Display device and manufacturing method thereof

Abstract

The invention relates to a display device and a manufacturing method thereof. According to one embodiment, a display device includes: a substrate; a lower electrode disposed above the substrate; an organic layer disposed on the lower electrode and including a light-emitting layer; an upper electrode disposed on the organic layer; an insulating layer disposed above the upper electrode; a color filter having a first surface facing the insulating layer and a second surface on the opposite side of the first surface; a first lens disposed on the first surface directly above the lower electrode, formed in a convex shape, and covered by the insulating layer; and a second lens disposed on the second surface directly above the lower electrode and formed in a convex shape, in which the second lens includes at least a first layer having a first refractive index and formed in a hemispherical shape, and a second layer having a second refractive index higher than the first refractive index and covering the first layer.

Description

[0001] Cross-references to related applications

[0002] This application claims the priority based on Japanese Patent Application No. 2023-109459 filed on July 3, 2023, and cites all the contents described in the Japanese application. Technical Field

[0003] Embodiments of the present invention relate to a display device and a method for manufacturing the same. Background Art

[0004] In recent years, display devices using organic light emitting diodes (OLEDs) as display elements have been put into practical use. The display element includes: a lower electrode; an upper electrode facing the lower electrode; and an organic layer including a light emitting layer located between the lower electrode and the upper electrode.

[0005] In such a display element, a technology for efficiently extracting light generated by a light-emitting layer to the outside is required. In one example, a technology using an inner extraction layer formed on the inner surface of a substrate facing the display element and an outer extraction layer formed on the outer surface of the substrate is known. Summary of the invention

[0006] An object of the embodiment is to provide a display device that improves light extraction efficiency and can widen the viewing angle, and a method for manufacturing the same.

[0007] A display device according to one embodiment includes:

[0008] A substrate; a lower electrode, which is arranged above the aforementioned substrate; an organic layer, which is arranged above the aforementioned lower electrode and includes a light-emitting layer; an upper electrode, which is arranged above the aforementioned organic layer; an insulating layer, which is arranged above the aforementioned upper electrode; a color filter, which has a first surface opposite to the aforementioned insulating layer and a second surface on the opposite side of the aforementioned first surface; a first lens, which is arranged on the aforementioned first surface just above the aforementioned lower electrode, is formed in a convex shape, and is covered by the aforementioned insulating layer; and a second lens, which is arranged on the aforementioned second surface just above the aforementioned lower electrode and is formed in a convex shape, wherein the aforementioned second lens at least has a first layer having a first refractive index and formed in a hemispherical shape, and a second layer having a second refractive index higher than the aforementioned first refractive index and covering the aforementioned first layer.

[0009] A method for manufacturing a display device according to one embodiment, wherein:

[0010] An insulating layer is formed from an organic material above a display element, a patterned resist is formed on the insulating layer, a portion of the insulating layer is removed using the resist as a mask to form a recess, a first lens is formed to fill the recess, a color filter is formed on the first lens, and a convex second lens is formed on the color filter, wherein the process of forming the second lens at least includes: forming a hemispherical first layer from a material having a first refractive index, and forming a second layer covering the first layer from a material having a second refractive index higher than the first refractive index.

[0011] According to the embodiments, it is possible to provide a display device that improves light extraction efficiency and can achieve a wide viewing angle, and a method for manufacturing the same. BRIEF DESCRIPTION OF THE DRAWINGS

[0012] Figure 1 It is a diagram showing a configuration example of a display device.

[0013] Figure 2 It is a diagram showing a configuration example of sub-pixels SP1 , SP2 , and SP3 .

[0014] Figure 3 It is a diagram showing an example of the layout of sub-pixels SP1 , SP2 , and SP3 .

[0015] Figure 4 It is a diagram showing an example of the layout of the color filters CF1 , CF2 , CF3 , the first lens LS1 , and the second lens LS2 .

[0016] Figure 5 It is shown along Figure 4 A cross-sectional view of a configuration example of a display device DSP taken along line AB in FIG.

[0017] Figure 6 This is a diagram for explaining the effect of the first lens LS1.

[0018] Figure 7 It is a diagram for explaining the effect of the second lens LS2.

[0019] Figure 8 It is a figure for demonstrating the manufacturing method of the 1st lens LS1 and the color filter CF.

[0020] Fig. 9 It is a diagram for explaining a method of manufacturing the second lens LS2.

[0021] Fig.10 It is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2.

[0022] Fig.11 It is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2.

[0023] Fig.12 It is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2.

[0024] Fig.13 It is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. DETAILED DESCRIPTION

[0025] One embodiment will be described with reference to the drawings.

[0026] The disclosed content is only an example, and for those skilled in the art, the content that can be easily thought of with respect to appropriate changes that maintain the gist of the invention is of course included in the scope of the present invention. In addition, in order to make the description clearer, the drawings sometimes schematically show the width, thickness, shape, etc. of each part compared to the actual method, but this is only an example and does not limit the interpretation of the present invention. In addition, in this specification and each figure, the same reference numerals are sometimes used to mark the constituent elements that perform the same or similar functions as the constituent elements described above with respect to the already appeared figures, and repeated detailed descriptions are appropriately omitted.

[0027] It should be noted that, in the accompanying drawings, as needed, for easy understanding, mutually orthogonal X-axis, Y-axis and Z-axis are recorded. The direction along the X-axis is called the first direction X, the direction along the Y-axis is called the second direction Y, and the direction along the Z-axis is called the third direction Z. The situation of observing various elements parallel to the third direction Z is called top view. It should be noted that the terms such as upper, above, between, and opposite to each other that represent the positional relationship between two or more constituent elements not only include the situation where two or more constituent elements of an object are in direct contact, but also include the situation where they are separated from each other by gaps or other constituent elements. In addition, the positive direction of the Z-axis is called upper or above.

[0028] The display device involved in this embodiment is an organic electroluminescent (EL) display device having an organic light emitting diode (OLED) as a display element, and can be mounted on a television, a personal computer, an in-vehicle device, a tablet terminal, a smartphone, a mobile phone terminal, etc.

[0029] Figure 1 This is a diagram showing a configuration example of a DSP of a display device.

[0030] The display device DSP includes a display area DA for displaying an image and a peripheral area SA around the display area DA on an insulating substrate 10. The substrate 10 may be glass or a flexible resin film.

[0031] In the present embodiment, the shape of the substrate 10 in a plan view is a rectangle. However, the shape of the substrate 10 in a plan view is not limited to a rectangle, and may be other shapes such as a square, a circle, or an ellipse.

[0032] The display area DA includes a plurality of pixels PX arranged in a matrix in the first direction X and the second direction Y. The pixel PX includes a plurality of sub-pixels SP. In one example, the pixel PX includes a sub-pixel SP1 of a first color, a sub-pixel SP2 of a second color, and a sub-pixel SP3 of a third color. The first color, the second color, and the third color are mutually different colors. It should be noted that the pixel PX may also include a sub-pixel SP of another color such as white together with the sub-pixels SP1, SP2, and SP3, or instead of any of the sub-pixels SP1, SP2, and SP3. It should be noted that the combination of sub-pixels may be composed of a combination of two elements instead of three elements, or may be composed of four or more elements such as a sub-pixel SP4 in addition to the sub-pixels SP1 to SP3.

[0033] The sub-pixel SP includes a pixel circuit 1 and a display element 20 driven by the pixel circuit 1. The pixel circuit 1 includes a pixel switch 2, a driving transistor 3, and a capacitor 4. The pixel switch 2 and the driving transistor 3 are switching elements composed of, for example, thin film transistors.

[0034] The gate electrode of the pixel switch 2 is connected to the scanning line GL. One of the source electrode and the drain electrode of the pixel switch 2 is connected to the signal line SL, and the other is connected to the gate electrode of the driving transistor 3 and the capacitor 4. In the driving transistor 3, one of the source electrode and the drain electrode is connected to the power line PL and the capacitor 4, and the other is connected to the anode of the display element 20.

[0035] It should be noted that the configuration of the pixel circuit 1 is not limited to the illustrated example. For example, the pixel circuit 1 may include more thin film transistors and capacitors.

[0036] The display element 20 is an organic light emitting diode (OLED) as a light emitting element, sometimes referred to as an organic EL element.

[0037] The peripheral area SA is provided with terminals for connecting an IC chip or a flexible printed circuit board, but detailed description thereof is omitted.

[0038] Figure 2 It is a diagram showing a configuration example of sub-pixels SP1 , SP2 , and SP3 .

[0039] Sub-pixels SP1, SP2, and SP3 include display elements 201, 202, and 203 as display elements 20, respectively. Sub-pixel SP1 includes a color filter CF1 facing display element 201, sub-pixel SP2 includes a color filter CF2 facing display element 202, and sub-pixel SP3 includes a color filter CF3 facing display element 203.

[0040] The display element 201 includes a lower electrode LE1, an upper electrode UE, and an organic layer OR1 including a light-emitting layer EM1. The organic layer OR1 is disposed between the lower electrode LE1 and the upper electrode UE. The light-emitting layer EM1 is formed of a material that emits light of a first color. The color filter CF1 is colored in the first color.

[0041] The display element 202 includes a lower electrode LE2, an upper electrode UE, and an organic layer OR2 including a light-emitting layer EM2. The organic layer OR2 is disposed between the lower electrode LE2 and the upper electrode UE. The light-emitting layer EM2 is formed of a material that emits light of a second color. The color filter CF2 is colored in the second color.

[0042] The display element 203 includes a lower electrode LE3, an upper electrode UE, and an organic layer OR3 including a light-emitting layer EM3. The organic layer OR3 is disposed between the lower electrode LE3 and the upper electrode UE. The light-emitting layer EM3 is formed of a material that emits light of a third color. The color filter CF3 is colored in the third color.

[0043] In one example, the lower electrodes LE1, LE2, and LE3 correspond to anodes of the display elements, and the upper electrode UE corresponds to cathodes or common electrodes of the display elements.

[0044] In the example shown in the figure, the organic layers OR1 , OR2 , and OR3 include a common layer CL1 and a common layer CL2 .

[0045] The common layer CL1 includes, for example, a hole injection layer, a hole transport layer, an electron blocking layer, etc. The common layer CL1 is disposed between the lower electrode LE1 and the light emitting layer EM1 , between the lower electrode LE2 and the light emitting layer EM2 , and between the lower electrode LE3 and the light emitting layer EM3 .

[0046] The common layer CL2 includes, for example, an electron injection layer, an electron transport layer, a hole blocking layer, etc. The common layer CL2 is disposed between the light emitting layer EM1 and the upper electrode UE, between the light emitting layer EM2 and the upper electrode UE, and between the light emitting layer EM3 and the upper electrode UE.

[0047] Figure 3 It is a diagram showing an example of the layout of sub-pixels SP1 , SP2 , and SP3 .

[0048] In the example shown in the figure, the sub-pixel SP1 and the sub-pixel SP2 are arranged in the first direction X, the sub-pixel SP1 and the sub-pixel SP3 are arranged in the first direction X, and the sub-pixel SP2 and the sub-pixel SP3 are arranged in the second direction Y.

[0049] When the sub-pixels SP1, SP2, and SP3 are arranged in this way, columns in which the sub-pixels SP2 and SP3 are alternately arranged in the second direction Y and columns in which a plurality of sub-pixels SP1 are arranged in the second direction Y are formed in the display area DA. These columns are alternately arranged in the first direction X.

[0050] It should be noted that the layout of the sub-pixels SP1, SP2, and SP3 is not limited to Figure 3 As another example of the layout, the sub-pixels SP1, SP2, and SP3 may be arranged in sequence in the first direction X.

[0051] The rib RB indicated by the dotted line has openings AP1, AP2, and AP3 in the sub-pixels SP1, SP2, and SP3, respectively. In the example shown in the figure, the areas of the openings AP1, AP2, and AP3 are different from each other. That is, the area of ​​the opening AP3 is smaller than the area of ​​the opening AP1, and the area of ​​the opening AP2 is smaller than the area of ​​the opening AP3.

[0052] In the sub-pixel SP1, the lower electrode LE1 indicated by the dotted line and the light emitting layer EM1 indicated by the double-dashed line both overlap with the opening AP1 in a plan view. Figure 1 The lower electrode LE1 and the light emitting layer EM1 have their respective peripheral portions overlapped with the rib RB.

[0053] In the sub-pixel SP2, the lower electrode LE2 and the light emitting layer EM2 overlap with the opening AP2 in a plan view. The lower electrode LE2 is electrically connected to the pixel circuit 1 of the sub-pixel SP2. The peripheral edge portions of the lower electrode LE2 and the light emitting layer EM2 overlap with the rib RB.

[0054] In the sub-pixel SP3, the lower electrode LE3 and the light emitting layer EM3 overlap with the opening AP3 in a plan view. The lower electrode LE3 is electrically connected to the pixel circuit 1 of the sub-pixel SP3. The peripheral edge portions of the lower electrode LE3 and the light emitting layer EM3 overlap with the rib RB.

[0055] The lower electrodes LE1, LE2, LE3 are separated from each other. In addition, the light emitting layers EM1, EM2, EM3 are separated from each other. The common layers CL1, CL2 and the upper electrode UE overlap with the openings AP1, AP2, AP3, respectively, and overlap with the rib RB.

[0056] It should be noted that the outer shapes of the openings AP1 , AP2 , AP3 , the lower electrodes LE1 , LE2 , LE3 , and the light emitting layers EM1 , EM2 , EM3 are not limited to those reflecting the correct shapes.

[0057] Figure 4 1 is a diagram showing an example of the layout of the color filters CF1, CF2, CF3, the first lens LS1, and the second lens LS2. Figure 4 In the figure, illustration of the lower electrode, organic layer, upper electrode, etc. of the display element constituting each sub-pixel is omitted.

[0058] The color filters CF1, CF2, and CF3 are separated from each other. The light shielding layer BM overlaps with the ribs RB and is formed in a lattice shape surrounding the openings AP1, AP2, and AP3.

[0059] In the sub-pixel SP1 , the color filter CF1 indicated by the two-dot chain line overlaps with the opening AP1 in a plan view. The peripheral edge of the color filter CF1 overlaps with the rib RB and the light shielding layer BM.

[0060] In the sub-pixel SP2, the color filter CF2 overlaps with the opening AP2 in a plan view. The peripheral edge of the color filter CF2 overlaps with the rib RB and the light shielding layer BM.

[0061] In the sub-pixel SP3, the color filter CF3 overlaps with the opening AP3 in a plan view. The peripheral edge of the color filter CF3 overlaps with the rib RB and the light shielding layer BM.

[0062] In each of the sub-pixels SP1, SP2, and SP3, the first lens LS1 indicated by the dotted line and the second lens LS2 indicated by the solid line are both surrounded by the rib RB when viewed from above. In other words, in the sub-pixel SP1, the first lens LS1 and the second lens LS2 overlap with the opening AP1 and the color filter CF1. In addition, in the sub-pixel SP2, the first lens LS1 and the second lens LS2 overlap with the opening AP2 and the color filter CF2. In addition, in the sub-pixel SP3, the first lens LS1 and the second lens LS2 overlap with the opening AP3 and the color filter CF3.

[0063] Each first lens LS1 is formed into a circular shape when viewed from above. The first lens LS1 is, for example, a single-layer body formed of a single material. In the example shown in the figure, the plurality of first lenses LS1 have the same diameter. It should be noted that at least one first lens LS1 may have a diameter different from that of the other first lenses LS1.

[0064] Each second lens LS2 is formed into a circular shape when viewed from above. The second lens LS2 is a multilayer body of at least two layers, and in the example shown in the figure, has a first layer 21, a second layer 22 covering the first layer 21, and a third layer 23 covering the second layer 22. The first layer 21, the second layer 22, and the third layer 23 are formed of different materials. The refractive indexes of the first layer 21, the second layer 22, and the third layer 23 are different from each other. The outer edge of the first layer 21, the outer edge of the second layer 22, and the outer edge of the third layer 23 are formed into concentric circles when viewed from above. In the example shown in the figure, the plurality of second lenses LS2 have the same diameter. It should be noted that at least one second lens LS2 may have a diameter different from that of the other second lenses LS2.

[0065] In the example shown in the figure, in each sub-pixel, the number of the first lenses LS1 is the same as the number of the second lenses LS2. It should be noted that the number of the first lenses LS1 may be different from the number of the second lenses LS2.

[0066] In the example shown in the figure, the diameter of the second lens LS2 is the same as that of the first lens LS1. However, the diameter of the second lens LS2 may be different from that of the first lens LS1.

[0067] In the example shown in the figure, the second lens LS2 overlaps with the first lens LS1 in a plan view. It should be noted that the second lens LS2 may be arranged offset from the first lens LS1 in a plan view, but preferably overlaps with at least a portion of the first lens LS1.

[0068] Figure 5 It is shown along Figure 4 1 is a cross-sectional view of a configuration example of the display device DSP taken along line AB in FIG. Here, the cross-sectional structure of the sub-pixel SP1 will be mainly described.

[0069] The circuit layer 11 is disposed on the substrate 10. The circuit layer 11 includes Figure 1 The circuit layer 11 is covered with an insulating layer 12 , which includes various circuits such as the pixel circuit 1 and various wirings such as the scanning line GL, the signal line SL, and the power supply line PL. The insulating layer 12 includes an organic insulating layer that flattens the unevenness generated in the circuit layer 11 .

[0070] The lower electrode LE1 of the display element 201 is disposed on the insulating layer 12. The other lower electrodes LE2 and LE3 are similarly disposed on the insulating layer 12. The lower electrode LE1 is a multilayer structure including, for example, an oxide conductive layer such as indium tin oxide (ITO) and a metal layer such as silver.

[0071] The rib RB is disposed on the insulating layer 12. The rib RB covers the peripheral edge of the lower electrode LE1. The rib RB is formed of an organic material or an inorganic material.

[0072] The common layer CL1 is disposed on the lower electrode LE1 and the rib RB. The light emitting layer EM1 is located directly above the lower electrode LE1 and is disposed on the common layer CL1. The common layer CL2 is disposed on the light emitting layer EM1 and is disposed on the common layer CL1 outside the light emitting layer EM1. Figure 2 As described, the common layer CL1 , the light emitting layer EM1 , and the common layer CL2 constitute the organic layer OR1 .

[0073] The upper electrode UE is disposed on the common layer CL2 and is formed of a metal material such as an alloy of magnesium and silver (MgAg).

[0074] The cap layer 13 is disposed on the upper electrode UE. The cap layer 13 is a transparent multilayer body. The refractive indexes of the layers constituting the cap layer 13 are different from each other. Such a cap layer 13 functions as an optical adjustment layer for adjusting the optical characteristics of light emitted from the light emitting layer EM1.

[0075] The sealing layer 14 is disposed on the cap layer 13. The sealing layer 14 is formed of a transparent inorganic material such as silicon nitride (SiNx), silicon oxide (SiOx), or silicon oxynitride (SiON).

[0076] The insulating layer 15 is disposed on the sealing layer 14. The insulating layer 15 is formed of a transparent organic material.

[0077] The color filter CF1 and the light shielding layer BM are arranged on the insulating layer 15. The color filter CF1 is arranged directly above the display element 201. The light shielding layer BM is arranged directly above the rib RB. The peripheral portion of the color filter CF1 overlaps with the light shielding layer BM. Such a light shielding layer BM absorbs external light and suppresses reflection of undesired light.

[0078] The color filter CF1 has a first surface (lower surface) CFA facing the insulating layer 15 and a second surface (upper surface) CFB on the opposite side of the first surface CFA.

[0079] The first lens LS1 is disposed on the first surface CFA just above the lower electrode LE1 and is formed in a convex shape toward the display element 201. The first lens LS1 is covered by the insulating layer 15. In other words, the first lens LS1 fills the concave portion of the insulating layer 15. As shown in the figure, the first lens LS1 has a semicircular cross section and has a Figure 4 The first lens LS1 has a circular outer edge as shown in FIG. 1 and is formed into a hemispherical shape. The first lens LS1 is formed of a transparent organic material. The refractive index of the first lens LS1 is higher than the refractive index of the insulating layer 15.

[0080] The second lens LS2 is disposed on the second surface CFB directly above the lower electrode LE1, and is formed into a convex shape on the side opposite to the first lens LS1. In the illustrated example, the second lens LS2 is located directly above the first lens LS1. The first layer 21 of the second lens LS2 is formed into a hemispherical shape in the second surface CFB, and has a first refractive index. The second layer 22 has an almost constant thickness, covers the first layer 21, is in contact with the second surface CFB, and has a second refractive index higher than the first refractive index. The third layer 23 has an almost constant thickness, covers the second layer 22, is in contact with the second surface CFB, and has a third refractive index higher than the second refractive index.

[0081] The first layer 21 is formed of a transparent organic material. In one example, the first refractive index of the first layer 21 is about 1.4 or less. The second layer 22 and the third layer 23 are each formed of a transparent inorganic material or a transparent organic material. In one example, the third refractive index of the third layer 23 is about 1.6 or more, and the second refractive index of the second layer 22 is greater than 1.4 and less than 1.6.

[0082] It should be noted that the second lens LS2 can be composed of at least the first layer 21 and the second layer 22, and can also be composed of a multilayer body of four or more layers. In short, in the second lens LS2, the first layer 21 has the smallest refractive index, and the outer layers relative to the first layer 21 have higher refractive indexes.

[0083] In such a display element 201, when a potential difference is formed between the lower electrode LE1 and the upper electrode UE, the light emitting layer EM1 in the organic layer OR1 emits light. The light emitted from the light emitting layer EM1 passes through the cap layer 13, the sealing layer 14, and the insulating layer 15, is appropriately converged by the first lens LS1, passes through the color filter CF1, and is appropriately diverged by the second lens LS2.

[0084] According to the configuration in which the color filter CF1 is disposed above the display element 201 and the light shielding layer BM is disposed overlapping the peripheral portion of the color filter CF1, the transmittance of light emitted from the light emitting layer EM1 is increased compared to the configuration in which an anti-reflection circular polarizing plate is disposed. Therefore, high brightness can be obtained with low power, and a long life can be achieved.

[0085] Figure 6 This is a diagram for explaining the effect of the first lens LS1.

[0086] The light emitted from the light emitting layer EM1 of the display element 201 is divergent light, and a part of the light is confined inside the display device.

[0087] Here, in this embodiment, the convex first lens LS1 is arranged toward the display element 201 so as to be in contact with the insulating layer 15, and the refractive index of the first lens LS1 is higher than the refractive index of the insulating layer 15. Therefore, the light reaching the first lens LS1 from the display element 201 is refracted and appropriately converged at the interface between the insulating layer 15 and the first lens LS1, and is emitted in the normal direction of the display device. As a result, the light confined inside the display device is reduced, and the light extraction efficiency can be improved.

[0088] The inventors of the present application conducted a simulation to compare the brightness of a comparative example in which the first lens LS1 is not provided and the brightness of an example in which the first lens LS1 is provided, and confirmed that the brightness obtained in the example is higher than that of the comparative example, and in particular, the brightness in the normal direction of the display device is about 1.8 times that of the comparative example.

[0089] Figure 7 It is a diagram for explaining the effect of the second lens LS2.

[0090] As described above, the second lens LS2 is a multilayer body, and the refractive index of each layer is different from each other. Therefore, the light incident on the second lens LS2 from the color filter CF1 is refracted in a divergent manner at the interface between the first layer 21 and the second layer 22, and further refracted in a divergent manner at the interface between the second layer 22 and the third layer 23, and further refracted in a divergent manner at the interface between the third layer 23 and the air. That is, the light passing through the second lens LS2 is diverged at a large angle relative to the normal line of the display device.

[0091] In addition, the second lens LS2 is formed in a hemispherical shape. Therefore, the second lens LS2 is not limited to a specific orientation, and can isotropically diverge light in all directions of the XY plane.

[0092] Therefore, even when the display device DSP is observed at a large viewing angle relative to the normal, it is possible to visually recognize light from the display element 201. In addition, the light extraction efficiency is improved by the first lens LS1, and the light after appropriate convergence enters the second lens LS2, so that the viewing angle at which high-brightness light can be visually recognized can be expanded.

[0093] Next, refer to Figure 8 and Fig. 9 A method for manufacturing the display device DSP will be described below. Here, a method for manufacturing the first lens LS1, the color filter, and the second lens LS2 will be described in particular.

[0094] First, if Figure 8As shown in step ST1 of the method, an insulating layer 15 is formed of an organic material above the display element 20 . The display element 20 here corresponds to the above-mentioned display elements 201 , 202 , and 203 . Then, a patterned resist RS is formed on the upper surface 15U of the insulating layer 15 .

[0095] Next, as shown in step ST2 , a part of the insulating layer 15 is removed by ashing using the resist RS as a mask, thereby forming the recessed portion 15C. Then, the resist RS is removed.

[0096] Next, as shown in step ST3, the material M for forming the first lens LS1 is applied to the upper surface 15U of the insulating layer 15 and filled in the concave portion 15C. The material M is a material having a refractive index higher than that of the insulating layer 15, for example, an organic material such as acrylic resin. As an example of acrylic resin, polymethyl methacrylate (PMMA) can be applied.

[0097] Next, as shown in step ST4, the material M overlapping the upper surface 15U is removed. Thus, the first lens LS1 filling the concave portion 15C is formed. It should be noted that the material M overlapping the upper surface 15U may remain. The first lens LS1 of each of the sub-pixels SP1, SP2, and SP3 is formed simultaneously.

[0098] Next, as shown in step ST5, a color filter CF is formed on the first lens LS1. It should be noted that, strictly speaking, before forming the color filter CF, Figure 5 Then, the color filter CF1 of the sub-pixel SP1, the color filter CF2 of the sub-pixel SP2, and the color filter CF3 of the sub-pixel SP3 are sequentially formed as the color filter CF. However, the order of forming the color filters CF1, CF2, and CF3 is optional.

[0099] Next, if Fig. 9 As shown in step ST11, the material M1 for forming the first layer 21 of the second lens LS2 is applied to the upper surface CFU of the color filter CF. The upper surface CFU here corresponds to, for example, Figure 5 The second surface CFB of the substrate. The material M1 is a material having a first refractive index, such as an organic material such as a fluorine resin or a silicone resin. As an example of a fluorine resin, polytetrafluoroethylene (PTFE) can be applied. As an example of a silicone resin, polydimethylsiloxane (PDMS) can be applied.

[0100] Next, as shown in step ST12 , the material M1 is patterned, and the remaining material M1 is reflowed as necessary, thereby forming the hemispherical first layer 21 .

[0101] Next, as shown in step ST13, the upper surface CFU and the first layer 21 are covered with the material M2 for forming the second layer 22 of the second lens LS2. The material M2 is a material having a second refractive index higher than the first refractive index, for example, an inorganic material such as silicon oxide (SiO2) or an organic material such as PMMA. When the material M2 is an inorganic material, the material M2 is deposited on the upper surface CFU by, for example, CVD (Chemical-Vapor Deposition) or sputtering. When the material M2 is an organic material, the material M2 is coated on the upper surface CFU.

[0102] Next, as shown in step ST14 , the material M2 is patterned to form the second layer 22 .

[0103] Next, as shown in step ST15, the upper surface CFU and the second layer 22 are covered with the material M3 for forming the third layer 23 of the second lens LS2. The material M3 is a material having a third refractive index higher than the second refractive index, for example, an inorganic material such as zirconium oxide (ZrO2) and tantalum oxide (TaO5) or an organic material such as epoxy resin. When the material M3 is an inorganic material, the material M3 is deposited on the upper surface CFU by CVD or sputtering, for example. When the material M3 is an organic material, the material M3 is coated on the upper surface CFU.

[0104] Next, as shown in step ST16, the material M3 is patterned to form the third layer 23 and the second lens LS2.

[0105] It should be noted that in each of the following configuration examples, the first lens LS1 and the second lens LS2 in the sub-pixel SP1 are described, and the display element is omitted in the figures corresponding to each configuration example.

[0106] Fig.10 It is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2.

[0107] Fig.10 The examples shown in Figure 4 Compared with the example shown in , the number of first lenses LS1 arranged in the sub-pixel SP1 is greater than the number of second lenses LS2. By arranging more first lenses LS1, it is possible to further reduce the light confined in the display device and improve the light extraction efficiency.

[0108] Fig.11 It is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2.

[0109] Fig.11 The examples shown in Figure 4 Compared with the example shown in , the number of second lenses LS2 arranged in the sub-pixel SP1 is greater than the number of first lenses LS1. By arranging more second lenses LS2, a wide viewing angle can be achieved.

[0110] Fig.12 It is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2.

[0111] Fig.12 The examples shown in Figure 4 Compared with the example shown in , the number of the first lenses LS1 arranged in the sub-pixel SP1 is greater than the number of the second lenses LS2, and the diameter of the second lens LS2 is larger than the diameter of the first lens LS1. A plurality of first lenses LS1 overlap with one second lens LS2 in a plan view. The same effect as described above can also be obtained in such a configuration example.

[0112] Fig.13 It is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2.

[0113] Fig.13 The examples shown in Figure 4 Compared with the example shown in , the number of second lenses LS2 arranged in the sub-pixel SP1 is greater than the number of first lenses LS1, and the diameter of the first lens LS1 is larger than the diameter of the second lens LS2. A plurality of second lenses LS2 overlap with one first lens LS1 in a plan view. The same effect as described above can also be obtained in such a configuration example.

[0114] As described above, according to the present embodiment, it is possible to provide a display device that improves light extraction efficiency and can achieve a wide viewing angle, and a method for manufacturing the same.

[0115] Based on the display device and the manufacturing method thereof described above as the embodiments of the present invention, any display device and the manufacturing method thereof that can be implemented by appropriately designing and modifying by a person skilled in the art also belongs to the scope of the present invention as long as it includes the gist of the present invention.

[0116] Within the scope of the present invention, those skilled in the art can think of various variations, which also belong to the scope of the present invention. For example, embodiments obtained by adding, deleting or designing the above-mentioned embodiments appropriately by those skilled in the art, or embodiments obtained by adding, omitting or changing the conditions of the processes, are included in the scope of the present invention as long as they have the gist of the present invention.

[0117] In addition, regarding other effects brought about by the methods described in the above-mentioned embodiments, regarding the effects that are clear based on the records in this specification, or the effects that can be appropriately thought of by those skilled in the art, it is of course understood that they are the effects brought about by the present invention.

Claims

1. A display device comprising: substrate; A lower electrode disposed above the substrate; an organic layer, which is disposed on the lower electrode and includes a light-emitting layer; An upper electrode, which is disposed on the organic layer; an insulating layer, disposed above the upper electrode; a color filter having a first surface facing the insulating layer and a second surface on the opposite side of the first surface; a first lens disposed on the first surface just above the lower electrode, formed in a convex shape, and covered by the insulating layer; and a second lens, which is arranged on the second surface just above the lower electrode and is formed in a convex shape, in, The second lens includes at least a first layer having a first refractive index and formed in a hemispherical shape, and a second layer having a second refractive index higher than the first refractive index and covering the first layer.

2. The display device according to claim 1, wherein: The second lens further includes a third layer having a third refractive index higher than the second refractive index and covering the second layer.

3. The display device according to claim 2, wherein: The outer edge of the first layer, the outer edge of the second layer, and the outer edge of the third layer are formed in a concentric circle shape in a plan view.

4. The display device according to claim 2, wherein: The first layer is formed of an organic material, The second layer and the third layer are formed of an inorganic material or an organic material.

5. The display device according to claim 1, wherein: The second lens overlaps at least a portion of the first lens in a plan view.

6. The display device according to claim 1, further comprising: a capping layer disposed on the upper electrode; and a sealing layer, which is disposed on the cover layer and is formed of an inorganic material, in, The insulating layer is disposed on the sealing layer and is formed of an organic material. The first lens is formed of an organic material having a refractive index higher than that of the insulating layer.

7. The display device according to claim 1, further comprising a rib covering the peripheral edge of the lower electrode, The first lens and the second lens are surrounded by the rib in a plan view.

8. The display device according to claim 7, wherein: The plurality of first lenses and the plurality of second lenses are surrounded by the rib in a plan view. The number of the first lenses is the same as the number of the second lenses.

9. The display device according to claim 7, wherein: The plurality of first lenses and the plurality of second lenses are surrounded by the rib in a plan view. The number of the first lenses is different from the number of the second lenses.

10. The display device according to claim 1, further comprising a rib covering a peripheral edge of the lower electrode, The plurality of first lenses are surrounded by the rib in a plan view and overlap with one second lens.

11. The display device according to claim 1, further comprising a rib covering a peripheral edge of the lower electrode, The plurality of second lenses are surrounded by the rib in a plan view and overlap with one first lens.

12. A method for manufacturing a display device, wherein: An insulating layer is formed of organic material above the display element. forming a patterned resist over the insulating layer, Using the resist as a mask, a portion of the insulating layer is removed to form a recessed portion. forming a first lens to fill the concave portion, forming a color filter on the first lens, A convex second lens is formed on the color filter, The process of forming the second lens at least includes: The first layer is formed into a hemispherical shape by a material having a first refractive index, A step of forming a second layer covering the first layer from a material having a second refractive index higher than the first refractive index.

13. The method for manufacturing a display device according to claim 12, wherein: The step of forming the second lens further includes the step of forming a third layer covering the second layer from a material having a third refractive index higher than the second refractive index.

14. The method for manufacturing a display device according to claim 13, wherein: The first layer is formed of an organic material, The second layer and the third layer are formed of an inorganic material or an organic material.

15. The method for manufacturing a display device according to claim 12, wherein: The first lens is formed of an organic material having a refractive index higher than that of the insulating layer.

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