Display device and manufacturing method of them

Abstract

To improve a light extraction efficiency and suppress a reflection of an external light.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, a rib covering a peripheral edge part of the lower electrode, and a light emission layer that is arranged onto the lower electrode; an upper electrode arranged onto the organic layer; a support body that includes a first surface that is arranged to the upper direction of the upper electrode, and is opposite to the lower electrode 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, and is formed in a convex shape; an over coat layer that coats the first lens; a second lens that is arranged onto the second surface on just above the rib, and is formed in the convex shape; and a shading layer that covers the second lens. The first lens at least comprises: a first layer that is contacted to the first surface and includes a first refraction factor; and a second layer that includes a second refraction factor that is higher than the first refraction factor, and is overlapped with 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 suppressing reflection of external light, and a manufacturing method thereof. [Means for solving the problem]

[0006] A display device according to an embodiment includes: the first lens is disposed on the first surface directly above the lower electrode and formed in a convex shape; an overcoat layer covering the first lens; a second lens is disposed on the second surface directly above the rib and formed in a convex shape; and a light-shielding layer covering the second lens. The first lens comprises at least a first layer in contact with the first surface and having a first refractive index, and a second layer having a second refractive index higher than the first refractive index and overlapping the first layer.

[0007] A method for manufacturing a display device according to an embodiment includes the steps of: The steps of forming a first lens on a first surface of a support, covering the first lens with an overcoat layer, forming a second lens on a second surface of the support, forming a light-shielding layer covering the second lens, adhering the overcoat layer to an insulating layer arranged above a display element, and forming the first lens include at least the steps of 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. [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 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 this embodiment. [Figure 7] FIG. 7 is a diagram for explaining another effect of the present embodiment. [Figure 8] FIG. 8 is a diagram for explaining a manufacturing method of the first lens LS1. [Figure 9A] FIG. 9A is a diagram for explaining a manufacturing method of the second lens LS2. [Figure 9B] FIG. 9B is a diagram for explaining a manufacturing method of the display device DSP. [Figure 10] FIG. 10 is a diagram for explaining another method for forming the first lens LS1. [Figure 11] FIG. 11 is a cross-sectional view showing another example of the configuration of the display device DSP. 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 include display elements 201, 202, and 203, respectively, as the display element 20. In the example shown in the figure, 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. These color filters CF1, CF2, and CF3 may be omitted.

[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 the first lens LS1 and the second lens LS2. Note that in Fig. 4, the lower electrode, organic layer, upper electrode, and the like that constitute the display element of each subpixel are omitted.

[0039] 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 each of the subpixels SP1, SP2, and SP3, the first lens LS1 indicated by the dashed line is surrounded by the rib RB in a plan view. In other words, in the subpixel SP1, the first lens LS1 overlaps the aperture AP1. In the subpixel SP2, the first lens LS1 overlaps the aperture AP2. In the subpixel SP3, the first lens LS1 overlaps the aperture AP3.

[0041] Each of the first lenses LS1 is formed to have a circular shape in a plan view. The first lens LS1 is a multilayer body of at least two layers, and in the illustrated example, 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 to have a concentric shape in a plan view. 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. With respect to 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)。

[0042] In the illustrated example, the multiple first lenses LS1 all have the same diameter. However, at least one of the first lenses LS1 may have a diameter different from the other first lenses LS1.

[0043] 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 disposed between the openings AP1 and AP2, between the openings AP1 and AP3, and between the openings AP2 and AP3.

[0044] Each of the second lenses LS2 is formed to have a circular shape in a plan view. The second lenses LS2 are, for example, single-layer bodies formed of a single material. In the illustrated example, the second lenses LS2 all have the same diameter. Note that at least one of the second lenses LS2 may have a diameter different from the other second lenses LS2. The diameter of the second lens LS2 may be equal to the diameter of the first lens LS1, or may be different from the diameter of the first lens LS1.

[0045] 5 is a cross-sectional view showing a configuration example of the display device DSP along the line AB in FIG. 4. Here, the cross-sectional structure of the subpixel SP1 will be mainly described. Note that the example shown here corresponds to an example in which a color filter is omitted. However, a color filter may be provided above the display device DSP shown in the figure.

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

[0055] The support 30 has a first surface (lower surface) 30A facing the display element 201 including the lower electrode LE1, and a second surface (upper surface) 30B opposite to the first surface 30A.

[0056] 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 with an overcoat layer OC. The first lens LS1 has a semicircular cross section as shown in the figure, and also has a circular outer edge as shown in FIG. 4, and is formed in a hemispherical shape.

[0057] 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 the first layer L1, is spaced 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 the second layer L2, is spaced from the first surface 30A, and has a third refractive index higher than the second refractive index.

[0058] 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. The third layer L3 has a third refractive index of about 1.56 to 1.6.

[0059] The overcoat layer OC covers the third layer L3 and is in contact with the peripheral edges of the first layer L1 and the second layer L2. It is desirable for such an overcoat layer OC to have a refractive index smaller than at least the third refractive index.

[0060] The first lens LS1 can be composed of at least a first layer L1 and a second layer L2, and may be composed of a multi-layer body of four or more layers. In any case, in the first lens LS1, the first layer L1 has the smallest refractive index, and the layers further away from the first layer L1 have higher refractive indexes.

[0061] The second lens LS2 is disposed on the second surface 30B directly above the rib RB, and is formed in a convex shape on the opposite side to the first lens LS1. The second lens LS2 is disposed at a position shifted from the first lens LS1. Such a second lens LS2 is formed of a transparent organic material.

[0062] The light-shielding layer BM is disposed directly above the rib RB, contacts the second surface 30B, and covers the second lens LS2. Such a light-shielding layer BM is formed of an organic material containing, for example, a black pigment, and absorbs external light and suppresses undesired reflection of light.

[0063] 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, the insulating layer 15, and the overcoat layer OC, and is appropriately converged or diverged by the first lens LS1.

[0064] In a configuration in which a light-shielding layer BM is disposed on the periphery of the display element 201, 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 display element.

[0065] FIG. 6 is a diagram for explaining the effect of this embodiment. As described above, the first lens LS1 is a multi-layer body, and each layer has a different refractive index. When external light Ex enters the first lens LS1, the reflectance of the external light Ex can be reduced by the interference of light reflected at the interfaces between the layers of the first lens LS1. Furthermore, external light Ex directed toward the second lens LS2 is absorbed by the light-shielding layer BM. Because the light-shielding layer BM covers the convex surface of the second lens LS2, the installation area of ​​the light-shielding layer BM is increased compared to the case where the second lens LS2 does not exist, and the reflectance of the external light Ex can be further reduced.

[0066] FIG. 7 is a diagram for explaining another effect of the present embodiment.

[0067] 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.

[0068] Therefore, in this embodiment, the first lens LS1 is disposed so as to be convex toward the display element 201, and the third refractive index of the third layer L3 is higher than the refractive index of the overcoat layer OC. Therefore, the light reaching the first lens LS1 from the display element 201 is refracted at the interface between the overcoat layer OC and the third layer L3, and is appropriately converged. This reduces the amount of light trapped inside the display device, and improves the light extraction efficiency.

[0069] Moreover, 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. In other words, the light transmitted through the first lens LS1 is diverged at a large angle with respect to the normal to the display device.

[0070] In addition, the first lens LS1 is formed in a hemispherical shape, and therefore the first lens LS1 can diverge light isotropically in all directions on the XY plane, without being limited to a specific direction.

[0071] Therefore, even when the display device DSP is observed at a viewing angle that is a large angle with respect to the normal line, it is possible to view the light from the display element 201. Furthermore, the first lens LS1 improves the light extraction efficiency and can expand the viewing angle at which high-luminance light can be viewed.

[0072] 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.

[0073] Next, a method for manufacturing the above-mentioned display device DSP will be described with reference to Figures 8, 9A, and 9B. In particular, a method for manufacturing the first lens LS1 and the second lens LS2 will be described.

[0074] First, as shown in FIG. 8, in step ST1, the first surface 30A of the support 30 is cleaned. For example, oxygen plasma treatment can be applied to the cleaning process. Alternatively, the first surface 30A may be cleaned using an organic solvent. Thereafter, a material M1 for forming the first layer L1 of the first lens LS1 is applied to the first surface 30A of the support 30. The material M1 is a material having a first refractive index, and is, for example, an organic material such as a silicone resin. As an example of the silicone resin, polydimethylsiloxane (PDMS) can be applied.

[0075] 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, for example, an organic material such as an acrylic resin. As an example of the acrylic resin, polymethylmethacrylate resin (PMMA) can be used.

[0076] Thereafter, a material M3 for forming a 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 an epoxy resin.

[0077] Next, in order to form the first lens LS1, the materials M1, M2, and M3 are patterned collectively.

[0078] In step ST2, a mask MK1 is placed above the material M3 and ultraviolet light is applied. The mask MK1 has an opening MA1 and a shielding portion MB1. When the materials M1, M2, and M3 are positive-type photosensitive materials, the shielding portion MB1 is disposed at a position where the first lens LS1 is to be formed. When the materials M1, M2, and M3 are negative-type photosensitive materials, the opening MA1 is disposed at a position where the first lens LS1 is to be formed. Thereafter, in step ST3, the materials M1, M2, and M3 are developed to remove the areas irradiated with the ultraviolet light.

[0079] Next, in step ST4, the materials M1, M2, and M3 remaining after patterning are reflowed. This forms the hemispherical first lens LS1. The first lenses LS1 of the subpixels SP1, SP2, and SP3 are simultaneously formed by the above process.

[0080] Next, in step ST5, an overcoat layer OC that covers the first lens LS1 is formed.

[0081] 9A, 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.

[0082] Next, in step ST12, a mask MK2 is placed above the material M4 and ultraviolet light is applied. The mask MK2 has an opening MA2 and a shielding portion MB2. When the material M4 is a positive-type photosensitive material, the shielding portion MB2 is disposed at a position where the second lens LS2 is to be formed. When the material M4 is a negative-type photosensitive material, the opening MA2 is disposed at a position where the second lens LS2 is to be formed.

[0083] Subsequently, in step ST13, the material M4 is developed to remove the area irradiated with the ultraviolet light.

[0084] Next, in step ST14, the remaining material M4 is reflowed, thereby forming a hemispherical second lens LS2 at a position that does not overlap with the first lens LS1.

[0085] Subsequently, in step ST15, a light-shielding layer BM that covers the second surface 30B and the second lens LS2 is formed. Subsequently, in step ST16, the light-shielding layer BM is patterned.

[0086] Next, as shown in Fig. 9B, the overcoat layer OC is bonded to the insulating layer 15. At this time, the first lenses LS1 are disposed directly above the display elements 201, 202, and 203, respectively. The second lens LS2 is disposed directly above the rib RB. In this manner, the display device DSP shown in Fig. 5 is manufactured.

[0087] 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.

[0088] FIG. 10 is a diagram for explaining another method for forming the first lens LS1.

[0089] First, in step ST21, a material M1 for forming a first layer L1 is applied, a material M2 for forming a second layer L2 is applied, and a material M3 for forming a third layer L3 is applied. In addition, in FIG. 10, the laminate of the materials M1, M2, and M3 is referred to as material M.

[0090] Next, in step ST22, a mold MD is prepared. The mold MD has a recess MDC corresponding to the first lens LS1. Then, the support 30 is placed on the heating plate HP, and the mold MD is placed above the material M. At this time, the recess MDC faces the material M.

[0091] Next, in step ST23, the material M is heated by the heating plate HP, and the die MD is pressed from above the material M. This causes the material M to melt and flow into the recess MDC, forming the convex first lens LS1.

[0092] Although another method for forming the first lens LS1 has been described here, the method described here can be applied as another method for forming the second lens LS2.

[0093] Next, another configuration example will be described.

[0094] FIG. 11 is a cross-sectional view showing another example of the configuration of the display device DSP.

[0095] The configuration example shown in FIG. 11 differs from the configuration example shown in FIG. 5 in that the support 30 is color filters CF1, CF2, and CF3. For example, in the subpixel SP1, the color filter CF1 has a first surface CFA facing the display element 201 and a second surface CFB opposite the first surface CFA. 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 second lens LS2 is disposed on the second surface CFB directly above the rib RB and is formed in a convex shape opposite to the first lens LS1. The light-shielding layer BM is disposed directly above the rib RB and covers the second lens LS2. In this configuration example as well, the same effects as those in the above configuration example can be obtained. A support 30 may be provided in addition to the color filters CF1, CF2, and CF3.

[0096] As described above, according to the present embodiment, it is possible to provide a display device capable of improving the light extraction efficiency and suppressing the reflection of external light, and a manufacturing method thereof.

[0097] 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.

[0098] 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.

[0099] 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]

[0100] 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 SP…Support 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; a rib covering a peripheral portion of the lower electrode; an organic layer including a light-emitting layer disposed on the lower electrode; an upper electrode disposed over the organic layer; a support 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 directly above the lower electrode and formed in a convex shape; an overcoat layer covering the first lens; a second lens disposed on the second surface directly above the rib and formed in a convex shape; a light-shielding layer covering the second lens, The first lens includes at least a first layer in contact with the first surface and having a first refractive index, and a second layer having a second refractive index higher than the first refractive index and overlapping the first layer. Display device.

2. the first lens further comprising a third layer having a third refractive index higher than the second refractive index and overlying the second layer. 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, the second layer, and the third layer are formed of an organic material; The display device according to claim 2 .

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

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

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

8. forming a first lens on a first surface of the support; covering the first lens with an overcoat layer; forming a second lens on a second surface of the support; forming a light-shielding layer covering the second lens; Adhering the overcoat layer to an insulating layer disposed above a display element; The step of forming the first lens includes at least: forming a first layer on the first surface using 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.

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

10. the first lens is disposed directly above the display element; The second lens is disposed directly above a rib surrounding the display element. The method for manufacturing a display device according to claim 8 .

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

12. the step of forming the first lens includes a step of heating the first layer and the second layer and pressing a die having a recess from above the second layer. The method for manufacturing a display device according to claim 8 .

13. 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; patterning the first layer, the second layer, and the third layer collectively; The method for manufacturing a display device according to claim 8 .

14. 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 heating the first layer, the second layer, and the third layer and pressing a mold having a recess from above the third layer; The method for manufacturing a display device according to claim 8 .

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

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