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; a rib portion covering a peripheral portion of the lower electrode; an organic layer disposed on the lower electrode and including a light-emitting layer; an upper electrode disposed on the organic layer; a support body having a first surface disposed above the upper electrode and facing the lower electrode, 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 and formed in a convex shape; an outer coating layer covering the first lens; a second lens disposed on the second surface directly above the rib and formed in a convex shape; and a light shielding layer that covers the second lens, in which the first lens includes at least a first layer that is in contact with the first surface and has a first refractive index, and a second layer that has a second refractive index higher than the first refractive index and overlaps the first layer.

Description

[0001] Cross-references to related applications

[0002] This application claims the priority based on Japanese Patent Application No. 2023-112439 filed on July 7, 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 the light-emitting layer to the outside is required. In one example, a technology is known that uses 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. Summary of the invention

[0006] An object of the embodiment is to provide a display device and a method for manufacturing the display device that can improve light extraction efficiency and suppress reflection of external light.

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

[0008] A substrate; a lower electrode, which is arranged above the aforementioned substrate; a rib, which covers the peripheral portion of the aforementioned lower electrode; an organic layer, which is arranged on the aforementioned lower electrode and includes a light-emitting layer; an upper electrode, which is arranged on the aforementioned organic layer; a support body, which has a first surface arranged above the aforementioned upper electrode and opposite to the aforementioned lower electrode 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 and is formed in a convex shape; an overcoat layer, which covers the aforementioned first lens; a second lens, which is arranged on the aforementioned second surface just above the aforementioned rib and is formed in a convex shape; and a light-shielding layer, which covers the aforementioned second lens, wherein the aforementioned first lens at least has a first layer that is in contact with the aforementioned first surface and has a first refractive index, and a second layer that has a second refractive index higher than the aforementioned first refractive index and overlaps with the aforementioned first layer.

[0009] In a method for manufacturing a display device according to one embodiment,

[0010] A first lens is formed on the first surface of a support body, the first lens is covered by an outer covering layer, a second lens is formed on the second surface of the support body, a light shielding layer covering the second lens is formed, and the outer covering layer is bonded to an insulating layer arranged above a display element, wherein the process of forming the first lens at least includes: forming a first layer on the first surface from a material having a first refractive index, and forming a second layer on 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 capable of improving light extraction efficiency and suppressing reflection of external light, 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 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 It is a diagram for explaining the effects of this embodiment.

[0018] Figure 7 It is a diagram for explaining another effect of this embodiment.

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

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

[0021] Fig. 9B It is a diagram for explaining a method of manufacturing the display device DSP.

[0022] Fig.10 It is a diagram for explaining another method for forming the first lens LS1.

[0023] Fig.11 It is a cross-sectional view showing another configuration example of the display device DSP. DETAILED DESCRIPTION

[0024] One embodiment will be described with reference to the drawings.

[0025] 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.

[0026] 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 terms such as top, above, between, and opposite to each other that represent the positional relationship between two or more constituent elements include not only the situation where two or more constituent elements of an object are in direct contact, but also 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 top or above.

[0027] 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.

[0028] Figure 1 This is a diagram showing a configuration example of a DSP of a display device.

[0029] 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.

[0030] In the present embodiment, the shape of the substrate 10 in plan view is a rectangle, however, the shape of the substrate 10 in plan view is not limited to a rectangle, and may be other shapes such as a square, a circle, or an ellipse.

[0031] 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.

[0032] 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.

[0033] 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.

[0034] 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.

[0035] The display element 20 is an organic light emitting diode (OLED) as a light emitting element, sometimes referred to as an organic EL element.

[0036] 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.

[0037] Figure 2 It is a diagram showing a configuration example of sub-pixels SP1 , SP2 , and SP3 .

[0038] The sub-pixels SP1, SP2, and SP3 each include a display element 201, 202, and 203 as the display element 20. In the example shown in the figure, the sub-pixel SP1 includes a color filter CF1 facing the display element 201, the sub-pixel SP2 includes a color filter CF2 facing the display element 202, and the sub-pixel SP3 includes a color filter CF3 facing the display element 203. It should be noted that at least one of these color filters CF1, CF2, and CF3 may be omitted.

[0039] 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.

[0040] 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.

[0041] 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.

[0042] 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.

[0043] In the example shown in the figure, the organic layers OR1 , OR2 , and OR3 include a common layer CL1 and a common layer CL2 .

[0044] 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 .

[0045] 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.

[0046] Figure 3 It is a diagram showing an example of the layout of sub-pixels SP1 , SP2 , and SP3 .

[0047] 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.

[0048] 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.

[0049] 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.

[0050] The rib RB indicated by the single-dot chain 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 AP2 is smaller than the area of ​​the opening AP1, and the area of ​​the opening AP3 is smaller than the area of ​​the opening AP2.

[0051] 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.

[0052] 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.

[0053] 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.

[0054] 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.

[0055] 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 accurate shapes.

[0056] Figure 4 1 is a diagram showing an example of the layout of the first lens LS1 and the second lens LS2. Figure 4 In the figure, illustration of the lower electrode, organic layer, upper electrode, etc., which constitute the display element of each sub-pixel, is omitted.

[0057] The light shielding layer BM overlaps with the rib portion RB and is formed in a lattice shape surrounding the openings AP1 , AP2 , and AP3 .

[0058] In each of the sub-pixels SP1, SP2, and SP3, the first lens LS1 indicated by the dotted line is surrounded by the rib RB in a plan view. In other words, in the sub-pixel SP1, the first lens LS1 overlaps with the opening AP1. In addition, in the sub-pixel SP2, the first lens LS1 overlaps with the opening AP2. In addition, in the sub-pixel SP3, the first lens LS1 overlaps with the opening AP3.

[0059] Each of the first lenses LS1 is formed into a circular shape when observed from above. The first lens LS1 is a multilayer body of at least two layers, and in the example shown in the figure, has a first layer L1, a second layer L2 overlapping the first layer L1, and a third layer L3 overlapping the second layer L2. The first layer L1, the second layer L2, and the third layer L3 are formed of different materials. The outer edge of the first layer L1, the outer edge of the second layer L2, and the outer edge of the third layer L3 are formed into concentric circles when observed from above. The outer edge of the third layer L3 is located at the center of the first lens LS1, the outer edge of the second layer L2 is located outside the third layer L3, and the outer edge of the first layer L1 is located outside the second layer L2. Regarding the width along the first direction X, the width W2 of the second layer L2 is larger than the width W3 of the third layer L3, and the width W1 of the first layer L1 is larger than the width W2 of the second layer L2 (W3 <W2<W1)。

[0060] In the example shown in the figure, the plurality of first lenses LS1 all have the same diameter. However, at least one first lens LS1 may have a diameter different from that of the other first lenses LS1.

[0061] The second lens LS2 indicated by the solid line overlaps with the rib RB and the light shielding layer BM in a plan view. Each of the openings AP1, AP2, and AP3 is surrounded by a plurality of second lenses LS2. In addition, a plurality of second lenses LS2 are respectively arranged between the openings AP1 and AP2, between the openings AP1 and AP3, and between the openings AP2 and AP3.

[0062] Each of the second lenses LS2 is formed into a circle when viewed from above. The second lens LS2 is, for example, a single-layer body formed of a single material. 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. The diameter of the second lens LS2 may be the same as or different from that of the first lens LS1.

[0063] Figure 5 It is shown along Figure 4A cross-sectional view of a configuration example of a display device DSP along line AB in FIG. Here, the cross-sectional structure of the sub-pixel SP1 is mainly described. It should be noted that the example shown here is equivalent to an example in which a color filter is omitted. However, a color filter may also be provided above the display device DSP shown in the figure.

[0064] 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 .

[0065] 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.

[0066] 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 an insulating layer and is formed of an organic material or an inorganic material.

[0067] 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 .

[0068] 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).

[0069] 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 properties of the light emitted from the light emitting layer EM1. It should be noted that the cap layer 13 may also be omitted.

[0070] 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).

[0071] The insulating layer 15 is disposed on the sealing layer 14. The insulating layer 15 is formed of a transparent organic material.

[0072] The overcoat layer OC is disposed on the insulating layer 15. In one example, the overcoat layer OC is bonded to the insulating layer 15. Such an overcoat layer OC is formed of a transparent organic material.

[0073] The support body 30 includes a first surface (lower surface) 30A facing the display element 201 including the lower electrode LE1 and a second surface (upper surface) 30B on the opposite side to the first surface 30A.

[0074] The first lens LS1 is disposed on the first surface 30A directly 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 overcoat layer OC. As shown in the figure, the first lens LS1 has a semicircular cross section and has Figure 4 The outer edge of the circle is as shown in FIG. 1 and is formed into a hemispherical shape.

[0075] The first layer L1 of the first lens LS1 has a substantially constant thickness, is in contact with the first surface 30A, and has a first refractive index. The second layer L2 has a substantially constant thickness, overlaps with the first layer L1 and is separated from the first surface 30A, and has a second refractive index higher than the first refractive index. The third layer L3 has a substantially constant thickness, overlaps with the second layer L2 and is separated from the first surface 30A, and has a third refractive index higher than the second refractive index.

[0076] The first layer L1, the second layer L2, and the third layer L3 are formed of a transparent organic material. In one example, the first layer L1 has a first refractive index of about 1.42, the second layer L2 has a second refractive index of about 1.49 to 1.5, and the third layer L3 has a third refractive index of about 1.56 to 1.6.

[0077] The overcoat layer OC covers the third layer L3 and is in contact with the peripheral edge portions of the first layer L1 and the second layer L2. It is desirable that such an overcoat layer OC has a refractive index at least smaller than the third refractive index.

[0078] It should be noted that the first lens LS1 can be composed of at least the first layer L1 and the second layer L2, and can also be composed of a multilayer body of four or more layers. In short, in the first lens LS1, the first layer L1 has the smallest refractive index, and the layers farther away from the first layer L1 have higher refractive indices.

[0079] The second lens LS2 is disposed on the second surface 30B just above the rib RB and is formed in a convex shape on the opposite side of the first lens LS1. The second lens LS2 is disposed at a position offset from the first lens LS1. The second lens LS2 is formed of a transparent organic material.

[0080] The light shielding layer BM is disposed just above the rib RB and in contact with the second surface 30B, and covers the second lens LS2. Such a light shielding layer BM is formed of an organic material including a black pigment, for example, and absorbs external light to suppress reflection of undesired light.

[0081] 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, the insulating layer 15, and the overcoat layer OC, and is appropriately converged or diverged by the first lens LS1.

[0082] The configuration in which the light shielding layer BM is disposed at the periphery of the display element 201 increases the transmittance of light emitted from the light emitting layer EM1 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 longer life can be achieved.

[0083] Figure 6 It is a diagram for explaining the effects of this embodiment.

[0084] As described above, the first lens LS1 is a multilayer body, and each layer has a different refractive index. When external light Ex enters such a first lens LS1, the reflectivity of the external light Ex can be reduced by interference of light reflected at the interface between the layers of the first lens LS1.

[0085] In addition, the external light Ex toward the second lens LS2 is absorbed by the light shielding layer BM. Since the light shielding layer BM covers the surface of the convex second lens LS2, the setting area of ​​the light shielding layer BM is increased compared to the case where the second lens LS2 does not exist, and the reflectivity of the external light Ex can be further reduced.

[0086] Figure 7 It is a diagram for explaining another effect of this embodiment.

[0087] 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.

[0088] Here, in this embodiment, the convex first lens LS1 is arranged toward the display element 201, and the third refractive index of the third layer L3 is higher than the refractive index of the outer cover layer OC. Therefore, the light reaching the first lens LS1 from the display element 201 is refracted at the interface between the outer cover layer OC and the third layer L3 and is appropriately converged. As a result, the light trapped inside the display device is reduced, and the light extraction efficiency can be improved.

[0089] The light transmitted through the third layer L3 is refracted so as to diverge at the interface between the second layer L2 and the third layer L3, and is also refracted so as to diverge at the interface between the first layer L1 and the second layer L2. That is, the light transmitted through the first lens LS1 diverges at a large angle with respect to the normal line of the display device.

[0090] In addition, the first lens LS1 is formed in a hemispherical shape. Therefore, the first lens LS1 is not limited to a specific orientation, and can isotropically diverge light in all directions of the XY plane.

[0091] Therefore, even when the display device DSP is observed at a large viewing angle relative to the normal line, light from the display element 201 can be visually recognized. In addition, the first lens LS1 can improve light extraction efficiency and expand the viewing angle at which high-brightness light can be visually recognized.

[0092] 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.

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

[0094] First, if Figure 8 As shown, in step ST1, the first surface 30A of the support body 30 is cleaned. In the cleaning process, for example, oxygen plasma treatment can be applied. In addition, the first surface 30A can also be cleaned using an organic solvent. Then, a material M1 for forming the first layer L1 of the first lens LS1 is applied to the first surface 30A of the support body 30. The material M1 is a material having a first refractive index, for example, an organic material such as silicone resin. As an example of silicone resin, polydimethylsiloxane (PDMS) can be applied.

[0095] Then, a material M2 for forming the second layer L2 of the first lens LS1 is applied onto the material M1. The material M2 is a material having a second refractive index higher than the first refractive index, and is an organic material such as acrylic resin. As an example of acrylic resin, polymethyl methacrylate (PMMA) can be applied.

[0096] Then, a material M3 for forming the third layer L3 of the first lens LS1 is applied onto the material M2. The material M3 is a material having a third refractive index higher than the second refractive index, and is, for example, an organic material such as epoxy resin.

[0097] Next, in order to form the first lens LS1 , the materials M1 , M2 , and M3 are patterned together.

[0098] In step ST2, a mask MK1 is placed above the material M3 and ultraviolet rays are irradiated. The mask MK1 has an opening MA1 and a shielding portion MB1. When the materials M1, M2, and M3 are positive photosensitive materials, the shielding portion MB1 is arranged at a position where the first lens LS1 is formed. It should be noted that when the materials M1, M2, and M3 are negative photosensitive materials, the opening MA1 is arranged at a position where the first lens LS1 is formed.

[0099] Then, in step ST3 , the materials M1 , M2 , and M3 are developed to remove the areas irradiated with ultraviolet rays.

[0100] Next, in step ST4, the materials M1, M2, and M3 remaining after patterning are reflowed, thereby forming a hemispherical first lens LS1. The first lenses LS1 of the sub-pixels SP1, SP2, and SP3 are simultaneously formed through the above steps.

[0101] Next, in step ST5 , the cover layer OC is formed to cover the first lens LS1 .

[0102] Then, if Fig. 9A As shown, in step ST11, a material M4 for forming the second lens LS2 is applied to the second surface 30B of the support 30. The material M4 is, for example, an organic material.

[0103] Next, in step ST12, a mask MK2 is placed above the material M4 and ultraviolet rays are irradiated. The mask MK2 has an opening MA2 and a shielding portion MB2. When the material M4 is a positive photosensitive material, the shielding portion MB2 is arranged at a position where the second lens LS2 is formed. It should be noted that when the material M4 is a negative photosensitive material, the opening MA2 is arranged at a position where the second lens LS2 is formed.

[0104] Next, in step ST13 , the material M4 is developed to remove the region irradiated with ultraviolet rays.

[0105] Next, in step ST14, the remaining material M4 is reflowed, thereby forming a hemispherical second lens LS2 at a position not overlapping with the first lens LS1.

[0106] Next, in step ST15 , a light shielding layer BM is formed to cover the second surface 30B and the second lens LS2 .

[0107] Next, in step ST16 , the light shielding layer BM is patterned.

[0108] Then, if Fig. 9B As shown, the cover layer OC is bonded to the insulating layer 15. At this time, the first lens LS1 is arranged directly above each of the display elements 201, 202, and 203. In addition, the second lens LS2 is arranged directly above the rib RB. In this way, a Figure 5 The display device DSP is shown in FIG.

[0109] In the above example, the first lens LS1 is formed by collectively patterning the first layer L1 , the second layer L2 , and the third layer L3 , but the present invention is not limited to this example.

[0110] Fig.10 It is a diagram for explaining another method for forming the first lens LS1.

[0111] First, in step ST21, a material M1 for forming the first layer L1 is applied, a material M2 for forming the second layer L2 is applied, and a material M3 for forming the third layer L3 is applied. It should be noted that: Fig.10 In FIG. 1 , a stack of materials M1 , M2 , and M3 is referred to as material M.

[0112] Next, in step ST22 , a mold MD is prepared. The mold MD has a concave portion MDC corresponding to the first lens LS1 . Then, the support 30 is placed on the heating plate HP, and the mold MD is set above the material M. At this time, the concave portion MDC faces the material M.

[0113] Next, in step ST23 , the material M is heated by the heating plate HP, and is pressed against the mold MD from above the material M. Thus, the material M melts and enters the concave portion MDC, thereby forming a convex first lens LS1 .

[0114] It should be noted that, here, another method of forming the first lens LS1 is described, but the method described here can be applied as another method of forming the second lens LS2.

[0115] Next, another configuration example will be described.

[0116] Fig.11 It is a cross-sectional view showing another configuration example of the display device DSP.

[0117] Fig.11 The configuration example shown in Figure 5Compared with the configuration example shown in , the support body 30 is different in that the color filter CF1, CF2, and CF3. For example, in the sub-pixel SP1, the color filter CF1 has a first surface CFA opposite to the display element 201 and a second surface CFB on the opposite side of the first surface CFA. The first lens LS1 is arranged on the first surface CFA just above the lower electrode LE1 and is formed in a convex shape toward the display element 201. The second lens LS2 is arranged on the second surface CFB just above the rib RB and is formed in a convex shape on the opposite side of the first lens LS1. The light shielding layer BM is arranged just above the rib RB and covers the second lens LS2.

[0118] Even in such a configuration example, the same effects as those in the above-described configuration example can be obtained.

[0119] It should be noted that the support body 30 may be provided separately from the color filters CF1 , CF2 , and CF3 .

[0120] As described above, according to the present embodiment, it is possible to provide a display device capable of improving light extraction efficiency and suppressing reflection of external light, and a method for manufacturing the display device.

[0121] 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.

[0122] 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.

[0123] 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; a rib covering a peripheral portion of the lower electrode; 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; a support body disposed above the upper electrode and having a first surface facing the lower electrode and a second surface opposite to the first surface; a first lens disposed on the first surface just above the lower electrode and formed in a convex shape; An outer covering layer covering the first lens; a second lens disposed on the second surface just above the rib and formed in a convex shape; and a light shielding layer covering the second lens, The first lens includes at least a first layer that is in contact with the first surface and has a first refractive index, and a second layer that has a second refractive index higher than the first refractive index and overlaps with the first layer.

2. The display device according to claim 1, wherein: The first lens further includes a third layer having a third refractive index higher than the second refractive index and overlapping 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, the second layer, and the third layer are formed of an organic material.

5. The display device according to claim 1, wherein: The second lens is formed of an organic material.

6. The display device according to claim 1, further comprising: A capping layer disposed on the upper electrode; a sealing layer disposed on the cap layer and formed of an inorganic material; and an insulating layer, which is disposed on the sealing layer and is formed of an organic material, in, The outer cover is bonded to the insulating layer.

7. The display device according to claim 1, wherein: The support is a color filter.

8. A method for manufacturing a display device, wherein: A first lens is formed on a first surface of the support body, The first lens is covered by an outer cover layer, forming a second lens on the second surface of the support body, forming a light shielding layer covering the second lens, The outer cover layer is bonded to the insulating layer disposed above the display element, The process of forming the first lens at least includes: A first layer is formed on the first surface with a material having a first refractive index, A step of forming a second layer on the first layer using a material having a second refractive index higher than the first refractive index.

9. The method for manufacturing a display device according to claim 8, wherein: The second lens is formed at a position not overlapping with the first lens.

10. The method for manufacturing a display device according to claim 8, wherein: The first lens is arranged directly above the display element. The second lens is arranged directly above the rib surrounding the display element.

11. The method for manufacturing a display device according to claim 8, wherein: The step of forming the first lens includes the step of patterning the first layer and the second layer together.

12. The method for manufacturing a display device according to claim 8, wherein: The step of forming the first lens includes heating the first layer and the second layer and pressing the second layer against a mold having a recessed portion from above.

13. The method for manufacturing a display device according to claim 8, wherein: The step of forming the first lens further includes: forming a third layer on the second layer from a material having a third refractive index higher than the second refractive index, A step of patterning the first layer, the second layer, and the third layer at a time.

14. The method for manufacturing a display device according to claim 8, wherein: The step of forming the first lens further includes: forming a third layer on the second layer from a material having a third refractive index higher than the second refractive index, The first layer, the second layer, and the third layer are heated, and the third layer is pressed against a mold having a recessed portion from above.

15. The method for manufacturing a display device according to claim 8, wherein: The first lens and the second lens are formed of an organic material.

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