Display device and manufacturing method of them

Abstract

To improve a light extraction efficiency, and enable a wide-field cornification.SOLUTION: According to an embodiment, a display device comprises: an organic layer containing a substrate, a lower electrode arranged to an upper direction of the substrate, and a light emission layer that is arranged onto the lower electrode; an upper electrode arranged onto the organic layer; an insulation layer arranged to the upper direction of the upper electrode; a color filter having a first surface that is opposite to the insulation layer and a second surface on the side that is opposite to the first surface; a first lens that is arranged onto the first surface on just above the lower electrode, is formed in a convex shape, and is converted with the insulation layer; and a second lens that is arranged onto the second surface on just above the lower electrode, and is formed in the convex shape. The second lens at least comprises: a first layer that includes a first refraction factor, and is formed in a hemispherical shape; and a second layer that includes a second refraction factor that is higher than the first refraction factor and covers the first layer.SELECTED DRAWING: Figure 5

Description

[Technical field]

[0001] 1. Field of the Invention The present invention relates to a display device and a manufacturing method thereof. [Background technology]

[0002] In recent years, display devices using organic light-emitting diodes (OLEDs) as display elements have been put to practical use. The display elements include 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.

[0003] In the display element described above, a technique for efficiently extracting the light generated in the light-emitting layer to the outside is required. As an example, a technique is known in which an inner extraction layer is formed on the inner surface of a substrate facing the display element and an outer extraction layer is formed on the outer surface of the substrate. [Prior art documents] [Patent documents]

[0004] [Patent Document 1] JP 2016-18785 A Summary of the Invention [Problem to be solved by the invention]

[0005] An object of the present invention is to provide a display device capable of improving light extraction efficiency and achieving a wide viewing angle, and a method for manufacturing the same. [Means for solving the problem]

[0006] A display device according to an embodiment includes: The pixel comprises a substrate, a lower electrode disposed above the substrate, an organic layer disposed on the lower electrode and including an 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 opposite the first surface, a first lens disposed on the first surface directly above the lower electrode, formed in a convex shape and covered with the insulating layer, and a second lens disposed on the second surface directly above the lower electrode, formed in a convex shape, the second lens comprising 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.

[0007] A method for manufacturing a display device according to an embodiment includes the steps of: The steps of forming an insulating layer made of an organic material above a display element, forming a patterned resist on the insulating layer, removing a portion of the insulating layer using the resist as a mask to form a recess, forming a first lens filling the recess, forming a color filter on the first lens, and forming a convex second lens on the color filter, and forming the second lens include at least the steps of forming a hemispherical first layer made of a material having a first refractive index, and forming a second layer covering the first layer with a material having a second refractive index higher than the first refractive index. [Brief description of the drawings]

[0008] [Figure 1] FIG. 1 is a diagram showing an example of the configuration of a display device. [Diagram 2] FIG. 2 is a diagram showing an example of the configuration of the subpixels SP1, SP2, and SP3. [Diagram 3] FIG. 3 is a diagram showing an example of the layout of the subpixels SP1, SP2, and SP3. [Figure 4] FIG. 4 is a diagram showing an example of the layout of the color filters CF1, CF2, and CF3, the first lens LS1, and the second lens LS2. [Diagram 5] FIG. 5 is a cross-sectional view showing an example of the configuration of the display device DSP taken along the line AB in FIG. [Figure 6]FIG. 6 is a diagram for explaining the effect of the first lens LS1. [Figure 7] FIG. 7 is a diagram for explaining the effect of the second lens LS2. [Figure 8] FIG. 8 is a diagram for explaining a manufacturing method of the first lens LS1 and the color filter CF. [Figure 9] FIG. 9 is a diagram for explaining a manufacturing method of the second lens LS2. [Figure 10] FIG. 10 is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. [Figure 11] FIG. 11 is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. [Figure 12] FIG. 12 is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. [Figure 13] FIG. 13 is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. DETAILED DESCRIPTION OF THE PREFERRED EMBODIMENTS

[0009] An embodiment will be described with reference to the drawings. The disclosure is merely an example, and those who are skilled in the art can easily conceive of appropriate modifications while maintaining the gist of the invention are naturally included in the scope of the present invention. In addition, the drawings may be schematic in width, thickness, shape, etc. of each part compared to the actual embodiment in order to make the explanation clearer, but they are merely examples and do not limit the interpretation of the present invention. In addition, in this specification and each figure, components that perform the same or similar functions as those described above with respect to the previous figures are given the same reference numerals, and duplicate detailed explanations may be omitted as appropriate.

[0010] In addition, in the drawings, an X-axis, a Y-axis, and a Z-axis that are perpendicular to each other are shown as necessary to facilitate understanding. The direction along the X-axis is called the first direction, the direction along the Y-axis is called the second direction, and the direction along the Z-axis is called the third direction. Viewing various elements parallel to the third direction Z is called a planar view.

[0011] The display device according to this embodiment is an organic electroluminescence (EL) display device having an organic light-emitting diode (OLED) as a display element, and can be installed in televisions, personal computers, in-vehicle devices, tablet terminals, smartphones, mobile phone terminals, and the like.

[0012] FIG. 1 is a diagram showing an example of the configuration of a display device DSP.

[0013] The display device DSP has 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.

[0014] In this embodiment, the shape of the substrate 10 in a plan view is rectangular. 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.

[0015] The display area DA includes a plurality of pixels PX arranged in a matrix in a first direction X and a second direction Y. The pixels PX include a plurality of subpixels SP. In one example, the pixel PX includes a subpixel SP1 of a first color, a subpixel SP2 of a second color, and a subpixel SP3 of a third color. The first color, the second color, and the third color are different from each other. The pixel PX may include a subpixel SP of another color, such as white, in addition to the subpixels SP1, SP2, and SP3, or instead of any of the subpixels SP1, SP2, and SP3.

[0016] The subpixel 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 drive transistor 3, and a capacitor 4. The pixel switch 2 and the drive transistor 3 are switching elements constituted by, for example, thin film transistors.

[0017] The gate electrode of the pixel switch 2 is connected to the scanning line GL. One of the source electrode and 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 drive transistor 3 and the capacitor 4. In the drive transistor 3, one of the source electrode and 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.

[0018] It should be noted that the configuration of the pixel circuit 1 is not limited to the example shown in the drawing. For example, the pixel circuit 1 may include more thin film transistors and capacitors.

[0019] The display element 20 is an organic light-emitting diode (OLED) as a light-emitting element, and may be called an organic EL element.

[0020] Although not described in detail, terminals for connecting an IC chip and a flexible printed circuit board are provided in the peripheral area SA.

[0021] FIG. 2 is a diagram showing an example of the configuration of the subpixels SP1, SP2, and SP3.

[0022] The subpixels SP1, SP2, and SP3 respectively include display elements 201, 202, and 203 as the display element 20. The subpixel SP1 includes a color filter CF1 facing the display element 201, the subpixel SP2 includes a color filter CF2 facing the display element 202, and the subpixel SP3 includes a color filter CF3 facing the display element 203.

[0023] The display element 201 includes a lower electrode LE1, an organic layer OR1 including an emitting layer EM1, and an upper electrode UE. The organic layer OR1 is disposed between the lower electrode LE1 and the upper electrode UE. The 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.

[0024] The display element 202 includes a lower electrode LE2, an organic layer OR2 including an emitting layer EM2, and an upper electrode UE. The organic layer OR2 is disposed between the lower electrode LE2 and the upper electrode UE. The 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.

[0025] The display element 203 includes a lower electrode LE3, an organic layer OR3 including an emitting layer EM3, and an upper electrode UE. The organic layer OR3 is disposed between the lower electrode LE3 and the upper electrode UE. The 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.

[0026] In one example, the lower electrodes LE1, LE2, and LE3 correspond to the anodes of the respective display elements, and the upper electrode UE corresponds to the cathode or common electrode of the respective display elements.

[0027] In the illustrated example, the organic layers OR1, OR2, OR3 include a common layer CL1 and a common layer CL2. The common layer CL1 has, 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. The common layer CL2 has, for example, an electron injection layer, an electron transport layer, a hole blocking layer, etc. The common layer CL2 is disposed between the emitting layer EM1 and the upper electrode UE, between the emitting layer EM2 and the upper electrode UE, and between the emitting layer EM3 and the upper electrode UE.

[0028] FIG. 3 is a diagram showing an example of the layout of the subpixels SP1, SP2, and SP3.

[0029] In the illustrated example, the subpixels SP1 and SP2 are aligned in the first direction X, the subpixels SP1 and SP3 are aligned in the first direction X, and the subpixels SP2 and SP3 are aligned in the second direction Y.

[0030] When the subpixels SP1, SP2, and SP3 are laid out in this manner, the display area DA is formed with a column in which the subpixels SP2 and the subpixels SP3 are alternately arranged in the second direction Y, and a column in which a plurality of subpixels SP1 are arranged in the second direction Y. These columns are arranged alternately in the first direction X.

[0031] It should be noted that the layout of the subpixels SP1, SP2, and SP3 is not limited to the example in Fig. 3. As an example of another layout, the subpixels SP1, SP2, and SP3 may be arranged in order in the first direction X.

[0032] The rib RB indicated by the dashed line has openings AP1, AP2, and AP3 in the subpixels SP1, SP2, and SP3, respectively. In the illustrated example, 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.

[0033] In the subpixel SP1, the lower electrode LE1 indicated by the dashed line and the emitting layer EM1 indicated by the two-dot chain line overlap the aperture AP1 in a plan view. The lower electrode LE1 is electrically connected to the pixel circuit 1 (see FIG. 1) of the subpixel SP1. The peripheral portions of the lower electrode LE1 and the emitting layer EM1 overlap the rib RB.

[0034] In the subpixel SP2, the lower electrode LE2 and the emitting layer EM2 overlap the aperture AP2 in a plan view. The lower electrode LE2 is electrically connected to the pixel circuit 1 of the subpixel SP2. The peripheral portions of the lower electrode LE2 and the emitting layer EM2 overlap the rib RB.

[0035] In the subpixel SP3, the lower electrode LE3 and the emitting layer EM3 overlap the aperture AP3 in a plan view. The lower electrode LE3 is electrically connected to the pixel circuit 1 of the subpixel SP3. The peripheral portions of the lower electrode LE3 and the emitting layer EM3 overlap the rib RB.

[0036] The lower electrodes LE1, LE2, and LE3 are spaced apart from one another. The light emitting layers EM1, EM2, and EM3 are spaced apart from one another. The common layers CL1 and CL2, and the upper electrode UE overlap the openings AP1, AP2, and AP3, respectively, and also overlap the rib RB.

[0037] The respective outer shapes of the openings AP1, AP2, and AP3, the lower electrodes LE1, LE2, and LE3, and the light-emitting layers EM1, EM2, and EM3 do not necessarily reflect accurate shapes.

[0038] Fig. 4 is a diagram showing an example of the layout of color filters CF1, CF2, and CF3, a first lens LS1, and a second lens LS2. Note that Fig. 4 does not show the lower electrode, organic layer, upper electrode, and the like that constitute the display element of each subpixel.

[0039] The color filters CF1, CF2, and CF3 are spaced apart from one another. The light-shielding layer BM overlaps the rib RB and is formed in a lattice shape surrounding the openings AP1, AP2, and AP3.

[0040] In the subpixel SP1, the color filter CF1 indicated by the two-dot chain line overlaps the aperture AP1 in plan view. The peripheral edge of the color filter CF1 overlaps the rib RB and the light-shielding layer BM. In the subpixel SP2, the color filter CF2 overlaps the aperture AP2 in a plan view. The peripheral edge of the color filter CF2 overlaps the rib RB and the light-shielding layer BM. In the subpixel SP3, the color filter CF3 overlaps the aperture AP3 in a plan view. The peripheral edge of the color filter CF3 overlaps the rib RB and the light-shielding layer BM.

[0041] In each of the subpixels SP1, SP2, and SP3, the first lens LS1 indicated by the dashed line and the second lens LS2 indicated by the solid line are both surrounded by the rib RB in a plan view. In other words, in the subpixel SP1, the first lens LS1 and the second lens LS2 overlap the opening AP1 and further overlap the color filter CF1. In the subpixel SP2, the first lens LS1 and the second lens LS2 overlap the opening AP2 and further overlap the color filter CF2. In the subpixel SP3, the first lens LS1 and the second lens LS2 overlap the opening AP3 and further overlap the color filter CF3.

[0042] Each of the first lenses LS1 is formed to have a circular shape in a plan view. The first lenses LS1 are, for example, single-layer bodies made of a single material. In the illustrated example, the multiple first lenses LS1 all have the same diameter. Note that at least one of the first lenses LS1 may have a diameter different from the other first lenses LS1.

[0043] Each of the second lenses LS2 is formed in a circular shape in a plan view. The second lens LS2 is a multilayer body of at least two layers, and in the illustrated example, includes 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 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 in a concentric shape in a plan view. In the illustrated example, all of the multiple second lenses LS2 have the same diameter. At least one second lens LS2 may have a diameter different from the other second lenses LS2.

[0044] In the illustrated example, the number of first lenses LS1 is the same as the number of second lenses LS2 in each subpixel. Note that the number of first lenses LS1 may be different from the number of second lenses LS2. In the illustrated example, the diameter of the second lens LS2 is equal to that of the first lens LS1. However, the diameter of the second lens LS2 may be different from that of the first lens LS1. In the illustrated example, the second lens LS2 overlaps the first lens LS1 in a plan view. The second lens LS2 may be arranged offset from the first lens LS1 in a plan view, but it is preferable that the second lens LS2 overlaps at least a portion of the first lens LS1.

[0045] Fig. 5 is a cross-sectional view showing a configuration example of the display device DSP taken along the line AB in Fig. 4. Here, the cross-sectional structure of the subpixel SP1 will be mainly described.

[0046] The circuit layer 11 is disposed on the substrate 10. The circuit layer 11 includes various circuits such as the pixel circuit 1 shown in Fig. 1, and various wirings such as the scanning line GL, the signal line SL, and the power supply line PL. The circuit layer 11 is covered with an insulating layer 12. The insulating layer 12 includes an organic insulating layer that flattens unevenness caused by the circuit layer 11.

[0047] The lower electrode LE1 of the display element 201 is disposed on an 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 body including, for example, an oxide conductive layer such as indium tin oxide (ITO) and a metal layer such as silver.

[0048] The rib RB is disposed on the insulating layer 12. The rib RB covers the periphery of the lower electrode LE1. The rib RB is made of an organic material or an inorganic material.

[0049] The common layer CL1 is disposed on the lower electrode LE1 and the rib RB. The emitting layer EM1 is located directly on the lower electrode LE1 and is disposed on the common layer CL1. The common layer CL2 is disposed on the emitting layer EM1 and is disposed on the common layer CL1 outside the emitting layer EM1. The common layer CL1, the emitting layer EM1, and the common layer CL2 constitute the organic layer OR1 as described with reference to FIG. 2.

[0050] The upper electrode UE is disposed on the common layer CL2. The upper electrode UE is made of a metal material such as an alloy of magnesium and silver (MgAg).

[0051] The cap layer 13 is disposed on the upper electrode UE. The cap layer 13 is a transparent multilayer body. The layers constituting the cap layer 13 have different refractive indices. 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.

[0052] The sealing layer 14 is disposed on the cap layer 13. The sealing layer 14 is formed of a transparent inorganic material such as, for example, silicon nitride (SiNx), silicon oxide (SiOx), or silicon oxynitride (SiON).

[0053] The insulating layer 15 is disposed on the sealing layer 14. The insulating layer 15 is formed of a transparent organic material.

[0054] The color filter CF1 and the light-shielding layer BM are disposed on the insulating layer 15. The color filter CF1 is disposed directly above the display element 201. The light-shielding layer BM is disposed directly above the rib RB. The peripheral portion of the color filter CF1 overlaps the light-shielding layer BM. Such a light-shielding layer BM absorbs external light and suppresses undesired reflection of light. Color filter CF1 has a first surface (lower surface) CFA facing insulating layer 15, and a second surface (upper surface) CFB opposite to the first surface CFA.

[0055] The first lens LS1 is disposed on the first surface CFA directly above the lower electrode LE1, and is formed in a convex shape toward the display element 201. The first lens LS1 is covered with the insulating layer 15. In other words, the first lens LS1 is filled in a recess of the insulating layer 15. The first lens LS1 has a semicircular cross section as shown in the figure, and has a circular outer edge as shown in FIG. 4, and is formed in a hemispherical shape. Such a 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.

[0056] The second lens LS2 is disposed on the second surface CFB directly above the lower electrode LE1, and is formed in a convex shape on the opposite side 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 in a hemispherical shape on the second surface CFB, and has a first refractive index. The second layer 22 has a substantially constant thickness, covers the first layer 21, contacts the second surface CFB, and has a second refractive index higher than the first refractive index. The third layer 23 has a substantially constant thickness, covers the second layer 22, contacts the second surface CFB, and has a third refractive index higher than the second refractive index. 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.

[0057] The second lens LS2 can be composed of at least a first layer 21 and a second layer 22, and may be composed of a multi-layer body of four or more layers. In any case, in the second lens LS2, the first layer 21 has the smallest refractive index, and the layers on the outer side of the first layer 21 have higher refractive indexes.

[0058] In such a display element 201, when a potential difference is generated 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.

[0059] In a configuration in which a color filter CF1 is disposed above the display element 201 and a light-shielding layer BM is disposed so as to overlap the periphery of the color filter CF1, the transmittance of the light emitted from the light-emitting layer EM1 is increased compared to a configuration in which an anti-reflection circular polarizer is disposed, which makes it possible to obtain high brightness with low power consumption and to extend the life of the device.

[0060] FIG. 6 is a diagram for explaining the effect of the first lens LS1.

[0061] The light emitted from the light-emitting layer EM1 of the display element 201 is divergent light, and a part of it is trapped inside the display device.

[0062] Therefore, in this embodiment, the first lens LS1, which is convex toward the display element 201, is disposed so as to be in contact with the insulating layer 15, and the refractive index of the first lens LS1 is higher than that of the insulating layer 15. Therefore, light that reaches the first lens LS1 from the display element 201 is refracted at the interface between the insulating layer 15 and the first lens LS1, appropriately converged, and emitted in the normal direction of the display device. This reduces the amount of light trapped inside the display device, and improves the light extraction efficiency.

[0063] The inventors performed a simulation to compare the luminance of a comparative example in which the first lens LS1 was not provided with that of an example in which the first lens LS1 was provided. It was confirmed that the luminance obtained in the example was higher than that of the comparative example, and in particular, the luminance in the normal direction of the display device was approximately 1.8 times that of the comparative example.

[0064] FIG. 7 is a diagram for explaining the effect of the second lens LS2.

[0065] As described above, the second lens LS2 is a multi-layered 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 so as to diverge at the interface between the first layer 21 and the second layer 22, is refracted so as to diverge at the interface between the second layer 22 and the third layer 23, and is further refracted so as to diverge at the interface between the third layer 23 and air. In other words, the light transmitted through the second lens LS2 is diverged at a large angle with respect to the normal to the display device.

[0066] In addition, the second lens LS2 is formed in a hemispherical shape, and therefore the second lens LS2 can diverge light isotropically in all directions on the XY plane, without being limited to a specific direction.

[0067] Therefore, even when the display device DSP is observed at a viewing angle that is a large angle with respect to the normal, it is possible to view the light from the display element 201. Furthermore, the light extraction efficiency is improved by the first lens LS1, and appropriately converged light is incident on the second lens LS2, so that the viewing angle at which high-brightness light can be viewed can be expanded.

[0068] Next, a method for manufacturing the above-mentioned display device DSP will be described with reference to Figures 8 and 9. In particular, a method for manufacturing the first lens LS1, the color filter, and the second lens LS2 will be described.

[0069] 8, an insulating layer 15 is formed of an organic material above a 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 an upper surface 15U of the insulating layer 15.

[0070] Next, as shown in step ST2, a part of the insulating layer 15 is removed by ashing using the resist RS as a mask to form a recess 15 C. Thereafter, the resist RS is removed.

[0071] Next, as shown in step ST3, a material M for forming the first lens LS1 is applied to the upper surface 15U of the insulating layer 15 and fills the recess 15C. The material M is a material having a refractive index higher than that of the insulating layer 15, and is, for example, an organic material such as an acrylic resin. As an example of the acrylic resin, polymethylmethacrylate resin (PMMA) can be used.

[0072] Next, as shown in step ST4, the material M overlapping the upper surface 15U is removed. This forms the first lens LS1 filling the recess 15C. Note that the material M overlapping the upper surface 15U may remain. The first lenses LS1 of the subpixels SP1, SP2, and SP3 are formed at the same time.

[0073] Next, as shown in step ST5, a color filter CF is formed on the first lens LS1. Strictly speaking, before forming the color filter CF, the light-shielding layer BM shown in FIG. 5 is formed. Then, as the color filters CF, a color filter CF1 for the subpixel SP1, a color filter CF2 for the subpixel SP2, and a color filter CF3 for the subpixel SP3 are formed in this order. However, the order in which the color filters CF1, CF2, and CF3 are formed is arbitrary.

[0074] Next, as shown in step ST11 of Fig. 9, a 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, the second surface CFB of Fig. 5. The material M1 is a material having a first refractive index, and is, for example, an organic material such as a fluorine-based resin or a silicone resin. An example of the fluorine-based resin that can be used is polytetrafluoroethylene (PTFE). An example of the silicone resin that can be used is polydimethylsiloxane (PDMS).

[0075] Subsequently, as shown in step ST12, the material M1 is patterned, and if necessary, the remaining material M1 is reflowed, thereby forming the first layer 21 having a hemispherical shape.

[0076] Subsequently, as shown in step ST13, the upper surface CFU and the first layer 21 are covered with a 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, and is, for example, an inorganic material such as silicon oxide (SiO2) or an organic material such as PMMA. If 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. If the material M2 is an organic material, the material M2 is applied to the upper surface CFU.

[0077] Subsequently, as shown in step ST14, the material M2 is patterned, thereby forming the second layer 22.

[0078] Subsequently, as shown in step ST15, the upper surface CFU and the second layer 22 are covered with a 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, and is, for example, an inorganic material such as zirconium oxide (ZrO2) or tantalum oxide (TaO5), or an organic material such as an epoxy resin. If the material M3 is an inorganic material, the material M3 is deposited on the upper surface CFU by, for example, CVD or sputtering. If the material M3 is an organic material, the material M3 is applied to the upper surface CFU.

[0079] Subsequently, as shown in step ST16, the material M3 is patterned, thereby forming the third layer 23 and the second lens LS2.

[0080] Next, some other configuration examples will be described. Note that in each of the following configuration examples, the first lens LS1 and the second lens LS2 in the subpixel SP1 will be described, and in the drawings corresponding to each configuration example, the display element is omitted.

[0081] FIG. 10 is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. The example shown in Fig. 10 differs from the example shown in Fig. 4 in that the number of first lenses LS1 arranged in the subpixel SP1 is greater than the number of second lenses LS2. By arranging a large number of first lenses LS1, the amount of light trapped in the display device is further reduced, and the light extraction efficiency can be improved.

[0082] FIG. 11 is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. The example shown in Fig. 11 differs from the example shown in Fig. 4 in that the number of second lenses LS2 arranged in the subpixel SP1 is greater than the number of first lenses LS1. By arranging a large number of second lenses LS2, a wider viewing angle can be achieved.

[0083] FIG. 12 is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. The example shown in Fig. 12 differs from the example shown in Fig. 4 in that the number of first lenses LS1 arranged in the subpixel SP1 is greater than the number of second lenses LS2, and the diameter of the second lenses LS2 is greater than the diameter of the first lenses LS1. The multiple first lenses LS1 overlap one second lens LS2 in a plan view. In this configuration example, the same effects as those described above can be obtained.

[0084] FIG. 13 is a diagram showing another example of the layout of the first lens LS1 and the second lens LS2. The example shown in Fig. 13 differs from the example shown in Fig. 4 in that the number of second lenses LS2 arranged in the subpixel SP1 is greater than the number of first lenses LS1, and the diameter of the first lenses LS1 is greater than the diameter of the second lenses LS2. The multiple second lenses LS2 overlap one first lens LS1 in a plan view. Even in this configuration example, the same effects as those described above can be obtained.

[0085] As described above, according to the present embodiment, it is possible to provide a display device capable of improving light extraction efficiency and achieving a wide viewing angle, and a manufacturing method thereof.

[0086] All display devices and manufacturing methods thereof that can be implemented by a person skilled in the art through appropriate design modifications based on the display device and manufacturing method thereof described above as embodiments of the present invention are within the scope of the present invention as long as they include the gist of the present invention.

[0087] Within the scope of the concept of the present invention, a person skilled in the art may conceive of various modifications, and such modifications are also understood to fall within the scope of the present invention. For example, those in which a person skilled in the art appropriately adds or removes components or modifies the design of the above-mentioned embodiment, or adds or omits steps or modifies conditions, are also included in the scope of the present invention as long as they include the gist of the present invention.

[0088] Furthermore, with regard to other effects and advantages brought about by the aspects described in the above-mentioned embodiments, those which are obvious from the description in this specification or which can be appropriately thought up by a person skilled in the art are naturally understood to be brought about by the present invention. [Explanation of symbols]

[0089] DSP…display device 10...Substrate 15...Insulating layer RB…Rib AP1,AP2,AP3…Opening SP1, SP2, SP3...Subpixels 201, 202, 203...Display element (organic EL element) LE1, LE2, LE3...Lower electrode UE...Upper electrode OR1, OR2, OR3…Organic layer EM1, EM2, EM3...Emitting layer LS1: 1st lens LS2: 2nd lens CF1, CF2, CF3: Color filters BM: Light-shielding layer

Claims

1. A substrate; a lower electrode disposed above the substrate; an organic layer including a light-emitting layer disposed on the lower electrode; an upper electrode disposed over 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 opposite to the first surface; a first lens that is disposed on the first surface directly above the lower electrode, has a convex shape, and is covered with the insulating layer; a second lens disposed on the second surface directly above the lower electrode and formed in a convex shape, 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. Display device.

2. the second lens further comprising a third layer overlying the second layer, the third layer having a third refractive index higher than the second refractive index. The display device according to claim 1 .

3. an outer edge of the first layer, an outer edge of the second layer, and an outer edge of the third layer are formed concentrically in a plan view; The display device according to claim 2 .

4. 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; The display device according to claim 2 .

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

6. moreover, a cap layer disposed on the upper electrode; a sealing layer disposed on the cap layer and formed of an inorganic material; the insulating layer is disposed on the encapsulation 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. The display device according to claim 1 .

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

8. the first lenses and the 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. The display device according to claim 7.

9. the first lenses and the 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. The display device according to claim 7.

10. The first lenses are surrounded by the rib in a plan view and overlap one of the second lenses. The display device according to claim 1 .

11. The second lenses are surrounded by the rib in a plan view and overlap one of the first lenses. The display device according to claim 1 .

12. forming an insulating layer of an organic material above the display element; forming a patterned resist on the insulating layer; Using the resist as a mask, a portion of the insulating layer is removed to form a recess; forming a first lens filled in the recess; forming a color filter on the first lens; forming a convex second lens on the color filter; The step of forming the second lens includes at least forming a hemispherical first layer from a material having a first refractive index; forming a second layer over the first layer of a material having a second refractive index higher than the first refractive index; A method for manufacturing a display device.

13. forming the second lens further comprises forming a third layer overlying the second layer with a material having a third refractive index higher than the second refractive index. The method for manufacturing the display device according to claim 12 .

14. 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. The method for manufacturing the display device according to claim 13 .

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

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