor.
前記反応装置は、外部から供給される、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素を含む金属酸化物ナノ粒子の第1前駆体と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素を含む金属酸化物ナノ粒子の第2前駆体と、亜鉛元素を含む金属酸化物ナノ粒子の第3前駆体と、反応剤とを、混合して排出するマイクロミキサーと、一方側の端部が供給端部であり、他方側の端部が排出端部であり、前記マイクロミキサーから排出された流体が前記供給端部から供給されるマイクロチャネルと、前記マイクロチャネルの少なくとも一部の反応条件を制御するマイクロリアクターと、を含む。 The reaction apparatus includes a micromixer that mixes and discharges a first precursor of metal oxide nanoparticles containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second precursor of metal oxide nanoparticles containing a second element that is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semi-metallic element, a third precursor of metal oxide nanoparticles containing zinc, and a reactant, all supplied from the outside; a microchannel having a supply end on one side and a discharge end on the other side, and into which the fluid discharged from the micromixer is supplied from the supply end; and a microreactor that controls the reaction conditions in at least a portion of the microchannel.
本実施形態においては、上述した反応装置として、図4に示す反応装置10を用いて、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアのみで構成されたコア構造の金属酸化物ナノ粒子を製造した場合を一例に挙げて説明するが、これに限定されることはない。 In this embodiment, the reaction apparatus described above is the reaction apparatus 10 shown in FIG. 4, and an example will be given of the production of metal oxide nanoparticles having a core structure consisting only of a core containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element, zinc, and oxygen, but the present invention is not limited to this.
図4に示すように、反応装置10は、第1供給口Inlet1、第2供給口Inlet2及び第1排出口Outlet1を含む第1マイクロミキサー16と、第3供給口Inlet3、第4供給口Inlet4及び第2排出口Outlet2を含む第2マイクロミキサー19とを含むマイクロミキサーを備えており、第1排出口Outlet1から排出された流体は第3供給口Inlet3から供給され、第2排出口Outlet2から排出された流体は前記マイクロチャネル20の供給端部から供給されるようになっている。さらに、反応装置10は、第1供給口Inlet1、第2供給口Inlet2及び第4供給口Inlet4のうちの一つに、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素を含む金属酸化物ナノ粒子の第1前駆体と、亜鉛元素を含む金属酸化物ナノ粒子の第3前駆体と、第1溶媒とを含む第1溶液を第1流速で供給する第1供給部11と、第1供給口Inlet1、第2供給口Inlet2及び第4供給口Inlet4のうちの他の一つに、前記反応剤と第2溶媒とを含む第2溶液を第2流速で供給する第2供給部12と、第1供給口Inlet1、第2供給口Inlet2及び第4供給口Inlet4のうちのさらに他の一つに、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素を含む金属酸化物ナノ粒子の第2前駆体と第3溶媒とを含む第3溶液を第3流速で供給する第3供給部13と、を含む。反応装置10は、図4に示すように、一方側の端部が供給端部であり、他方側の端部が排出端部であり、第2マイクロミキサー19の第2排出口Outlet2から排出された流体が前記供給端部から供給されるマイクロチャネル20と、マイクロチャネル20の少なくとも一部の反応条件を制御するマイクロリアクター21とを含む。 As shown in Figure 4, the reaction apparatus 10 is equipped with a micromixer including a first micromixer 16 including a first supply port Inlet1, a second supply port Inlet2, and a first outlet Outlet1, and a second micromixer 19 including a third supply port Inlet3, a fourth supply port Inlet4, and a second outlet Outlet2, and the fluid discharged from the first outlet Outlet1 is supplied from the third supply port Inlet3, and the fluid discharged from the second outlet Outlet2 is supplied from the supply end of the microchannel 20. The reaction apparatus 10 further includes a first supply unit 11 configured to supply a first solution containing a first precursor of metal oxide nanoparticles containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a third precursor of metal oxide nanoparticles containing zinc, and a first solvent to one of the first supply port Inlet1, the second supply port Inlet2, and the fourth supply port Inlet4 at a first flow rate; a second supply unit 12 that supplies a second solution containing the reactant and a second solvent at a second flow rate to another one of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4; and a third supply unit 13 that supplies a third solution containing a third solvent and a second precursor of metal oxide nanoparticles containing a second element, the second element being a semi-metallic element or an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements, to yet another one of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4 at a third flow rate. As shown in FIG. 4 , the reaction apparatus 10 includes a microchannel 20 having one end as a supply end and the other end as a discharge end, to which a fluid discharged from the second discharge port Outlet 2 of the second micromixer 19 is supplied from the supply end, and a microreactor 21 that controls the reaction conditions in at least a portion of the microchannel 20.
図4に示す反応装置10を用いて、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアのみで構成されたコア構造の金属酸化物ナノ粒子を製造する方法は、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素を含む金属酸化物ナノ粒子の第1前駆体として、例えば、酢酸マグネシウム(Magnesium Acetate)と、亜鉛元素を含む金属酸化物ナノ粒子の第3前駆体として、例えば、酢酸亜鉛(Zinc Acetate)と、第1溶媒である極性溶媒として、例えば、ジメチルスルホキシド(DMSO)とを含む第1溶液を第1供給部11から第1流速で第1供給口Inlet1に供給し、反応剤として、例えば、アルカリ性反応剤であるテトラメチルアンモニウム水酸化物(例えば、TMAH・5H2O)と、第2溶媒として、例えば、アルコール系溶媒であるエタノールとを含む第2溶液を第2供給部12から第2流速で第2供給口Inlet2に供給し、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素を含む金属酸化物ナノ粒子の第2前駆体として、例えば、テトラアルコキシシランであるテトラエトキシシラン(TEOS(Tetraethyl orthosilicate))と、第3溶媒として、例えば、アルコール系溶媒であるエタノールとを含む第3溶液を第3供給部13から第3流速で第4供給口Inlet4に供給する第1工程と、マイクロチャネル20の排出端部から、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素と、を含むコアのみで構成されたコア構造の金属酸化物ナノ粒子の分散液を回収する第2工程と、を含む。 A method for producing metal oxide nanoparticles having a core structure consisting of only a core containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element, zinc, and oxygen, using a reaction apparatus 10 shown in FIG. 4, includes the steps of: (1) preparing a first precursor of the metal oxide nanoparticles containing the first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, such as magnesium acetate; and (2) preparing a third precursor of the metal oxide nanoparticles containing zinc, such as zinc acetate. A first solution containing tetramethylammonium hydroxide (e.g., TMAH.5H 2 O), an alkaline reactant, as a reactant, and ethanol, an alcoholic solvent, as a second solvent, is supplied from a second supply unit 12 to a second supply port Inlet 2 at a second flow rate . A second precursor of metal oxide nanoparticles containing a second element, which is an element selected from nonmetallic elements excluding hydrogen, oxygen, and Group 18 elements, or a semimetallic element, is supplied from a first supply unit 11 to a first supply port Inlet 1 at a first flow rate. orthosilicate) and a third solvent, for example, ethanol, which is an alcohol-based solvent, from a third supply unit 13 to a fourth supply port Inlet 4 at a third flow rate; and a second step of recovering, from the discharge end of the microchannel 20, a dispersion of metal oxide nanoparticles having a core structure composed only of a core containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a semi-metallic element, zinc, and oxygen.
図4に示すように、反応装置10は、第1マイクロミキサー16の第1供給口Inlet1と第1供給部11の排出口とを連結する第1供給流路14と、第1マイクロミキサー16の第2供給口Inlet2と第2供給部12の排出口とを連結する第2供給流路15と、第1マイクロミキサー16の第1排出口Outlet1と第2マイクロミキサー19の第3供給口Inlet3とを連結する第3供給流路17と、第2マイクロミキサー19の第4供給口Inlet4と第3供給部13の排出口とを連結する第4供給流路18と、マイクロチャネル20の排出端部から排出される流体を回収するための回収部22と、をさらに含む。第1供給流路14と第2供給流路15とは、流路径や流路長などが同じである同一供給流路であることが好ましく、第3供給流路17と第4供給流路18とは、流路径や流路長などが同じである同一供給流路であることが好ましい。図示してないが、第1供給部11の排出口が第1マイクロミキサー16の第1供給口Inlet1に直結されている場合には、反応装置10は第1供給流路14を備えていなくてもよく、第2供給部12の排出口が第1マイクロミキサー16の第2供給口Inlet2に直結されている場合には、反応装置10は第2供給流路15を備えていなくてもよく、第3供給部13の排出口が第2マイクロミキサー19の第4供給口Inlet4に直結されている場合には、反応装置10は第4供給流路18を備えていなくてもよく、第1マイクロミキサー16の第1排出口Outlet1と第2マイクロミキサー19の第3供給口Inlet3とが直結されている場合には、反応装置10は第3供給流路17を備えていなくてもよい。また、反応装置10は、回収部22を備えていなくてもよく、この場合には、反応装置10のユーザが回収部22を準備すればよい。なお、マイクロチャネル20の少なくとも一部の反応条件を制御するマイクロリアクター21は、例えば、マイクロチャネル20の一部を、マイクロチャネル20内を流れる流体の反応に最適な温度に制御する。本実施形態においては、上述したように、第1前駆体として酢酸マグネシウム(Magnesium Acetate)を、第2前駆体としてテトラエトキシシラン(TEOS(Tetraethyl orthosilicate))を、第3前駆体として酢酸亜鉛(Zinc Acetate)をそれぞれ用いているので、第1マイクロミキサー16内においては、例えば、ZnOH及びMgOHが生成され、第2マイクロミキサー19内においては、例えば、ZnOH、MgOH及びSi(OH)X(OC2H5)4-X(X=0、1、2、3、4)が生成され、マイクロリアクター21によって、反応条件が制御されるマイクロチャネル20の一部においては、ZnOH、MgOH及びSi(OH)X(OC2H5)4-X(X=0、1、2、3、4)同士の脱水反応が競争的に競争反応として起こる。したがって、例えば、図4に示す反応装置10を用いて製造した金属酸化物ナノ粒子は、前記第1元素と、前記第2元素と、亜鉛元素と、酸素元素と、を含むコアのみで構成されたコア構造の金属酸化物ナノ粒子となり、コアとコアの外側にコアとは異なる組成で設けられるシェルとを有するコア/シェル構造のナノ粒子にはならない。なお、上述したように、脱水反応は主にマイクロチャネル20で起こるので、前記第1溶液を第1供給部11から第1流速で第1供給口Inlet1、第2供給口Inlet2及び第4供給口Inlet4のうちの一つに、前記第2溶液を第2供給部12から第2流速で第1供給口Inlet1、第2供給口Inlet2及び第4供給口Inlet4のうちの他の一つに、前記第3溶液を第3供給部13から第3流速で第1供給口Inlet1、第2供給口Inlet2及び第4供給口Inlet4のうちのさらに他の一つに供給すればよい。 4 , the reaction apparatus 10 further includes a first supply flow path 14 connecting a first supply port Inlet 1 of the first micromixer 16 to an outlet of the first supply unit 11, a second supply flow path 15 connecting a second supply port Inlet 2 of the first micromixer 16 to an outlet of the second supply unit 12, a third supply flow path 17 connecting a first outlet Outlet 1 of the first micromixer 16 to a third supply port Inlet 3 of the second micromixer 19, a fourth supply flow path 18 connecting a fourth supply port Inlet 4 of the second micromixer 19 to an outlet of the third supply unit 13, and a recovery unit 22 for recovering a fluid discharged from an outlet end of the microchannel 20. The first supply flow path 14 and the second supply flow path 15 are preferably the same supply flow path having the same flow path diameter and flow path length, and the third supply flow path 17 and the fourth supply flow path 18 are preferably the same supply flow path having the same flow path diameter and flow path length. Although not shown, when the outlet of the first supply unit 11 is directly connected to the first supply port Inlet 1 of the first micromixer 16, the reaction apparatus 10 does not need to have the first supply flow path 14, when the outlet of the second supply unit 12 is directly connected to the second supply port Inlet 2 of the first micromixer 16, the reaction apparatus 10 does not need to have the second supply flow path 15, when the outlet of the third supply unit 13 is directly connected to the fourth supply port Inlet 4 of the second micromixer 19, the reaction apparatus 10 does not need to have the fourth supply flow path 18, and when the first outlet Outlet 1 of the first micromixer 16 and the third supply port Inlet 3 of the second micromixer 19 are directly connected, the reaction apparatus 10 does not need to have the third supply flow path 17. Furthermore, the reaction apparatus 10 does not need to have the recovery unit 22, and in this case, the user of the reaction apparatus 10 can prepare the recovery unit 22. The microreactor 21 that controls the reaction conditions in at least a part of the microchannel 20 controls, for example, the temperature of a part of the microchannel 20 to an optimum temperature for the reaction of the fluid flowing in the microchannel 20 . In this embodiment, as described above, magnesium acetate is used as the first precursor, tetraethoxysilane (TEOS (Tetraethyl orthosilicate)) is used as the second precursor, and zinc acetate is used as the third precursor. Therefore, for example, ZnOH and MgOH are produced in the first micromixer 16, and for example, ZnOH, MgOH, and Si(OH) X (OC 2 H 5 ) 4-X (X = 0, 1, 2, 3, 4) are produced in the second micromixer 19. In a part of the microchannel 20 where the reaction conditions are controlled by the microreactor 21, dehydration reactions between ZnOH, MgOH, and Si(OH) X (OC 2 H 5 ) 4-X (X = 0, 1, 2, 3, 4) occur competitively. 4 , the metal oxide nanoparticles produced using the reaction apparatus 10 shown in FIG. 4 are core-structured metal oxide nanoparticles composed solely of a core containing the first element, the second element, zinc, and oxygen, and are not core/shell nanoparticles having a core and a shell with a different composition from the core. As described above, since the dehydration reaction occurs primarily in the microchannel 20, the first solution may be supplied from the first supply unit 11 at a first flow rate to one of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4, the second solution may be supplied from the second supply unit 12 at a second flow rate to the other of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4, and the third solution may be supplied from the third supply unit 13 at a third flow rate to the other of the first supply port Inlet 1, the second supply port Inlet 2, and the fourth supply port Inlet 4.
図4に示すように、反応装置10は、平面視において、T字形状の第1マイクロミキサー16及びT字形状の第2マイクロミキサー19を備えており、平面視において、T字形状の第1マイクロミキサー16及びT字形状の第2マイクロミキサー19により乱流を利用するフローマイクロリアクタータイプの特殊反応場を実現できる。本実施形態においては、反応装置10が、平面視において、T字形状の第1マイクロミキサー16及びT字形状の第2マイクロミキサー19を備えている場合を一例に挙げて説明するが、これに限定されることはなく、反応装置10は、T字形状の第1マイクロミキサー16及びT字形状の第2マイクロミキサー19の少なくとも一方の代わりに、例えば、平面視において、V字形状のマイクロミキサーを備えていてもよく、平面視において、V字形状のマイクロミキサーによっても、乱流を利用するフローマイクロリアクタータイプの特殊反応場を実現できる。さらに、反応装置10は、T字形状の第1マイクロミキサー16及びT字形状の第2マイクロミキサー19の少なくとも一方の代わりに、例えば、直線形状のマイクロミキサーを備えていてもよく、直線形状のマイクロミキサーによっては、2つの供給口から供給された流体が並行流として流れるフローマイクロリアクタータイプの特殊反応場を実現できる。 As shown in FIG. 4, the reactor 10 includes a T-shaped first micromixer 16 and a T-shaped second micromixer 19 in a planar view. The T-shaped first micromixer 16 and the T-shaped second micromixer 19 can realize a flow microreactor-type special reaction field that utilizes turbulence in a planar view. In this embodiment, the reactor 10 includes a T-shaped first micromixer 16 and a T-shaped second micromixer 19 in a planar view. However, this is not limited to this. The reactor 10 may include, for example, a V-shaped micromixer in a planar view instead of at least one of the T-shaped first micromixer 16 and the T-shaped second micromixer 19. A V-shaped micromixer in a planar view can also realize a flow microreactor-type special reaction field that utilizes turbulence. Furthermore, the reaction apparatus 10 may be equipped with, for example, a linear micromixer instead of at least one of the T-shaped first micromixer 16 and the T-shaped second micromixer 19. A linear micromixer can realize a special reaction field of the flow microreactor type in which fluids supplied from two supply ports flow in parallel.
図5に示すように、上述した第1溶液においては、Mg2+とZn2+の濃度比が15:85になるように、酢酸亜鉛(Zinc Acetate)及び酢酸マグネシウム(Magnesium Acetate)それぞれの量を調整するとともに、第1溶液の濃度が0.1Mになるように、酢酸亜鉛(Zinc Acetate)及び酢酸マグネシウム(Magnesium Acetate)の量と、第1溶媒であるジメチルスルホキシド(DMSO)の量とを調整した。また、上述した第2溶液においては、第2溶液の濃度が0.25Mになるように、テトラメチルアンモニウム水酸化物((例えば、TMAH・5H2O)及び第2溶媒であるエタノールそれぞれの量を調整した。さらに、図5に示すように、第1溶液におけるMg2+及びZn2+と、第2溶液におけるテトラメチルアンモニウム水酸化物(例えば、TMAH・5H2O)とのモル比(mol ratio)は、1:1.3になるように調整した。また、上述した第3溶液においては、第3溶液の濃度が0.169Mになるように、テトラエトキシシラン(TEOS(Tetraethyl orthosilicate))及び第3溶媒であるエタノールそれぞれの量を調整した。最終生成物である金属酸化物ナノ粒子を得る量を考慮し、第1溶液のフロー量と第2溶液のフロー量と第3溶液のフロー量とを適宜決定することができ、本実施形態においては、第1溶液のフロー量を12.6mlとし、第2溶液のフロー量を6.552mlとし、第3溶液のフロー量を16mlとした。第1供給部11からの第1溶液の供給時間と第2供給部12からの第2溶液の供給時間と第3供給部13からの第3溶液の供給時間とを何れも84分とするため、第1供給部11は、第1溶液を第1流速、例えば、9ml/hで供給し、第2供給部12は、第2溶液を第2流速、例えば、4.68ml/hで供給し、第3供給部13は、第3溶液を第3流速、例えば、11.5ml/hで供給した。 As shown in FIG. 5 , in the first solution described above, the amounts of zinc acetate and magnesium acetate were adjusted so that the concentration ratio of Mg 2+ to Zn 2+ was 15:85, and the amounts of zinc acetate and magnesium acetate and the amount of dimethyl sulfoxide (DMSO) as the first solvent were adjusted so that the concentration of the first solution was 0.1 M. In the second solution, the amounts of tetramethylammonium hydroxide (e.g., TMAH.5H 2 O) and ethanol, which is the second solvent, were adjusted so that the concentration of the second solution would be 0.25 M. Furthermore, as shown in FIG. 5, the molar ratio of Mg 2+ and Zn 2+ in the first solution to tetramethylammonium hydroxide (e.g., TMAH.5H 2 O) in the second solution was adjusted to 1:1.3. In the third solution, tetraethoxysilane (TEOS (Tetraethyl The amounts of the first solution, the second solution, and the third solvent, ethanol, were adjusted. The flow rates of the first solution, the second solution, and the third solution can be appropriately determined taking into account the amount of metal oxide nanoparticles to be obtained as the final product. In this embodiment, the flow rates of the first solution were 12.6 mL, the second solution 6.552 mL, and the third solution 16 mL. To set the supply time of the first solution from the first supply unit 11, the second solution from the second supply unit 12, and the third solution from the third supply unit 13 to 84 minutes, the first supply unit 11 supplied the first solution at a first flow rate, e.g., 9 mL/h, the second supply unit 12 supplied the second solution at a second flow rate, e.g., 4.68 mL/h, and the third supply unit 13 supplied the third solution at a third flow rate, e.g., 11.5 mL/h.
図6に示すように、金属酸化物ナノ粒子の製造方法は、上述したように、所定濃度A、本実施形態においては、0.1Mの第1溶液と、所定濃度B、本実施形態においては、0.25Mの第2溶液と、所定濃度C、本実施形態においては、0.169Mの第3溶液とを調液する工程S11と、所定流速D、本実施形態においては、9ml/hで第1溶液を第1マイクロミキサー16の第1供給口Inlet1に供給し、所定流速E、本実施形態においては、4.68ml/hで第2溶液を第1マイクロミキサー16の第2供給口Inlet2に供給し、所定流速F、本実施形態においては、11.5ml/hで第3溶液を第2マイクロミキサー19の第4供給口Inlet4に供給する工程S12と、マイクロチャネル20の排出端部から生成されたMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の分散液を回収する工程S13と、を含む。なお、Mg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の分散液を回収する工程S13においては、初期の一定期間の間及び最後の一定期間の間にマイクロチャネル20の排出端部から排出される流体は別途回収し、前記期間以外の中間期間にマイクロチャネル20の排出端部から排出される流体のみをMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の分散液として回収することが好ましい。 As shown in Figure 6, the method for producing metal oxide nanoparticles includes, as described above, step S11 of preparing a first solution having a predetermined concentration A (0.1 M in this embodiment), a second solution having a predetermined concentration B (0.25 M in this embodiment), and a third solution having a predetermined concentration C (0.169 M in this embodiment); step S12 of supplying the first solution to the first supply port Inlet 1 of the first micromixer 16 at a predetermined flow rate D (9 ml/h in this embodiment), supplying the second solution to the second supply port Inlet 2 of the first micromixer 16 at a predetermined flow rate E (4.68 ml/h in this embodiment), and supplying the third solution to the fourth supply port Inlet 4 of the second micromixer 19 at a predetermined flow rate F (11.5 ml/h in this embodiment); and step S13 of recovering the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si produced from the discharge end of the microchannel 20. In step S13 of recovering the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si, it is preferable to separately recover the fluid discharged from the discharge end of the microchannel 20 during the initial fixed period and the final fixed period, and to recover only the fluid discharged from the discharge end of the microchannel 20 during an intermediate period other than the above periods as a dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si.
図7に示すように、金属酸化物ナノ粒子の製造方法は、図6に示す工程S13において回収されたMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の分散液を遠沈管に移し、貧溶媒(例えば、酢酸エチル)を添加することで、超ナノサイズのMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子を析出させる工程S21と、遠心分離によって、固形分と溶液を分離する工程S22と、上澄液(例えば、反応物のジメチルスルホキシド(DMSO)、エタノール(EtOH)混合液)を取り除く工程S23と、を、さらに含むことが好ましい。金属酸化物ナノ粒子の製造方法が、図7に示す金属酸化物ナノ粒子の回収工程を含むことで、不純物などが除去されたMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の分散液を得ることができる。また、金属酸化物ナノ粒子の製造方法は、図7に示す工程S23において、前記上澄液を含む前記溶液を取り除き、前記固形分(Mg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子)を溶媒(例えば、エタノールまたはブタノール)に再度分散させたMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の再分散液を調液する工程S24をさらに含んでいてもよい。この方法の場合、希望する特定の溶媒に再分散されたMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の再分散液を得ることができる。また、上述した再分散液を調液する工程においては、分散性をさらに向上させるために、モノエタノールアミン(MEA)のような有機リガンドをさらに追加してもよい。 As shown in Figure 7, the method for producing metal oxide nanoparticles preferably further includes step S21 of transferring the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si recovered in step S13 shown in Figure 6 to a centrifuge tube and adding a poor solvent (e.g., ethyl acetate) to precipitate ultranano-sized oxide nanoparticles containing Mg, Zn, and Si, step S22 of separating the solids from the solution by centrifugation, and step S23 of removing the supernatant (e.g., a mixture of the reactants dimethyl sulfoxide (DMSO) and ethanol (EtOH)). By including the metal oxide nanoparticle recovery step shown in Figure 7 in the method for producing metal oxide nanoparticles, a dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si from which impurities have been removed can be obtained. Furthermore, the method for producing metal oxide nanoparticles may further include step S24 of removing the solution containing the supernatant and redispersing the solids (ultranano-sized oxide nanoparticles containing Mg, Zn, and Si) in a solvent (e.g., ethanol or butanol) to prepare a redispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si in step S23 shown in FIG. 7 . This method allows for the production of a redispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si redispersed in a desired specific solvent. Furthermore, in the step of preparing the redispersion, an organic ligand such as monoethanolamine (MEA) may be added to further improve dispersibility.
図8に示すように、図2に示す発光素子30に備えられた電子機能層4に含まれるMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子のFT-IRの結果においては、Zn-O結合、Mg-O結合及びSi-O結合それぞれに該当する波数(Wavenumber)で吸収があり、Mg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子は、Zn-O結合と、Mg-O結合と、Si-O結合とを含むことが確認された。 As shown in Figure 8, the FT-IR results for the ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si contained in the electronic function layer 4 of the light-emitting element 30 shown in Figure 2 showed absorption at the wavenumbers corresponding to Zn-O bonds, Mg-O bonds, and Si-O bonds, respectively, confirming that the ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si contain Zn-O bonds, Mg-O bonds, and Si-O bonds.
図4に示す反応装置10を用いて製造された金属酸化物ナノ粒子、すなわち、上述したMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の再分散液を用いて、粒度分布を測定した結果を図9に示す。なお、ここでの再分散液は、Mg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子を溶媒であるエタノールに分散させた溶液である。 Figure 9 shows the results of measuring the particle size distribution using a redispersion of metal oxide nanoparticles produced using the reaction apparatus 10 shown in Figure 4, i.e., the ultranano-sized oxide nanoparticles containing Mg, Zn, and Si described above. Note that the redispersion here is a solution in which ultranano-sized oxide nanoparticles containing Mg, Zn, and Si are dispersed in ethanol, which is a solvent.
図9に示すように、Mg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の再分散液における粒径基準累積50%(D50)である金属酸化物ナノ粒子の粒径は、1.76nmで、1.80nm以下であった。また、Mg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の再分散液における粒径基準累積90%(D90)である金属酸化物ナノ粒子の粒径と粒径基準累積10%(D10)である金属酸化物ナノ粒子の粒径との差が、2.05nmで、2.10nm以下であった。なお、図9に示す粒度分布はDLS(動的光散乱法)で測定した結果であり、Microtaract社製のNanotrac waveIIを用いて測定した。 As shown in Figure 9, the particle size of the metal oxide nanoparticles at particle size cumulative 50% (D50) in a redispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si was 1.76 nm, less than 1.80 nm. Furthermore, the difference in particle size between the metal oxide nanoparticles at particle size cumulative 90% (D90) and particle size cumulative 10% (D10) in a redispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si was 2.05 nm, less than 2.10 nm. The particle size distribution shown in Figure 9 was measured using DLS (dynamic light scattering) using a Nanotrac wave II manufactured by Microtaract.
本実施形態においては、図5に示すような条件で、反応装置10を用いて、Mg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子を製造しているので、上述したように、粒径基準累積50%(D50)である金属酸化物ナノ粒子の粒径は、1.76nmで、粒径基準累積90%(D90)である金属酸化物ナノ粒子の粒径と粒径基準累積10%(D10)である金属酸化物ナノ粒子の粒径との差が、2.05nmであったが、これに限定されることはない。例えば、第1供給部11からの第1溶液の供給時間と第2供給部12からの第2溶液の供給時間と第3供給部13からの第3溶液の供給時間とを何れも84分よりも長くなるようにまたは短くなるように、上述した第1流速、第2流速及び第3流速を調整することで、第2マイクロミキサー19の第2排出口Outlet2から排出される流体が、マイクロリアクター21によって、反応条件が制御されるマイクロチャネル20の一部に留まる時間を調整できるので、粒径基準累積50%(D50)である金属酸化物ナノ粒子の粒径の値が、例えば、4nm以下であり、粒径基準累積90%(D90)である金属酸化物ナノ粒子の粒径と粒径基準累積10%(D10)である金属酸化物ナノ粒子の粒径との差が、例えば、3nm以下であるMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子を得ることができる。 In this embodiment, ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si are produced using the reaction apparatus 10 under the conditions shown in Figure 5. As described above, the particle size of metal oxide nanoparticles at 50% cumulative particle size (D50) is 1.76 nm, and the difference between the particle size of metal oxide nanoparticles at 90% cumulative particle size (D90) and the particle size of metal oxide nanoparticles at 10% cumulative particle size (D10) is 2.05 nm, but this is not limited to this. For example, by adjusting the first flow rate, second flow rate, and third flow rate described above so that the supply time of the first solution from the first supply unit 11, the supply time of the second solution from the second supply unit 12, and the supply time of the third solution from the third supply unit 13 are all longer or shorter than 84 minutes, the time that the fluid discharged from the second outlet Outlet 2 of the second micromixer 19 remains in a portion of the microchannel 20 where the reaction conditions are controlled by the microreactor 21 can be adjusted. This makes it possible to obtain ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si in which the particle size of metal oxide nanoparticles at particle size cumulative 50% (D50) is, for example, 4 nm or less, and the difference between the particle size of metal oxide nanoparticles at particle size cumulative 90% (D90) and the particle size of metal oxide nanoparticles at particle size cumulative 10% (D10) is, for example, 3 nm or less.
図示してないが、図6に示す工程S13で回収したMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の分散液における粒径基準累積50%(D50)である金属酸化物ナノ粒子の粒径も、1.80nm以下であった。また、図6に示す工程S13で回収したMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子の分散液における粒径基準累積90%(D90)である金属酸化物ナノ粒子の粒径と粒径基準累積10%(D10)である金属酸化物ナノ粒子の粒径との差も、2.10nm以下であった。 Although not shown, the particle size of the metal oxide nanoparticles at 50% cumulative particle size (D50) in the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si recovered in step S13 shown in Figure 6 was also 1.80 nm or less. Furthermore, the difference in particle size between the metal oxide nanoparticles at 90% cumulative particle size (D90) and the metal oxide nanoparticles at 10% cumulative particle size (D10) in the dispersion of ultranano-sized oxide nanoparticles containing Mg, Zn, and Si recovered in step S13 shown in Figure 6 was also 2.10 nm or less.
以上のように、反応装置10を用いて製造されたMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子は、粒径及び粒径のばらつきが小さい。このように、粒径及び粒径のばらつきが小さいMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子を製造できるのは、第1溶液、第2溶液及び第3溶液が常に流れながら反応し、Mg、Zn及びSiを含む超ナノサイズのコア構造の酸化物ナノ粒子が生成されることと、Mgを含む分子と、Siを含む分子と、Znを含む分子との競争反応によって、Mg、Zn及びSiを含む超ナノサイズのコア構造の酸化物ナノ粒子が生成されることによる効果であると考えられる。 As described above, the ultranano-sized oxide nanoparticles containing Mg, Zn, and Si produced using the reaction apparatus 10 have small particle sizes and particle size variations. The ability to produce ultranano-sized oxide nanoparticles containing Mg, Zn, and Si with small particle sizes and particle size variations is believed to be due to the fact that the first solution, second solution, and third solution constantly flow and react to produce oxide nanoparticles with an ultranano-sized core structure containing Mg, Zn, and Si, and the competitive reactions between molecules containing Mg, molecules containing Si, and molecules containing Zn produce oxide nanoparticles with an ultranano-sized core structure containing Mg, Zn, and Si.
図10は、参考例1の発光素子及び参考例2の発光素子それぞれの電流密度と輝度との関係、すなわち、概略的な発光効率を示す図である。なお、ここでは、赤色発光素子を用いた結果を一例として示しているが、緑色発光素子及び青色発光素子においても同様の結果が得られる。 Figure 10 shows the relationship between current density and luminance for the light-emitting element of Reference Example 1 and the light-emitting element of Reference Example 2, i.e., the approximate luminous efficiency. Note that while the results using a red light-emitting element are shown here as an example, similar results can be obtained with green and blue light-emitting elements.
図10に示す参考例1の発光素子(赤色発光素子)は、Agで形成されたアノードと、酸化ニッケルのナノ粒子で形成された正孔注入層と、ポリ[(9,9-ジオクチルフルオレニル-2,7-ジイル)-co-(4,4’-(N-(4-sec-ブチルフェニル))ジフェニルアミン)](TFB)で形成された正孔輸送層と、赤色発光量子ドットとしてInPを含む発光層と、酸化亜鉛ナノ粒子で形成された電子機能層である電子輸送層と、ITO(indium tin oxide)で形成されたカソードとが、この順に積層された発光素子である。 The light-emitting element (red light-emitting element) of Reference Example 1 shown in Figure 10 is a light-emitting element formed in this order: an anode made of Ag; a hole injection layer made of nickel oxide nanoparticles; a hole transport layer made of poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4'-(N-(4-sec-butylphenyl))diphenylamine)] (TFB); a light-emitting layer containing InP as red-emitting quantum dots; an electron transport layer that is an electronic functional layer made of zinc oxide nanoparticles; and a cathode made of ITO (indium tin oxide).
酸化亜鉛ナノ粒子は、亜鉛元素のみを含む金属酸化物ナノ粒子であるため、上述したMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子と比較して、粒径及び粒径のばらつきが大きい。したがって、参考例1の発光素子(赤色発光素子)に備えられたこのような酸化亜鉛ナノ粒子で形成された電子機能層である電子輸送層は、緻密性が不足するため、電子輸送層を形成する工程の後工程であるカソードを形成する工程におけるカソードの成膜プロセス、例えば、蒸着工程またはスパッタリング工程に対する耐性が高くなく、カソードを形成する工程後には、電子輸送層の下層である発光層までもダメージを受け、発光効率が著しく低下してしまうので、図10に示すように、参考例1の発光素子(赤色発光素子)においては、満足できる程の発光効率は得られない。 Because zinc oxide nanoparticles are metal oxide nanoparticles containing only zinc element, they have a larger particle size and particle size variation than the ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si described above. Therefore, the electron transport layer, which is an electronic functional layer formed from such zinc oxide nanoparticles and provided in the light-emitting element (red light-emitting element) of Reference Example 1, lacks density and is therefore not highly resistant to the cathode formation process, such as the vapor deposition or sputtering process, that occurs in the cathode formation step, which is a step that follows the electron transport layer formation step. After the cathode formation step, even the light-emitting layer below the electron transport layer is damaged, resulting in a significant decrease in luminous efficiency. As a result, as shown in Figure 10, the light-emitting element (red light-emitting element) of Reference Example 1 does not achieve satisfactory luminous efficiency.
一方、図10に示す参考例2の発光素子(赤色発光素子)は、Agで形成されたアノードと、酸化ニッケルのナノ粒子で形成された正孔注入層と、ポリ[(9,9-ジオクチルフルオレニル-2,7-ジイル)-co-(4,4’-(N-(4-sec-ブチルフェニル))ジフェニルアミン)](TFB)で形成された正孔輸送層と、赤色発光量子ドットとしてInPを含む発光層と、酸化亜鉛ナノ粒子とPVP(ポリビニルピロリドン)とを混合した材料で形成された電子機能層である電子輸送層と、ITO(indium tin oxide)で形成されたカソードとが、この順に積層された発光素子である。なお、参考例1の発光素子(赤色発光素子)と参考例2の発光素子(赤色発光素子)とにおいては、各層の膜厚を同一に形成しており、電子機能層である電子輸送層以外の層である、アノード、正孔注入層、正孔輸送層、赤色発光量子ドットを含む発光層及びカソード)それぞれは、同一組成の同一材料を用いて形成した。 On the other hand, the light-emitting element (red light-emitting element) of Reference Example 2 shown in Figure 10 is a light-emitting element in which an anode made of Ag, a hole injection layer made of nickel oxide nanoparticles, a hole transport layer made of poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4'-(N-(4-sec-butylphenyl))diphenylamine)] (TFB) are stacked in this order, a light-emitting layer containing InP as red-emitting quantum dots, an electron transport layer which is an electronic functional layer made of a material that is a mixture of zinc oxide nanoparticles and PVP (polyvinylpyrrolidone), and a cathode made of ITO (indium tin oxide). In the light-emitting element (red light-emitting element) of Reference Example 1 and the light-emitting element (red light-emitting element) of Reference Example 2, each layer was formed to have the same film thickness, and each of the layers other than the electron transport layer, which is the electronic functional layer (anode, hole injection layer, hole transport layer, light-emitting layer containing red-emitting quantum dots, and cathode) was formed using the same material with the same composition.
酸化亜鉛ナノ粒子とPVP(ポリビニルピロリドン)とを混合した材料で形成された比較例2の電子機能層である電子輸送層は、比較例1の電子機能層である電子輸送層と比較して緻密性が若干改善され、比較例2の電子機能層である電子輸送層を備えた赤色発光素子においては、図10に示すように、若干の発光効率の改善を実現できる。しかしながら、酸化亜鉛ナノ粒子とPVP(ポリビニルピロリドン)とを混合した材料で形成された比較例2の電子機能層である電子輸送層のような有機無機ハイブリッド状態の電子輸送層は、非常に安定性が悪く、電子輸送層を形成する工程において、有機材料と無機材料が相分離してしまうなどの問題があるとともに、酸化亜鉛のナノ粒子が有するそもそもの粒径のばらつきの大きさの影響により、依然として、満足できる程の高い緻密性が得られず、比較例2の電子機能層である電子輸送層を備えた赤色発光素子においては満足できる程の高い発光効率が得られない。 The electron transport layer, which is the electronic functional layer of Comparative Example 2 and is formed from a material that is a mixture of zinc oxide nanoparticles and PVP (polyvinylpyrrolidone), has slightly improved density compared to the electron transport layer, which is the electronic functional layer of Comparative Example 1. As shown in Figure 10, a red light-emitting device equipped with the electron transport layer, which is the electronic functional layer of Comparative Example 2, can achieve a slightly improved luminous efficiency. However, an organic-inorganic hybrid electron transport layer, such as the electron transport layer, which is the electronic functional layer of Comparative Example 2 and is formed from a material that is a mixture of zinc oxide nanoparticles and PVP (polyvinylpyrrolidone), is very unstable and suffers from problems such as phase separation between the organic and inorganic materials during the electron transport layer formation process. Furthermore, due to the large variation in particle size inherent in the zinc oxide nanoparticles, it is still not possible to achieve a satisfactorily high density. Therefore, a red light-emitting device equipped with the electron transport layer, which is the electronic functional layer of Comparative Example 2, cannot achieve a satisfactorily high luminous efficiency.
図11は、実施例1の発光素子及び比較例1の発光素子それぞれの電流密度と輝度との関係、すなわち、概略的な発光効率を示す図である。なお、ここでは、青色発光素子を用いた結果を一例として示しているが、赤色発光素子及び緑色発光素子においても同様の結果が得られる。 Figure 11 shows the relationship between current density and luminance for the light-emitting element of Example 1 and the light-emitting element of Comparative Example 1, i.e., the approximate luminous efficiency. Note that while the results using a blue light-emitting element are shown here as an example, similar results can be obtained with red and green light-emitting elements.
図11に示す比較例1の発光素子(青色発光素子)は、Agで形成されたアノードと、酸化ニッケルのナノ粒子で形成された正孔注入層と、ポリ[(9,9-ジオクチルフルオレニル-2,7-ジイル)-co-(4,4’-(N-(4-sec-ブチルフェニル))ジフェニルアミン)](TFB)で形成された正孔輸送層と、青色発光量子ドットとしてZnSeを含む発光層と、酸化亜鉛ナノ粒子とPVP(ポリビニルピロリドン)とを混合した材料で形成された比較例2の電子機能層である電子輸送層と、ITO(indium tin oxide)で形成されたカソードとが、この順に積層された発光素子である。 The light-emitting element (blue light-emitting element) of Comparative Example 1 shown in Figure 11 is a light-emitting element formed in this order: an anode made of Ag; a hole injection layer made of nickel oxide nanoparticles; a hole transport layer made of poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4'-(N-(4-sec-butylphenyl))diphenylamine)] (TFB); a light-emitting layer containing ZnSe as blue-emitting quantum dots; an electron transport layer, which is the electronic functional layer of Comparative Example 2, made of a material mixture of zinc oxide nanoparticles and PVP (polyvinylpyrrolidone); and a cathode made of ITO (indium tin oxide).
図11に示す比較例1の発光素子(青色発光素子)は、図10に示す参考例2の発光素子(赤色発光素子)と同様の理由により、満足できる程の高い発光効率が得られない。 The light-emitting element of Comparative Example 1 (blue light-emitting element) shown in Figure 11 does not achieve a satisfactorily high luminous efficiency for the same reasons as the light-emitting element of Reference Example 2 (red light-emitting element) shown in Figure 10.
図11に示す実施例1の発光素子(青色発光素子)は、Agで形成されたアノードと、酸化ニッケルのナノ粒子で形成された正孔注入層と、ポリ[(9,9-ジオクチルフルオレニル-2,7-ジイル)-co-(4,4’-(N-(4-sec-ブチルフェニル))ジフェニルアミン)](TFB)で形成された正孔輸送層と、青色発光量子ドットとしてZnSeを含む発光層と、上述したMg、Zn及びSiを含む超ナノサイズのコア構造の酸化物ナノ粒子で形成された実施例1の電子機能層4である電子輸送層と、ITO(indium tin oxide)で形成されたカソードとが、この順に積層された発光素子である。なお、比較例1の発光素子(青色発光素子)と実施例1の発光素子(青色発光素子)とにおいては、各層の膜厚を同一に形成しており、電子機能層である電子輸送層以外の層である、アノード、正孔注入層、正孔輸送層、青色発光量子ドットを含む発光層及びカソード)それぞれは、同一組成の同一材料を用いて形成した。 The light-emitting element (blue light-emitting element) of Example 1 shown in Figure 11 is a light-emitting element in which an anode made of Ag, a hole injection layer made of nickel oxide nanoparticles, a hole transport layer made of poly[(9,9-dioctylfluorenyl-2,7-diyl)-co-(4,4'-(N-(4-sec-butylphenyl))diphenylamine)] (TFB), a light-emitting layer containing ZnSe as blue-emitting quantum dots, an electron transport layer which is electronic functional layer 4 of Example 1 made of oxide nanoparticles with an ultra-nano-sized core structure containing Mg, Zn, and Si as described above, and a cathode made of ITO (indium tin oxide) are stacked in this order. In the light-emitting element (blue light-emitting element) of Comparative Example 1 and the light-emitting element (blue light-emitting element) of Example 1, each layer was formed to have the same film thickness, and each of the layers other than the electron transport layer, which is the electronic functional layer (anode, hole injection layer, hole transport layer, light-emitting layer containing blue-emitting quantum dots, and cathode) were formed using the same materials with the same composition.
図11に示すように、実施例1の電子機能層4である電子輸送層を備えた青色発光素子においては、比較例2の電子機能層である電子輸送層を備えた青色発光素子と比較して、大きく改善された満足できる程の高い発光効率が得られた。電子機能層4である電子輸送層に含まれるMg、Zn及びSiを含む超ナノサイズの酸化物ナノ粒子は、粒径及び粒径のばらつきが小さく、高い緻密性を実現することができ、電子輸送層を形成する工程の後工程であるカソードを形成する工程におけるカソードの成膜プロセス、例えば、蒸着工程またはスパッタリング工程に対する耐性が高く、電子機能層4である電子輸送層を備えた発光素子は、高い発光効率を実現することができる。 As shown in Figure 11, the blue light-emitting device having the electron transport layer as the electronic functional layer 4 of Example 1 achieved a significantly improved and satisfactorily high luminous efficiency compared to the blue light-emitting device having the electron transport layer as the electronic functional layer of Comparative Example 2. The ultra-nano-sized oxide nanoparticles containing Mg, Zn, and Si contained in the electron transport layer as the electronic functional layer 4 have small particle size and particle size variation, allowing for high density and high resistance to the cathode formation process, such as the vapor deposition process or sputtering process, in the cathode formation step, which is a step subsequent to the step of forming the electron transport layer, and light-emitting devices having the electron transport layer as the electronic functional layer 4 can achieve high luminous efficiency.
Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子の群からなる、金属酸化物ナノ粒子群は、粒径基準累積50%(D50)である金属酸化物ナノ粒子の粒径は、1.80nm以下であってもよく、粒径基準累積90%(D90)である金属酸化物ナノ粒子の粒径と粒径基準累積10%(D10)である金属酸化物ナノ粒子の粒径との差が、2.10nm以下であってもよい。前記第2元素は、B、Si、Ge、As、Sb、Te、C、N、P、及びSの何れかであってもよい。また、前記金属酸化物ナノ粒子の単位体積においては、酸素元素の量は、前記第1元素の量、前記第2元素の量及び亜鉛元素の量それぞれよりも多く、前記第2元素の量及び亜鉛元素の量それぞれは、前記第1元素の量よりも多いことが好ましい。また、前記第1元素はMgであり、前記第2元素はSiであってもよく、この場合、前記金属酸化物ナノ粒子は、Zn-O結合と、Mg-O結合と、Si-O結合とを含む。 The metal oxide nanoparticle group is composed of a group of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf; a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element; and zinc and oxygen. The particle size of the metal oxide nanoparticles at a cumulative 50% (D50) particle size may be 1.80 nm or less, and the difference between the particle size of the metal oxide nanoparticles at a cumulative 90% (D90) particle size and the particle size of the metal oxide nanoparticles at a cumulative 10% (D10) particle size may be 2.10 nm or less. The second element may be any of B, Si, Ge, As, Sb, Te, C, N, P, and S. Furthermore, it is preferable that, per unit volume of the metal oxide nanoparticles, the amount of oxygen element is greater than the amount of the first element, the amount of the second element, and the amount of zinc element, and that the amount of the second element and the amount of zinc element are each greater than the amount of the first element. Furthermore, the first element may be Mg and the second element may be Si, in which case the metal oxide nanoparticles contain Zn—O bonds, Mg—O bonds, and Si—O bonds.
なお、本実施形態においては、反応装置10を用いて製造されたMg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子の群からなる、金属酸化物ナノ粒子群と溶媒とを含む金属酸化物ナノ粒子の分散液を用いて、電子機能層4を形成する場合を一例に挙げて説明したが、これに限定されることはなく、反応装置10を用いて製造された金属酸化物ナノ粒子群または、上述した金属酸化物ナノ粒子の分散液は、電子機能層以外の電子材料分野やその他の技術分野にも利用することができる。 In this embodiment, the electronic function layer 4 is formed using a dispersion of metal oxide nanoparticles containing a solvent and a group of metal oxide nanoparticles, the group of metal oxide nanoparticles comprising a core containing a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf produced using the reaction apparatus 10, a second element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element, and zinc and oxygen. However, this is not limited to this, and the metal oxide nanoparticles produced using the reaction apparatus 10 or the above-mentioned dispersion of metal oxide nanoparticles can also be used in the field of electronic materials other than electronic function layers and in other technical fields.
〔付記事項〕
本開示は上述した各実施形態に限定されるものではなく、請求項に示した範囲で種々の変更が可能であり、異なる実施形態にそれぞれ開示された技術的手段を適宜組み合わせて得られる実施形態についても本開示の技術的範囲に含まれる。さらに、各実施形態にそれぞれ開示された技術的手段を組み合わせることにより、新しい技術的特徴を形成することができる。
[Additional Notes]
The present disclosure is not limited to the above-described embodiments, and various modifications are possible within the scope of the claims. Embodiments obtained by appropriately combining the technical means disclosed in different embodiments are also included in the technical scope of the present disclosure. Furthermore, new technical features can be formed by combining the technical means disclosed in each embodiment.
本開示は、発光素子と、発光素子の製造方法と、表示装置と、金属酸化物ナノ粒子群と、金属酸化物ナノ粒子の分散液と、金属酸化物ナノ粒子の製造方法とに利用することができる。 The present disclosure can be used in light-emitting devices, methods for manufacturing light-emitting devices, display devices, metal oxide nanoparticle groups, dispersions of metal oxide nanoparticles, and methods for manufacturing metal oxide nanoparticles.
1 表示装置
2 アノード
3 正孔機能層
4 電子機能層
5 カソード
10 反応装置
11 第1供給部
12 第2供給部
13 第3供給部
14 第1供給流路
15 第2供給流路
16 第1マイクロミキサー
17 第3供給流路
18 第4供給流路
19 第2マイクロミキサー
20 マイクロチャネル
21 マイクロリアクター
22 回収部
30 発光素子
EM 発光層
RSP 赤色サブ画素
GSP 緑色サブ画素
BSP 青色サブ画素
PIX 画素
DA 表示領域
NDA 額縁領域
Inlet1 第1供給口
Inlet2 第2供給口
Inlet3 第3供給口
Inlet4 第4供給口
Outlet1 第1排出口
Outlet2 第2排出口
REFERENCE SIGNS LIST 1 display device 2 anode 3 hole functional layer 4 electron functional layer 5 cathode 10 reactor 11 first supply section 12 second supply section 13 third supply section 14 first supply flow path 15 second supply flow path 16 first micromixer 17 third supply flow path 18 fourth supply flow path 19 second micromixer 20 microchannel 21 microreactor 22 recovery section 30 light-emitting element EM light-emitting layer RSP red subpixel GSP green subpixel BSP blue subpixel PIX pixel DA display area NDA frame area Inlet1 first supply port Inlet2 second supply port Inlet3 third supply port Inlet4 fourth supply port Outlet1 first outlet Outlet2 second outlet
Claims (20)
カソードと、
前記アノードと前記カソードとの間に備えられた発光層と、
前記カソードと前記発光層との間に備えられた電子機能層と、を含み、
前記電子機能層は、Mg、Ti、Sn、W、Ta、Ba、Zr、Al、Y、Co、Cu、Mn及びHfから選択される第1元素と、非金属元素のうち水素元素と酸素元素と第18族元素とを除いた元素から選択される元素または半金属元素である第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子を複数個含む、発光素子。 an anode;
a cathode;
a light-emitting layer disposed between the anode and the cathode;
an electronic functional layer disposed between the cathode and the light-emitting layer;
The electronic functional layer comprises a plurality of metal oxide nanoparticles each having a core including a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second element which is an element selected from non-metallic elements excluding hydrogen, oxygen, and Group 18 elements, or a semi-metallic element, zinc, and oxygen.
酸素元素の量は、前記第1元素の量、前記第2元素の量及び亜鉛元素の量それぞれよりも多く、
前記第2元素の量及び亜鉛元素の量それぞれは、前記第1元素の量よりも多い、請求項1または2に記載の発光素子。 In a unit volume of the metal oxide nanoparticles,
the amount of oxygen element is greater than the amount of the first element, the amount of the second element, and the amount of zinc element,
The light-emitting element according to claim 1 , wherein the amount of the second element and the amount of the zinc element are each greater than the amount of the first element.
前記第2元素はSiである、請求項1から3の何れか1項に記載の発光素子。 the first element is Mg,
The light-emitting device according to claim 1 , wherein the second element is Si.
前記10×N個の前記金属酸化物ナノ粒子の粒径の値を小さい順に並べた場合、
5×N番目の金属酸化物ナノ粒子の粒径は、1.8nm以下である、請求項4または5に記載の発光素子。 In a part of a cross section cut along the thickness direction of the electronic functional layer, the cross section contains 10×N metal oxide nanoparticles (N is a natural number of 2 or more),
When the particle diameters of the 10×N metal oxide nanoparticles are arranged in ascending order,
The light-emitting device according to claim 4 or 5, wherein the particle diameter of the 5×Nth metal oxide nanoparticle is 1.8 nm or less.
酸素元素の量は、前記第1元素の量、前記第2元素の量及び亜鉛元素の量それぞれよりも多く、
前記第2元素の量及び亜鉛元素の量それぞれは、前記第1元素の量よりも多い、請求項10または11に記載の金属酸化物ナノ粒子群。 In a unit volume of the metal oxide nanoparticles,
the amount of oxygen element is greater than the amount of the first element, the amount of the second element, and the amount of zinc element,
The group of metal oxide nanoparticles according to claim 10 or 11, wherein the amount of the second element and the amount of zinc element are each greater than the amount of the first element.
前記第2元素はSiである、請求項10から12の何れか1項に記載の金属酸化物ナノ粒子群。 the first element is Mg,
The group of metal oxide nanoparticles according to claim 10 , wherein the second element is Si.
粒径基準累積90%(D90)である金属酸化物ナノ粒子の粒径と粒径基準累積10%(D10)である金属酸化物ナノ粒子の粒径との差が、2.1nm以下である、請求項13または14に記載の金属酸化物ナノ粒子群。 The particle size of the metal oxide nanoparticles at particle size-based cumulative 50% (D50) is 1.8 nm or less;
15. The group of metal oxide nanoparticles according to claim 13 or 14, wherein the difference between the particle size of the metal oxide nanoparticles at particle size-based cumulative 90% (D90) and the particle size of the metal oxide nanoparticles at particle size-based cumulative 10% (D10) is 2.1 nm or less.
一方側の端部が供給端部であり、他方側の端部が排出端部であり、前記マイクロミキサーから排出された流体が前記供給端部から供給されるマイクロチャネルと、
前記マイクロチャネルの少なくとも一部の反応条件を制御するマイクロリアクターと、を含む反応装置を用いて、前記第1元素と、前記第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子を製造する、金属酸化物ナノ粒子の製造方法。 a micromixer that mixes and discharges a first precursor of metal oxide nanoparticles that contains a first element selected from Mg, Ti, Sn, W, Ta, Ba, Zr, Al, Y, Co, Cu, Mn, and Hf, a second precursor of metal oxide nanoparticles that contains a second element that is an element selected from non-metal elements excluding hydrogen, oxygen, and Group 18 elements or a metalloid element, a third precursor of metal oxide nanoparticles that contains zinc, and a reactant, all of which are supplied from the outside;
a microchannel having a supply end at one end and a discharge end at the other end, the microchannel receiving the fluid discharged from the micromixer from the supply end;
a microreactor that controls the reaction conditions in at least a portion of the microchannel, to produce metal oxide nanoparticles having a core that contains the first element, the second element, zinc, and oxygen.
前記第1排出口から排出された流体は前記第3供給口から供給され、
前記第2排出口から排出された流体は前記マイクロチャネルの前記供給端部から供給され、
前記反応装置は、
前記第1供給口、前記第2供給口及び前記第4供給口のうちの一つに、前記第1前駆体と、前記第3前駆体と、第1溶媒とを含む第1溶液を第1流速で供給する第1供給部と、
前記第1供給口、前記第2供給口及び前記第4供給口のうちの他の一つに、前記反応剤と第2溶媒とを含む第2溶液を第2流速で供給する第2供給部と、
前記第1供給口、前記第2供給口及び前記第4供給口のうちのさらに他の一つに、前記第2前駆体と第3溶媒とを含む第3溶液を第3流速で供給する第3供給部と、を含む、請求項17に記載の金属酸化物ナノ粒子の製造方法。 the micromixer includes a first micromixer including a first supply port, a second supply port, and a first discharge port, and a second micromixer including a third supply port, a fourth supply port, and a second discharge port;
The fluid discharged from the first outlet is supplied from the third supply port,
the fluid discharged from the second outlet is supplied to the supply end of the microchannel;
The reactor comprises:
a first supply unit that supplies a first solution containing the first precursor, the third precursor, and a first solvent at a first flow rate to one of the first supply port, the second supply port, and the fourth supply port;
a second supply unit that supplies a second solution containing the reactant and a second solvent at a second flow rate to another one of the first supply port, the second supply port, and the fourth supply port;
18. The method for producing metal oxide nanoparticles according to claim 17, further comprising: a third supply unit that supplies a third solution containing the second precursor and a third solvent at a third flow rate to yet another one of the first supply port, the second supply port, and the fourth supply port.
前記マイクロチャネルの前記排出端部から、前記第1元素と、前記第2元素と、亜鉛元素と、酸素元素とを含むコアで構成された金属酸化物ナノ粒子の分散液を回収する第2工程と、を含む、請求項18に記載の金属酸化物ナノ粒子の製造方法。 a first step of supplying the first solution containing magnesium acetate as the first precursor, zinc acetate as the third precursor, and a polar solvent as the first solvent from the first supply unit to the first supply port, supplying the second solution containing the reactant and an alcohol-based solvent as the second solvent from the second supply unit to the second supply port, and supplying the third solution containing tetraalkoxysilane as the second precursor and an alcohol-based solvent as the third solvent from the third supply unit to the fourth supply port;
a second step of recovering a dispersion of metal oxide nanoparticles composed of a core containing the first element, the second element, zinc element, and oxygen element from the discharge end of the microchannel.
遠心分離によって、固形分と溶液を分離する第4工程と、
上澄液を含む前記溶液を取り除く第5工程と、
前記固形分を溶媒に再分散させた前記金属酸化物ナノ粒子の再分散液を調液する第6工程と、を含む、請求項19に記載の金属酸化物ナノ粒子の製造方法。 a third step of transferring the dispersion of the metal oxide nanoparticles recovered in the second step to a centrifuge tube and adding a poor solvent to precipitate the metal oxide nanoparticles;
a fourth step of separating the solids and the solution by centrifugation;
a fifth step of removing the solution including the supernatant;
and a sixth step of preparing a redispersion of the metal oxide nanoparticles by redispersing the solid content in a solvent.
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| WO2017135393A1 (en) * | 2016-02-02 | 2017-08-10 | エム・テクニック株式会社 | Method for producing color characteristic-controlled oxide particles, oxide particles, and coating or film composition containing said oxide particles |
| JP2022547328A (en) * | 2019-09-13 | 2022-11-11 | フォルナノ ホールディング ゲーエムベーハー | METHOD FOR MANUFACTURING METAL OR METAL OXIDE NANOPARTICLES |
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| WO2017135393A1 (en) * | 2016-02-02 | 2017-08-10 | エム・テクニック株式会社 | Method for producing color characteristic-controlled oxide particles, oxide particles, and coating or film composition containing said oxide particles |
| JP2022547328A (en) * | 2019-09-13 | 2022-11-11 | フォルナノ ホールディング ゲーエムベーハー | METHOD FOR MANUFACTURING METAL OR METAL OXIDE NANOPARTICLES |
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