Display device and method of manufacturing same

Abstract

The invention provides a display device. The display device includes a substrate and a pixel definition layer. The pixel defining layer is arranged on the substrate, wherein the pixel defining layer is provided with an upper surface and a side surface defining an included angle.

Description

Technical Field

[0001] The present disclosure relates to a display device, and more particularly to a display device including a pixel definition layer having a specific profile. Background Art

[0002] Display devices including optical component layers have been widely used in most electronic devices. In recent years, there has been a demand for larger display devices. However, in the method of manufacturing display devices, there are steps with poor light extraction efficiency. In fact, one of the challenges recognized by the public in the field is to improve the light extraction efficiency of display devices. Therefore, the display device industry is seeking a method to solve the above issues. Summary of the invention

[0003] A display device includes a substrate and a pixel definition layer. The pixel definition layer is disposed on the substrate, wherein the pixel definition layer has an upper surface and a side surface defining an angle.

[0004] A display device includes a substrate, a plurality of pixel definition layers and a light emitting structure. The plurality of pixel definition layers are disposed on the substrate. The light emitting structure is disposed on the plurality of pixel definition layers. The upper surface of the light emitting structure has a plurality of protrusions above one of the plurality of pixel definition layers. BRIEF DESCRIPTION OF THE DRAWINGS

[0005] Figure 1 is a cross-sectional view of a display device according to some embodiments.

[0006] Figure 2 According to certain embodiments, Figure 1 A partial enlarged view of the display device shown.

[0007] Figure 3 is a cross-sectional view of a display device according to some embodiments.

[0008] Figure 4A , 4B 4C and 4D illustrate display devices at different manufacturing stages according to methods of certain embodiments of the present disclosure. DETAILED DESCRIPTION

[0009] The following disclosure provides many different embodiments or examples for implementing different features of the present application. Specific examples of components and configurations are described below to simplify the disclosure of the present application. Of course, these are only examples and are not intended to limit the present application. For example, the following description of forming a first feature on or above a second feature may include embodiments in which first and second features are formed in direct contact, and may also include embodiments in which other features are formed between the first and second features, so that the first and second features are not in direct contact. In addition, the present application may repeat component symbols and / or letters in different examples. This repetition is for the purpose of simplicity and clarity, and does not govern the relationship between different embodiments and / or the architectures discussed.

[0010] Furthermore, this application may use spatially corresponding terms, such as "below," "below," "lower," "above," "higher," and similar terms, to describe the relationship of one component or feature to another component or feature in the drawings. Spatially corresponding terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the drawings. The device may be positioned (rotated 90 degrees or at other orientations) and the spatially corresponding descriptors used herein interpreted accordingly.

[0011] Although the numerical ranges and parameters disclosed in the broad scope of the present disclosure are approximate values, the numerical values ​​described in the specific embodiments are as accurate as possible. However, any numerical value inherently contains certain errors caused by the standard deviation obtained in the individual test measurements. Furthermore, as used herein, "about" generally refers to within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, the term "about" refers to within the acceptable standard error of the average value considered by the ordinary technician in the art. Except in the operation / working examples, or unless otherwise specified, all numerical ranges, amounts, values ​​and ratios disclosed herein, such as the amount of material, time period, temperature, operating conditions, ratio of amounts, and the like, should be understood to be modified by the term "about" in all cases. Therefore, unless otherwise stated, the numerical parameters of the present disclosure and the scope of the patent application are all approximate values ​​that can be varied as needed. Each numerical parameter should be interpreted at least according to the number of significant figures reported and using ordinary rounding techniques. In this article, the range can be expressed as from one endpoint to another, or between two endpoints. Unless otherwise stated, all ranges disclosed herein are inclusive of the endpoints.

[0012] Figure 1 is a cross-sectional view of a display device 10 according to some embodiments.

[0013] In some embodiments, the display device 10 includes a substrate 110, an electrode 121, an electrode 122, a pixel definition layer 130, a light emitting structure 140, and a light guide layer 150. In some embodiments, the display device 10 may include a pixel or a portion of a pixel. In some embodiments, the display device 10 is configured to emit a first color, a second color, and a third color. In some embodiments, the first color includes green light (e.g., light with a wavelength between 500nm and 580nm), the second color includes red light (e.g., light with a wavelength between 620nm and 780nm), and the third color includes blue light (e.g., light with a wavelength between 400nm and 500nm). In some embodiments, the display device 10 is configured to emit white light, ultraviolet light, infrared light, or other suitable light.

[0014] Figure 2 According to certain embodiments, Figure 1 A partial enlarged view of the display device shown.

[0015] In some embodiments, the substrate 110 includes a substrate (not shown), a dielectric layer (not shown), and one or more circuits (not shown) disposed on or in the substrate. In some embodiments, the substrate is a transparent substrate, or at least a portion is transparent. In some embodiments, the substrate is a non-flexible substrate, and the material of the substrate may include glass, quartz, low temperature polysilicon (LTPS) or other suitable materials. In some embodiments, the substrate is a flexible substrate, and the material of the substrate may include transparent epoxy resin, polyimide, polyvinyl chloride, methyl methacrylate or other suitable materials. The dielectric layer may be disposed on the substrate as needed. In some embodiments, the dielectric layer may include silicon oxide, silicon nitride, silicon oxynitride or other suitable materials.

[0016] In some embodiments, the circuit may include a complementary metal-oxide-semiconductor (CMOS) circuit, or include a plurality of transistors and a plurality of capacitors adjacent to the transistors, wherein the transistors and the capacitors are formed on a dielectric layer. In some embodiments, the transistors are thin-film transistors (TFTs). Each transistor includes a source / drain region (including at least one source region and a drain region), a channel region between the source / drain regions, a gate electrode disposed above the channel region, and a gate insulator between the channel region and the gate electrode. The channel region of the transistor may be made of a semiconductor material, such as silicon or other elements selected from Group IV or Group III and Group V.

[0017] In some embodiments, the substrate 110 includes components such as an interlayer dielectric structure and a metal layer (eg, a first metal layer, a second metal layer). The interlayer dielectric structure is disposed on a circuit or a transistor.

[0018] The electrodes 121 are disposed on the surface of the substrate 110. Each electrode 121 is configured to have one side connected to a circuit embedded or electrically connected to the substrate 110 and the other side contacting the light emitting structure 140. The electrode 121 includes a metal material, such as Ag, Mg, etc. In some embodiments, the electrode 121 includes indium tin oxide (ITO), indium zinc oxide (IZO), or other suitable materials. In some embodiments, the electrode 121 defines an opening 121o.

[0019] The pixel definition layer 130 is disposed on the substrate 110. The pixel definition layer 130 covers a portion of the electrode 121. A portion of the pixel definition layer 130 is disposed in the opening 121o. The pixel definition layer 130 may be disposed between two pixels. The opening of the pixel definition layer 130 may be used to define the light emitting area and / or profile of the above-mentioned pixel. The cross section of the pixel definition layer 130 may have a trapezoidal profile. In some embodiments, the surface area of ​​the upper surface of the pixel definition layer 130 (the surface 130s1 facing the light emitting structure 140) is smaller than the surface area of ​​the lower surface of the pixel definition layer 130 (the surface facing the substrate 110). In some embodiments, the pixel definition layer 130 includes a light absorbing material, and its light absorption rate may be greater than 85%, for example, 85%, 88%, 90%, 93%, 95%, 97%, 98% or 99%. The pixel definition layer 130 may include a dielectric material. In some embodiments, the material of the pixel definition layer 130 includes an inorganic material. In some embodiments, the material of the pixel definition layer 130 includes nitride, oxide and / or other suitable materials. When the pixel definition layer 130 includes an inorganic material, it can define a smaller line width, which helps to miniaturize the display device 10. In addition, inorganic materials have better weather resistance than organic materials. In addition, the pixel definition layer formed by organic materials and the pixel definition layer formed by inorganic materials will define different surface profiles after the reflow step. For example, in the cross-sectional view, the pixel definition layer formed by the organic material presents a partially circular or elliptical profile; the upper surface of the pixel definition layer formed by the inorganic material basically presents a trapezoidal profile.

[0020] In some embodiments, the pixel definition layer 130 may include a surface 130s1 and a surface 130s2. The surface 130s1 may also be referred to as an upper surface, and the surface 130s2 may also be referred to as a side surface, which is connected to the surface 130s1. In some embodiments, the surface 130s1 and the surface 130s2 form an angle θ. In some embodiments, the angle θ is in a range of about 95 degrees to 135 degrees, such as 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees, or 135 degrees.

[0021] The light emitting structure 140 is disposed on the electrode 121. The light emitting structure 140 is disposed on the pixel definition layer 130. The light emitting structure 140 covers the surface 130s1 and the surface 130s2 of the pixel definition layer 130. In some embodiments, the light emitting structure 140 is a composite structure. The light emitting structure 140 may include a carrier injection layer, a hole transportation layer (HTL), an electron transportation layer (ETL), an emissive layer (EML) and / or other suitable components. The carrier transportation layer and the hole transportation layer have the property of unidirectionally transporting electrons or holes. The light emitting layer may include different materials in different pixels to emit wavelengths of light in different bands, such as red light, green light, blue light and / or white light.

[0022] In some embodiments, the light emitting structure 140 may include a protrusion 141, a protrusion 142, and a protrusion 142'. The protrusion 141 may be located above the surface 130s1. In some embodiments, the protrusion 141 may overlap with the opening 121o of the electrode 121 in the vertical direction. In some embodiments, the protrusion 142 may be located above the junction of the surface 130s1 and the surface 130s2 or adjacent to the junction of the surface 130s1 and the surface 130s2, for example, located above or adjacent to the angle θ. In some embodiments, the surface (e.g., upper surface) of the protrusion 141 and the surface (e.g., upper surface) of the protrusion 142 may have different profiles.

[0023] In some embodiments, the maximum distance between the protrusion 141 and the substrate 110 can reach a height H1, the maximum distance between the protrusion 142 and the substrate 110 can reach a height H2, and the maximum distance between the protrusion 142' and the substrate 110 can reach a height H3. In some embodiments, the height H1 is not equal to the height H2. The height H1 is not equal to the height H3. The height H2 is not equal to the height H3. In some embodiments, Figure 2 The two protrusions 142 and 142 ′ depicted may present an asymmetrical profile.

[0024] In some embodiments, the surface of the protrusion 141 is composed of continuous points, that is, there are no saddle points and / or cusps on its surface. In some embodiments, there are discontinuous points on the surface of the protrusion 142, that is, there are saddle points and / or cusps (such as the apex of the protrusion 142) on its surface. In some embodiments, the contour of the surface of the light-emitting structure 140 located on the pixel definition layer 130 is a non-circular contour. In some embodiments, the contour of the surface of the light-emitting structure 140 located on the pixel definition layer 130 is basically a trapezoidal contour, that is, the light-emitting structure 140 has a protrusion corresponding to the pixel definition layer 130, and the protrusion has a substantially quadrilateral contour when viewed from above, and the contour of the protrusion conforms to the contour of the pixel definition layer 130, presenting a shape that is wide at the top and narrow at the bottom.

[0025] Although Figure 1 , Figure 2 Not shown, the carrier injection layer, the hole transport layer, the electron transport layer and / or the light emitting layer of the light emitting structure 140 each have a plurality of protrusions above the pixel definition layer 130 , and the profiles and positions of the protrusions may correspond to the protrusions 141 and 142 .

[0026] The electrode 122 is disposed on the light emitting structure 140. The electrode 122 includes a metal material, such as Ag, Mg, etc. In some embodiments, the electrode 122 includes indium tin oxide (ITO), indium zinc oxide (IZO) or other suitable materials. In some embodiments, the electrode 122 has a protrusion 1221 and a protrusion 1222. In some embodiments, the protrusion 1221 may overlap with the opening 121o of the electrode 121 in the vertical direction. In some embodiments, the protrusion 1222 may be located above the junction of the surface 130s1 and the surface 130s2, for example, located above the angle θ. In some embodiments, the surfaces (e.g., the upper surface) of the protrusion 1221 and the protrusion 1222 may have different profiles.

[0027] The light guiding layer 150 is disposed on the electrode 122. The light guiding layer 150 is configured to guide the light emitted by the light emitting structure 140 to a desired position. In some embodiments, the light guiding layer 150 may include a protrusion 151 and a protrusion 152. The protrusion 151 may be located above the surface 130s1. In some embodiments, the protrusion 151 may overlap with the opening 121o of the electrode 121 in a vertical direction. In some embodiments, the protrusion 152 may be located above the junction of the surface 130s1 and the surface 130s2, for example, above the angle θ. In some embodiments, the surfaces (for example, the upper surface) of the protrusion 151 and the protrusion 152 may have different profiles. Although Figure 1 and Figure 2The light guide layer 150 is shown to have the protrusion 151 and the protrusion 152 . In other embodiments, the upper surface of the light guide layer 150 may include a partial circular or elliptical profile without a saddle point and / or a sharp point, and is not limited thereto.

[0028] Figure 3 2 is a cross-sectional view of a display device 20 according to some embodiments. The display device 20 is similar to the display device 10 , except for the following differences: In some embodiments, the display device 20 further includes a planar layer 160 , a filling layer 170 , an optical component layer 181 , a filter layer 182 , and a cover plate 190 .

[0029] The planar layer 160 is disposed on the light emitting structure 140. The planar layer 160 covers the pixel definition layer 130. The planar layer 160 covers the electrode 122. The planar layer 160 is configured to provide a planar surface (eg, provide a planar upper surface). The planar layer 160 may include oxide, nitride or other dielectric materials.

[0030] The filling layer 170 is disposed on the flat layer 160. The filling layer 170 includes a substantially transparent material, such as a resin or other suitable material, and may include any filler. The light transmittance of the filling layer 170 may be greater than 85%, such as 85%, 88%, 90%, 93%, 95%, 97%, 98% or 99%.

[0031] In some embodiments, the optical component layer 181 is disposed in the filling layer 170. The optical component layer 181 is aligned with the space defined by two adjacent pixel definition layers 130 in the vertical direction. In some embodiments, the optical component layer 181 is configured to change the light path of the light emitted by the pixel. In some embodiments, the optical component layer 181 includes a lens or other suitable components. In some embodiments, the optical component layer 181 may have a profile protruding toward the substrate 110.

[0032] The filter layer 182 is disposed on the optical component layer 181 and is aligned with the optical component layer 181 in a vertical direction. In some embodiments, the filter layer 182 can allow light of different wavelengths to pass through corresponding to different pixels. For example, the filter layer 182 can allow green light, red light, blue light and / or white light to pass through. In some embodiments, the filter layer 182 can be removed.

[0033] The cover plate 190 is disposed on the filter layer 182. In some embodiments, the cover plate 190 includes a substantially transparent component, such as glass or other suitable components.

[0034] Figure 4A , 4B 4C and 4D illustrate display devices at different manufacturing stages according to methods of certain embodiments of the present disclosure.

[0035] See also Figure 4A , providing or receiving a substrate 110. An electrode 121 is formed on the substrate 110, and the electrode 121 defines an opening 121o to expose a portion of the upper surface of the substrate 110. The electrode 121 can be formed on the substrate 110 by vapor deposition, sputtering, atomic layer deposition (ALD), thermal evaporation, coating or jetting, and patterned by lithography and etching techniques.

[0036] See also Figure 4B , a dielectric layer 130' is formed to cover the electrode 121 and the substrate 110. The dielectric layer 130' may be filled into the opening 121o. The dielectric layer 130' may be formed by a deposition process or other suitable process.

[0037] See also Figure 4C , performing a patterning process to pattern the dielectric layer 130' to form the pixel definition layer 130. In some embodiments, the dielectric layer 130' comprises an inorganic material, such as a nitride, an oxide and / or other suitable materials. The patterning process may include forming a photoresist layer on the dielectric layer 130', exposing and developing the photoresist layer to define a pattern to be formed. In this embodiment, the patterning process may include performing an etching process. In this embodiment, the patterning process may include performing a dry etching process. In this embodiment, the patterning process may include reactive-ion etching (RIE).

[0038] See also Figure 4D , a light emitting structure 140, an electrode 122 and a light guide layer 150 are formed on the pixel definition layer 130 to form a display device, for example, Figure 1 The display device 10 shown in FIG. 1 is a display device 10. Forming the light emitting structure 140 may include forming a carrier injection layer, a carrier transport layer, a light emitting layer and / or other suitable components. In addition, the light emitting structure 140 may have at least one or more protrusions (e.g., protrusion 141 and protrusion 142) by changing the process conditions. The number of protrusions may be changed by parameters such as temperature and time of the process conditions and is not limited to Figure 4D The depicted aspect.

[0039] The foregoing summarizes the features of some embodiments so that those skilled in the art can better understand the various aspects of the present disclosure. Those skilled in the art will understand that the present disclosure can be easily used as a basis for designing or modifying other processes and structures to achieve the same purpose and / or achieve the same advantages as the embodiments of the present application. Those skilled in the art will also understand that this equivalent architecture does not depart from the spirit and scope of the present disclosure, and that those skilled in the art can make various changes, substitutions and replacements without departing from the spirit and scope of the present disclosure.

[0040] Furthermore, the scope of the present application is not limited to the specific embodiments of the processes, machines, manufactures, material compositions, means, methods, and steps in the specification. A person skilled in the art can understand from the disclosure of the present disclosure that existing or future developed processes, machines, manufactures, material compositions, means, methods, or steps that have the same functions or achieve substantially the same results as the corresponding embodiments described herein can be used according to the present disclosure. Accordingly, such processes, machines, manufactures, material compositions, means, methods, or steps are included in the scope of the patent application of the present application.

[0041] Description of the accompanying drawings

[0042] 10 Display Devices

[0043] 110 Substrate

[0044] 121 Electrode

[0045] 121o Opening

[0046] 122 Electrode

[0047] 1221 Protrusion

[0048] 1222 Protrusion

[0049] 130 pixels defined layer

[0050] 130s1 surface

[0051] 130s2 surface

[0052] 130' Dielectric Layer

[0053] 140 Light-emitting structure

[0054] 141 Protrusion

[0055] 142 Protrusion

[0056] 142' salient

[0057] 150 Light guide layer

[0058] 151 Protrusion

[0059] 152 Protrusion

[0060] 160 Flat Layer

[0061] 170 Filling layer

[0062] 181 Optical Components Layer

[0063] 182 filter layer

[0064] 190 Cover

[0065] 20 Display Devices

[0066] θ Angle

[0067] H1 Height

[0068] H2 Height

[0069] H3 Height

Claims

1. A display device, comprising: substrate; as well as A pixel definition layer is disposed on the substrate, The pixel definition layer has an upper surface and a side surface, and the upper surface and the side surface define an angle. 2 . The display device according to claim 1 , wherein the angle is in a range from 95 degrees to 135 degrees. The display device according to claim 1 , wherein a cross section of the pixel definition layer has a trapezoidal profile.

4. The display device according to claim 1, further comprising: The light emitting structure is disposed on the pixel definition layer, wherein the light emitting structure has a first protrusion located above the angle. 5 . The display device according to claim 4 , wherein the light emitting structure further comprises a second protrusion, and the second protrusion is located above the upper surface of the pixel definition layer. The display device according to claim 5 , wherein a profile of the first protrusion is different from a profile of the second protrusion. 7 . The display device according to claim 5 , wherein the first protrusion is at a first height from the substrate, the second protrusion is at a second height from the substrate, and the first height is different from the second height. 8 . The display device according to claim 5 , wherein the light emitting structure further comprises a third protrusion, the first protrusion is at a first height from the substrate, the third protrusion is at a third height from the substrate, and the first height is different from the third height.

9. The display device according to claim 1, wherein the pixel definition layer comprises an inorganic material.

10. The display device according to claim 1, further comprising: The light emitting structure is disposed on the pixel definition layer, wherein the light emitting structure has a plurality of protrusions.

11. A display device, comprising: substrate; A plurality of pixel definition layers are disposed on the substrate; as well as A light emitting structure is disposed on the plurality of pixel definition layers, The upper surface of the light emitting structure has a plurality of protrusions above one of the plurality of pixel definition layers.

12. The display device according to claim 11, further comprising: A first electrode is disposed between the substrate and the plurality of pixel definition layers, The first electrode defines a plurality of openings for accommodating the plurality of pixel definition layers.

13. The display device according to claim 12, further comprising: The second electrode is disposed on the light emitting structure, wherein the second electrode has a plurality of protrusions. 14 . The display device according to claim 11 , wherein a cross section of the pixel definition layer has a trapezoidal profile.

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