Display device, display module, electronic device, and method for manufacturing a display device.

Abstract

Provided is a high-definition or high-resolution display device. The present invention includes a first light-emitting device, a second light-emitting device, a first insulating layer, a first coloring layer, and a second coloring layer. The first light-emitting device includes a first pixel electrode, a first light-emitting layer over the first pixel electrode, and a common electrode over the first light-emitting layer. The second light-emitting device includes a second pixel electrode, a second light-emitting layer over the second pixel electrode, and a common electrode over the second light-emitting layer. The first insulating layer covers the individual side faces of the first pixel electrode, the second pixel electrode, the first light-emitting layer, and the second light-emitting layer. The first coloring layer is disposed in a manner superimposed over the first light-emitting device. The second coloring layer is disposed in a manner superimposed over the second light-emitting device. The first light-emitting device and the second light-emitting device each have a function for emitting white light. The first coloring layer has a function for transmitting visible light having a color different from that of visible light transmitted by the second coloring layer.

Description

[Technical Field]

[0001] One aspect of the present invention relates to a display device, a display module, and electronic equipment. Another aspect of the present invention relates to a method for manufacturing a display device.

[0002] It should be noted that one aspect of the present invention is not limited to the above-mentioned technical field. Examples of technical fields of one aspect of the present invention include semiconductor devices, display devices, light-emitting devices, energy storage devices, memory devices, electronic devices, lighting devices, input devices (e.g., touch sensors), input / output devices (e.g., touch panels), methods for driving them, or methods for manufacturing them. [Background technology]

[0003] In recent years, information terminal devices such as smartphones and other mobile phones, tablet devices, and notebook PCs (personal computers) have become widespread. These devices require high-resolution display panels.

[0004] Furthermore, typical examples of display devices applicable to display panels include liquid crystal displays, organic EL (Electro-Luminescence) elements, light-emitting devices (also called light-emitting devices) such as light-emitting diodes (LEDs), and electronic paper that displays information using electrophoretic methods.

[0005] For example, the basic structure of an organic EL element (also called an organic EL device) consists of a layer containing a light-emitting organic compound sandwiched between a pair of electrodes. By applying a voltage to this element, light can be obtained from the light-emitting organic compound. Display devices using such organic EL elements do not require a backlight, which is necessary for liquid crystal displays and the like, thus enabling the realization of thin, lightweight, high-contrast, and low-power display devices. For example, an example of a display device using an organic EL element is described in Patent Document 1. [Prior art documents]

Patent Document

[0006]

Patent Document 1

Summary of the Invention

Problems to be Solved by the Invention

[0007] One aspect of the present invention aims to provide a high-definition display device. One aspect of the present invention aims to provide a high-resolution display device. One aspect of the present invention aims to provide a display device with a high aperture ratio. One aspect of the present invention aims to provide a large-sized display device. One aspect of the present invention aims to provide a small-sized display device. One aspect of the present invention aims to provide a highly reliable display device.

[0008] One aspect of the present invention aims to provide a method for manufacturing a high-definition display device. One aspect of the present invention aims to provide a method for manufacturing a high-resolution display device. One aspect of the present invention aims to provide a method for manufacturing a display device with a high aperture ratio. One aspect of the present invention aims to provide a method for manufacturing a large-sized display device. One aspect of the present invention aims to provide a method for manufacturing a small-sized display device. One aspect of the present invention aims to provide a method for manufacturing a highly reliable display device. One aspect of the present invention aims to provide a method for manufacturing a display device with a high yield.

[0009] Note that the description of these problems does not preclude the existence of other problems. One aspect of the present invention does not necessarily need to solve all of these problems. It is possible to extract other problems from the description of the specification, drawings, and claims.

Means for Solving the Problems

[0010] One aspect of the present invention has a first light-emitting device, a second light-emitting device, a first insulating layer, a second insulating layer, a first coloring layer, and a second coloring layer. The first light-emitting device has a first pixel electrode, a first light-emitting layer on the first pixel electrode, and a common electrode on the first light-emitting layer. The second light-emitting device has a second pixel electrode, a second light-emitting layer on the second pixel electrode, and a common electrode on the second light-emitting layer. The ends of the first pixel electrode and the ends of the second pixel electrode are each covered by the first insulating layer. The second insulating layer is disposed on the first insulating layer. The second insulating layer covers the side surfaces of the first light-emitting layer and the second light-emitting layer respectively. The first coloring layer is disposed to overlap the first light-emitting device. The second coloring layer is disposed to overlap the second light-emitting device. The first light-emitting device and the second light-emitting device each have a function of emitting white light. The first coloring layer has a function of transmitting visible light of a color different from that of the second coloring layer. It is a display device.

[0011] The above display device has a third insulating layer. The second insulating layer has an inorganic material. The third insulating layer has an organic material. And it is preferable that the third insulating layer overlaps the side surfaces of the first light-emitting layer and the second light-emitting layer respectively, and the first insulating layer via the second insulating layer.

[0012] The above display device preferably has a common layer between the first light-emitting layer and the common electrode in the first light-emitting device, and a common layer between the second light-emitting layer and the common electrode in the second light-emitting device. The common layer preferably has at least one of a hole injection layer, a hole blocking layer, a hole transport layer, an electron transport layer, an electron blocking layer, and an electron injection layer.

[0013] Preferably, the first light-emitting layer has the same material as the second light-emitting layer in the above display device.

[0014] Another aspect of the present invention comprises a first light-emitting device, a second light-emitting device, a first insulating layer, a second insulating layer, a first coloring layer, and a second coloring layer, wherein the first light-emitting device comprises a first pixel electrode, a first light-emitting unit on the first pixel electrode, a first charge generation layer on the first light-emitting unit, a second light-emitting unit on the first charge generation layer, and a common electrode on the second light-emitting unit, wherein the second light-emitting device comprises a second pixel electrode, a third light-emitting unit on the second pixel electrode, a second charge generation layer on the third light-emitting unit, a fourth light-emitting unit on the second charge generation layer, and a common electrode on the fourth light-emitting unit. A display device having electrodes and a second, wherein the ends of the first and second pixel electrodes are each covered by a first insulating layer, the second insulating layer is placed on the first insulating layer, the second insulating layer covers the sides of the first and second pixel electrodes, the first charge generation layer, and the second charge generation layer, the first colored layer is placed superimposed on the first light-emitting device, the second colored layer is placed superimposed on the second light-emitting device, the first and second light-emitting devices each have the function of emitting white light, and the first colored layer has the function of transmitting visible light of a different color from the second colored layer.

[0015] Preferably, the above-described display device has a third insulating layer, the second insulating layer is made of an inorganic material, the third insulating layer is made of an organic material, and the third insulating layer overlaps with the first charge generation layer, the sides of the second charge generation layer, and the first insulating layer via the second insulating layer.

[0016] Preferably, in the above-described display device, the first light-emitting device has a common layer between the second light-emitting unit and the common electrode, and the second light-emitting device has a common layer between the fourth light-emitting unit and the common electrode, and the common layer has at least one of a hole injection layer, a hole suppression layer, a hole transport layer, an electron transport layer, an electron suppression layer, and an electron injection layer.

[0017] Preferably, in the above-described display device, the first light-emitting unit has the same material as the third light-emitting unit, the first charge generation layer has the same material as the second charge generation layer, and the second light-emitting unit has the same material as the fourth light-emitting unit.

[0018] One aspect of the present invention is a display module having a display device with any of the above configurations, to which a connector such as a Flexible Printed Circuit (FPC) or TCP (Tape Carrier Package) is attached, or a display module on which an integrated circuit (IC) is mounted by a COG (Chip On Glass) method or a COF (Chip On Film) method, etc.

[0019] One aspect of the present invention is an electronic device having the above-mentioned display module and at least one of a housing, a battery, a camera, a speaker, and a microphone.

[0020] Another aspect of the present invention involves forming a first pixel electrode and a second pixel electrode on an insulating surface, forming a first insulating layer covering the ends of the first pixel electrode and the ends of the second pixel electrode, forming a first layer on the first pixel electrode and the second pixel electrode, forming a first sacrificial layer on the first layer, processing the first layer and the first sacrificial layer to form a second layer on the first pixel electrode, a second sacrificial layer on the second layer, a third layer on the second pixel electrode, and a third sacrificial layer on the third layer, wherein at least the upper surface of the first insulating layer and the second This is a method for manufacturing a display device, comprising: forming a first insulating film covering the sides of the layer, the sides of the third layer, the sides and top of the second sacrificial layer, and the sides and top of the third sacrificial layer; processing the first insulating film to form a second insulating layer covering at least the top of the first insulating layer, the sides of the second layer, and the sides of the third layer; removing the second and third sacrificial layers; forming common electrodes on the second and third layers; and forming a first colored layer superimposed on the second layer and a second colored layer superimposed on the third layer on the common electrodes.

[0021] Another aspect of the present invention involves forming a first pixel electrode and a second pixel electrode on an insulating surface, forming a first insulating layer covering the ends of the first pixel electrode and the ends of the second pixel electrode, forming a first layer on the first pixel electrode and the second pixel electrode, forming a first sacrificial layer on the first layer, processing the first layer and the first sacrificial layer to form a second layer on the first pixel electrode, a second sacrificial layer on the second layer, a third layer on the second pixel electrode, and a third sacrificial layer on the third layer, and using an inorganic material, forming at least the upper surface of the first insulating layer, the side surface of the second layer, the side surface of the third layer, and the side surface of the second sacrificial layer A method for manufacturing a display device, comprising: forming a first insulating film covering the top surface of the first insulating layer, the sides and top surface of the third sacrificial layer; forming a second insulating film on the first insulating film using an organic material; processing the first insulating film and the second insulating film to form at least a second insulating layer covering the top surface of the first insulating layer, the sides of the second layer, and the sides of the third layer, and a third insulating layer on the second insulating layer; removing the second and third sacrificial layers; forming common electrodes on the second and third layers; and forming a first colored layer superimposed on the second layer and a second colored layer superimposed on the third layer on the common electrodes.

[0022] In the above method for manufacturing the display device, it is preferable to use a photosensitive resin as the organic material to form a second insulating film.

[0023] In the above method for manufacturing the display device, it is preferable to form a first sacrificial film and a second sacrificial film on the first sacrificial film as the first sacrificial layer, form a first resist mask on the second sacrificial film, process the second sacrificial film using the first resist mask, remove the first resist mask, process the first sacrificial film using the processed second sacrificial film as a mask, and process the first layer using the processed first sacrificial film as a mask.

[0024] In the above method for manufacturing the display device, it is preferable to remove the second sacrificial layer and the third sacrificial layer, then form a fourth layer on the second layer and the third layer, and form a common electrode on the fourth layer. [Effects of the Invention]

[0025] According to one aspect of the present invention, a high-definition display device can be provided. According to one aspect of the present invention, a high-resolution display device can be provided. According to one aspect of the present invention, a display device with a high aperture ratio can be provided. According to one aspect of the present invention, a large display device can be provided. According to one aspect of the present invention, a small display device can be provided. According to one aspect of the present invention, a highly reliable display device can be provided.

[0026] According to one aspect of the present invention, a method for manufacturing a high-definition display device can be provided. According to one aspect of the present invention, a method for manufacturing a high-resolution display device can be provided. According to one aspect of the present invention, a method for manufacturing a display device with a high aperture ratio can be provided. According to one aspect of the present invention, a method for manufacturing a large display device can be provided. According to one aspect of the present invention, a method for manufacturing a small display device can be provided. According to one aspect of the present invention, a method for manufacturing a highly reliable display device can be provided. According to one aspect of the present invention, a method for manufacturing a display device with a high yield can be provided.

[0027] Furthermore, the description of these effects does not preclude the existence of other effects. One aspect of the present invention does not necessarily have to possess all of these effects. Other effects can be extracted from the description, drawings, and claims. [Brief explanation of the drawing]

[0028] Figure 1A is a top view showing an example of a display device. Figure 1B is a cross-sectional view showing an example of a display device. Figures 2A and 2B are cross-sectional views showing an example of a display device. Figures 3A to 3C are cross-sectional views showing an example of a display device. Figure 4A is a top view showing an example of a display device. Figure 4B is a cross-sectional view showing an example of a display device. Figures 5A to 5F are top views showing an example of a pixel. Figures 6A to 6F are top views showing an example of a pixel. Figures 7A to 7G are top views showing an example of a pixel. Figures 8A to 8D are top views showing an example of a pixel. Figures 9A to 9C are schematic diagrams showing examples of electronic devices. Figures 10A to 10D are top views showing an example of a pixel. Figures 10E to 10G are cross-sectional views showing an example of a display device. Figures 11A and 11B are top views showing an example of a method for manufacturing a display device. Figures 12A to 12C are cross-sectional views showing an example of a method for manufacturing a display device. Figures 13A to 13C are cross-sectional views showing an example of a method for manufacturing a display device. Figures 14A to 14C are cross-sectional views showing an example of a method for manufacturing a display device. Figures 15A to 15C are cross-sectional views showing an example of a method for manufacturing a display device. Figures 16A to 16D are cross-sectional views showing an example of a method for manufacturing a display device. Figures 17A to 17F are cross-sectional views showing an example of a method for manufacturing a display device. Figures 18A and 18B are cross-sectional views showing an example of a display device. Figures 19A and 19B are cross-sectional views showing an example of a display device. Figure 20 is a perspective view showing an example of a display device. Figure 21A is a cross-sectional view showing an example of a display device. Figures 21B and 21C are cross-sectional views showing an example of a transistor. Figure 22 is a cross-sectional view showing an example of a display device. Figures 23A and 23B are perspective views showing an example of a display module. Figure 24 is a cross-sectional view showing an example of a display device. Figure 25 is a cross-sectional view showing an example of a display device. Figure 26 is a cross-sectional view showing an example of a display device. Figure 27 is a cross-sectional view showing an example of a display device. Figure 28 is a cross-sectional view showing an example of a display device. Figure 29A is a block diagram showing an example of a display device. Figures 29B to 29D show examples of pixel circuits. Figures 30A to 30D show examples of transistors. Figures 31A and 31B show examples of electronic devices. Figures 32A and 32B show examples of electronic devices. Figures 33A and 33B show examples of electronic devices. Figures 34A to 34D show examples of electronic devices. Figures 35A to 35G show examples of electronic devices. [Modes for carrying out the invention]

[0029] Embodiments will be described in detail with reference to the drawings. However, it will be readily apparent to those skilled in the art that the present invention is not limited to the following description, and that its form and details can be modified in various ways without departing from the spirit and scope of the present invention. Accordingly, the present invention shall not be construed as being limited to the descriptions of the embodiments shown below.

[0030] In the invention described below, the same reference numerals are used in common across different drawings for identical parts or parts having similar functions, and repeated explanations are omitted. Furthermore, when referring to similar functions, the same hatching pattern may be used, and reference numerals may not be assigned.

[0031] Furthermore, the position, size, and scope of each component shown in the drawings may not represent the actual position, size, and scope for the sake of ease of understanding. Therefore, the disclosed invention is not necessarily limited to the position, size, and scope disclosed in the drawings.

[0032] It should be noted that the terms "film" and "layer" can be interchanged depending on the context or situation. For example, the term "conductive layer" can be changed to "conductive film." Or, for example, the term "insulating film" can be changed to "insulating layer."

[0033] (Embodiment 1) In this embodiment, a display device according to one aspect of the present invention and a method for manufacturing the same will be explained with reference to Figures 1 to 17.

[0034] A display device according to one aspect of the present invention has a display unit in which pixels are arranged in a matrix, and an image can be displayed on the display unit. Each pixel has a light-emitting device that emits white light and a colored layer superimposed on the light-emitting device. Full-color display can be achieved by using a colored layer that transmits visible light of a different color in the sub-pixels provided in each pixel. Furthermore, since the light-emitting devices used in each pixel can be formed using the same material, the manufacturing process can be simplified and manufacturing costs can be reduced.

[0035] As the light-emitting device, it is preferable to use, for example, OLED (Organic Light Emitting Diode) or QLED (Quantum-dot Light Emitting Diode). Examples of light-emitting materials for the light-emitting device include fluorescent materials, phosphorescent materials, inorganic compounds (such as quantum dot materials), and thermally activated delayed fluorescence (Thermally Activated Delayed Fluorescence (TADF) materials). In addition, LEDs such as microLEDs (Light Emitting Diodes) can also be used as the light-emitting device.

[0036] When the light-emitting device for each pixel is formed from a white-emitting organic EL device, it is not necessary to coat the light-emitting layer separately for each pixel. Therefore, layers other than the pixel electrodes included in the light-emitting device (e.g., the light-emitting layer) can be common to each pixel. However, some layers included in the light-emitting device are relatively conductive, and if a highly conductive layer is provided in common to each pixel, leakage current may occur between pixels. In particular, as the display device becomes higher resolution or has a higher aperture ratio, and the distance between pixels becomes smaller, this leakage current becomes a significant issue that can cause a decrease in the display quality of the display device. Therefore, in a display device according to one aspect of the present invention, the resolution of the display device is increased by forming at least a part of the light-emitting device in an island shape in each pixel. Here, the island-shaped portion of the light-emitting device includes a light-emitting layer.

[0037] For example, island-shaped light-emitting layers can be deposited using a vacuum deposition method with a metal mask (also called a shadow mask). However, with this method, deviations from the design occur in the shape and position of the island-shaped light-emitting layers due to various factors such as the precision of the metal mask, misalignment between the metal mask and the substrate, deflection of the metal mask, and the spreading of the contour of the deposited film due to vapor scattering. This makes it difficult to achieve high resolution and high aperture ratio in display devices. In addition, the contour of the layer may become blurred during deposition, and the thickness at the edges may become thinner. In other words, the thickness of the island-shaped light-emitting layer may vary depending on the location. Furthermore, when manufacturing large, high-resolution, or high-definition display devices, there is a concern that the low dimensional accuracy of the metal mask and deformation due to heat, etc., may lead to low manufacturing yield.

[0038] In a method for manufacturing a display device according to one aspect of the present invention, island-shaped pixel electrodes (also called lower electrodes) are formed, an insulating layer is formed to cover the ends of the pixel electrodes, then a layer including an emissive layer (which can be called an EL layer or a part of an EL layer) is formed on one surface, and a sacrificial layer is formed on the EL layer. Then, a resist mask is formed on the sacrificial layer, and the EL layer and the sacrificial layer are processed using the resist mask to form island-shaped EL layers on the island-shaped pixel electrodes. In this specification, the sacrificial layer may also be referred to as a mask layer.

[0039] Thus, in the method for manufacturing a display device according to one aspect of the present invention, the island-shaped EL layer is not formed using a fine metal mask, but rather by processing after the EL layer has been deposited on one surface. Therefore, it is possible to realize a high-definition display device or a display device with a high aperture ratio, which has been difficult to achieve until now. Furthermore, by providing a sacrificial layer on the EL layer, the damage the EL layer receives during the manufacturing process of the display device can be reduced, and the reliability of the light-emitting device can be improved.

[0040] While it is difficult to reduce the spacing between adjacent light-emitting devices to less than 10 μm using, for example, a metal mask formation method, the above method allows for narrowing the spacing to 8 μm or less, 6 μm or less, 4 μm or less, 3 μm or less, 2 μm or less, or even 1 μm or less. Furthermore, by using, for example, an exposure apparatus for LSIs, the spacing can be narrowed to 500 nm or less, 200 nm or less, 100 nm or less, and even 50 nm or less. This significantly reduces the area of ​​the non-emitting region that may exist between two light-emitting devices, making it possible to approach an aperture ratio of 100%. For example, an aperture ratio of 50% or more, 60% or more, 70% or more, 80% or more, and even 90% or more, can be achieved, and even less than 100%.

[0041] Furthermore, the pattern of the EL layer itself (which can also be called the processing size) can be made extremely small compared to when a metal mask is used. Also, for example, when a metal mask is used to create different EL layers, variations in thickness occur between the center and edges of the EL layer, so the effective area that can be used as an emitting region is small relative to the area of ​​the EL layer. On the other hand, with the above manufacturing method, the EL layer is formed by processing a film deposited to a uniform thickness, so the thickness can be made uniform within the EL layer, and even if the pattern is fine, almost the entire area can be used as an emitting region. As a result, it is possible to manufacture a display device that combines high resolution and a high aperture ratio.

[0042] Furthermore, in light-emitting devices that emit white light, it is not necessary to form all the layers constituting the EL layer in an island-like manner; some layers can be deposited in the same process. In a method for manufacturing a display device according to one aspect of the present invention, after forming some of the layers constituting the EL layer in an island-like manner for each pixel, the sacrificial layer can be removed, and the remaining layers constituting the EL layer (e.g., the carrier injection layer) and the common electrode (also called the upper electrode) can be formed in common.

[0043] On the other hand, the carrier injection layer is often a relatively conductive layer within the light-emitting device. Therefore, there is a risk of a short circuit occurring in the light-emitting device if the carrier injection layer comes into contact with the side surface of the island-shaped EL layer. Furthermore, even when the carrier injection layer is provided in an island shape and only a common electrode is formed in common between the light-emitting devices, there is a risk of a short circuit occurring in the light-emitting device if the common electrode comes into contact with the side surface of the island-shaped EL layer or the side surface of the pixel electrode.

[0044] Therefore, a display device according to one aspect of the present invention has an insulating layer covering the side surface of an island-shaped EL layer (e.g., a light-emitting layer) and an insulating layer covering the end of a pixel electrode. This prevents at least a portion of the island-shaped EL layer and the pixel electrode from coming into contact with the carrier injection layer or common electrode. Thus, short circuits in the light-emitting device can be suppressed, and the reliability of the light-emitting device can be improved.

[0045] A display device according to one aspect of the present invention includes a pixel electrode that functions as an anode, an island-shaped hole injection layer, a hole transport layer, an emissive layer, and an electron transport layer provided on the pixel electrode in this order, an insulating layer covering the end of the pixel electrode, an insulating layer provided to cover the respective sides of the hole injection layer, hole transport layer, emissive layer, and electron transport layer, an electron injection layer provided on the electron transport layer, and a common electrode provided on the electron injection layer that functions as a cathode.

[0046] Alternatively, a display device according to one aspect of the present invention includes a pixel electrode that functions as a cathode, an island-shaped electron injection layer, an electron transport layer, an emissive layer, and a hole transport layer provided in this order on the pixel electrode, an insulating layer covering the end of the pixel electrode, an insulating layer provided to cover the respective sides of the electron injection layer, electron transport layer, emissive layer, and hole transport layer, a hole injection layer provided on the hole transport layer, and a common electrode provided on the hole injection layer that functions as an anode.

[0047] Alternatively, a display device according to one aspect of the present invention includes a pixel electrode, a first light-emitting unit on the pixel electrode, an intermediate layer (also called a charge generation layer) on the first light-emitting unit, a second light-emitting unit on the intermediate layer, an insulating layer covering the ends of the pixel electrode, an insulating layer provided to cover the respective sides of the first light-emitting unit, the intermediate layer, and the second light-emitting unit, and a common electrode provided on the second light-emitting unit. A common layer may be provided between the second light-emitting unit and the common electrode for each color of light-emitting device.

[0048] Hole injection layers, electron injection layers, or charge generation layers are often relatively conductive layers within the EL layer. In a display device according to one aspect of the present invention, the sides of these layers are covered with an insulating layer, thereby suppressing contact with common electrodes and the like. Therefore, short circuits in the light-emitting device can be suppressed, and the reliability of the light-emitting device can be improved.

[0049] This configuration makes it possible to manufacture highly detailed, high-resolution, and reliable display devices. For example, it is not necessary to apply special pixel arrangement methods such as the PenTile method to artificially increase detail; even with an arrangement method that uses three or more subpixels per pixel, an extremely high-resolution display device can be realized. For example, with a so-called stripe arrangement in which R, G, and B are each arranged in one direction, a display device with a detail of 500 ppi or more, 1000 ppi or more, 2000 ppi or more, even 3000 ppi or more, and even 5000 ppi or more can be realized.

[0050] The insulating layer covering the sides of island-shaped EL layers may be a single-layer structure or a multi-layer structure. In particular, it is preferable to apply a two-layer insulating layer. For example, since the first insulating layer is formed in contact with the EL layer, it is preferable to form it using an inorganic insulating material. In particular, it is preferable to form it using the atomic layer deposition (ALD) method, which causes less film deposition damage. In addition, it is preferable to form the inorganic insulating layer using the sputtering method, chemical vapor deposition (CVD) method, or plasma-enhanced chemical vapor deposition (PECVD) method, which have a faster film deposition rate than the ALD method. This makes it possible to manufacture highly reliable display devices with high productivity. Furthermore, it is preferable to form the second insulating layer using an organic material so as to flatten the recesses formed in the first insulating layer.

[0051] For example, an aluminum oxide film formed by the ALD method can be used as the first layer of the insulating layer, and a photosensitive organic resin film can be used as the second layer of the insulating layer.

[0052] Furthermore, a single-layer insulating layer may be formed. For example, by forming a single-layer insulating layer using an inorganic material, the insulating layer can be used as a protective insulating layer for the EL layer. This can improve the reliability of the display device. Alternatively, by forming a single-layer insulating layer using an organic material, for example, the space between adjacent EL layers can be filled with the insulating layer and flattened. This can improve the coverage of the common electrode (upper electrode) formed on the EL layer and the insulating layer.

[0053] [Example of display device configuration 1] Figures 1A and 1B show a display device according to one embodiment of the present invention.

[0054] Figure 1A shows a top view (which can also be called a plan view) of the display device 100. The display device 100 has a display unit in which a plurality of pixels 110 are arranged in a matrix, and a connection unit 140 outside the display unit.

[0055] A stripe array is applied to the pixel 110 shown in Figure 1A. The pixel 110 shown in Figure 1A is composed of three subpixels: subpixels 110a, 110b, and 110c. The subpixels 110a, 110b, and 110c have light-emitting devices 130a, 130b, and 130c (hereinafter sometimes collectively referred to as light-emitting device 130) that emit white light. Color layers 129a, 129b, and 129c (hereinafter sometimes collectively referred to as color layer 129) are superimposed on the light-emitting devices 130a, 130b, and 130c, causing each subpixel to emit light of a different color. Examples of subpixels 110a, 110b, and 110c include subpixels of three colors: red (R), green (G), and blue (B), and subpixels of three colors: yellow (Y), cyan (C), and magenta (M).

[0056] Figure 1A shows an example where subpixels of different colors are arranged side by side in the X direction, and subpixels of the same color are arranged side by side in the Y direction. Alternatively, subpixels of different colors may be arranged side by side in the Y direction, and subpixels of the same color may be arranged side by side in the X direction.

[0057] Figure 1A shows an example where the connection portion 140 is located below the display portion in a top view (which can also be called a plan view), but it is not particularly limited. The connection portion 140 only needs to be provided at least one location on the top, right, left, or bottom of the display portion in a top view, and may be provided so as to surround all four sides of the display portion. Also, there may be one or more connection portions 140.

[0058] Figure 1B shows a cross-sectional view between the dashed line X1 and X2 in Figure 1A.

[0059] As shown in Figure 1B, the display device 100 has light-emitting devices 130a, 130b, and 130c arranged on a layer 101 containing transistors, and protective layers 131 and 132 are provided to cover these light-emitting devices. Coloring layers 129a, 129b, and 129c are provided on the protective layer 132. Furthermore, a substrate 120 is bonded on top of that by a resin layer 122. In addition, an insulating layer 125 and an insulating layer 127 on the insulating layer 125 are provided in the region between adjacent light-emitting devices.

[0060] A display device according to one aspect of the present invention may be a top-emission type that emits light in the direction opposite to the substrate on which the light-emitting device is formed, a bottom-emission type that emits light toward the substrate on which the light-emitting device is formed, or a dual-emission type that emits light on both sides.

[0061] The layer 101 containing transistors can be, for example, a laminated structure in which multiple transistors are provided on a substrate and an insulating layer is provided to cover these transistors. The layer 101 containing transistors may have recesses between adjacent light-emitting devices. For example, recesses may be provided in the insulating layer located on the outermost surface of the layer 101 containing transistors. Examples of the configuration of the layer 101 containing transistors will be described later in Embodiments 3 and 4.

[0062] The light-emitting devices 130a, 130b, and 130c preferably emit white (W) light. By providing colored layers 129a, 129b, and 129c on these that transmit light of different colors, sub-pixels 110a, 110b, and 110c that emit light of different colors can be formed.

[0063] For the light-emitting devices 130a, 130b, and 130c, it is preferable to use, for example, OLEDs or QLEDs. Examples of light-emitting materials for the light-emitting devices include fluorescent materials, phosphorescent materials, inorganic compounds (such as quantum dot materials), and thermally activated delayed fluorescence (TADF materials). As for the TADF material, a material in which the singlet excited state and the triplet excited state are in thermal equilibrium may be used. Since such TADF materials have a shorter luminescence lifetime (excitation lifetime), it is possible to suppress the decrease in efficiency in the high-brightness region of the light-emitting device.

[0064] The light-emitting device has an EL layer between a pair of electrodes. In this specification, one of the pair of electrodes may be referred to as the pixel electrode and the other as the common electrode.

[0065] In a light-emitting device, one electrode functions as the anode and the other as the cathode. The following explanation uses the example where the pixel electrode functions as the anode and the common electrode functions as the cathode.

[0066] The light-emitting device 130a includes a pixel electrode 111a on a layer 101 containing a transistor, an island-shaped first layer 113a on the pixel electrode 111a, a fifth layer 114 on the island-shaped first layer 113a, and a common electrode 115 on the fifth layer 114. In the light-emitting device 130a, the first layer 113a and the fifth layer 114 can be collectively referred to as the EL layer.

[0067] The configuration of the light-emitting device in this embodiment is not particularly limited and may be a single structure or a tandem structure. An example of the configuration of the light-emitting device will be described later in Embodiment 2.

[0068] The light-emitting device 130b includes a pixel electrode 111b on a layer 101 containing a transistor, an island-shaped second layer 113b on the pixel electrode 111b, a fifth layer 114 on the island-shaped second layer 113b, and a common electrode 115 on the fifth layer 114. In the light-emitting device 130b, the second layer 113b and the fifth layer 114 can be collectively referred to as the EL layer.

[0069] The light-emitting device 130c includes a pixel electrode 111c on a layer 101 containing a transistor, an island-shaped third layer 113c on the pixel electrode 111c, a fifth layer 114 on the island-shaped third layer 113c, and a common electrode 115 on the fifth layer 114. In the light-emitting device 130c, the third layer 113c and the fifth layer 114 can be collectively referred to as the EL layer.

[0070] Each color of light-emitting device shares the same film as a common electrode. This common electrode, which is common to all light-emitting devices, is electrically connected to a conductive layer provided in the connection portion 140.

[0071] Of the pixel electrodes and common electrodes, the electrode that extracts light should preferably use a conductive film that transmits visible light. Furthermore, it is preferable to use a conductive film that reflects visible light on the electrode that does not extract light.

[0072] As materials for forming the pair of electrodes (pixel electrode and common electrode) of a light-emitting device, metals, alloys, electrically conductive compounds, and mixtures thereof can be used as appropriate. Specifically, examples include indium tin oxide (In-Sn oxide, also called ITO), In-Si-Sn oxide (also called ITSO), indium zinc oxide (In-Zn oxide), In-W-Zn oxide, aluminum-containing alloys such as aluminum, magnesium, nickel, and lanthanum alloys (Al-Ni-La), as well as silver-containing alloys such as silver-magnesium alloys and silver-palladium-copper alloys (Ag-Pd-Cu, also written as APC). In addition, metals such as aluminum (Al), titanium (Ti), chromium (Cr), manganese (Mn), iron (Fe), cobalt (Co), nickel (Ni), copper (Cu), gallium (Ga), zinc (Zn), indium (In), tin (Sn), molybdenum (Mo), tantalum (Ta), tungsten (W), palladium (Pd), gold (Au), platinum (Pt), silver (Ag), yttrium (Y), neodymium (Nd), and alloys containing these in appropriate combinations can also be used. Furthermore, elements belonging to Group 1 or Group 2 of the periodic table not exemplified above (e.g., lithium (Li), cesium (Cs), calcium (Ca), strontium (Sr)), rare earth metals such as europium (Eu), ytterbium (Yb), and alloys containing these in appropriate combinations, graphene, etc., can also be used. Furthermore, the above-mentioned metals, alloys, electrically conductive compounds, and mixtures thereof may be appropriately stacked to form a pair of electrodes (pixel electrodes and common electrodes) for a light-emitting device.

[0073] It is preferable that the light-emitting device has a microcavity structure. Therefore, it is preferable that one of the pair of electrodes in the light-emitting device has an electrode that is transparent to and reflective to visible light (a semi-transmissive / semi-reflective electrode), and the other has an electrode that is reflective to visible light (a reflective electrode). By having a microcavity structure in the light-emitting device, the light emitted from the light-emitting layer can be resonated between the two electrodes, thereby strengthening the light emitted from the light-emitting device.

[0074] Furthermore, semi-transmissive / semi-reflective electrodes can have a laminated structure consisting of a reflective electrode and an electrode that transmits visible light (also called a transparent electrode).

[0075] The light transmittance of the transparent electrode shall be 40% or more. For example, it is preferable to use an electrode in the light-emitting device that has a transmittance of 40% or more for visible light (light with a wavelength of 400 nm or more and less than 750 nm). The visible light reflectance of the semi-transparent / semi-reflective electrode shall be 10% or more and 95% or less, preferably 30% or more and 80% or less. The visible light reflectance of the reflective electrode shall be 40% or more and 100% or less, preferably 70% or more and 100% or less. The resistivity of these electrodes shall be 1 × 10⁻⁶ -2 A value of Ωcm or less is preferable.

[0076] The first layer 113a, the second layer 113b, and the third layer 113c are each provided in an island-like manner. The first layer 113a, the second layer 113b, and the third layer 113c each have an emissive layer. Preferably, the first layer 113a, the second layer 113b, and the third layer 113c have an emissive layer that emits white light. Here, it is preferable that the island-like first layer 113a, the island-like second layer 113b, and the island-like third layer 113c are made of the same material. In other words, it is preferable that the island-like first layer 113a, the island-like second layer 113b, and the island-like third layer 113c are formed by patterning films deposited in the same process.

[0077] The luminescent layer is a layer containing a luminescent material. The luminescent layer may contain one or more types of luminescent materials. Suitable luminescent materials include those exhibiting colors such as blue, purple, blue-violet, green, yellow-green, yellow, orange, and red. Furthermore, materials emitting near-infrared light may also be used as luminescent materials.

[0078] Examples of luminescent materials include fluorescent materials, phosphorescent materials, TADF materials, and quantum dot materials.

[0079] Examples of fluorescent materials include pyrene derivatives, anthracene derivatives, triphenylene derivatives, fluorene derivatives, carbazole derivatives, dibenzothiophene derivatives, dibenzofuran derivatives, dibenzoquinoxaline derivatives, quinoxaline derivatives, pyridine derivatives, pyrimidine derivatives, phenanthrene derivatives, and naphthalene derivatives.

[0080] Examples of phosphorescent materials include organometallic complexes (especially iridium complexes) having a 4H-triazole skeleton, 1H-triazole skeleton, imidazole skeleton, pyrimidine skeleton, pyrazine skeleton, or pyridine skeleton; organometallic complexes (especially iridium complexes) using phenylpyridine derivatives having electron-withdrawing groups as ligands; platinum complexes; and rare earth metal complexes.

[0081] The light-emitting layer may contain one or more types of organic compounds (host material, assist material, etc.) in addition to the light-emitting substance (guest material). One or more of these organic compounds may be hole-transporting materials and / or electron-transporting materials. Alternatively, one or more of these organic compounds may be bipolar materials or TADF materials.

[0082] The light-emitting layer preferably comprises, for example, a phosphorescent material and a combination of a hole-transporting material and an electron-transporting material that readily forms an excitation complex. This configuration allows for efficient emission using ExTET (Exciplex-Triplet Energy Transfer), which is energy transfer from the excitation complex to the light-emitting substance (phosphorescent material). By selecting a combination that forms an excitation complex that exhibits emission overlapping with the wavelength of the lowest-energy absorption band of the light-emitting substance, energy transfer becomes smoother, and light emission can be obtained efficiently. This configuration simultaneously achieves high efficiency, low-voltage operation, and a long lifespan for the light-emitting device.

[0083] The first layer 113a, the second layer 113b, and the third layer 113c may further include layers other than the light-emitting layer, such as a material with high hole injection properties, a material with high hole transport properties, a hole blocking material, a material with high electron transport properties, a material with high electron injection properties, an electron blocking material, or a bipolar material (a material with high electron transport and hole transport properties).

[0084] The light-emitting device may use either low-molecular-weight compounds or high-molecular-weight compounds, and may also contain inorganic compounds. The layers constituting the light-emitting device can be formed by methods such as vapor deposition (including vacuum deposition), transfer, printing, inkjet, and coating.

[0085] For example, the first layer 113a, the second layer 113b, and the third layer 113c may each have one or more of the following: a hole injection layer, a hole transport layer, a hole blocking layer, an electron blocking layer, an electron transport layer, and an electron injection layer.

[0086] Among the EL layers, one or more of the following layers can be applied to each light-emitting device: a hole injection layer, a hole transport layer, a hole blocking layer (sometimes called a hole suppression layer), an electron blocking layer (sometimes called an electron suppression layer), an electron transport layer, and an electron injection layer. For example, a carrier injection layer (hole injection layer or electron injection layer) may be formed as the fifth layer 114. Furthermore, all layers of the EL layer may be manufactured separately for each color. In other words, the EL layer does not necessarily have to have layers that are formed in common for each color of light-emitting device.

[0087] Preferably, the first layer 113a, the second layer 113b, and the third layer 113c each have an emissive layer and a carrier transport layer on the emissive layer. This suppresses exposure of the emissive layer to the outermost surface during the manufacturing process of the display device 100, thereby reducing damage to the emissive layer. This improves the reliability of the light-emitting device.

[0088] The hole injection layer is a layer that injects holes from the anode into the hole transport layer, and is a layer containing a material with high hole injection capabilities. Examples of materials with high hole injection capabilities include aromatic amine compounds and composite materials containing hole transport materials and acceptor materials (electron-accepting materials).

[0089] The hole transport layer is a layer that transports holes injected from the anode by the hole injection layer to the light-emitting layer. The hole transport layer is a layer containing a hole-transporting material. The hole-transporting material is 1 × 10⁻¹⁶ -6 cm 2 Materials having a hole mobility of / Vs or higher are preferred. However, other materials can also be used as long as they have higher hole transport capabilities than electron transport. Preferred hole transport materials include π-electron-rich heteroaromatic compounds (e.g., carbazole derivatives, thiophene derivatives, furan derivatives, etc.) and aromatic amines (compounds having an aromatic amine skeleton), which are materials with high hole transport capabilities.

[0090] The electron transport layer is a layer that transports electrons injected from the cathode by the electron injection layer to the light-emitting layer. The electron transport layer is a layer containing an electron-transporting material. The electron-transporting material is 1 × 10⁻¹⁶ -6 cm 2 Materials having an electron mobility of 1 / Vs or higher are preferred. However, other materials can also be used as long as they have higher electron transport capabilities than holes. Examples of electron-transporting materials include metal complexes having a quinoline skeleton, metal complexes having a benzoquinoline skeleton, metal complexes having an oxazole skeleton, metal complexes having a thiazole skeleton, as well as oxadiazole derivatives, triazole derivatives, imidazole derivatives, oxazole derivatives, thiazole derivatives, phenanthroline derivatives, quinoline derivatives having a quinoline ligand, benzoquinoline derivatives, quinoxaline derivatives, dibenzoquinoxaline derivatives, pyridine derivatives, bipyridine derivatives, pyrimidine derivatives, and other π-electron-deficient heteroaromatic compounds containing nitrogen-containing heteroaromatic compounds, which are materials with high electron transport capabilities.

[0091] Furthermore, the electron transport layer may have a multilayer structure, and may also have a hole blocking layer in contact with the light-emitting layer to block holes moving from the anode side through the light-emitting layer to the cathode side.

[0092] The electron injection layer is a layer that injects electrons from the cathode to the electron transport layer, and is a layer containing a material with high electron injection capabilities. Alkali metals, alkaline earth metals, or compounds thereof can be used as materials with high electron injection capabilities. Composite materials containing both electron transport materials and donor materials (electron-donating materials) can also be used as materials with high electron injection capabilities.

[0093] Examples of electron injection layers include lithium, cesium, ytterbium, lithium fluoride (LiF), cesium fluoride (CsF), and calcium fluoride (CaF). x (where X is any number), 8-(quinolinolato)lithium (abbreviation: Liq), 2-(2-pyridyl)phenolatrium (abbreviation: LiPP), 2-(2-pyridyl)-3-pyridinolatrium (abbreviation: LiPPy), 4-phenyl-2-(2-pyridyl)phenolatrium (abbreviation: LiPPP), lithium oxide (LiO x Alkali metals such as cesium carbonate, alkaline earth metals, or compounds thereof can be used. Furthermore, the electron injection layer may be a multilayer structure of two or more layers. For example, this multilayer structure may consist of lithium fluoride in the first layer and ytterbium in the second layer.

[0094] Alternatively, an electron-transporting material may be used as the electron injection layer. For example, a compound having a lone pair of electrons and an electron-deficient heteroaromatic ring can be used as the electron-transporting material. Specifically, a compound having at least one of a pyridine ring, a diazine ring (pyrimidine ring, pyrazine ring, pyridazine ring), or a triazine ring can be used.

[0095] Furthermore, it is preferable that the lowest unoccupied molecular orbital (LUMO) of an organic compound containing a lone pair of electrons is between -3.6 eV and -2.3 eV. In addition, the highest occupied molecular orbital (HOMO) level and LUMO level of an organic compound can generally be estimated by methods such as cyclic voltammetry (CV), photoelectron spectroscopy, optical absorption spectroscopy, and inverse photoelectron spectroscopy.

[0096] For example, 4,7-diphenyl-1,10-phenanthroline (abbreviated as BPhen), 2,9-bis(naphthalene-2-yl)-4,7-diphenyl-1,10-phenanthroline (abbreviated as NBPhen), diquinoxalino[2,3-a:2',3'-c]phenazine (abbreviated as HATNA), and 2,4,6-tris[3'-(pyridine-3-yl)biphenyl-3-yl]-1,3,5-triazine (abbreviated as TmPPPyTz) can be used in organic compounds containing lone pairs of electrons. NBPhen has a higher glass transition temperature (Tg) and superior heat resistance compared to BPhen.

[0097] Furthermore, when fabricating a tandem light-emitting device, an intermediate layer is provided between the two light-emitting units. The intermediate layer has the function of injecting electrons into one of the two light-emitting units and holes into the other when a voltage is applied between the pair of electrodes.

[0098] As the intermediate layer, for example, a material applicable to the electron injection layer, such as lithium, can be suitably used. Alternatively, as the intermediate layer, a material applicable to the hole injection layer can be suitably used. Furthermore, the intermediate layer can include a layer containing a hole transport material and an acceptor material (electron-accepting material). Alternatively, the intermediate layer can include a layer containing an electron transport material and a donor material. By forming an intermediate layer having such a layer, the increase in driving voltage when light-emitting units are stacked can be suppressed.

[0099] Each end of the pixel electrodes 111a, 111b, and 111c is covered by an insulating layer 121.

[0100] The insulating layer 121 can be a single-layer structure or a multilayer structure using one or both of an inorganic insulating film and an organic insulating film.

[0101] When an inorganic insulating film is used as the insulating layer 121 covering the edges of the pixel electrodes, impurities are less likely to enter the light-emitting device compared to when an organic insulating film is used, thereby improving the reliability of the light-emitting device. When an organic insulating film is used as the insulating layer 121 covering the edges of the pixel electrodes, the step coverage is higher compared to when an inorganic insulating film is used, and it is less affected by the shape of the pixel electrodes. Therefore, short circuits in the light-emitting device can be prevented. Specifically, when an organic insulating film is used as the insulating layer 121, the shape of the insulating layer 121 can be processed into a tapered shape or the like. In this specification, a tapered shape refers to a shape in which at least a part of the side surface of the structure is inclined with respect to the substrate surface. For example, it is preferable to have a region in which the angle between the inclined side surface and the substrate surface (also called the taper angle) is less than 90°.

[0102] Each side of the first layer 113a, the second layer 113b, and the third layer 113c is covered by insulating layers 125 and 127 provided on the insulating layer 121. This prevents the fifth layer 114 (or common electrode 115) from coming into contact with any of the sides of the first layer 113a, the second layer 113b, and the third layer 113c, thereby preventing a short circuit in the light-emitting device.

[0103] Furthermore, if the first layer 113a, the second layer 113b, and the third layer 113c have a tandem structure, the sides of each of the multiple light-emitting units and the intermediate layer included in these layers are also covered by the insulating layer 125 and the insulating layer 127. This prevents the fifth layer 114 (or common electrode 115) from coming into contact with any of the sides of the multiple light-emitting units and the intermediate layer, thereby suppressing short circuits in the light-emitting device.

[0104] The insulating layer 125 preferably covers the sides of the first layer 113a, the second layer 113b, and the third layer 113c. The insulating layer 125 can be configured to be in contact with each of the sides of the first layer 113a, the second layer 113b, and the third layer 113c. Alternatively, the lower surface of the insulating layer 125 can be in contact with the upper surface of the insulating layer 121.

[0105] The insulating layer 127 is provided on the insulating layer 125 so as to fill the recesses formed in the insulating layer 125. The insulating layer 127 can be configured to overlap the sides of the first layer 113a, the second layer 113b, and the third layer 113c, and the upper surface of the insulating layer 121, via the insulating layer 125.

[0106] It is also possible to omit either the insulating layer 125 or the insulating layer 127. For example, if the insulating layer 125 is not provided, the insulating layer 127 can be configured to be in contact with the respective sides of the first layer 113a, the second layer 113b, and the third layer 113c.

[0107] The fifth layer 114 and the common electrode 115 are provided on the first layer 113a, the second layer 113b, the third layer 113c, the insulating layer 125, and the insulating layer 127. Before the insulating layer 125 and the insulating layer 127 are provided, a step difference occurs due to the region where the EL layer is provided and the region where the EL layer is not provided (the region between light-emitting devices). In one embodiment of the present invention, the presence of the insulating layer 125 and the insulating layer 127 can flatten this step difference and improve the coverage of the fifth layer 114 and the common electrode 115. Therefore, connection failures due to step breaks can be suppressed. Alternatively, it is possible to suppress the local thinning of the common electrode 115 due to the step difference, which would increase electrical resistance.

[0108] To improve the flatness of the forming surfaces of the fifth layer 114 and the common electrode 115, it is preferable that the heights of the upper surfaces of the insulating layer 125 and the insulating layer 127 match or approximately match the height of at least one of the upper surfaces of the first layer 113a, the second layer 113b, and the third layer 113c, respectively. Furthermore, it is preferable that the upper surface of the insulating layer 127 has a flat shape, and may have convex portions, convex curved surfaces, concave curved surfaces, or recesses.

[0109] The insulating layer 125 has regions that are in contact with the sides of the first layer 113a, the second layer 113b, and the third layer 113c, and functions as a protective insulating layer for the first layer 113a, the second layer 113b, and the third layer 113c. By providing the insulating layer 125, it is possible to suppress the intrusion of impurities (oxygen, moisture, etc.) into the interior from the sides of the first layer 113a, the second layer 113b, and the third layer 113c, thereby enabling a highly reliable display device.

[0110] In a cross-sectional view, if the width (thickness) of the insulating layer 125 in the region in contact with the sides of the first layer 113a, the second layer 113b, and the third layer 113c is large, the spacing between the first layer 113a, the second layer 113b, and the third layer 113c may increase, resulting in a lower aperture ratio. Conversely, if the width (thickness) of the insulating layer 125 is small, the effect of suppressing the intrusion of impurities into the interior from the sides of the first layer 113a, the second layer 113b, and the third layer 113c may be reduced. The width (thickness) of the insulating layer 125 in the region in contact with the sides of the first layer 113a, the second layer 113b, and the third layer 113c is preferably 3 nm to 200 nm, more preferably 3 nm to 150 nm, more preferably 5 nm to 150 nm, more preferably 5 nm to 100 nm, more preferably 10 nm to 100 nm, and more preferably 10 nm to 50 nm. By setting the width (thickness) of the insulating layer 125 within the above range, a display device with a high aperture ratio and high reliability can be made.

[0111] The insulating layer 125 can be an insulating layer having an inorganic material. For example, inorganic insulating films such as oxide insulating films, nitride insulating films, oxidative nitride insulating films, and nitride oxide insulating films can be used for the insulating layer 125. The insulating layer 125 may be a single layer or a laminated structure. Examples of oxide insulating films include silicon oxide film, aluminum oxide film, magnesium oxide film, indium gallium zinc oxide film, gallium oxide film, germanium oxide film, yttrium oxide film, zirconium oxide film, lanthanum oxide film, neodymium oxide film, hafnium oxide film, and tantalum oxide film. Examples of nitride insulating films include silicon nitride film and aluminum nitride film. Examples of oxidative nitride insulating films include silicon oxidative nitride film and aluminum oxidative nitride film. Examples of nitride oxide insulating films include silicon nitride oxide film and aluminum nitride oxide film. In particular, aluminum oxide is preferred because it has a high selectivity ratio with the EL layer during etching and has the function of protecting the EL layer during the formation of the insulating layer 127, which will be described later. In particular, by applying inorganic insulating films such as aluminum oxide films, hafnium oxide films, silicon oxide films, and silicon nitride films formed by the ALD method to the insulating layer 125, it is possible to form an insulating layer 125 with fewer pinholes and excellent protection for the EL layer. Furthermore, when using inorganic materials to form a laminated film for the insulating layer 125, a laminated structure of aluminum oxide film and silicon nitride film is preferable.

[0112] In this specification, the term "oxide-nitride" refers to a material in which the oxygen content is greater than the nitrogen content, and the term "nitride oxide" refers to a material in which the nitrogen content is greater than the oxygen content. For example, when "silicon oxynitride" is written, it refers to a material in which the oxygen content is greater than the nitrogen content, and when "silicon nitride oxide" is written, it refers to a material in which the nitrogen content is greater than the oxygen content.

[0113] The insulating layer 125 can be formed using sputtering, CVD, PLD, ALD, or other methods. It is preferable to form the insulating layer 125 using the ALD method, which provides good coverage.

[0114] The insulating layer 127 provided on the insulating layer 125 has the function of flattening the recess in the insulating layer 125 formed between adjacent light-emitting devices. In other words, the presence of the insulating layer 127 improves the flatness of the surface on which the common electrode 115 is formed. Suitable insulating layers 127 include those made of organic materials. For example, acrylic resin, polyimide resin, epoxy resin, imide resin, polyamide resin, polyimidoamide resin, silicone resin, siloxane resin, benzocyclobutene resin, phenol resin, and precursors of these resins can be used as the insulating layer 127. Alternatively, organic materials such as polyvinyl alcohol (PVA), polyvinyl butyral, polyvinylpyrrolidone, polyethylene glycol, polyglycerin, pullulan, water-soluble cellulose, or alcohol-soluble polyamide resin may be used as the insulating layer 127. Furthermore, a photosensitive resin can be used as the insulating layer 127. A photoresist may be used as the photosensitive resin. The photosensitive resin can be a positive-type material or a negative-type material.

[0115] The difference between the height of the upper surface of the insulating layer 127 and the height of the upper surface of any of the first layer 113a, the second layer 113b, and the third layer 113c is preferably 0.5 times or less the thickness of the insulating layer 127, and more preferably 0.3 times or less. Alternatively, the insulating layer 127 may be provided such that the upper surface of any of the first layer 113a, the second layer 113b, and the third layer 113c is higher than the upper surface of the insulating layer 127. Alternatively, the insulating layer 127 may be provided such that the upper surface of the insulating layer 127 is higher than the upper surface of the light-emitting layer of the first layer 113a, the second layer 113b, or the third layer 113c.

[0116] Furthermore, by providing the insulating layer 127, it is possible to suppress contact between at least a portion of the island-shaped EL layers and the carrier injection layer or common electrode. Therefore, short circuits in the light-emitting device can be suppressed, and the reliability of the light-emitting device can be improved. In addition, by providing the insulating layer 127, the gaps between adjacent island-shaped EL layers can be filled, thereby reducing the unevenness of the surface on which layers (carrier injection layer, common electrode, etc.) are formed on the island-shaped EL layers, making them flatter. Therefore, the coverage of the carrier injection layer or common electrode can be improved.

[0117] Furthermore, since the insulating layer 127 can be formed simultaneously with the external lead-out terminal portion (for example, the external connection portion 140 of the display portion described later), it can be formed without increasing the manufacturing process. In addition, providing the insulating layer 127 has the effect of preventing film peeling. Specifically, since the organic layer (for example, one or more selected from hole injection layer, hole transport layer, light-emitting layer, electron transport layer, and electron injection layer) and the insulating layer can be provided in contact, adhesion can be improved compared to a configuration without an insulating layer.

[0118] Furthermore, by using a photosensitive organic resin film as the insulating layer 127 and an aluminum oxide film formed by the ALD method as the insulating layer 125, it is possible to create a configuration in which the photosensitive organic resin film and the side surface of the EL layer do not come into direct contact. For example, in a configuration in which the side surface of the EL layer and the photosensitive organic resin film come into direct contact, organic solvents that may be contained in the photosensitive organic resin film may damage the side surface of the EL layer. On the other hand, in one embodiment of the present invention, the side surface of the EL layer is covered with the aluminum oxide film formed by the ALD method, so that organic solvents that may be contained in the photosensitive organic resin film do not come into direct contact with the side surface of the EL layer.

[0119] It is preferable to have protective layers 131 and 132 on the light-emitting devices 130a, 130b, and 130c. Providing protective layers 131 and 132 can improve the reliability of the light-emitting devices.

[0120] The conductivity of the protective layers 131 and 132 is not required. At least one of an insulating film, a semiconductor film, and a conductive film can be used as the protective layers 131 and 132.

[0121] The presence of an inorganic film or inorganic insulating film in the protective layers 131 and 132 prevents oxidation of the common electrode 115 and suppresses the intrusion of impurities (such as moisture and oxygen) into the light-emitting devices 130a, 130b, and 130c, thereby suppressing degradation of the light-emitting devices and improving the reliability of the display device.

[0122] For the protective layers 131 and 132, inorganic insulating films such as oxide insulating films, nitride insulating films, oxidative nitride insulating films, and nitride oxide insulating films can be used. Examples of oxide insulating films include silicon oxide films, aluminum oxide films, gallium oxide films, germanium oxide films, yttrium oxide films, zirconium oxide films, lanthanum oxide films, neodymium oxide films, hafnium oxide films, and tantalum oxide films. Examples of nitride insulating films include silicon nitride films and aluminum nitride films. Examples of oxidative nitride insulating films include silicon oxide nitride films and aluminum oxide nitride films. Examples of nitride oxide insulating films include silicon oxide nitride films and aluminum oxide nitride films.

[0123] The protective layers 131 and 132 preferably each have a nitride insulating film or a nitride oxide insulating film, and more preferably a nitride insulating film.

[0124] Furthermore, the protective layers 131 and 132 may also be made of an inorganic film containing In-Sn oxide (also known as ITO), In-Zn oxide, Ga-Zn oxide, Al-Zn oxide, or indium gallium zinc oxide (In-Ga-Zn oxide, also known as IGZO). The inorganic film is preferably highly resistive, and more specifically, it is preferably more resistive than the common electrode 115. The inorganic film may also contain nitrogen. For example, when the common electrode 115 is made of a metal that is easily degraded by impurities (moisture, oxygen, etc.), such as a silver-magnesium alloy, In-Ga-Zn oxide or the like can be used as the protective layer 131.

[0125] When the light emitted from a light-emitting device is extracted via protective layers 131 and 132, it is preferable that the protective layers 131 and 132 have high transmittance to visible light. For example, ITO, IGZO, and aluminum oxide are preferred because they are inorganic materials with high transmittance to visible light.

[0126] For example, protective layers 131 and 132 can be a laminated structure of an aluminum oxide film and a silicon nitride film on the aluminum oxide film, or a laminated structure of an aluminum oxide film and an IGZO film on the aluminum oxide film. By using such a laminated structure, it is possible to suppress impurities (water, oxygen, etc.) from entering the EL layer.

[0127] Furthermore, the protective layers 131 and 132 may have an organic film. For example, the protective layer 132 may have both an organic film and an inorganic film.

[0128] Different film deposition methods may be used for protective layer 131 and protective layer 132. Specifically, protective layer 131 may be formed using atomic layer deposition (ALD), and protective layer 132 may be formed using sputtering.

[0129] A colored layer 129 (colored layer 129a, colored layer 129b, and colored layer 129c) is provided on the protective layer 132. Colored layer 129a has a region that overlaps with the light-emitting device 130a, colored layer 129b has a region that overlaps with the light-emitting device 130b, and colored layer 129c has a region that overlaps with the light-emitting device 130c. Colored layers 129a, 129b, and 129c each have a region that overlaps with at least the light-emitting layer of their respective light-emitting devices 130.

[0130] The colored layers 129a, 129b, and 129c have the function of transmitting light of different colors from each other. For example, colored layer 129a has the function of transmitting red light, colored layer 129b has the function of transmitting green light, and colored layer 129c has the function of transmitting blue light. As a result, the display device 100 can display in full color. In addition, colored layers 129a, 129b, and 129c may also have the function of transmitting cyan, magenta, and yellow light.

[0131] Here, it is preferable that two adjacent colored layers 129 have overlapping regions. Specifically, it is preferable that two adjacent colored layers 129 have overlapping regions in a region that does not overlap with the light-emitting device 130. By overlapping two colored layers 129 that transmit light of different colors, the two colored layers 129 can function as light-shielding layers in the region where they overlap. Therefore, it is possible to suppress the leakage of light emitted by the light-emitting device 130 to adjacent sub-pixels. For example, it is possible to suppress the incidence of light emitted by the light-emitting device 130a, which overlaps with colored layer 129a, onto colored layer 129b. Therefore, the contrast of the image displayed on the display device can be increased, and a display device with high display quality can be realized.

[0132] It is not necessary for two adjacent colored layers 129 to have overlapping regions. In this case, it is preferable to provide a light-shielding layer in a region that does not overlap with the light-emitting device 130. The light-shielding layer can be provided, for example, on the side of the substrate 120 facing the resin layer 122. Alternatively, the colored layer 129 may be provided on the side of the substrate 120 facing the resin layer 122.

[0133] Furthermore, by forming the colored layer 129 on the protective layer 131, the alignment of each light-emitting device 130 and each colored layer 129 is easier compared to the case where the colored layer 129 is formed on the substrate 120, enabling the realization of an extremely high-definition display device.

[0134] In this specification, devices fabricated using a metal mask or an FMM (Fine Metal Mask, a high-resolution metal mask) may be referred to as MM (Metal Mask) structured devices. Furthermore, in this specification, devices fabricated without using a metal mask or an FMM may be referred to as MML (Metal Maskless) structured devices.

[0135] Furthermore, in this specification and other documents, a light-emitting device capable of emitting white light may be referred to as a white light-emitting device. As described above, a white light-emitting device can be combined with a colored layer (for example, a color filter) to realize a full-color display device.

[0136] Furthermore, light-emitting devices can be broadly classified into single-structure and tandem-structure devices. A single-structure device has one light-emitting unit between a pair of electrodes, and it is preferable that this light-emitting unit includes one or more light-emitting layers. To obtain white light emission, one should select light-emitting layers such that the light emitted from each of the two or more layers is complementary in color. For example, by making the light-emitting color of the first light-emitting layer and the light-emitting color of the second light-emitting layer complementary, a configuration that emits white light as a whole can be obtained. The same applies to light-emitting devices having three or more light-emitting layers.

[0137] A tandem device preferably has two or more light-emitting units between a pair of electrodes, and each light-emitting unit preferably includes one or more light-emitting layers. To obtain white light emission, the device should be configured such that the light from the light-emitting layers of the multiple light-emitting units is combined to produce white light emission. The configuration for obtaining white light emission is the same as that for a single-structure device. In a tandem device, it is preferable to provide an intermediate layer, such as a charge-generating layer, between the multiple light-emitting units.

[0138] Furthermore, the aforementioned white light-emitting devices (single or tandem structures) are preferable to structures that produce separate light-emitting devices for each color (which can be called SBS (Side By Side) structures) because the manufacturing process is simpler, which can lead to lower manufacturing costs or higher manufacturing yields.

[0139] The display device of this embodiment can reduce the distance between light-emitting devices. Specifically, the distance between light-emitting devices, the distance between EL layers, or the distance between pixel electrodes can be less than 10 μm, 5 μm or less, 3 μm or less, 2 μm or less, 1 μm or less, 500 nm or less, 200 nm or less, 100 nm or less, 90 nm or less, 70 nm or less, 50 nm or less, 30 nm or less, 20 nm or less, 15 nm or less, or 10 nm or less. In other words, the distance between the side surface of the first layer 113a and the side surface of the second layer 113b, or the distance between the side surface of the second layer 113b and the side surface of the third layer 113c, has a region of 1 μm or less, preferably a region of 0.5 μm (500 nm) or less, and more preferably a region of 100 nm or less.

[0140] A light-shielding layer may be provided on the surface of the substrate 120 facing the resin layer 122. Various optical components can also be placed on the outside of the substrate 120. Examples of optical components include polarizing plates, phase difference plates, light diffusion layers (such as diffusion films), anti-reflective layers, and light-collecting films. Furthermore, an antistatic film to suppress the adhesion of dust, a water-repellent film to make it difficult for dirt to adhere, a hard coat film to suppress the occurrence of scratches during use, and an impact-absorbing layer may also be placed on the outside of the substrate 120.

[0141] The substrate 120 can be made of glass, quartz, ceramic, sapphire, resin, metal, alloy, semiconductor, etc. The substrate on the side that extracts light from the light-emitting device should be made of a material that transmits the light. If a flexible material is used for the substrate 120, the flexibility of the display device can be increased, and a flexible display can be realized. Alternatively, a polarizing plate may be used as the substrate 120.

[0142] As the substrate 120, polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), polyacrylonitrile resin, acrylic resin, polyimide resin, polymethyl methacrylate resin, polycarbonate (PC) resin, polyethersulfone (PES) resin, polyamide resin (nylon, aramid, etc.), polysiloxane resin, cycloolefin resin, polystyrene resin, polyamide-imide resin, polyurethane resin, polyvinyl chloride resin, polyvinylidene chloride resin, polypropylene resin, polytetrafluoroethylene (PTFE) resin, ABS resin, cellulose nanofiber, etc. may be used. Glass with a thickness sufficient to provide flexibility may also be used as the substrate 120.

[0143] Furthermore, when a circular polarizing plate is superimposed on a display device, it is preferable to use a substrate with high optical isotropy for the substrate of the display device. A substrate with high optical isotropy has low birefringence (or a small amount of birefringence).

[0144] For substrates with high optical isotropy, the absolute value of the retardation (phase difference) is preferably 30 nm or less, more preferably 20 nm or less, and even more preferably 10 nm or less.

[0145] Examples of films with high optical isotropy include triacetylcellulose (TAC, also known as cellulose triacetate) film, cycloolefin polymer (COP) film, cycloolefin copolymer (COC) film, and acrylic film.

[0146] Furthermore, when using a film as the substrate, the film may absorb water, potentially causing wrinkles or other shape changes in the display panel. Therefore, it is preferable to use a film with low water absorption for the substrate. For example, it is preferable to use a film with a water absorption rate of 1% or less, more preferable to use a film with a water absorption rate of 0.1% or less, and even more preferable to use a film with a water absorption rate of 0.01% or less.

[0147] As the resin layer 122, various types of curing adhesives can be used, such as UV-curing adhesives, reaction-curing adhesives, thermosetting adhesives, and anaerobic adhesives. Examples of these adhesives include epoxy resins, acrylic resins, silicone resins, phenolic resins, polyimide resins, imide resins, PVC (polyvinyl chloride) resins, PVB (polyvinyl butyral) resins, and EVA (ethylene vinyl acetate) resins. Materials with low moisture permeability, such as epoxy resins, are particularly preferred. Two-component mixed resins may also be used. Adhesive sheets may also be used.

[0148] Materials that can be used for conductive layers such as the gate, source, and drain of transistors, as well as various wirings and electrodes that constitute display devices, include metals such as aluminum, titanium, chromium, nickel, copper, yttrium, zirconium, molybdenum, silver, tantalum, and tungsten, as well as alloys mainly composed of these metals. Films containing these materials can be used as single layers or in a multilayer structure.

[0149] Furthermore, conductive oxides such as indium oxide, indium tin oxide, indium zinc oxide, zinc oxide, and zinc oxide containing gallium, or graphene can be used as the light-transmitting conductive material. Alternatively, metallic materials such as gold, silver, platinum, magnesium, nickel, tungsten, chromium, molybdenum, iron, cobalt, copper, palladium, and titanium, or alloy materials containing such metallic materials, can be used. Alternatively, nitrides of such metallic materials (e.g., titanium nitride) may be used. When using metallic materials or alloy materials (or their nitrides), it is preferable to make them thin enough to be light-transmitting. In addition, a laminated film of the above materials can be used as a conductive layer. For example, using a laminated film of a silver-magnesium alloy and indium tin oxide is preferable because it can enhance conductivity. These can also be used as conductive layers for various wirings and electrodes that constitute a display device, and as conductive layers (conductive layers that function as pixel electrodes or common electrodes) in light-emitting devices.

[0150] Examples of insulating materials that can be used for each insulating layer include resins such as acrylic resin and epoxy resin, and inorganic insulating materials such as silicon oxide, silicon oxide nitride, silicon nitride, and aluminum oxide.

[0151] Next, we will describe modified cross-sectional shapes of the display device 100 using Figures 2 and 3.

[0152] As shown in Figure 2A, the display device 100 may be configured to include a microlens 134. Here, the display device 100 shown in Figure 2A has a first substrate 135 and a second substrate 136. The first substrate 135 includes a layer 101 containing transistors, pixel electrodes 111a, 111b, 111c, a first layer 113a, a second layer 113b, a third layer 113c, a fifth layer 114, a common electrode 115, protective layers 131, 132, and insulating layers 121, 125, 127. The second substrate 136 includes a substrate 120, coloring layers 129a, 129b, 129c, an insulating layer 133, and a microlens 134.

[0153] The second substrate 136, relative to substrate 120, has a colored layer 129 on substrate 120, an insulating layer 133 on the colored layer 129, and a microlens 134 on the insulating layer 133. The microlens 134 and the colored layer 129 are arranged to overlap with one of the corresponding light-emitting devices 130.

[0154] The microlens 134 may be made of a resin or glass with high light transmittance to visible light. The microlens 134 may be formed separately for each subpixel, or it may be integrated for multiple subpixels. By providing the microlens 134, the light emitted by the light-emitting device 130 can be focused, improving the light extraction efficiency of the display device 100.

[0155] The insulating layer 133 may be an inorganic insulating film or an organic insulating film that can be used for the protective layers 131 and 132. Furthermore, it is preferable that the insulating layer 133 functions as a planarization film, in which case it is preferable to use an organic insulating film as the insulating layer 133. Alternatively, the insulating layer 133 may not be provided.

[0156] As shown in Figure 2B, the display device 100 shown in Figure 2A can be formed by bonding a first substrate 135 and a second substrate 136 together with a resin layer 122.

[0157] Furthermore, although Figure 1B shows a configuration in which an insulating layer 125 is provided, the present invention is not limited to this, and a configuration without an insulating layer 125 may also be used, as shown in Figure 3A. In this case, the lower surface of the insulating layer 127 is in contact with the upper surface of the insulating layer 121. In addition, it is preferable to use an organic material for the insulating layer 127 that causes little damage to the first layer 113a, the second layer 113b, and the third layer 113c. For example, it is preferable to use an organic material such as polyvinyl alcohol (PVA), polyvinyl butyral, polyvinylpyrrolidone, polyethylene glycol, polyglycerin, pullulan, water-soluble cellulose, or alcohol-soluble polyamide resin for the insulating layer 127.

[0158] Furthermore, while Figure 1B shows a configuration in which the heights of the upper surfaces of the insulating layer 125 and the insulating layer 127 coincide with or roughly coincide with the height of at least one of the upper surfaces of the first layer 113a, the second layer 113b, and the third layer 113c, respectively, the present invention is not limited thereto. For example, as shown in Figure 3B, the upper surfaces of the insulating layer 125 and the insulating layer 127 may be higher than the upper surfaces of the first layer 113a, the second layer 113b, and the third layer 113c.

[0159] As shown in Figure 3B, one or both of the first sacrificial layer 118 and the second sacrificial layer 119 may be formed on the first layer 113a, the second layer 113b, and / or the third layer 113c. For example, the first sacrificial layer 118 may be formed on the top surface of the first layer 113a, the top surface of the second layer 113b, and the third layer 113c, and the second sacrificial layer 119 may be formed on the first sacrificial layer 118. One side of the first sacrificial layer 118 and one side of the second sacrificial layer 119 are in contact with the insulating layer 125. The other side of the first sacrificial layer 118 and the other side of the second sacrificial layer 119 are in contact with the fifth layer 114. The first sacrificial layer 118 and the second sacrificial layer 119 are sacrificial layers used in the manufacturing process of the display device 100, and details will be described later.

[0160] Here, it is preferable that the plane formed by the side surface of the first sacrificial layer 118, the side surface of the second sacrificial layer 119, a part of the side surface of the insulating layer 125, and a part of the side surface of the insulating layer 127 has a tapered shape in cross-sectional view. Having a tapered shape in cross-sectional view of this plane allows for good coverage of the fifth layer 114 and the common electrode 115, which are formed covering the first sacrificial layer 118, the second sacrificial layer 119, the insulating layer 125, and the insulating layer 127, and prevents the occurrence of stepped breaks and other defects.

[0161] Furthermore, although Figure 2A shows a configuration in which the microlens 134 is provided on the substrate 120 side, the present invention is not limited to this. For example, as shown in Figure 3C, it may be provided on the layer 101 side that includes the transistor. In this case, an insulating layer 133 is provided on the colored layer 129, and the microlens 134 is provided on the insulating layer 133. The substrate 120 is bonded by the resin layer 122 provided on the microlens 134.

[0162] As shown in Figure 4A, a pixel can be configured to have four types of subpixels.

[0163] Figure 4A shows a top view of the display device 100. The display device 100 has a display unit in which a plurality of pixels 110 are arranged in a matrix, and a connection unit 140 outside the display unit.

[0164] The pixel 110 shown in Figure 4A is composed of four types of subpixels: subpixels 110a, 110b, 110c, and 110d.

[0165] For example, the sub-pixels 110a, 110b, 110c, and 110d can each have a light-emitting device that emits light of a different color. Sub-pixel 110d also has a light-emitting device 130d that emits white light, similar to sub-pixels 110a, 110b, and 110c. However, unlike sub-pixels 110a, 110b, and 110c, sub-pixel 110d does not have a colored layer. With this configuration, for example, sub-pixels 110a, 110b, and 110c can be red, green, and blue sub-pixels, respectively, and sub-pixel 110d can be a white sub-pixel.

[0166] Figure 4A shows an example where one pixel 110 is composed of two rows and three columns. Pixel 110 has three subpixels (subpixels 110a, 110b, and 110c) in the top row (1st row) and three subpixels 110d in the bottom row (2nd row). In other words, pixel 110 has subpixels 110a and 110d in the left column (1st column), subpixels 110b and 110d in the middle column (2nd column), and subpixels 110c and 110d in the right column (3rd column). As shown in Figure 4A, by aligning the arrangement of subpixels in the top row and the bottom row, it becomes possible to efficiently remove dust and other debris that may occur during the manufacturing process. Therefore, a display device with high display quality can be provided.

[0167] Figure 4B shows a cross-sectional view of the section between X3 and X4 shown by the dashed line in Figure 4A. The configuration shown in Figure 4B is the same as that in Figure 1B, except that it has a light-emitting device 130d. Therefore, the explanation of the parts that are the same as in Figure 1B will be omitted.

[0168] As shown in Figure 4B, the display device 100 has light-emitting devices 130a, 130b, 130c, and 130d arranged on a layer 101 containing transistors, and protective layers 131 and 132 are provided to cover these light-emitting devices. A substrate 120 is bonded to the protective layer 132 by a resin layer 122. In addition, insulating layers 125 and 127 are provided in the region between adjacent light-emitting devices. Insulating layers 125 and 127 are provided on insulating layer 121.

[0169] Light-emitting devices 130a, 130b, 130c, and 130d emit white light. A colored layer 129a is superimposed on light-emitting device 130a, a colored layer 129b is superimposed on light-emitting device 130b, and a colored layer 129c is superimposed on light-emitting device 130c. No colored layer is provided on light-emitting device 130d. For example, by configuring the colored layer 129a to transmit red (R) light, the colored layer 129b to transmit green (G) light, and the colored layer 129c to transmit blue (B) light, it is possible to create combinations that emit four colors of light: red (R), green (G), blue (B), and white (W).

[0170] The light-emitting device 130d includes a pixel electrode 111d on a layer 101 containing a transistor, an island-shaped fourth layer 113d on the pixel electrode 111d, a fifth layer 114 on the island-shaped fourth layer 113d, and a common electrode 115 on the fifth layer 114. In the light-emitting device 130d, the fourth layer 113d and the fifth layer 114 can be collectively called the EL layer. The pixel electrode 111d may be made of the same material as the pixel electrodes 111a, 111b, and 111c. The fourth layer 113d may be made of the same material as the first layer 113a, the second layer 113b, and the third layer 113c.

[0171] Each of the three subpixels 110d may have its own independent light-emitting device 130d, or they may share a single light-emitting device 130d. In other words, a pixel 110 may have one light-emitting device 130d, or it may have three.

[0172] [Pixel layout] Next, we will describe a pixel layout different from those shown in Figures 1A and 4A. There are no particular limitations on the arrangement of subpixels, and various methods can be applied. Examples of subpixel arrangements include stripe arrangements, S-stripe arrangements, matrix arrangements, delta arrangements, Bayer arrangements, and pentile arrangements.

[0173] Furthermore, the top surface shape of a sub-pixel can be, for example, a polygon such as a triangle, quadrilateral (including rectangles and squares), or pentagon, or a polygon with rounded corners, or an ellipse or a circle. Here, the top surface shape of a sub-pixel corresponds to the top surface shape of the light-emitting region of the light-emitting device.

[0174] The pixel 110 shown in Figure 5A has an S-stripe array applied to it. The pixel 110 shown in Figure 5A is composed of three subpixels: subpixels 110a, 110b, and 110c. For example, as shown in Figure 6A, subpixel 110a may be a blue subpixel B, subpixel 110b may be a red subpixel R, and subpixel 110c may be a green subpixel G.

[0175] The pixel 110 shown in Figure 5B includes a sub-pixel 110a with a roughly trapezoidal top surface shape with rounded corners, a sub-pixel 110b with a roughly triangular top surface shape with rounded corners, and a sub-pixel 110c with a roughly quadrilateral or roughly hexagonal top surface shape with rounded corners. Furthermore, sub-pixel 110a has a larger light-emitting area than sub-pixel 110b. Thus, the shape and size of each sub-pixel can be determined independently. For example, the size of a sub-pixel can be reduced to a level that provides a more reliable light-emitting device. For example, as shown in Figure 6B, sub-pixel 110a may be a green sub-pixel G, sub-pixel 110b may be a red sub-pixel R, and sub-pixel 110c may be a blue sub-pixel B.

[0176] A Pentile array is applied to pixels 124a and 124b shown in Figure 5C. Figure 5C shows an example in which pixels 124a having subpixels 110a and 110b and pixels 124b having subpixels 110b and 110c are arranged alternately. For example, as shown in Figure 6C, subpixel 110a may be a red subpixel R, subpixel 110b may be a green subpixel G, and subpixel 110c may be a blue subpixel B.

[0177] Pixels 124a and 124b shown in Figures 5D and 5E utilize a delta array. Pixel 124a has two subpixels (subpixels 110a and 110b) in the top row (1st row) and one subpixel (subpixel 110c) in the bottom row (2nd row). Pixel 124b has one subpixel (subpixel 110c) in the top row (1st row) and two subpixels (subpixels 110a and 110b) in the bottom row (2nd row). For example, as shown in Figure 6D, subpixel 110a may be a red subpixel R, subpixel 110b may be a green subpixel G, and subpixel 110c may be a blue subpixel B.

[0178] Figure 5D shows an example where each subpixel has a roughly square top shape with rounded corners, and Figure 5E shows an example where each subpixel has a circular top shape.

[0179] Figure 5F shows an example where the subpixels of each color are arranged in a zigzag pattern. Specifically, in a top view, the upper edges of two subpixels aligned in the column direction (for example, subpixels 110a and 110b, or subpixels 110b and 110c) are offset. For example, as shown in Figure 6E, subpixel 110a may be the red subpixel R, subpixel 110b may be the green subpixel G, and subpixel 110c may be the blue subpixel B.

[0180] In photolithography, the finer the pattern being processed, the more significant the effects of light diffraction become. This compromises the fidelity of the transfer of the photomask pattern through exposure, making it difficult to process the resist mask into the desired shape. Therefore, even if the photomask pattern is rectangular, patterns with rounded corners are likely to be formed. Consequently, the top surface shape of subpixels may be a polygon with rounded corners, an ellipse, or a circle.

[0181] Furthermore, in a method for manufacturing a display device according to one aspect of the present invention, the EL layer is processed into an island shape using a resist mask. The resist film formed on the EL layer needs to be cured at a temperature lower than the heat resistance temperature of the EL layer. Therefore, depending on the heat resistance temperature of the EL layer material and the curing temperature of the resist material, the curing of the resist film may be insufficient. A resist film that is not sufficiently cured may take a shape that deviates from the desired shape during processing. As a result, the top surface shape of the EL layer may become a polygon with rounded corners, an ellipse, or a circle. For example, if an attempt is made to form a resist mask with a square top surface, a resist mask with a circular top surface may be formed, resulting in a circular top surface shape for the EL layer.

[0182] Furthermore, in order to achieve the desired shape of the upper surface of the EL layer, a technique (OPC (Optical Proximity Correction) technique) may be used to pre-correct the mask pattern so that the design pattern and the transferred pattern match. Specifically, in the OPC technique, a correction pattern is added to the corners of the shape on the mask pattern.

[0183] Furthermore, even in the pixel 110 to which the stripe arrangement shown in Figure 1A is applied, for example, as shown in Figure 6F, sub-pixel 110a can be a red sub-pixel R, sub-pixel 110b can be a green sub-pixel G, and sub-pixel 110c can be a blue sub-pixel B.

[0184] The pixels 110 shown in Figures 7A to 7C are arranged in a stripe pattern.

[0185] Figure 7A shows an example where each subpixel has a rectangular top surface shape, Figure 7B shows an example where each subpixel has a top surface shape formed by connecting two semicircles and a rectangle, and Figure 7C shows an example where each subpixel has an elliptical top surface shape.

[0186] The pixels 110 shown in Figures 7D to 7F have a matrix array applied to them.

[0187] Figure 7D shows an example where each subpixel has a square top surface shape, Figure 7E shows an example where each subpixel has a roughly square top surface shape with rounded corners, and Figure 7F shows an example where each subpixel has a circular top surface shape.

[0188] The pixel 110 shown in Figures 7A to 7F is composed of four subpixels: subpixels 110a, 110b, 110c, and 110d. Each subpixel 110a, 110b, 110c, and 110d emits light of a different color. For example, subpixels 110a, 110b, 110c, and 110d can be red, green, blue, and white subpixels, respectively. For example, as shown in Figures 8A and 8B, subpixels 110a, 110b, 110c, and 110d can be red, green, blue, and white subpixels, respectively. Alternatively, subpixels 110a, 110b, 110c, and 110d can be red, green, blue, and infrared emitting subpixels, respectively.

[0189] Figure 7G shows an example where a single pixel 110 is composed of 2 rows and 3 columns. Pixel 110 has three subpixels (subpixels 110a, 110b, and 110c) in the top row (row 1) and one subpixel (subpixel 110d) in the bottom row (row 2). In other words, pixel 110 has subpixel 110a in the left column (column 1), subpixel 110b in the middle column (column 2), subpixel 110c in the right column (column 3), and subpixel 110d across these three columns.

[0190] Furthermore, in the pixel 110 shown in Figures 4A and 7G, for example, as shown in Figures 8C and 8D, sub-pixel 110a can be a red sub-pixel R, sub-pixel 110b can be a green sub-pixel G, sub-pixel 110c can be a blue sub-pixel B, and sub-pixel 110d can be a white sub-pixel W.

[0191] An electronic device equipped with a display device according to one aspect of the present invention may have either or both a flashlight function using sub-pixels W and an illumination function using sub-pixels W.

[0192] Here, the white light emitted by the sub-pixel W may be a light with high instantaneous brightness, like a flashlight or strobe light, or a light with high color rendering, like a reading lamp. When using white light for reading lamps, the color temperature of the white light emission should be lowered. For example, by making the white light incandescent (e.g., 2500K to less than 3250K) or warm white (3250K to less than 3800K), a light source that is gentle on the user's eyes can be created.

[0193] A strobe light function can be implemented, for example, by a configuration that repeatedly switches between emitting and not emitting light in short cycles. A flashlight function can also be implemented, for example, by a configuration that generates a flash of light through instantaneous discharge using principles such as the electric double layer.

[0194] For example, if the electronic device 70 is equipped with a camera function, by using the strobe light function or flash light function, images can be taken with the electronic device 70 even at night, as shown in Figure 9A. Here, the display device 100 of the electronic device 70 functions as a surface light source, and since shadows are less likely to be cast on the subject, clear images can be taken. Note that the strobe light function or flash light function can be used not only at night. When equipping the electronic device 70 with a strobe light function or flash light function, the color temperature of the white light emission should be increased. For example, the color temperature of the light emitted from the electronic device 70 can be set to white (3800K or more and less than 4500K), neutral white (4500K or more and less than 5500K), or daylight (5500K or more and less than 7100K).

[0195] Furthermore, if the flash emits excessively strong light, areas that originally have variations in brightness may appear as a single white color in the image (so-called overexposure). On the other hand, if the flash is too weak, dark areas may appear as a single black color in the image (so-called underexposure). To address this, the display device may be configured to detect the brightness around the subject using a light-receiving device, thereby allowing the light-emitting device of the sub-pixel to adjust to the optimal light intensity. In other words, the electronic device 70 can be said to function as an exposure meter.

[0196] Furthermore, the strobe light function and flash light function can be used for crime prevention or self-defense purposes. For example, as shown in Figure 9B, the electronic device 70 can be used to intimidate an attacker by emitting light towards them. Also, in emergencies such as being attacked by an attacker, it may be difficult to remain calm and direct the light of a self-defense light with a narrow beam of light at the attacker's face. In contrast, since the display device 100 of the electronic device 70 is a surface light source, even if the orientation of the display device 100 is slightly off, the light emitted from the display device 100 can be brought into the attacker's field of vision.

[0197] Furthermore, as shown in Figure 9B, when the device is used as a flashlight for crime prevention or self-defense, it is preferable to increase the brightness compared to the nighttime shooting shown in Figure 9A. Also, by making the display device 100 flash intermittently multiple times, it is possible to make it easier to intimidate an assailant. In addition, the electronic device 70 may emit a relatively loud buzzer sound or other sound to call for help from those around it. Emitting the sound near the assailant's face is preferable because it can intimidate the assailant not only with light but also with sound.

[0198] Furthermore, to improve the color rendering of the light emitted by the light-emitting device of the subpixel W, it is preferable to increase the number of light-emitting layers contained in the light-emitting device or the types of light-emitting materials contained in the light-emitting layers. This makes it possible to obtain a broad emission spectrum with intensity over a wider range of wavelengths, and to exhibit light emission with higher color rendering that is closer to sunlight.

[0199] For example, as shown in Figure 9C, an electronic device 70 capable of emitting light with high color rendering may be used as a reading lamp. In Figure 9C, the electronic device 70 is fixed to the desk 74 using a support 72. By using such a support 72, the electronic device 70 can be used as a reading lamp. Since the display device 100 of the electronic device 70 functions as a surface light source, shadows are less likely to be cast on the object (a book in Figure 9C), and the distribution of reflected light from the object is gentle, so light reflections are less likely. This improves the visibility of the object and makes it easier to see. In addition, since the emission spectrum of the white light-emitting device is broad, blue light is also relatively reduced. Therefore, eye strain for the user of the electronic device 70 can be reduced.

[0200] The configuration of the support 72 is not limited to that shown in Figure 9C. Arms or movable parts may be provided as appropriate to maximize the range of motion. Furthermore, while Figure 9C shows the support 72 gripping the electronic device 70 by clamping it, the present invention is not limited to this configuration. For example, a configuration using magnets or suction cups may also be used.

[0201] For the above-mentioned lighting applications, white is preferred as the emitted color. However, there are no particular limitations on the emitted color for lighting applications, and the implementer may select one or more of the most suitable emitted colors as appropriate, such as white, blue, purple, blue-violet, green, yellow-green, yellow, orange, and red.

[0202] A display device according to one aspect of the present invention may have a light-receiving device in each pixel.

[0203] Of the four subpixels of pixel 110 shown in Figure 4A, three may be configured to have light-emitting devices, and the remaining one may be configured to have a light-receiving device.

[0204] For example, a pn-type or pin-type photodiode can be used as the light-receiving device. The light-receiving device functions as a photoelectric conversion device (also called a photoelectric conversion element) that detects light incident on it and generates an electric charge. The amount of charge generated from the light-receiving device is determined by the amount of light incident on it.

[0205] In particular, it is preferable to use an organic photodiode having a layer containing an organic compound as the light-receiving device. Organic photodiodes can be easily made thinner, lighter, and larger in area, and because they offer a high degree of freedom in shape and design, they can be applied to various display devices.

[0206] In one aspect of the present invention, an organic EL device is used as the light-emitting device, and an organic photodiode is used as the light-receiving device. The organic EL device and the organic photodiode can be formed on the same substrate. Therefore, an organic photodiode can be incorporated into a display device using an organic EL device.

[0207] The light-receiving device has an active layer that functions as at least a photoelectric conversion layer between a pair of electrodes. In this specification, one of the pair of electrodes may be referred to as the pixel electrode and the other as the common electrode.

[0208] For example, sub-pixels 110a, 110b, and 110c may be sub-pixels of three colors, R, G, and B, and sub-pixel 110d may be a sub-pixel having a light-receiving device. In this case, the fourth layer 113d has at least an active layer.

[0209] In a photodetector, one electrode functions as the anode and the other as the cathode. The following explanation uses the example where the pixel electrode functions as the anode and the common electrode functions as the cathode. The photodetector can detect incoming light, generate an electric charge, and extract it as an electric current by applying a reverse bias between the pixel electrode and the common electrode. Alternatively, the pixel electrode may function as the cathode and the common electrode as the anode.

[0210] The same manufacturing methods as for light-emitting devices can be applied to light-receiving devices. The island-shaped active layer (also called the photoelectric conversion layer) of the light-receiving device is not formed using a fine metal mask, but rather by depositing a film that will become the active layer onto one surface and then processing it, so that the island-shaped active layer can be formed with a uniform thickness. In addition, by providing a sacrificial layer on the active layer, the damage that the active layer receives during the manufacturing process of the display device can be reduced, and the reliability of the light-receiving device can be improved.

[0211] Here, the layer shared by the light-receiving device and the light-emitting device may have different functions in the light-emitting device and the light-receiving device. In this specification, components may be named based on their functions in the light-emitting device. For example, the hole injection layer functions as a hole injection layer in the light-emitting device and as a hole transport layer in the light-receiving device. Similarly, the electron injection layer functions as an electron injection layer in the light-emitting device and as an electron transport layer in the light-receiving device. Also, the layer shared by the light-receiving device and the light-emitting device may have the same functions in the light-emitting device and the light-receiving device. The hole transport layer functions as a hole transport layer in both the light-emitting device and the light-receiving device, and the electron transport layer functions as an electron transport layer in both the light-emitting device and the light-receiving device.

[0212] The active layer of the light-receiving device contains a semiconductor. Examples of such semiconductors include inorganic semiconductors such as silicon and organic semiconductors containing organic compounds. In this embodiment, an example of using an organic semiconductor as the semiconductor in the active layer is shown. Using an organic semiconductor is preferable because the light-emitting layer and the active layer can be formed by the same method (e.g., vacuum evaporation method), and the manufacturing equipment can be shared.

[0213] Examples of the material of the n-type semiconductor in the active layer include electron-accepting organic semiconductor materials such as fullerene (e.g., C 60 fullerene, C 70 fullerene, etc.), fullerene derivatives, etc. Fullerene has a shape like a soccer ball, and this shape is energetically stable. Fullerene has both a deep (low) HOMO level and LUMO level. Since fullerene has a deep LUMO level, it has extremely high electron-accepting (acceptor) properties. Usually, when π-electron conjugation (resonance) spreads in a plane like benzene, the electron-donating (donor) property becomes high. However, because fullerene has a spherical shape, despite the large spread of π electrons, its electron-accepting property is high. High electron-accepting property is beneficial for a light-receiving device because it enables efficient and rapid charge separation. C 60 fullerene, C70 Both fullerenes and C have a broad absorption band in the visible light region, and C 70 Fullerenes are C 60 Compared to fullerenes, it is preferable because it has a larger π-electron conjugation system and a broad absorption band in the long-wavelength region. Other examples of fullerene derivatives include [6,6]-Phenyl-C71-butyric acid methyl ester (abbreviated as PC70BM), [6,6]-Phenyl-C61-butyric acid methyl ester (abbreviated as PC60BM), and 1',1'',4',4''-Tetrahydro-di[1,4]methanonaphthaleno[1,2:2',3',56,60:2'',3''][5,6]fullerene-C60 (abbreviated as ICBA).

[0214] Furthermore, examples of n-type semiconductor materials include metal complexes having a quinoline skeleton, metal complexes having a benzoquinoline skeleton, metal complexes having an oxazole skeleton, metal complexes having a thiazole skeleton, oxadiazole derivatives, triazole derivatives, imidazole derivatives, oxazole derivatives, thiazole derivatives, phenanthroline derivatives, quinoline derivatives, benzoquinoline derivatives, quinoxaline derivatives, dibenzoquinoxaline derivatives, pyridine derivatives, bipyridine derivatives, pyrimidine derivatives, naphthalene derivatives, anthracene derivatives, coumarin derivatives, rhodamine derivatives, triazine derivatives, and quinone derivatives.

[0215] Examples of p-type semiconductor materials for the active layer include electron-donating organic semiconductor materials such as copper(II) phthalocyanine (CuPc), tetraphenyldibenzoperiflanthene (DBP), zinc phthalocyanine (ZnPc), tin(II) phthalocyanine (SnPc), and quinacridone.

[0216] Furthermore, examples of p-type semiconductor materials include carbazole derivatives, thiophene derivatives, furan derivatives, and compounds having an aromatic amine skeleton. In addition, examples of p-type semiconductor materials include naphthalene derivatives, anthracene derivatives, pyrene derivatives, triphenylene derivatives, fluorene derivatives, pyrrole derivatives, benzofuran derivatives, benzothiophene derivatives, indole derivatives, dibenzofuran derivatives, dibenzothiophene derivatives, indrocarbazole derivatives, porphyrin derivatives, phthalocyanine derivatives, naphthalocyanine derivatives, quinacridone derivatives, polyphenylenevinylene derivatives, polyparaphenylene derivatives, polyfluorene derivatives, polyvinylcarbazole derivatives, and polythiophene derivatives.

[0217] The HOMO level of electron-donating organic semiconductor materials is preferably shallower (higher) than the HOMO level of electron-accepting organic semiconductor materials. The LUMO level of electron-donating organic semiconductor materials is preferably shallower (higher) than the LUMO level of electron-accepting organic semiconductor materials.

[0218] It is preferable to use spherical fullerenes as electron-accepting organic semiconductor materials and organic semiconductor materials with a near-planar shape as electron-donating organic semiconductor materials. Molecules with similar shapes tend to aggregate, and when molecules of the same type aggregate, their molecular orbital energy levels are close, which can improve carrier transport.

[0219] For example, the active layer is preferably formed by co-depositing an n-type semiconductor and a p-type semiconductor. Alternatively, the active layer may be formed by stacking an n-type semiconductor and a p-type semiconductor.

[0220] The photodetector may further include layers other than the active layer, such as a material with high hole transport properties, a material with high electron transport properties, or a bipolar material (a material with high electron and hole transport properties). Furthermore, it may also further include layers containing a material with high hole injection properties, a hole blocking material, a material with high electron injection properties, an electron blocking material, etc.

[0221] The light-receiving device may use either low-molecular-weight compounds or high-molecular-weight compounds, and may also contain inorganic compounds. The layers constituting the light-receiving device can be formed by methods such as vapor deposition (including vacuum deposition), transfer, printing, inkjet, and coating.

[0222] For example, polymer compounds such as poly(3,4-ethylenedioxythiophene) / poly(styrenesulfonic acid) (PEDOT / PSS), and inorganic compounds such as molybdenum oxide and copper iodide (CuI) can be used as hole transport materials. In addition, inorganic compounds such as zinc oxide (ZnO) can be used as electron transport materials.

[0223] Furthermore, the active layer can use polymer compounds such as Poly[[4,8-bis[5-(2-ethylhexyl)-2-thienyl]benzo[1,2-b:4,5-b']dithiophene-2,6-diyl]-2,5-thiophenediyl[5,7-bis(2-ethylhexyl)-4,8-dioxo-4H,8H-benzo[1,2-c:4,5-c']dithiophene-1,3-diyl]]polymer (abbreviated as PBDB-T) or PBDB-T derivatives, which function as donors. For example, a method of dispersing the acceptor material in PBDB-T or a PBDB-T derivative can be used.

[0224] Furthermore, the active layer may contain a mixture of three or more materials. For example, to broaden the wavelength range, a third material may be mixed with an n-type semiconductor material and a p-type semiconductor material. In this case, the third material may be a low-molecular-weight compound or a high-molecular-weight compound.

[0225] In a display device having light-emitting and light-receiving devices in its pixels, the pixels have a light-receiving function, allowing for the detection of contact or proximity of an object while displaying an image. For example, not only can the display device display an image using all of its subpixels, but some subpixels can also emit light as a light source, while the remaining subpixels display an image.

[0226] A display device according to one aspect of the present invention has a display unit in which light-emitting devices are arranged in a matrix, and an image can be displayed on the display unit. Furthermore, light-receiving devices are arranged in a matrix on the display unit, and the display unit has an image display function, as well as one or both of an imaging function and a sensing function. The display unit can be used as an image sensor or a touch sensor. That is, by detecting light on the display unit, an image can be captured, or the proximity or contact of an object (such as a finger, hand, or pen) can be detected. Moreover, in a display device according to one aspect of the present invention, the light-emitting devices can be used as a light source for a sensor. Therefore, it is not necessary to provide a separate light-receiving unit and light source from the display device, and the number of components in the electronic device can be reduced.

[0227] In one embodiment of the present invention, when an object reflects (or scatters) light emitted by a light-emitting device of the display unit, a light-receiving device can detect the reflected light (or scattered light), thus enabling image capture or touch detection even in dark places.

[0228] When a light-receiving device is used as an image sensor, the display device can capture an image using the light-receiving device. For example, the display device of this embodiment can be used as a scanner.

[0229] For example, an image sensor can be used to acquire biometric data such as fingerprints and palm prints. In other words, a biometric authentication sensor can be built into the display device. By having the display device incorporate the biometric authentication sensor, the number of components in the electronic device can be reduced compared to when a separate biometric authentication sensor is provided, enabling miniaturization and weight reduction of the electronic device.

[0230] Furthermore, when a light-receiving device is used as a touch sensor, the display device can use the light-receiving device to detect the proximity or contact of an object.

[0231] The pixels shown in Figures 10A and 10B have sub-pixels G, B, R, and PS.

[0232] The pixels shown in Figure 10A have a stripe array applied. The pixels shown in Figure 10B have a matrix array applied.

[0233] The pixels shown in Figures 10C and 10D have sub-pixels G, B, R, PS, and IRS.

[0234] Figures 10C and 10D show an example where one pixel is arranged across two rows and three columns. The top row (first row) has three subpixels (subpixel G, subpixel B, and subpixel R). In Figure 10C, the bottom row (second row) has three subpixels (one subpixel PS and two subpixels IRS). On the other hand, in Figure 10D, the bottom row (second row) has two subpixels (one subpixel PS and one subpixel IRS). As shown in Figure 10C, by aligning the arrangement of subpixels in the top and bottom rows, it becomes possible to efficiently remove dust and other debris that may occur during the manufacturing process. Therefore, a display device with high display quality can be provided. Note that the layout of subpixels is not limited to the configuration shown in Figures 10A to 10D.

[0235] Sub-pixels R, G, and B each have a light-emitting device that emits white light. In sub-pixels R, G, and B, a corresponding colored layer is provided superimposed on the light-emitting device.

[0236] Sub-pixels PS and IRS each have a light-receiving device. The wavelength of light detected by sub-pixels PS and IRS is not particularly limited.

[0237] In Figure 10C, the two sub-pixel IRS may each have an independent photodetector, or they may share a single photodetector. In other words, the pixel 110 shown in Figure 10C can be configured to have one photodetector for the sub-pixel PS and one or two photodetectors for the sub-pixel IRS.

[0238] The light-receiving area of ​​the sub-pixel PS is smaller than that of the sub-pixel IRS. A smaller light-receiving area results in a narrower imaging range, which helps suppress blurring in the image and improves resolution. Therefore, using sub-pixel PS allows for higher-definition or higher-resolution imaging compared to using sub-pixel IRS. For example, sub-pixel PS can be used to capture images for personal authentication, such as fingerprints, palm prints, irises, pulse patterns (including vein and artery patterns), or faces.

[0239] The light-receiving device in the sub-pixel PS preferably detects visible light, and more preferably detects one or more colors such as blue, purple, blue-violet, green, yellow-green, yellow, orange, and red. Alternatively, the light-receiving device in the sub-pixel PS may also detect infrared light.

[0240] Furthermore, sub-pixel IRS can be used in touch sensors (also called direct touch sensors) or near-touch sensors (also called hover sensors, hover-touch sensors, non-contact sensors, or touchless sensors). Depending on the application, the wavelength of light detected by the sub-pixel IRS can be appropriately determined. For example, it is preferable for the sub-pixel IRS to detect infrared light. This enables touch detection even in dark places.

[0241] Here, the touch sensor or near-touch sensor can detect the proximity or contact of an object (such as a finger, hand, or pen).

[0242] A touch sensor can detect an object by making direct contact with the display device. A near-touch sensor can detect an object even if the object does not touch the display device. For example, it is preferable that the display device can detect an object when the distance between the display device and the object is in the range of 0.1 mm to 300 mm, preferably 3 mm to 50 mm. With this configuration, it becomes possible to operate the display device without the object directly touching it, in other words, it becomes possible to operate the display device without contact (touchless). With the above configuration, the risk of the display device becoming dirty or scratched can be reduced, or it becomes possible to operate the display device without the object directly touching any dirt (e.g., dust or viruses) attached to the display device.

[0243] Furthermore, a display device according to one aspect of the present invention can have a variable refresh rate. For example, power consumption can be reduced by adjusting the refresh rate according to the content displayed on the display device (for example, adjusting within a range of 1 Hz to 240 Hz). In addition, the drive frequency of the touch sensor or near touch sensor may be changed according to the refresh rate. For example, if the refresh rate of the display device is 120 Hz, the drive frequency of the touch sensor or near touch sensor can be set to a frequency higher than 120 Hz (typically 240 Hz). This configuration makes it possible to achieve low power consumption and to increase the response speed of the touch sensor or near touch sensor.

[0244] The display device 100 shown in Figures 10E to 10G has a layer 353 having a light-receiving device, a functional layer 355, and a layer 357 having a light-emitting device between substrate 351 and substrate 359.

[0245] The functional layer 355 includes circuits for driving a light-receiving device and circuits for driving a light-emitting device. The functional layer 355 may be equipped with switches, transistors, capacitors, resistors, wiring, terminals, etc. However, when the light-emitting and light-receiving devices are driven using a passive matrix system, the configuration may omit switches and transistors.

[0246] For example, as shown in Figure 10E, in layer 357 which has a light-emitting device, the light emitted by the light-emitting device is reflected by a finger 352 that is in contact with the display device 100, and the light-receiving device in layer 353 which has a light-receiving device detects the reflected light. This makes it possible to detect that the finger 352 has come into contact with the display device 100. Alternatively, as shown in Figures 10F and 10G, the device may have a function to detect or image objects that are close to (but not in contact with) the display device. Figure 10F shows an example of detecting a person's finger, and Figure 10G shows an example of detecting information around, on the surface of, or inside a person's eye (such as the number of blinks, eyeball movements, and eyelid movements).

[0247] By equipping a single pixel with two types of light-receiving devices, it becomes possible to add two additional functions to the display function, thus enabling the multi-functionality of the display device.

[0248] Furthermore, in order to perform high-resolution imaging, it is preferable that sub-pixels PS be provided on all pixels of the display device. On the other hand, sub-pixels IRS used in touch sensors or near-touch sensors do not require the same high detection accuracy as detection using sub-pixels PS, so it is sufficient to provide them on only some of the pixels of the display device. By reducing the number of sub-pixels IRS in the display device to fewer than the number of sub-pixels PS, the detection speed can be increased.

[0249] As described above, one embodiment of the present invention enables the multi-functionalization of a display device by equipping a single pixel with two types of light-receiving devices, thereby adding two additional functions to the display function. For example, it can realize a high-definition imaging function and a sensing function such as a touch sensor or near-touch sensor. Furthermore, the functionality of the display device can be further increased by combining a pixel equipped with two types of light-receiving devices with a pixel with a different configuration. For example, a pixel having an infrared light-emitting device or various sensor devices can be used.

[0250] [Examples of methods for manufacturing display devices] Next, an example of a method for manufacturing a display device will be explained using Figures 11 to 17. Figures 11A and 11B are top views showing the method for manufacturing a display device. Figures 12A to 12C show the cross-sectional view between the dashed-dotted line X1-X2 and the cross-sectional view between Y1-Y2 in Figure 1A side by side. Figures 13 to 16 are similar to Figure 12. Figures 17A to 17F show enlarged views showing the cross-sectional structure of the insulating layer 127 and its surrounding area.

[0251] Thin films (insulating films, semiconductor films, and conductive films, etc.) that constitute display devices can be formed using sputtering, chemical vapor deposition (CVD), vacuum deposition, pulsed laser deposition (PLD), ALD, and other methods. CVD methods include plasma-enhanced CVD (PECVD) and thermal CVD. One type of thermal CVD is metal-organic CVD (MOCVD).

[0252] Furthermore, thin films (insulating films, semiconductor films, conductive films, etc.) that constitute the display device can be formed by methods such as spin coating, dip coating, spray coating, inkjet printing, dispensing, screen printing, offset printing, doctor knife coating, slit coating, roll coating, curtain coating, and knife coating.

[0253] In particular, vacuum processes such as vapor deposition and solution processes such as spin coating and inkjet can be used to fabricate light-emitting devices. Examples of vapor deposition methods include physical vapor deposition (PVD) methods such as sputtering, ion plating, ion beam deposition, molecular beam deposition, and vacuum deposition, as well as chemical vapor deposition (CVD). Functional layers included in the EL layer (hole injection layer, hole transport layer, light-emitting layer, electron transport layer, electron injection layer, hole blocking layer, electron blocking layer, etc.) can be formed by vapor deposition (vacuum deposition, etc.), coating methods (dip coating, die coating, bar coating, spin coating, spray coating, etc.), and printing methods (inkjet, screen printing, offset printing, flexographic printing, gravure, or microcontact printing, etc.).

[0254] Furthermore, when processing the thin film that constitutes the display device, photolithography or the like can be used. Alternatively, the thin film may be processed by nanoimprint lithography, sandblasting, lift-off lithography, or the like. In addition, island-shaped thin films may be directly formed by a film deposition method using a shielding mask such as a metal mask.

[0255] There are two main methods of photolithography. One method involves forming a resist mask on the thin film to be processed, then processing the thin film by etching or other means, and removing the resist mask. The other method involves forming a photosensitive thin film, then exposing and developing it to process the thin film into the desired shape.

[0256] In photolithography, the light used for exposure can be, for example, i-line (wavelength 365 nm), g-line (wavelength 436 nm), h-line (wavelength 405 nm), or a mixture thereof. Other options include ultraviolet light, KrF laser light, or ArF laser light. Exposure may also be performed using immersion lithography. Furthermore, extreme ultraviolet (EUV) light or X-rays may be used as the light source for exposure. An electron beam can also be used instead of the light source. Using extreme ultraviolet light, X-rays, or an electron beam is preferable because it allows for extremely fine processing. Note that when exposure is performed by scanning a beam such as an electron beam, a photomask may not be necessary.

[0257] For etching thin films, methods such as dry etching, wet etching, and sandblasting can be used.

[0258] First, as shown in Figure 12A, pixel electrodes 111a, 111b, 111c, and a conductive layer 123 are formed on the layer 101 containing the transistor. Each pixel electrode is provided on the display section, and the conductive layer 123 is provided on the connection section 140.

[0259] When forming the pixel electrodes 111a, 111b, 111c and the conductive layer 123, a portion of the layer 101 containing the transistor (specifically, the insulating layer located on the outermost surface) may be processed to form a recess.

[0260] Next, an insulating layer 121 is formed to cover the ends of the pixel electrodes 111a, 111b, and 111c and the ends of the conductive layer 123. This prevents the light-emitting device from short-circuiting due to contact between the later-formed film (the film constituting the EL layer, or the common electrode) and the pixel electrodes 111a, 111b, and 111c.

[0261] Then, a first layer 113A is formed on the pixel electrodes 111a, 111b, 111c, and the insulating layer 121. A first sacrificial layer 118A is formed on the first layer 113A, and a second sacrificial layer 119A is formed on the first sacrificial layer 118A. In this specification and the like, the first sacrificial layer 118A and the second sacrificial layer 119A can also be referred to as sacrificial films, respectively.

[0262] The materials that can be used as the pixel electrodes are as described above. For forming the pixel electrodes, for example, a sputtering method or a vacuum evaporation method can be used. Further, the pixel electrodes can be processed by a wet etching method or a dry etching method. The processing of the pixel electrodes is preferably performed by anisotropic etching.

[0263] The insulating layer 121 can have a single-layer structure or a laminated structure using one or both of an inorganic insulating film and an organic insulating film.

[0264] Examples of the organic insulating materials that can be used for the insulating layer 121 include acrylic resins, epoxy resins, polyimide resins, polyamide resins, polyimide amide resins, polysiloxane resins, benzocyclobutene-based resins, and phenolic resins. Further, as the inorganic insulating film that can be used for the insulating layer 121, the inorganic insulating films that can be used for the protective layers 131 and 132 can be used.

[0265] As shown in FIG. 12A, in the cross-sectional view between Y1 - Y2, the end portion on the connection portion 140 side of the first layer 113A is located inside the end portion of the first sacrificial layer 118A. For example, by using a mask (also referred to as an area mask or a rough metal mask, etc., distinguished from a fine metal mask) for defining the film formation area, the film formation areas formed by the first layer 113A, the first sacrificial layer 118A, and the second sacrificial layer 119A can be changed. In one aspect of the present invention, a resist mask is used to form a light-emitting device. However, by combining it with an area mask as described above, a light-emitting device can be fabricated by a relatively simple process.

[0266] The first layer 113A will later become the first layer 113a, the second layer 113b, and the third layer 113c. Therefore, the configurations applicable to the above-described first layer 113a, second layer 113b, and third layer 113c can be applied. The first layer 113A can be formed by methods such as vapor deposition (including vacuum vapor deposition), transfer printing, printing, inkjet printing, coating, etc. The first layer 113A is preferably formed using the vapor deposition method. In film formation using the vapor deposition method, a premix material may be used. Note that, in this specification, etc., a premix material is a composite material in which a plurality of materials are previously blended or mixed.

[0267] For the first sacrificial layer 118A and the second sacrificial layer 119A, a film with high resistance to the processing conditions of the first layer 113A, etc., specifically, a film with a large etching selectivity ratio with respect to various EL layers, is used.

[0268] For the formation of the first sacrificial layer 118A and the second sacrificial layer 119A, for example, a sputtering method, an ALD method (including a thermal ALD method and a PEALD method), a CVD method, or a vacuum vapor deposition method can be used. Note that the first sacrificial layer 118A formed in contact with the EL layer is preferably formed using a formation method that causes less damage to the EL layer than the second sacrificial layer 119A. For example, it is preferable to form the first sacrificial layer 118A using an ALD method or a vacuum vapor deposition method rather than a sputtering method. Also, the first sacrificial layer 118A and the second sacrificial layer 119A are formed at a temperature lower than the heat-resistant temperature of the EL layer (typically 200°C or lower, preferably 100°C or lower, more preferably 80°C or lower).

[0269] For the first sacrificial layer 118A and the second sacrificial layer 119A, it is preferable to use a film that can be removed by a wet etching method. By using the wet etching method, the damage applied to the first layer 113A during the processing of the first sacrificial layer 118A and the second sacrificial layer 119A can be reduced compared to the case of using a dry etching method.

[0270] Furthermore, it is preferable to use a film for the first sacrificial layer 118A that has a high etching selectivity ratio with the second sacrificial layer 119A.

[0271] In the manufacturing process of the display device according to this embodiment, it is desirable that each layer constituting the EL layer (hole injection layer, hole transport layer, light-emitting layer, hole blocking layer, electron blocking layer, and electron transport layer, etc.) be difficult to process, and that the various sacrificial layers be difficult to process in the manufacturing process of each layer constituting the EL layer. It is desirable to select the material and processing method of the sacrificial layer and the processing method of the EL layer taking these factors into consideration.

[0272] In this embodiment, an example is shown in which the sacrificial layer is formed with a two-layer structure consisting of a first sacrificial layer and a second sacrificial layer. However, the sacrificial layer may be a single-layer structure or a laminated structure of three or more layers.

[0273] For the first sacrificial layer 118A and the second sacrificial layer 119A, for example, inorganic films such as metal films, alloy films, metal oxide films, semiconductor films, and inorganic insulating films can be used, respectively.

[0274] The first sacrificial layer 118A and the second sacrificial layer 119A can be made of metallic materials such as gold, silver, platinum, magnesium, nickel, tungsten, chromium, molybdenum, iron, cobalt, copper, palladium, titanium, aluminum, yttrium, zirconium, and tantalum, or alloy materials containing such metallic materials. In particular, it is preferable to use low-melting-point materials such as aluminum or silver. It is preferable to use a metallic material capable of shielding ultraviolet light in one or both of the first sacrificial layer 118A and the second sacrificial layer 119A, as this can suppress irradiation of the EL layer with ultraviolet light and thus suppress deterioration of the EL layer.

[0275] Furthermore, metal oxides such as In-Ga-Zn oxide can be used for the first sacrificial layer 118A and the second sacrificial layer 119A. For example, an In-Ga-Zn oxide film can be formed as the first sacrificial layer 118A or the second sacrificial layer 119A using a sputtering method. In addition, indium oxide, In-Zn oxide, In-Sn oxide, indium titanium oxide (In-Ti oxide), indium tin zinc oxide (In-Sn-Zn oxide), indium titanium zinc oxide (In-Ti-Zn oxide), indium gallium tin zinc oxide (In-Ga-Sn-Zn oxide), etc. can be used. Alternatively, indium tin oxide containing silicon can also be used.

[0276] In addition, element M (where M is one or more elements selected from aluminum, silicon, boron, yttrium, copper, vanadium, beryllium, titanium, iron, nickel, germanium, zirconium, molybdenum, lanthanum, cerium, neodymium, hafnium, tantalum, tungsten, or magnesium) may be used instead of gallium.

[0277] Furthermore, various inorganic insulating films that can be used for protective layers 131 and 132 can be used as the first sacrificial layer 118A and the second sacrificial layer 119A. In particular, oxide insulating films are preferred because they have higher adhesion to the EL layer compared to nitride insulating films. For example, inorganic insulating materials such as aluminum oxide, hafnium oxide, and silicon oxide can be used for the first sacrificial layer 118A and the second sacrificial layer 119A. For example, an aluminum oxide film can be formed as the first sacrificial layer 118A or the second sacrificial layer 119A using the ALD method. Using the ALD method is preferable because it reduces damage to the substrate (especially the EL layer).

[0278] For example, an inorganic insulating film (e.g., an aluminum oxide film) formed using the ALD method can be used as the first sacrificial layer 118A, and a tungsten film formed using the sputtering method can be used as the second sacrificial layer 119A. Alternatively, an aluminum film or an In-Ga-Zn oxide film may be used as the second sacrificial layer 119A.

[0279] As the first sacrificial layer 118A and the second sacrificial layer 119A, materials that are soluble in a chemically stable solvent may be used for at least the film located at the top of the first layer 113A. In particular, materials soluble in water or alcohol can be suitably used for the first sacrificial layer 118A or the second sacrificial layer 119A. When forming a film of such a material, it is preferable to apply it by a wet film formation method while dissolved in a solvent such as water or alcohol, and then perform a heat treatment to evaporate the solvent. At this time, performing the heat treatment under a reduced pressure atmosphere is preferable because it allows the solvent to be removed at a low temperature and in a short time, thereby reducing thermal damage to the EL layer.

[0280] The first sacrificial layer 118A and the second sacrificial layer 119A may be formed using wet film formation methods such as spin coating, dip coating, spray coating, inkjet printing, dispensing, screen printing, offset printing, doctor knife method, slit coating, roll coating, curtain coating, and knife coating.

[0281] The first sacrificial layer 118A and the second sacrificial layer 119A may be made of organic materials such as polyvinyl alcohol (PVA), polyvinyl butyral, polyvinylpyrrolidone, polyethylene glycol, polyglycerin, pullulan, water-soluble cellulose, or alcohol-soluble polyamide resin.

[0282] Next, as shown in Figure 12B, a resist mask 190a is formed on the second sacrificial layer 119A. The resist mask can be formed by applying a photosensitive resin (photoresist), followed by exposure and development.

[0283] The resist mask may be fabricated using either a positive resist material or a negative resist material.

[0284] As shown in FIG. 11A, the resist mask 190a is provided at a position overlapping the pixel electrodes 111a, 111b, and 111c. As the resist mask 190a, it is preferable that one island-shaped pattern is provided for one sub-pixel 110a, sub-pixel 110b, or sub-pixel 110c. Alternatively, as the resist mask 190a, one strip-shaped pattern may be formed for a plurality of sub-pixels 110a, sub-pixels 110b, or sub-pixels 110c arranged in a row (arranged in the Y direction in FIG. 11A).

[0285] Note that the resist mask 190a is preferably provided at a position overlapping the conductive layer 123. Thereby, it is possible to prevent the conductive layer 123 from being damaged during the manufacturing process of the display device.

[0286] Next, as shown in FIG. 12C, a part of the second sacrificial layer 119A is removed using the resist mask 190a to form the second sacrificial layer 119a. The second sacrificial layer 119a remains in a region overlapping the pixel electrodes 111a, 111b, and 111c and a region overlapping the conductive layer 123.

[0287] When etching the second sacrificial layer 119A, it is preferable to use etching conditions with a high selectivity so that the first sacrificial layer 118A is not removed by the etching. Also, in the processing of the second sacrificial layer 119A, since the EL layer is not exposed, the range of selection of the processing method is wider than that of the processing of the first sacrificial layer 118A. Specifically, when a gas containing oxygen is used as the etching gas during the processing of the second sacrificial layer 119A, deterioration of the EL layer can be further suppressed.

[0288] Subsequently, the resist mask 190a is removed. For example, the resist mask 190a can be removed by ashing using oxygen plasma. Alternatively, the resist mask 190a may be removed by wet etching. In this case, since the first sacrificial layer 118A is located on the outermost surface and the first layer 113A is not exposed, damage to the first layer 113A can be suppressed during the resist mask 190a removal process. Furthermore, the range of selectable methods for removing the resist mask 190a can be broadened.

[0289] Next, as shown in Figure 13A, the second sacrificial layer 119a is used as a hard mask to remove a portion of the first sacrificial layer 118A and form the first sacrificial layer 118a.

[0290] The first sacrificial layer 118A and the second sacrificial layer 119A can be processed by wet etching or dry etching, respectively. It is preferable to process the first sacrificial layer 118A and the second sacrificial layer 119A by anisotropic etching.

[0291] By using the wet etching method, the damage to the first layer 113A during processing of the first sacrificial layer 118A and the second sacrificial layer 119A can be reduced compared to using the dry etching method. When using the wet etching method, it is preferable to use chemical solutions such as a developer, an aqueous solution of tetramethylammonium hydroxide (TMAH), dilute hydrofluoric acid, oxalic acid, phosphoric acid, acetic acid, nitric acid, or a mixture thereof.

[0292] Furthermore, when using the dry etching method, the degradation of the first layer 113A can be suppressed by not using an oxygen-containing gas as the etching gas. When using the dry etching method, it is preferable to use a gas containing noble gases (also called rare gases) such as CF4, C4F8, SF6, CHF3, Cl2, H2O, BCl3, or He as the etching gas.

[0293] For example, if an aluminum oxide film formed using the ALD method is used as the first sacrificial layer 118A, the first sacrificial layer 118A can be processed by dry etching using CHF3 and He. Also, if a tungsten film formed using the sputtering method is used as the second sacrificial layer 119A, the second sacrificial layer 119A can be processed by dry etching using CF4 and Cl2.

[0294] Next, as shown in Figure 13B, the second sacrificial layer 119a and the first sacrificial layer 118a are used as a hard mask to remove a portion of the first layer 113A, thereby forming the first layer 113a, the second layer 113b, and the third layer 113c.

[0295] As a result, as shown in Figure 13B, the stacked structure of the first layer 113a, the first sacrificial layer 118a, and the second sacrificial layer 119a remains on the pixel electrode 111a. The stacked structure of the second layer 113b, the first sacrificial layer 118a, and the second sacrificial layer 119a remains on the pixel electrode 111b. The stacked structure of the third layer 113c, the first sacrificial layer 118a, and the second sacrificial layer 119a remains on the pixel electrode 111c. In addition, at the connection portion 140, the stacked structure of the first sacrificial layer 118a and the second sacrificial layer 119a remains on the conductive layer 123.

[0296] Through the above process, it is possible to remove the regions of the first layer 113A, the first sacrificial layer 118A, and the second sacrificial layer 119A that do not overlap with the resist mask 190a.

[0297] Alternatively, a resist mask 190a may be used to remove a portion of the first layer 113A. The resist mask 190a may then be removed.

[0298] The first layer 113A is preferably processed by anisotropic etching. In particular, anisotropic dry etching is preferred. Alternatively, wet etching may be used.

[0299] When using the dry etching method, the degradation of the first layer 113A can be suppressed by not using an oxygen-containing gas as the etching gas.

[0300] Furthermore, an etching gas containing oxygen may be used. Including oxygen in the etching gas can increase the etching rate. Therefore, etching can be performed under low power conditions while maintaining a sufficiently fast etching rate. This suppresses damage to the first layer 113A. Additionally, it suppresses problems such as the adhesion of reaction products generated during etching.

[0301] When using the dry etching method, it is preferable to use an etching gas containing one or more noble gases such as H2, CF4, C4F8, SF6, CHF3, Cl2, H2O, BCl3, or He, Ar. Alternatively, it is preferable to use an etching gas containing one or more of these and oxygen. Or, oxygen gas may be used as the etching gas. Specifically, for example, a gas containing H2 and Ar, or a gas containing CF4 and He, can be used as the etching gas. Also, for example, a gas containing CF4, He, and oxygen can be used as the etching gas.

[0302] Furthermore, it is preferable that the sides of the first layer 113a, the second layer 113b, and the third layer 113c are perpendicular or approximately perpendicular to the surface to be formed. For example, it is preferable that the angle between the surface to be formed and these sides be 60 degrees or more and 90 degrees or less.

[0303] Next, as shown in Figure 13C, an insulating film 125A is formed to cover the insulating layer 121, the first layer 113a, the second layer 113b, the third layer 113c, the first sacrificial layer 118a, and the second sacrificial layer 119a.

[0304] For the insulating film 125A, inorganic insulating films such as oxide insulating films, nitride insulating films, oxidative nitride insulating films, and nitride oxide insulating films can be used. Examples of oxide insulating films include silicon oxide films, aluminum oxide films, magnesium oxide films, gallium oxide films, germanium oxide films, yttrium oxide films, zirconium oxide films, lanthanum oxide films, neodymium oxide films, hafnium oxide films, and tantalum oxide films. Examples of nitride insulating films include silicon nitride films and aluminum nitride films. Examples of oxidative nitride insulating films include silicon oxidative nitride films and aluminum oxidative nitride films. Examples of nitride oxide insulating films include silicon nitride film and aluminum nitride film. In addition, metal oxide films such as indium gallium zinc oxide films may be used.

[0305] Furthermore, it is preferable that the insulating film 125A functions as a barrier insulating film against at least one of water and oxygen. Alternatively, it is preferable that the insulating film 125A has a function to suppress the diffusion of at least one of water and oxygen. Alternatively, it is preferable that the insulating film 125A has a function to capture or fix (also called gettering) at least one of water and oxygen.

[0306] In this specification, a barrier insulating film refers to an insulating film having barrier properties. In this specification, barrier properties refer to the function of suppressing the diffusion of the corresponding substance (also called low permeability). Alternatively, in this specification, barrier properties refer to the function of capturing or fixing the corresponding substance (also called gettering).

[0307] The insulating film 125A has the function of a barrier insulating film or a gettering function as described above, thereby suppressing the intrusion of impurities (typically water or oxygen) that could diffuse from the outside into each light-emitting device. This configuration makes it possible to provide a display device with excellent reliability.

[0308] Next, as shown in Figure 14A, an insulating film 127A is formed on the insulating film 125A.

[0309] Organic materials can be used for the insulating film 127A. Examples of organic materials include acrylic resins, polyimide resins, epoxy resins, imide resins, polyamide resins, polyimidoamide resins, silicone resins, siloxane resins, benzocyclobutene resins, phenolic resins, and precursors of these resins. Alternatively, the insulating film 127A may also be made of organic materials such as polyvinyl alcohol (PVA), polyvinyl butyral, polyvinylpyrrolidone, polyethylene glycol, polyglycerin, pullulan, water-soluble cellulose, or alcohol-soluble polyamide resins. Furthermore, a photosensitive resin can be used for the insulating film 127A. A photoresist may be used as the photosensitive resin. The photosensitive resin can be a positive-type material or a negative-type material.

[0310] There are no particular limitations on the method for forming the insulating film 127A. For example, it can be formed using wet film deposition methods such as spin coating, dip coating, spray coating, inkjet printing, dispensing, screen printing, offset printing, doctor knife method, slit coating, roll coating, curtain coating, and knife coating. In particular, it is preferable to form the insulating film 127A by spin coating.

[0311] It is preferable that insulating film 125A and insulating film 127A are formed using a method that causes minimal damage to the EL layer. In particular, since insulating film 125A is formed in contact with the side surface of the EL layer, it is preferable that it be formed using a method that causes less damage to the EL layer than insulating film 127A. Furthermore, insulating films 125A and insulating films 127A are formed at a temperature lower than the heat resistance temperature of the EL layer (typically 200°C or lower, preferably 100°C or lower, and even more preferably 80°C or lower). For example, an aluminum oxide film can be formed as insulating film 125A using the ALD method. The ALD method is preferable because it can reduce film formation damage and allow for the formation of a film with high coverage.

[0312] Next, as shown in Figure 14B, insulating layers 125 and 127 are formed by processing insulating film 125A and insulating film 127A. Insulating layer 127 is formed so as to be in contact with the side surface and the upper surface of the recess of insulating layer 125. Insulating layer 125 is provided in contact with the upper surface of insulating layer 121. Furthermore, it is preferable that insulating layers 125 and 127 be provided so as to cover the side surfaces of the first layer 113a, the second layer 113b, and the third layer 113c. This suppresses contact between the later formed films and the side surfaces of these layers, thereby suppressing short circuits in the light-emitting device. It also suppresses damage to the first layer 113a, the second layer 113b, and the third layer 113c in later processes.

[0313] Furthermore, in the connection portion 140, it is preferable that the insulating layer 125 (and even the insulating layer 127) be provided so as to cover the side surface of the conductive layer 123.

[0314] The insulating film 127A is preferably processed by, for example, ashing using oxygen plasma.

[0315] The insulating film 125A is preferably processed by a dry etching method. The insulating film 125A is preferably processed by anisotropic etching. The insulating film 125A can be processed using the etching gas that can be used when processing the first sacrificial layer 118A and the second sacrificial layer 119A.

[0316] Next, as shown in Figure 14C, the first sacrificial layer 118a and the second sacrificial layer 119a are removed. As a result, the first layer 113a is exposed on the pixel electrode 111a, the second layer 113b is exposed on the pixel electrode 111b, the third layer 113c is exposed on the pixel electrode 111c, and the conductive layer 123 is exposed at the connection portion 140.

[0317] Preferably, the heights of the upper surfaces of the insulating layer 125 and the insulating layer 127 are equal to or approximately equal to the height of at least one of the upper surfaces of the first layer 113a, the second layer 113b, and the third layer 113c, respectively. Furthermore, the upper surface of the insulating layer 127 is preferably flat, and may have convex portions, convex curved surfaces, concave curved surfaces, or recesses.

[0318] The same method as the sacrificial layer processing method can be used for the sacrificial layer removal process. In particular, by using a wet etching method, the damage inflicted on the first layer 113a, the second layer 113b, and the third layer 113c when removing the first and second sacrificial layers can be reduced compared to when using a dry etching method.

[0319] The first sacrificial layer and the second sacrificial layer may be removed in separate processes or in the same process.

[0320] Alternatively, either the first sacrificial layer or the second sacrificial layer, or both, may be removed by dissolving them in a solvent such as water or alcohol. Examples of alcohols include ethyl alcohol, methyl alcohol, isopropyl alcohol (IPA), or glycerin.

[0321] After removing the first and second sacrificial layers, a drying treatment may be performed to remove water contained in the EL layer and water adsorbed on the surface of the EL layer. For example, a heat treatment can be performed in an inert gas atmosphere or a reduced pressure atmosphere. The heat treatment can be performed at a substrate temperature of 50°C to 200°C, preferably 60°C to 150°C, and more preferably 70°C to 120°C. A reduced pressure atmosphere is preferable because it allows drying at a lower temperature.

[0322] Next, as shown in Figure 15A, a fifth layer 114 is formed so as to cover the insulating layers 125, 127, the first layer 113a, the second layer 113b, the third layer 113c, and the conductive layer 123.

[0323] The materials that can be used as the fifth layer 114 are as described above. The fifth layer 114 can be formed by methods such as vapor deposition (including vacuum deposition), transfer, printing, inkjet, and coating. The fifth layer 114 may also be formed using a premixed material.

[0324] If insulating layers 125 and 127 are not provided, there is a risk that the sides of the first layer 113a, the second layer 113b, and the third layer 113c may come into contact with the fifth layer 114. If the fifth layer 114 has high conductivity, contact between these layers may cause a short circuit in the light-emitting device. However, in a display device according to one aspect of the present invention, insulating layers 125 and 127 cover the sides of the first layer 113a, the second layer 113b, and the third layer 113c, thereby suppressing contact between the highly conductive fifth layer 114 and these layers, and preventing a short circuit in the light-emitting device. This improves the reliability of the light-emitting device.

[0325] Then, as shown in Figure 15A, a common electrode 115 is formed on the fifth layer 114 and the conductive layer 123. As shown in Figure 15A, the conductive layer 123 and the common electrode 115 are electrically connected via the fifth layer 114.

[0326] The materials that can be used as the common electrode 115 are as described above. For the formation of the common electrode 115, for example, sputtering or vacuum deposition can be used. Alternatively, a film formed by deposition and a film formed by sputtering may be laminated together.

[0327] Subsequently, a protective layer 131 is formed on the common electrode 115, and a protective layer 132 is formed on the protective layer 131. Next, colored layers 129a, 129b, and 129c are formed on the protective layer 131, such that they overlap with the pixel electrodes 111a, 111b, and 111c. Furthermore, by using a resin layer 122 to bond the substrate 120 onto the colored layers 129a, 129b, and 129c, the display device 100 shown in Figure 1B can be manufactured.

[0328] The materials and film formation methods that can be used for protective layers 131 and 132 are as described above. Examples of film formation methods for protective layers 131 and 132 include vacuum deposition, sputtering, CVD, and ALD. Protective layers 131 and 132 may be formed using different film formation methods. Furthermore, protective layers 131 and 132 may each be a single-layer structure or a multilayer structure.

[0329] The colored layers 129a, 129b, and 129c can be formed at desired positions using methods such as inkjet etching or photolithography. Specifically, different colored layers 129 (colored layer 129a, colored layer 129b, or colored layer 129c) can be formed for each pixel.

[0330] Furthermore, when forming the common electrode 115, a mask (also called an area mask or rough metal mask) may be used to define the film formation area. Alternatively, the mask may not be used for forming the common electrode 115, and after the process shown in Figure 15A, the processing steps for the common electrode 115 and the fifth layer 114 shown in Figures 15B and 15C may be performed, and then the process for forming the protective layer 131 may be carried out.

[0331] As shown in Figure 15B, a resist mask 190b is formed on the common electrode 115. At the Y2 end of Figure 15B, there is a portion where the resist mask 190b is not provided. As shown in Figure 11B, the resist mask 190b is provided in the region that overlaps with each subpixel and the connection portion 140. In other words, the region where the resist mask 190b is not provided is located outside the connection portion 140.

[0332] Next, as shown in Figure 15C, a portion of the common electrode 115 and a portion of the fifth layer 114 are removed using the resist mask 190b. This completes the processing of the common electrode 115 and the fifth layer 114.

[0333] In the process described above, a configuration was shown in which a portion of the insulating layer 127 is removed by ashing or the like to expose the first sacrificial layer 118a, etc. (see Figure 14B). However, the present invention is not limited to this. For example, as shown in Figure 16A, the insulating layer 127 may be formed by providing openings in the insulating film 127A at positions that overlap with the pixel electrodes 111a, 111b, 111c and the conductive layer 123. For example, by applying a photosensitive resin as the insulating film 127A and performing exposure and development, a pattern can be formed in which openings are provided at positions that overlap with the pixel electrodes 111a, 111b, 111c and the conductive layer 123.

[0334] As shown in Figure 16A, after the insulating layer 127 has been patterned, the display device 100 can be formed in the same manner as the process described in Figures 14B to 15C above.

[0335] However, in this case, as shown in Figure 16B, the upper surfaces of the insulating layer 125 and the insulating layer 127 may be higher than the second sacrificial layer 119A. As a result, when the first sacrificial layer 118A and the second sacrificial layer 119A are removed, some of these may remain. Therefore, as shown in Figure 16B, even after the formation of the common electrode 115, one or both of the first sacrificial layer 118 and the second sacrificial layer 119, which could not be removed by etching, may be formed on the first layer 113a, the second layer 113b, the third layer 113c, and / or the conductive layer 123.

[0336] Here, it is preferable that the plane formed by the side surface of the first sacrificial layer 118, the side surface of the second sacrificial layer 119, a part of the side surface of the insulating layer 125, and a part of the side surface of the insulating layer 127 has a tapered shape in cross-sectional view. Having a tapered shape in cross-sectional view of this plane allows for good coverage of the fifth layer 114 and the common electrode 115, which are formed covering the first sacrificial layer 118, the second sacrificial layer 119, the insulating layer 125, and the insulating layer 127, and prevents the occurrence of stepped breaks and other defects.

[0337] By forming the display device 100 in this manner, the display device 100 shown in Figure 3B can be formed.

[0338] Furthermore, as shown in Figure 16C, the fifth layer 114 may be omitted, and the common electrode 115 may be formed to cover the insulating layers 125, 127, the first layer 113a, the second layer 113b, and the third layer 113c. In other words, all the layers constituting the EL layer may be manufactured differently in each subpixel light-emitting device. In this case, the EL layers of each light-emitting device are all formed in an island shape.

[0339] In this case, there is a risk of the light-emitting device short-circuiting if any of the pixel electrodes 111a, 111b, or 111c come into contact with the common electrode 115. However, in a display device according to one aspect of the present invention, the insulating layers 121, 125, and 127 cover the first layer 113a, the second layer 113b, the third layer 113c, and the sides of the pixel electrodes 111a, 111b, and 111c, thereby suppressing contact between the common electrode 115 and these layers and preventing a short circuit in the light-emitting device. This improves the reliability of the light-emitting device.

[0340] Furthermore, in the process shown in Figure 16D, in the cross-sectional view between Y1 and Y2, the end of the fifth layer 114 on the connection portion 140 side may be located inside the connection portion 140, leaving the conductive layer 123 exposed. For example, when forming the fifth layer 114, a mask (also called an area mask or rough metal mask) can be used to define the film formation area. In this case, since the fifth layer 114 is not provided on the conductive layer 123, the conductive layer 123 and the common electrode 115 are electrically connected without the fifth layer 114.

[0341] Figures 17A to 17F show the cross-sectional structure of the region 139 including the insulating layer 127 and its surrounding area.

[0342] Figure 17A shows an example where the thicknesses of the first layer 113a and the second layer 113b are different. The height of the upper surface of the insulating layer 125 is the same as or approximately the same as the height of the upper surface of the first layer 113a on the first layer 113a side, and the height of the upper surface of the second layer 113b on the second layer 113b side. The upper surface of the insulating layer 127 has a gentle slope, with the first layer 113a side being higher and the second layer 113b side being lower. Thus, it is preferable that the heights of the insulating layer 125 and insulating layer 127 are the same as the heights of the upper surfaces of adjacent EL layers. Alternatively, the upper surfaces may have a flat portion, with the heights of the upper surfaces being the same as the heights of either of the adjacent EL layers.

[0343] In Figure 17B, the upper surface of the insulating layer 127 has a region that is higher than the upper surfaces of the first layer 113a and the second layer 113b. Furthermore, the upper surface of the insulating layer 127 has a shape that is convex and gently bulges towards the center.

[0344] In Figure 17C, the insulating layer 127 has a region that is higher than the upper surfaces of the first layer 113a and the second layer 113b. In region 139, the display device 100 has at least one of the first sacrificial layer 118 and the second sacrificial layer 119, and the insulating layer 127 has a region that is higher than the upper surfaces of the first layer 113a and the second layer 113b and is located outside the insulating layer 125, and this region is located on at least one of the first sacrificial layer 118 and the second sacrificial layer 119. Also in Figure 17C, the upper surface of the insulating layer 127 has a shape that is convex toward the center and gently bulges out, and a recess is formed in the central part of the upper surface of the insulating layer 127. This recess has a shape that is gently indented toward the center.

[0345] In Figure 17D, the upper surface of the insulating layer 127 has a region that is lower than the upper surfaces of the first layer 113a and the second layer 113b. Furthermore, the upper surface of the insulating layer 127 has a gently concave shape that slopes toward the center.

[0346] In Figure 17E, the upper surface of the insulating layer 125 has a region that is higher than the upper surfaces of the first layer 113a and the second layer 113b. That is, on the surface where the fifth layer 114 is formed, the insulating layer 125 protrudes, forming a convex portion.

[0347] In forming the insulating layer 125, for example, if the insulating layer 125 is formed to match or approximately match the height of the sacrificial layer, a protruding shape of the insulating layer 125 may be formed, as shown in Figure 17E.

[0348] In Figure 17F, the upper surface of the insulating layer 125 has a region that is lower than the upper surface of the first layer 113a and the upper surface of the second layer 113b. That is, the insulating layer 125 forms a recess on the surface on which the fifth layer 114 is formed.

[0349] Thus, the insulating layer 125 and the insulating layer 127 can be made into various shapes.

[0350] As described above, in the manufacturing method of the display device of this embodiment, the island-shaped EL layer is formed not using a fine metal mask, but by processing after the EL layer has been deposited on one surface. Therefore, the island-shaped EL layer can be formed with a uniform thickness. This makes it possible to realize a high-definition display device or a display device with a high aperture ratio.

[0351] The first, second, and third layers constituting the white light-emitting device can be formed using the same process. Therefore, the manufacturing process for the display device can be simplified, and manufacturing costs can be reduced.

[0352] A display device according to one aspect of the present invention has an insulating layer covering the ends of the pixel electrodes and insulating layers covering the respective sides of the light-emitting layer and the carrier transport layer. In the manufacturing process of the display device, the EL layer is processed with the light-emitting layer and the carrier transport layer stacked, so the display device has a configuration that reduces damage applied to the light-emitting layer. Furthermore, the above-mentioned two types of insulating layers suppress contact between the pixel electrodes or light-emitting layer and the carrier injection layer or common electrode, thereby suppressing short circuits in the light-emitting device.

[0353] This embodiment can be combined with other embodiments as appropriate. Furthermore, if multiple configuration examples are shown within a single embodiment in this specification, these configuration examples can be combined as appropriate.

[0354] (Embodiment 2) In this embodiment, an example of the configuration of a light-emitting device that can be applied to a display device according to one aspect of the present invention will be described with reference to Figures 18 and 19.

[0355] The display device 500 shown in Figures 18A and 18B has a plurality of light-emitting devices 550W that emit white light. On each light-emitting device 550W, a colored layer 545R that transmits red light, a colored layer 545G that transmits green light, or a colored layer 545B that transmits blue light is provided. Here, it is preferable that the colored layers 545R, 545G, and 545B are provided on the light-emitting device 550W via a protective layer 540.

[0356] The light-emitting device 550W shown in Figure 18A has a light-emitting unit 512W between a pair of electrodes (electrode 501, electrode 502). Electrode 501 functions as a pixel electrode and is provided for each light-emitting device. Electrode 502 functions as a common electrode and is provided in common for multiple light-emitting devices.

[0357] In other words, the light-emitting device 550W shown in Figure 18A is a light-emitting device having one light-emitting unit. In this specification, a configuration having one light-emitting unit between a pair of electrodes, as in the light-emitting device 550W shown in Figure 18A, is referred to as a single structure.

[0358] As shown in Figure 18A, the light-emitting units 512W can each be formed as island-like layers. In other words, the light-emitting units 512W shown in Figure 18A correspond to the first layer 113a, the second layer 113b, or the third layer 113c shown in Figure 1B, etc. The light-emitting device 550W corresponds to the light-emitting device 130a, the light-emitting device 130b, or the light-emitting device 130c. The electrode 501 corresponds to the pixel electrode 111a, the pixel electrode 111b, or the pixel electrode 111c. The electrode 502 corresponds to the common electrode 115.

[0359] The light-emitting unit 512W has layers 521, 522, light-emitting layer 523Q_1, light-emitting layer 523Q_2, light-emitting layer 523Q_3, layer 524, etc. The light-emitting device 550W also has layers 525, etc. between the light-emitting unit 512W and the electrode 502.

[0360] Figure 18A shows an example where the light-emitting unit 512W does not have layer 525, and layer 525 is provided in common among the light-emitting devices. In this case, layer 525 can be called a common layer. By providing one or more common layers to multiple light-emitting devices in this way, the manufacturing process can be simplified, and thus manufacturing costs can be reduced. Alternatively, layer 525 may be provided for each light-emitting device. In other words, layer 525 may be included in the light-emitting unit 512W.

[0361] Layer 521 includes, for example, a layer containing a material with high hole injection capabilities (hole injection layer). Layer 522 includes, for example, a layer containing a material with high hole transport capabilities (hole transport layer). Layer 524 includes, for example, a layer containing a material with high electron transport capabilities (electron transport layer). Layer 525 includes, for example, a layer containing a material with high electron injection capabilities (electron injection layer).

[0362] Alternatively, the configuration may include layer 521 having an electron injection layer, layer 522 having an electron transport layer, layer 524 having a hole transport layer, and layer 525 having a hole injection layer.

[0363] In Figure 18A, layers 521 and 522 are shown separately, but the diagram is not limited to this. For example, if layer 521 has the functions of both a hole injection layer and a hole transport layer, or if layer 521 has the functions of both an electron injection layer and an electron transport layer, layer 522 may be omitted.

[0364] In the light-emitting device 550W shown in Figure 18A, white light can be obtained from the light-emitting device 550W by selecting light-emitting layers 523Q_1, 523Q_2, and 523Q_3 such that their light emission is in a complementary color relationship. Here, an example is shown in which the light-emitting unit 512W has three light-emitting layers, but the number of light-emitting layers is not limited; for example, it may have two layers.

[0365] By providing a colored layer 545R, a colored layer 545G, or a colored layer 545B on such a white-emitting light-emitting device 550W, red light emission, green light emission, or blue light emission can be performed for each pixel, enabling full-color display. While Figure 18A and other figures show an example where a colored layer 545R transmits red light, a colored layer 545G transmits green light, and a colored layer 545B transmits blue light, the present invention is not limited to this. The visible light transmitted by the colored layers should consist of at least two or more different colors of visible light, such as red, green, blue, cyan, magenta, or yellow, which can be appropriately selected.

[0366] Therefore, even if layers 521, 522, 524, 525, light-emitting layer 523Q_1, light-emitting layer 523Q_2, and light-emitting layer 523Q_3 have the same configuration (material, film thickness, etc.) for each color pixel, full-color display can be achieved by appropriately providing a colored layer. Thus, a display device according to one aspect of the present invention does not require the creation of a different light-emitting device for each pixel, thus simplifying the manufacturing process and reducing manufacturing costs. However, the present invention is not limited thereto, and one or more of layers 521, 522, 524, 525, light-emitting layer 523Q_1, light-emitting layer 523Q_2, and light-emitting layer 523Q_3 can have different configurations depending on the pixel.

[0367] The light-emitting device 550W shown in Figure 18B has a configuration in which two light-emitting units (light-emitting unit 512Q_1, light-emitting unit 512Q_2) are stacked between a pair of electrodes (electrode 501, electrode 502) with an intermediate layer 531 in between.

[0368] Furthermore, the intermediate layer 531 has the function of injecting electrons into one of the light-emitting units 512Q_1 and 512Q_2 and holes into the other when a voltage is applied between the electrodes 501 and 502. The intermediate layer 531 can also be called a charge generation layer.

[0369] As the intermediate layer 531, for example, a material applicable to the electron injection layer, such as lithium, can be suitably used. Alternatively, as the intermediate layer, a material applicable to the hole injection layer can be suitably used. Furthermore, the intermediate layer can include a layer containing a material with high hole transport properties (hole transport material) and an acceptor material (electron-accepting material). Alternatively, the intermediate layer can include a layer containing a material with high electron transport properties (electron-transport material) and a donor material. By forming an intermediate layer having such a layer, it is possible to suppress the increase in driving voltage when light-emitting units are stacked.

[0370] The light-emitting unit 512Q_1 has layers 521, 522, light-emitting layer 523Q_1, layer 524, etc. The light-emitting unit 512Q_2 has layers 522, light-emitting layer 523Q_2, layer 524, etc. The light-emitting device 550W has layers 525, etc. between the light-emitting unit 512Q_2 and the electrode 502. Note that layer 525 can also be considered as part of the light-emitting unit 512Q_2.

[0371] In the light-emitting device 550W shown in Figure 18B, white light emission can be obtained from the light-emitting device 550W by selecting light-emitting layers 523Q_1 and 523Q_2 such that their light emission is in a complementary color relationship. Preferably, light-emitting layers 523Q_1 and 523Q_2 each contain light-emitting materials that emit light such as R (red), G (green), B (blue), Y (yellow), and O (orange). Alternatively, it is preferable that the light emission of the light-emitting materials in light-emitting layers 523Q_1 and 523Q_2 contains spectral components of two or more colors from R, G, and B.

[0372] Here, we will explain an example of the combination of light-emitting colors of the light-emitting layers of each light-emitting unit that can be used in the 550W light-emitting device.

[0373] For example, if a 550W light-emitting device has two light-emitting units, a 550W light-emitting device that emits white light can be obtained by emitting red and green light from one unit and blue light from the other unit. Alternatively, a 550W light-emitting device that emits white light can be obtained by emitting yellow or orange light from one unit and blue light from the other unit.

[0374] Furthermore, for example, if the light-emitting device 550W has three light-emitting units, a light-emitting device 550W that emits white light can be obtained by obtaining red light from one of the light-emitting units, green light from another light-emitting unit, and blue light from the remaining light-emitting unit. Alternatively, a blue light-emitting layer can be used in the first light-emitting unit, a yellow, yellow-green, or green light-emitting layer in the second light-emitting unit, and a blue light-emitting layer in the third light-emitting unit. Alternatively, a blue light-emitting layer can be used in the first light-emitting unit, a laminated structure can be used in the second light-emitting unit consisting of a red light-emitting layer and a yellow, yellow-green, or green light-emitting layer, and a blue light-emitting layer in the third light-emitting unit.

[0375] Furthermore, for example, if the 550W light-emitting device has four light-emitting units, a blue light-emitting layer can be used in the first light-emitting unit, a red light-emitting layer in one of the second and third light-emitting units, a yellow, yellow-green, or green light-emitting layer in the other, and a blue light-emitting layer in the fourth light-emitting unit.

[0376] In this specification, a configuration in which multiple light-emitting units are connected in series via an intermediate layer 531, such as the light-emitting device 550W shown in Figure 18B, is referred to as a tandem structure. While this specification uses the term "tandem structure," it is not limited to this; for example, a tandem structure may also be called a stacked structure. Furthermore, a tandem structure enables a light-emitting device capable of high-brightness illumination. Compared to a single-unit structure, a tandem structure reduces the current required to achieve the same brightness, thereby reducing the power consumption of the display device and improving its reliability.

[0377] Here, we show an example where light-emitting units 512Q_1 and 512Q_2 each have one light-emitting layer, but the number of light-emitting layers in each light-emitting unit is not limited. For example, light-emitting units 512Q_1 and 512Q_2 may have different numbers of light-emitting layers. For example, one light-emitting unit may have two light-emitting layers, and the other light-emitting unit may have one light-emitting layer.

[0378] The display device 500 shown in Figure 19A is an example where the light-emitting device 550W has a configuration in which three light-emitting units are stacked. In Figure 19A, the light-emitting device 550W has a light-emitting unit 512Q_3 stacked on top of a light-emitting unit 512Q_2 via an intermediate layer 531. The light-emitting unit 512Q_3 has layers 522, light-emitting layer 523Q_3, layer 524, etc. The light-emitting unit 512Q_3 can be configured in the same way as the light-emitting unit 512Q_2.

[0379] When applying a tandem structure to a light-emitting device, the number of light-emitting units is not particularly limited and can be two or more.

[0380] Figure 19B shows an example where n light-emitting units 512Q_1 are stacked to form 512Q_n (where n is an integer greater than or equal to 2).

[0381] In this way, by increasing the number of stacked light-emitting units, the brightness obtained from the light-emitting device with the same amount of current can be increased in proportion to the number of stacks. Furthermore, by increasing the number of stacked light-emitting units, the current required to obtain the same brightness can be reduced, thus reducing the power consumption of the light-emitting device in proportion to the number of stacks.

[0382] In addition, the light-emitting material of the light-emitting layer in the display device 500 is not particularly limited. For example, in the display device 500 shown in Figure 3B, the light-emitting layer 523Q_1 of the light-emitting unit 512Q_1 may have a phosphorescent material, and the light-emitting layer 523Q_2 of the light-emitting unit 512Q_2 may have a fluorescent material. Alternatively, the light-emitting layer 523Q_1 of the light-emitting unit 512Q_1 may have a fluorescent material, and the light-emitting layer 523Q_2 of the light-emitting unit 512Q_2 may have a phosphorescent material.

[0383] The configuration of the light-emitting unit is not limited to the above. For example, in the display device 500 shown in Figure 3B, the light-emitting layer 523Q_1 of the light-emitting unit 512Q_1 may have a TADF material, and the light-emitting layer 523Q_2 of the light-emitting unit 512Q_2 may have either a fluorescent material or a phosphorescent material. By using different light-emitting materials in this way, for example, by combining a highly reliable light-emitting material with a highly efficient light-emitting material, it is possible to compensate for the shortcomings of each and create a display device that improves both reliability and luminous efficiency.

[0384] Furthermore, in one embodiment of the present invention, the display device may be configured such that all light-emitting layers are made of fluorescent material, or so may be configured such that all light-emitting layers are made of phosphorescent material.

[0385] This embodiment can be combined with other embodiments as appropriate.

[0386] (Embodiment 3) In this embodiment, a display device according to one aspect of the present invention will be described with reference to Figures 20 to 22.

[0387] The display device of this embodiment can be a high-resolution display device or a large-screen display device. Therefore, the display device of this embodiment can be used in electronic devices with relatively large screens, such as television sets, desktop or notebook personal computers, computer monitors, digital signage, and large game machines such as pachinko machines, as well as in the display units of digital cameras, digital video cameras, digital photo frames, mobile phones, portable game consoles, personal information terminals, and audio playback devices.

[0388] [Display device 100A] Figure 20 shows a perspective view of the display device 100A, and Figure 21A shows a cross-sectional view of the display device 100A.

[0389] The display device 100A has a configuration in which substrate 152 and substrate 151 are bonded together. In Figure 20, substrate 152 is clearly indicated by a dashed line.

[0390] The display device 100A includes a display unit 162, a connection unit 140, a circuit 164, wiring 165, etc. Figure 20 shows an example in which IC 173 and FPC 172 are mounted on the display device 100A. Therefore, the configuration shown in Figure 20 can also be described as a display module having the display device 100A, an IC (integrated circuit), and an FPC.

[0391] The connection portion 140 is provided on the outside of the display portion 162. The connection portion 140 can be provided along one or more sides of the display portion 162. There may be one or more connection portions 140. Figure 20 shows an example in which the connection portion 140 is provided so as to surround all four sides of the display portion. At the connection portion 140, the common electrode of the light-emitting device and the conductive layer are electrically connected, and a potential can be supplied to the common electrode.

[0392] For example, a scan line drive circuit can be used as circuit 164.

[0393] Wiring 165 has the function of supplying signals and power to the display unit 162 and the circuit 164. These signals and power are input to wiring 165 from an external source via FPC 172 or from IC 173.

[0394] Figure 20 shows an example in which IC 173 is mounted on the substrate 151 using a COG (Chip On Glass) method or COF (Chip On Film) method. IC 173 can be an IC having, for example, a scan line drive circuit or a signal line drive circuit. Note that the display device 100A and the display module may be configured without an IC. Alternatively, the IC may be mounted on an FPC using a COF method or the like.

[0395] Figure 21A shows an example of a cross-section of the display device 100A when a portion of the area including the FPC 172, a portion of the circuit 164, a portion of the display unit 162, a portion of the connection portion 140, and a portion of the area including the end portion are cut.

[0396] The display device 100A shown in Figure 21A has transistors 201 and 205, light-emitting devices 130a, 130b and 130c, and colored layers 129a, 129b and 129c between substrates 151 and 152. The light-emitting devices 130a, 130b and 130c emit white light. The colored layers 129a, 129b and 129c have the function of transmitting different colors to each other.

[0397] Here, if the pixels of the display device have three types of subpixels, each having a colored layer 129 that transmits different colors from each other, examples of these three subpixels include subpixels of three colors: R, G, and B; and subpixels of three colors: yellow (Y), cyan (C), and magenta (M). If there are four such subpixels, examples of these four subpixels include subpixels of four colors: R, G, B, and white (W); and subpixels of four colors: R, G, B, and Y.

[0398] The light-emitting devices 130a, 130b, and 130c each have the stacked structure shown in Figure 1B, except that they have an optical adjustment layer 126 (optical adjustment layer 126a, optical adjustment layer 126b, and optical adjustment layer 126c) between the pixel electrode and the EL layer. Light-emitting device 130a has an optical adjustment layer 126a, light-emitting device 130b has an optical adjustment layer 126b, and light-emitting device 130c has an optical adjustment layer 126c. Details of the light-emitting devices can be found in Embodiment 1.

[0399] Furthermore, as shown in Figure 21A, it is preferable that the optical adjustment layers 126 provided on each light-emitting device 130 have different thicknesses for each light-emitting device. For example, if the colored layer 129a transmits red light, the colored layer 129b transmits green light, and the colored layer 129c transmits blue light, then the thickness of the optical adjustment layer 126a should be the thickest and the thickness of the optical adjustment layer 126c should be the thinnest of the three optical adjustment layers 126. In this way, the optical distance (optical path length) in each light-emitting element can be changed.

[0400] Of the three light-emitting devices, the light-emitting device 130a that overlaps with the colored layer 129a has the longest optical path length, and therefore emits light with the longest wavelength (e.g., red light) being amplified. On the other hand, the light-emitting device 130c that overlaps with the colored layer 129c has the shortest optical path length, and therefore emits light with the shortest wavelength (e.g., blue light) being amplified. The light-emitting device 130b that overlaps with the colored layer 129b emits light with an intermediate wavelength (e.g., green light) being amplified.

[0401] This configuration eliminates the need to create separate light-emitting layers for each subpixel of a different color, allowing for highly accurate color reproduction using light-emitting devices with the same configuration.

[0402] Furthermore, a fifth layer 114 is provided on the first layer 113a, the second layer 113b, the third layer 113c, and the insulating layers 125 and 127, and a common electrode 115 is provided on the fifth layer 114. In addition, a protective layer 131 is provided on each of the light-emitting devices 130a, 130b, and 130c. A protective layer 132 is provided on the protective layer 131.

[0403] The protective layer 132 and the substrate 152 are bonded together via an adhesive layer 142. For sealing the light-emitting device, a solid sealing structure or a hollow sealing structure can be applied. In Figure 21A, the space between substrate 152 and substrate 151 is filled with the adhesive layer 142, demonstrating a solid sealing structure. Alternatively, the space may be filled with an inert gas (such as nitrogen or argon), demonstrating a hollow sealing structure. In this case, the adhesive layer 142 may be provided so as not to overlap with the light-emitting device. Furthermore, the space may be filled with a resin different from the frame-shaped adhesive layer 142.

[0404] The pixel electrodes 111a, 111b, and 111c are each connected to the conductive layer 222b of the transistor 205 through an opening provided in the insulating layer 214.

[0405] The edges of the pixel electrodes and the optical adjustment layer are covered by an insulating layer 121a, and the insulating layer 121a is covered by an insulating layer 121b. The pixel electrodes contain a material that reflects visible light, and the counter electrodes (common electrodes 115) contain a material that transmits visible light.

[0406] The insulating layer covering the edges of the pixel electrodes can be a single-layer or multi-layer structure using either an inorganic insulating film or an organic insulating film, or both. In this embodiment, an example is shown in which an insulating layer 121a is formed using an organic insulating film and an insulating layer 121b is formed using an inorganic insulating film.

[0407] Examples of organic insulating materials that can be used for the insulating layer 121a include acrylic resin, epoxy resin, polyimide resin, polyamide resin, polyimidoamide resin, polysiloxane resin, benzocyclobutene resin, and phenolic resin. Furthermore, as the inorganic insulating film that can be used for the insulating layer 121b, the same inorganic insulating films used for the protective layers 131 and 132 can be used.

[0408] Using an inorganic insulating film as an insulating layer covering the edges of the pixel electrodes makes it more difficult for impurities to enter the light-emitting device compared to using an organic insulating film, thereby improving the reliability of the light-emitting device. Using an organic insulating film as an insulating layer covering the edges of the pixel electrodes provides better step coverage and is less affected by the shape of the pixel electrodes compared to using an inorganic insulating film. Therefore, it is possible to prevent short circuits in the light-emitting device. Specifically, using an organic insulating film as the insulating layer 121a allows the shape of the insulating layer 121a to be processed into a tapered shape or the like.

[0409] It is preferable to use a two-layer structure for the insulating layer covering the edges of the pixel electrodes, such as insulating layers 121a and 121b, which consists of an organic insulating film and an inorganic insulating film, in order to further improve the reliability of the light-emitting device.

[0410] In the connection portion 140, a conductive layer 123 is provided on the insulating layer 214. The conductive layer 123 is shown as an example of a laminated structure consisting of a conductive film obtained by processing the same conductive film as the pixel electrodes 111a, 111b, and 111c, and a conductive film obtained by processing the same conductive film as the optical adjustment layers 126a, 126b, and 126c. The ends of the conductive layer 123 are covered by insulating layers 121a, 121b, 125, and 127. Furthermore, a fifth layer 114 is provided on the conductive layer 123, and a common electrode 115 is provided on the fifth layer 114. The conductive layer 123 and the common electrode 115 are electrically connected via the fifth layer 114. Note that the fifth layer 114 does not necessarily have to be formed in the connection portion 140. In this case, the conductive layer 123 and the common electrode 115 are in direct contact and electrically connected.

[0411] The display device 100A is a top-emission type. The light emitted from the light-emitting device is emitted towards the substrate 152. It is preferable to use a material with high transparency to visible light for the substrate 152.

[0412] The laminated structure from the substrate 151 to the insulating layer 214 corresponds to the layer 101 containing the transistor in Embodiment 1.

[0413] Both transistors 201 and 205 are formed on the substrate 151. These transistors can be manufactured using the same materials and the same process.

[0414] On the substrate 151, insulating layers 211, 213, 215, and 214 are provided in this order. A portion of insulating layer 211 functions as a gate insulating layer for each transistor. A portion of insulating layer 213 functions as a gate insulating layer for each transistor. Insulating layer 215 is provided covering the transistors. Insulating layer 214 is provided covering the transistors and functions as a planarization layer. The number of gate insulating layers and insulating layers covering the transistors are not limited and may be a single layer or two or more layers, respectively.

[0415] It is preferable to use a material that does not easily allow impurities such as water and hydrogen to diffuse into at least one layer of the insulating layer covering the transistor. This allows the insulating layer to function as a barrier insulating film. With such a configuration, the diffusion of impurities from the outside into the transistor can be effectively suppressed, thereby improving the reliability of the display device.

[0416] It is preferable to use inorganic insulating films for insulating layer 211, insulating layer 213, and insulating layer 215. Examples of inorganic insulating films that can be used include silicon nitride film, silicon oxide nitride film, silicon oxide film, silicon nitride oxide film, aluminum oxide film, and aluminum nitride film. Alternatively, hafnium oxide film, yttrium oxide film, zirconium oxide film, gallium oxide film, tantalum oxide film, magnesium oxide film, lanthanum oxide film, cerium oxide film, and neodymium oxide film may also be used. Furthermore, two or more of the above insulating films may be laminated together.

[0417] An organic insulating film is preferred for the insulating layer 214, which functions as a planarization layer. Examples of materials that can be used for the organic insulating film include acrylic resin, polyimide resin, epoxy resin, polyamide resin, polyimidoamide resin, siloxane resin, benzocyclobutene resin, phenol resin, and precursors of these resins. Alternatively, the insulating layer 214 may have a laminated structure of an organic insulating film and an inorganic insulating film. The outermost layer of the insulating layer 214 preferably functions as an etching protective film. This makes it possible to suppress the formation of recesses in the insulating layer 214 during processing of the pixel electrode 111a or the optical adjustment layer 126a. Alternatively, recesses may be provided in the insulating layer 214 during processing of the pixel electrode 111a or the optical adjustment layer 126a.

[0418] Here, organic insulating films often have lower barrier properties than inorganic insulating films. Therefore, it is preferable that the organic insulating film has an opening near the edge of the display device 100A. This prevents impurities from entering through the organic insulating film from the edge of the display device 100A. Alternatively, the organic insulating film may be formed so that its edge is inward from the edge of the display device 100A, so that the organic insulating film is not exposed at the edge of the display device 100A.

[0419] Transistors 201 and 205 have a conductive layer 221 that functions as a gate, an insulating layer 211 that functions as a gate insulating layer, conductive layers 222a and 222b that function as source and drain, a semiconductor layer 231, an insulating layer 213 that functions as a gate insulating layer, and a conductive layer 223 that functions as a gate. Here, the same hatching pattern is applied to multiple layers obtained by processing the same conductive film. The insulating layer 211 is located between the conductive layer 221 and the semiconductor layer 231. The insulating layer 213 is located between the conductive layer 223 and the semiconductor layer 231.

[0420] The transistor structure of the display device of this embodiment is not particularly limited. For example, planar transistors, staggered transistors, inverse staggered transistors, etc., can be used. Furthermore, either a top-gate or bottom-gate transistor structure may be used. Alternatively, gates may be provided above and below the semiconductor layer in which the channel is formed.

[0421] Transistors 201 and 205 are configured in which a semiconductor layer on which a channel is formed is sandwiched between two gates. The transistors may be driven by connecting the two gates and supplying them with the same signal. Alternatively, the threshold voltage of the transistors may be controlled by applying a potential to control the threshold voltage to one of the two gates and a potential to drive the other gate.

[0422] The crystallinity of the semiconductor material used in the transistor is not particularly limited; amorphous semiconductors, crystalline semiconductors (microcrystalline semiconductors, polycrystalline semiconductors, single-crystal semiconductors, or semiconductors with crystalline regions in part) may be used. Using a crystalline semiconductor is preferable because it can suppress the degradation of transistor characteristics.

[0423] The semiconductor layer of the transistor preferably has a metal oxide (also called an oxide semiconductor). In other words, the display device of this embodiment preferably uses a transistor (hereinafter referred to as an OS transistor) that uses a metal oxide in the channel formation region. Alternatively, the semiconductor layer of the transistor may have silicon. Examples of silicon include amorphous silicon and crystalline silicon (low-temperature polysilicon, single-crystal silicon, etc.).

[0424] The semiconductor layer preferably comprises, for example, indium, M (where M is one or more selected from gallium, aluminum, silicon, boron, yttrium, tin, copper, vanadium, beryllium, titanium, iron, nickel, germanium, zirconium, molybdenum, lanthanum, cerium, neodymium, hafnium, tantalum, tungsten, and magnesium), and zinc. In particular, M is preferably one or more selected from aluminum, gallium, yttrium, and tin.

[0425] In particular, it is preferable to use an oxide (also written as IGZO) containing indium (In), gallium (Ga), and zinc (Zn) as the semiconductor layer.

[0426] When the semiconductor layer is an In-M-Zn oxide, it is preferable that the atomic ratio of In in the In-M-Zn oxide is equal to or greater than the atomic ratio of M. Examples of such In-M-Zn oxide atomic ratios of metal elements include compositions where In:M:Zn=1:1:1 or close to it, In:M:Zn=1:1:1.2 or close to it, In:M:Zn=2:1:3 or close to it, In:M:Zn=3:1:2 or close to it, In:M:Zn=4:2:3 or close to it, In:M:Zn=4:2:4.1 or close to it, In:M:Zn=5:1:3 or close to it, In:M:Zn=5:1:6 or close to it, In:M:Zn=5:1:7 or close to it, In:M:Zn=5:1:8 or close to it, In:M:Zn=6:1:6 or close to it, In:M:Zn=5:2:5 or close to it, and so on. Note that "close to it" compositions include a range of ±30% of the desired atomic ratio.

[0427] For example, when describing a composition with an atomic ratio of In:Ga:Zn = 4:2:3 or a similar ratio, it includes cases where, when In is set to 4, Ga is between 1 and 3, and Zn is between 2 and 4. Also, when describing a composition with an atomic ratio of In:Ga:Zn = 5:1:6 or a similar ratio, it includes cases where, when In is set to 5, Ga is greater than 0.1 and 2 or less, and Zn is between 5 and 7. Furthermore, when describing a composition with an atomic ratio of In:Ga:Zn = 1:1:1 or a similar ratio, it includes cases where, when In is set to 1, Ga is greater than 0.1 and 2 or less, and Zn is greater than 0.1 and 2 or less.

[0428] The transistors in circuit 164 and the transistors in display unit 162 may have the same structure or different structures. The structures of the multiple transistors in circuit 164 may all be the same or there may be two or more different structures. Similarly, the structures of the multiple transistors in display unit 162 may all be the same or there may be two or more different structures.

[0429] Figures 21B and 21C show other examples of transistor configurations.

[0430] Transistors 209 and 210 each have a conductive layer 221 that functions as a gate, an insulating layer 211 that functions as a gate insulating layer, a semiconductor layer 231 having a channel forming region 231i and a pair of low-resistance regions 231n, a conductive layer 222a connected to one of the pair of low-resistance regions 231n, a conductive layer 222b connected to the other of the pair of low-resistance regions 231n, an insulating layer 225 that functions as a gate insulating layer, a conductive layer 223 that functions as a gate, and an insulating layer 215 covering the conductive layer 223. The insulating layer 211 is located between the conductive layer 221 and the channel forming region 231i. The insulating layer 225 is located at least between the conductive layer 223 and the channel forming region 231i. Furthermore, an insulating layer 218 covering the transistor may be provided.

[0431] In the transistor 209 shown in Figure 21B, an example is shown where the insulating layer 225 covers the top and sides of the semiconductor layer 231. The conductive layers 222a and 222b are connected to the low-resistance region 231n through openings provided in the insulating layers 225 and 215, respectively. Of the conductive layers 222a and 222b, one functions as the source and the other as the drain.

[0432] On the other hand, in the transistor 210 shown in Figure 21C, the insulating layer 225 overlaps with the channel formation region 231i of the semiconductor layer 231, but does not overlap with the low-resistance region 231n. For example, the structure shown in Figure 21C can be fabricated by processing the insulating layer 225 using the conductive layer 223 as a mask. In Figure 21C, an insulating layer 215 is provided covering the insulating layer 225 and the conductive layer 223, and the conductive layer 222a and conductive layer 222b are connected to the low-resistance region 231n, respectively, through openings in the insulating layer 215.

[0433] A connection portion 204 is provided in the region of substrate 151 where substrate 152 does not overlap. At the connection portion 204, wiring 165 is electrically connected to FPC 172 via conductive layer 166 and connection layer 242. The conductive layer 166 is shown as an example of a laminated structure consisting of a conductive film obtained by processing the same conductive film as the pixel electrodes 111a, 111b, and 111c, and a conductive film obtained by processing the same conductive film as the optical adjustment layers 126a, 126b, and 126c. The conductive layer 166 is exposed on the upper surface of the connection portion 204. This allows the connection portion 204 and FPC 172 to be electrically connected via the connection layer 242.

[0434] It is preferable to provide a light-shielding layer 117 on the surface of the substrate 152 that faces the substrate 151. The light-shielding layer 117 can be provided between adjacent light-emitting devices, at connection points 140, and in circuits 164, etc. Alternatively, colored layers 129a and 129b may be provided on the surface of the substrate 152 that faces the substrate 151. In Figure 21A, when viewed with respect to the substrate 152, the colored layers 129a, 129b, and 129c are provided so as to cover a portion of the light-shielding layer 117.

[0435] Furthermore, various optical components can be placed on the outside of the substrate 152. Examples of optical components include polarizing plates, phase difference plates, light diffusion layers (such as diffusion films), anti-reflective layers, and light-gathering films. Additionally, an antistatic film to suppress the adhesion of dust, a water-repellent film to make it difficult for dirt to adhere, a hard coat film to suppress the occurrence of scratches during use, and an impact-absorbing layer may be placed on the outside of the substrate 152.

[0436] By providing protective layers 131 and 132 that cover the light-emitting device, it is possible to suppress the ingress of impurities such as water into the light-emitting device and improve the reliability of the light-emitting device.

[0437] Substrates 151 and 152 can be made of glass, quartz, ceramic, sapphire, resin, metal, alloy, semiconductor, etc., respectively. The substrate on the side that extracts light from the light-emitting device should be made of a material that transmits the light. Using flexible materials for substrates 151 and 152 can increase the flexibility of the display device. Alternatively, a polarizing plate may be used as substrate 151 or substrate 152.

[0438] Substrates 151 and 152 can be made from polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), polyacrylonitrile resin, acrylic resin, polyimide resin, polymethyl methacrylate resin, polycarbonate (PC) resin, polyethersulfone (PES) resin, polyamide resin (nylon, aramid, etc.), polysiloxane resin, cycloolefin resin, polystyrene resin, polyamide-imide resin, polyurethane resin, polyvinyl chloride resin, polyvinylidene chloride resin, polypropylene resin, polytetrafluoroethylene (PTFE) resin, ABS resin, cellulose nanofiber, etc. One or both of substrates 151 and 152 may be made of glass of a thickness sufficient to provide flexibility.

[0439] Furthermore, when a circular polarizing plate is superimposed on a display device, it is preferable to use a substrate with high optical isotropy for the substrate of the display device. A substrate with high optical isotropy has low birefringence (or a small amount of birefringence).

[0440] For substrates with high optical isotropy, the absolute value of the retardation (phase difference) is preferably 30 nm or less, more preferably 20 nm or less, and even more preferably 10 nm or less.

[0441] Examples of films with high optical isotropy include triacetylcellulose (TAC, also known as cellulose triacetate) film, cycloolefin polymer (COP) film, cycloolefin copolymer (COC) film, and acrylic film.

[0442] Furthermore, when using a film as the substrate, the film may absorb water, potentially causing wrinkles or other shape changes in the display panel. Therefore, it is preferable to use a film with low water absorption for the substrate. For example, it is preferable to use a film with a water absorption rate of 1% or less, more preferable to use a film with a water absorption rate of 0.1% or less, and even more preferable to use a film with a water absorption rate of 0.01% or less.

[0443] As the adhesive layer 142, various types of curing adhesives can be used, such as UV-curing adhesives, reaction-curing adhesives, thermosetting adhesives, and anaerobic adhesives. Examples of these adhesives include epoxy resins, acrylic resins, silicone resins, phenolic resins, polyimide resins, imide resins, PVC (polyvinyl chloride) resins, PVB (polyvinyl butyral) resins, and EVA (ethylene vinyl acetate) resins. Materials with low moisture permeability, such as epoxy resins, are particularly preferred. Two-component mixed resins may also be used. Adhesive sheets may also be used.

[0444] As the connecting layer 242, an anisotropic conductive film (ACF), an anisotropic conductive paste (ACP), etc., can be used.

[0445] Materials that can be used for conductive layers such as the gate, source, and drain of transistors, as well as various wirings and electrodes that constitute display devices, include metals such as aluminum, titanium, chromium, nickel, copper, yttrium, zirconium, molybdenum, silver, tantalum, and tungsten, as well as alloys mainly composed of these metals. Films containing these materials can be used as single layers or in a multilayer structure.

[0446] Furthermore, conductive oxides such as indium oxide, indium tin oxide, indium zinc oxide, zinc oxide, and zinc oxide containing gallium, or graphene can be used as the light-transmitting conductive material. Alternatively, metallic materials such as gold, silver, platinum, magnesium, nickel, tungsten, chromium, molybdenum, iron, cobalt, copper, palladium, and titanium, or alloy materials containing such metallic materials, can be used. Alternatively, nitrides of such metallic materials (e.g., titanium nitride) may be used. When using metallic materials or alloy materials (or their nitrides), it is preferable to make them thin enough to be light-transmitting. In addition, a laminated film of the above materials can be used as a conductive layer. For example, using a laminated film of a silver-magnesium alloy and indium tin oxide is preferable because it can enhance conductivity. These can also be used as conductive layers for various wirings and electrodes that constitute a display device, and as conductive layers (conductive layers that function as pixel electrodes or common electrodes) in light-emitting devices.

[0447] Examples of insulating materials that can be used for each insulating layer include resins such as acrylic resin and epoxy resin, and inorganic insulating materials such as silicon oxide, silicon oxide nitride, silicon nitride, and aluminum oxide.

[0448] [Display device 100B] The display device 100B shown in Figure 22 differs from the display device 100A mainly in that it is a bottom-emission type. Parts that are the same as those of the display device 100A will not be explained.

[0449] The light emitted by the light-emitting device is projected onto the substrate 151. It is preferable to use a material with high transparency to visible light for the substrate 151. On the other hand, the light transmittance of the material used for the substrate 152 is not a requirement.

[0450] Furthermore, the display device 100B includes a material that transmits visible light for the pixel electrodes 111a, 111b, 111c and the optical adjustment layers 126a, 126b, 126c, and a material that reflects visible light for the common electrode 115. Here, the conductive layer 166, obtained by processing the same conductive film as the pixel electrodes 111a, 111b, 111c and the optical adjustment layers 126a, 126b, 126c, also includes a material that transmits visible light.

[0451] It is preferable to form a light-shielding layer 117 between the substrate 151 and the transistor 201, and between the substrate 151 and the transistor 205. Figure 22 shows an example in which a light-shielding layer 117 is provided on the substrate 151, an insulating layer 153 is provided on the light-shielding layer 117, and transistors 201, 205, etc. are provided on the insulating layer 153.

[0452] Furthermore, in the display device 100B, the colored layers 129a, 129b, and 129c are provided between the insulating layer 215 and the insulating layer 214. Preferably, the edges of the colored layers 129a, 129b, and 129c overlap with the light-shielding layer 117.

[0453] This embodiment can be combined with other embodiments as appropriate.

[0454] (Embodiment 4) In this embodiment, a display device according to one aspect of the present invention will be described with reference to Figures 23 to 28.

[0455] The display device of this embodiment can be a high-definition display device. Therefore, the display device of this embodiment can be used in the display section of wearable devices that can be worn on the head, such as information terminals (wearable devices) such as wristwatches and bracelets, as well as VR (Virtual Reality) devices such as head-mounted displays and AR (Augmented Reality) devices such as glasses.

[0456] [Display Module] Figure 23A shows a perspective view of the display module 280. The display module 280 includes a display device 100C and an FPC 290. Note that the display device included in the display module 280 is not limited to the display device 100C, but may be any of the display devices 100D to 100G described later.

[0457] The display module 280 has substrates 291 and 292. The display module 280 has a display unit 281. The display unit 281 is an area in the display module 280 that displays an image, and is an area in which light from each pixel provided in the pixel unit 284, which will be described later, can be seen.

[0458] Figure 23B shows a schematic perspective view illustrating the configuration of the substrate 291. On the substrate 291, a circuit section 282, a pixel circuit section 283 on the circuit section 282, and a pixel section 284 on the pixel circuit section 283 are stacked. In addition, a terminal section 285 for connecting to the FPC 290 is provided in the portion of the substrate 291 that does not overlap with the pixel section 284. The terminal section 285 and the circuit section 282 are electrically connected by a wiring section 286, which is composed of multiple wires.

[0459] The pixel section 284 has a plurality of periodically arranged pixels 284a. A magnified view of one pixel 284a is shown on the right side of Figure 23B. Pixel 284a has sub-pixels 110a, 110b, and 110c. The configuration of sub-pixels 110a, 110b, and 110c and their surroundings can be referenced from the previous embodiment. The plurality of sub-pixels can be arranged in a stripe arrangement as shown in Figure 23B. In addition, various arrangement methods for light-emitting devices, such as delta arrangement or pentile arrangement, can be applied.

[0460] The pixel circuit section 283 has a plurality of pixel circuits 283a arranged periodically.

[0461] A single pixel circuit 283a is a circuit that controls the light emission of three light-emitting devices in a single pixel 284a. A single pixel circuit 283a may be configured to have three circuits that control the light emission of one light-emitting device. For example, a pixel circuit 283a can be configured to have at least one selection transistor, one current control transistor (drive transistor), and a capacitive element for each light-emitting device. In this case, a gate signal is input to the gate of the selection transistor, and a source signal is input to either the source or the drain. This realizes an active-matrix type display device.

[0462] The circuit section 282 has circuits for driving each pixel circuit 283a of the pixel circuit section 283. For example, it is preferable to have one or both of a gate line drive circuit and a source line drive circuit. In addition, it may have at least one of the following: an arithmetic circuit, a memory circuit, and a power supply circuit.

[0463] The FPC290 functions as wiring for supplying video signals or power potential, etc., to the circuit section 282 from an external source. An IC may also be mounted on the FPC290.

[0464] The display module 280 can be configured such that one or both of the pixel circuit section 283 and the circuit section 282 are superimposed on the lower side of the pixel section 284, thereby enabling an extremely high aperture ratio (effective display area ratio) of the display section 281. For example, the aperture ratio of the display section 281 can be 40% or more and less than 100%, preferably 50% or more and 95%, and more preferably 60% or more and 95%. Furthermore, it is possible to arrange the pixels 284a at an extremely high density, enabling an extremely high resolution of the display section 281. For example, it is preferable that the pixels 284a in the display section 281 are arranged with a resolution of 20000 ppi or more, preferably 3000 ppi or more, more preferably 5000 ppi or more, and even more preferably 6000 ppi or more, and with a resolution of 20000 ppi or less, or 30000 ppi or less.

[0465] Because such a display module 280 is extremely high-resolution, it can be suitably used in VR devices such as head-mounted displays, or in glasses-type AR devices. For example, even in a configuration where the display part of the display module 280 is viewed through lenses, the display module 280 has an extremely high-resolution display part 281, so even when the display part is magnified with lenses, pixels are not visible, allowing for a highly immersive display. Furthermore, the display module 280 is not limited to this, and can be suitably used in electronic devices with relatively small display parts. For example, it can be suitably used in the display part of wearable electronic devices such as wristwatches.

[0466] [Display device 100C] The display device 100C shown in Figure 24 includes a substrate 301, sub-pixels 110a, 110b, 110c, a capacitor 240, and a transistor 310. Sub-pixel 110a has a light-emitting device 130a and a colored layer 129a, sub-pixel 110b has a light-emitting device 130b and a colored layer 129b, and sub-pixel 110c has a light-emitting device 130c and a colored layer 129c.

[0467] Substrate 301 corresponds to substrate 291 in Figures 23A and 23B. The laminated structure from substrate 301 to insulating layer 255b corresponds to layer 101 containing the transistor in Embodiment 1.

[0468] The transistor 310 is a transistor having a channel-forming region in the substrate 301. The substrate 301 can be a semiconductor substrate such as a single-crystal silicon substrate. The transistor 310 comprises a portion of the substrate 301, a conductive layer 311, a low-resistance region 312, an insulating layer 313, and an insulating layer 314. The conductive layer 311 functions as a gate electrode. The insulating layer 313 is located between the substrate 301 and the conductive layer 311 and functions as a gate insulating layer. The low-resistance region 312 is a region of the substrate 301 doped with impurities and functions as either a source or a drain. The insulating layer 314 is provided covering the side surface of the conductive layer 311.

[0469] Furthermore, an element isolation layer 315 is provided between two adjacent transistors 310 so as to be embedded in the substrate 301.

[0470] Furthermore, an insulating layer 261 is provided covering the transistor 310, and a capacitance 240 is provided on the insulating layer 261.

[0471] Capacitor 240 has a conductive layer 241, a conductive layer 245, and an insulating layer 243 located between them. The conductive layer 241 functions as one electrode of the capacitor 240, the conductive layer 245 functions as the other electrode of the capacitor 240, and the insulating layer 243 functions as the dielectric of the capacitor 240.

[0472] The conductive layer 241 is provided on the insulating layer 261 and embedded in the insulating layer 254. The conductive layer 241 is electrically connected to either the source or drain of the transistor 310 by a plug 271 embedded in the insulating layer 261. The insulating layer 243 is provided covering the conductive layer 241. The conductive layer 245 is provided in the region that overlaps with the conductive layer 241 via the insulating layer 243.

[0473] An insulating layer 255a is provided covering the capacitance 240, an insulating layer 255b is provided on the insulating layer 255a, and light-emitting devices 130a, 130b, 130c, etc. are provided on the insulating layer 255b. In this embodiment, an example is shown in which the light-emitting devices 130a, 130b, and 130c have the stacked structure shown in Figure 1B. The sides of the pixel electrodes 111a, 111b, and 111c are each covered by an insulating layer 121. The sides of the first layer 113a, the second layer 113b, and the third layer 113c are each covered by insulating layers 125 and 127. A fifth layer 114 is provided on the first layer 113a, the second layer 113b, the third layer 113c, and the insulating layers 125 and 127, and a common electrode 115 is provided on the fifth layer 114. Furthermore, a protective layer 131 is provided on the light-emitting devices 130a, 130b, and 130c. A protective layer 132 is provided on the protective layer 131, and colored layers 129a, 129b, and 129c are provided on the protective layer 132. A substrate 120 is bonded to the colored layers 129a, 129b, and 129c by a resin layer 122. Details of the components from the light-emitting devices to the substrate 120 can be found in Embodiment 1. The substrate 120 corresponds to the substrate 292 in Figure 23A.

[0474] Various inorganic insulating films such as oxide insulating films, nitride insulating films, oxidative nitride insulating films, and nitride-oxide insulating films can be suitably used as insulating layers 255a and 255b, respectively. For insulating layer 255a, it is preferable to use an oxide insulating film or oxidative nitride insulating film such as a silicon oxide film, silicon oxidative nitride film, or aluminum oxide film. For insulating layer 255b, it is preferable to use a nitride insulating film or oxidative nitride insulating film such as a silicon nitride film or silicon nitride-oxide film. More specifically, it is preferable to use a silicon oxide film as insulating layer 255a and a silicon nitride film as insulating layer 255b. It is preferable that insulating layer 255b functions as an etching protective film. Alternatively, a nitride insulating film or nitride-oxide insulating film may be used as insulating layer 255a, and an oxide insulating film or oxidative nitride insulating film may be used as insulating layer 255b. In this embodiment, an example is shown in which the insulating layer 255b does not have recesses, but the insulating layer 255b may have recesses.

[0475] The pixel electrodes of the light-emitting device are electrically connected to either the source or drain of the transistor 310 by plugs 256 embedded in insulating layers 255a and 255b, a conductive layer 241 embedded in insulating layer 254, and a plug 271 embedded in insulating layer 261. The height of the upper surface of insulating layer 255b and the height of the upper surface of plug 256 are equal or approximately equal. Various conductive materials can be used for the plugs.

[0476] [Display device 100D] The display device 100D shown in Figure 25 differs from the display device 100C mainly in its transistor configuration. Note that explanations of parts similar to those of the display device 100C may be omitted.

[0477] Transistor 320 is an OS transistor in which a metal oxide (also called an oxide semiconductor) is applied to the semiconductor layer where the channel is formed.

[0478] The transistor 320 has a semiconductor layer 321, an insulating layer 323, a conductive layer 324, a pair of conductive layers 325, an insulating layer 326, and a conductive layer 327.

[0479] Substrate 331 corresponds to substrate 291 in Figures 23A and 23B. The laminated structure from substrate 331 to insulating layer 255b corresponds to layer 101 containing the transistor in Embodiment 1. An insulating substrate or a semiconductor substrate can be used as substrate 331.

[0480] An insulating layer 332 is provided on the substrate 331. The insulating layer 332 functions as a barrier insulating film that prevents impurities such as water or hydrogen from diffusing from the substrate 331 to the transistor 320, and prevents oxygen from detaching from the semiconductor layer 321 to the insulating layer 332. As the insulating layer 332, for example, a film that is less susceptible to hydrogen or oxygen diffusion than a silicon oxide film can be used, such as an aluminum oxide film, a hafnium oxide film, or a silicon nitride film.

[0481] A conductive layer 327 is provided on an insulating layer 332, and an insulating layer 326 is provided covering the conductive layer 327. The conductive layer 327 functions as the first gate electrode of the transistor 320, and a portion of the insulating layer 326 functions as the first gate insulating layer. It is preferable to use an oxide insulating film, such as a silicon oxide film, for at least the portion of the insulating layer 326 that is in contact with the semiconductor layer 321. It is preferable that the upper surface of the insulating layer 326 is flattened.

[0482] The semiconductor layer 321 is provided on the insulating layer 326. Preferably, the semiconductor layer 321 has a metal oxide (also called an oxide semiconductor) film having semiconductor properties. Details of materials suitable for use in the semiconductor layer 321 will be described later.

[0483] A pair of conductive layers 325 are provided in contact with the semiconductor layer 321 and function as source and drain electrodes.

[0484] Furthermore, an insulating layer 328 is provided covering the top and side surfaces of the pair of conductive layers 325, as well as the side surfaces of the semiconductor layer 321, and an insulating layer 264 is provided on the insulating layer 328. The insulating layer 328 functions as a barrier insulating film that prevents impurities such as water or hydrogen from diffusing into the semiconductor layer 321 from the insulating layer 264, etc., and prevents oxygen from detaching from the semiconductor layer 321. As the insulating layer 328, an insulating film similar to that of the insulating layer 332 can be used.

[0485] An opening is provided in the insulating layer 328 and the insulating layer 264 that reaches the semiconductor layer 321. Inside this opening, the insulating layer 323 and the conductive layer 324 are embedded, in contact with the sides of the insulating layer 264, the insulating layer 328, and the conductive layer 325, as well as the upper surface of the semiconductor layer 321. The conductive layer 324 functions as a second gate electrode, and the insulating layer 323 functions as a second gate insulating layer.

[0486] The upper surfaces of the conductive layer 324, the insulating layer 323, and the insulating layer 264 are flattened so that their heights are the same or approximately the same, and the insulating layer 329 and insulating layer 265 are provided covering them.

[0487] Insulating layers 264 and 265 function as interlayer insulating layers. Insulating layer 329 functions as a barrier insulating film that prevents impurities such as water or hydrogen from diffusing into the transistor 320 from insulating layer 265, etc. As insulating layer 329, an insulating film similar to that used for insulating layers 328 and 332 can be used.

[0488] A plug 274, which is electrically connected to one of the pair of conductive layers 325, is provided so as to be embedded in the insulating layers 265, 329, and 264. Here, it is preferable that the plug 274 has a conductive layer 274a that covers the sides of the openings of the insulating layers 265, 329, 264, and 328, and a part of the upper surface of the conductive layer 325, and a conductive layer 274b that is in contact with the upper surface of the conductive layer 274a. In this case, it is preferable to use a conductive material that does not easily allow hydrogen and oxygen to diffuse as the conductive layer 274a.

[0489] The configuration from the insulating layer 254 to the substrate 120 in the display device 100D is the same as that of the display device 100C.

[0490] [Display device 100E] The display device 100E shown in Figure 26 has a configuration in which a transistor 310 with a channel formed on a substrate 301 and a transistor 320 containing a metal oxide in the semiconductor layer where the channel is formed are stacked. Note that parts that are the same as those of display devices 100C and 100D may be omitted from the explanation.

[0491] An insulating layer 261 is provided covering the transistor 310, and a conductive layer 251 is provided on the insulating layer 261. An insulating layer 262 is provided covering the conductive layer 251, and a conductive layer 252 is provided on the insulating layer 262. The conductive layers 251 and 252 each function as wiring. An insulating layer 263 and an insulating layer 332 are provided covering the conductive layer 252, and a transistor 320 is provided on the insulating layer 332. An insulating layer 265 is provided covering the transistor 320, and a capacitor 240 is provided on the insulating layer 265. The capacitor 240 and the transistor 320 are electrically connected by a plug 274.

[0492] Transistor 320 can be used as a transistor constituting a pixel circuit. Transistor 310 can also be used as a transistor constituting a pixel circuit, or as a transistor constituting a drive circuit (gate line drive circuit, source line drive circuit) for driving the pixel circuit. Furthermore, transistors 310 and 320 can be used as transistors constituting various circuits such as arithmetic circuits or memory circuits.

[0493] This configuration allows for the formation of not only pixel circuits but also drive circuits directly beneath the light-emitting device, making it possible to miniaturize the display device compared to cases where the drive circuits are located around the display area.

[0494] [Display device 100F] The display device 100F shown in Figure 27 has a configuration in which transistors 310A and 310B, each with a channel formed on a semiconductor substrate, are stacked.

[0495] The display device 100F has a configuration in which a substrate 301B on which transistor 310B, capacitor 240, and each light-emitting device are provided, and a substrate 301A on which transistor 310A is provided are bonded together.

[0496] In this case, it is preferable to provide an insulating layer 345 on the lower surface of the substrate 301B. It is also preferable to provide an insulating layer 346 on top of the insulating layer 261 provided on the substrate 301A. The insulating layers 345 and 346 are insulating layers that function as protective layers and can suppress the diffusion of impurities into the substrates 301B and 301A. As insulating layers 345 and 346, inorganic insulating films that can be used for protective layers 131 and 132, or insulating layer 332 can be used.

[0497] A plug 343 is provided on the substrate 301B, penetrating both the substrate 301B and the insulating layer 345. It is preferable to provide an insulating layer 344 covering the sides of the plug 343. The insulating layer 344 functions as a protective layer and can suppress the diffusion of impurities into the substrate 301B. As the insulating layer 344, an inorganic insulating film that can be used for the protective layers 131, 132, or the insulating layer 332 can be used.

[0498] Furthermore, a conductive layer 342 is provided on the back side of the substrate 301B (the side opposite to the substrate 120 side), beneath the insulating layer 345. Preferably, the conductive layer 342 is provided so as to be embedded in the insulating layer 335. Also, preferably, the undersides of the conductive layer 342 and the insulating layer 335 are flattened. Here, the conductive layer 342 is electrically connected to the plug 343.

[0499] On the other hand, the substrate 301A has a conductive layer 341 provided on an insulating layer 346. Preferably, the conductive layer 341 is provided so as to be embedded in the insulating layer 336. Furthermore, it is preferable that the upper surfaces of the conductive layer 341 and the insulating layer 336 are flattened.

[0500] The conductive layer 341 and the conductive layer 342 are bonded together, thereby electrically connecting the substrate 301A and the substrate 301B. By improving the flatness of the surface formed by the conductive layer 342 and the insulating layer 335, and the surface formed by the conductive layer 341 and the insulating layer 336, the bonding of the conductive layer 341 and the conductive layer 342 can be improved.

[0501] It is preferable to use the same conductive material for conductive layer 341 and conductive layer 342. For example, a metal film containing an element selected from Al, Cr, Cu, Ta, Ti, Mo, and W, or a metal nitride film (titanium nitride film, molybdenum nitride film, tungsten nitride film) composed of the above elements can be used. In particular, it is preferable to use copper for conductive layer 341 and conductive layer 342. This makes it possible to apply Cu-Cu (copper-copper) direct bonding technology (a technology that achieves electrical conductivity by connecting Cu (copper) pads to each other).

[0502] [Display device 100G] Figure 27 shows an example in which Cu-Cu direct bonding technology is used to bond conductive layer 341 and conductive layer 342, but the present invention is not limited to this. As shown in Figure 28, in the display device 100G, conductive layer 341 and conductive layer 342 may be bonded via bump 347.

[0503] As shown in Figure 28, the conductive layer 341 and the conductive layer 342 can be electrically connected by providing a bump 347 between them. The bump 347 can be formed using a conductive material containing, for example, gold (Au), nickel (Ni), indium (In), or tin (Sn). Solder may also be used as the bump 347. An adhesive layer 348 may also be provided between the insulating layer 345 and the insulating layer 346. Furthermore, when the bump 347 is provided, the insulating layer 335 and the insulating layer 336 may be omitted.

[0504] This embodiment can be combined with other embodiments as appropriate.

[0505] (Embodiment 5) This embodiment describes an example of a transistor configuration that can be applied to a display device according to one aspect of the present invention. In particular, it describes a case in which a transistor containing silicon is used as the semiconductor in which the channel is formed.

[0506] One aspect of the present invention is a display device having a light-emitting device and a pixel circuit. The display device can be a full-color display device by having, for example, three types of light-emitting devices that emit red (R), green (G), or blue (B) light, respectively.

[0507] It is preferable to use transistors in which the semiconductor layer in which the channel is formed is silicon for all transistors included in the pixel circuit that drives the light-emitting device. Examples of silicon include single-crystal silicon, polycrystalline silicon, and amorphous silicon. In particular, it is preferable to use transistors in which the semiconductor layer is low-temperature polysilicon (LTPS (Low Temperature Poly Silicon)) (hereinafter also referred to as LTPS transistors). LTPS transistors have high field-effect mobility and good frequency characteristics.

[0508] By using silicon-based transistors such as LTPS transistors, circuits that need to be driven at high frequencies (e.g., source driver circuits) can be fabricated on the same board as the display unit. This simplifies the external circuits implemented in the display device, reducing component and mounting costs.

[0509] Furthermore, it is preferable to use a transistor (hereinafter also called an OS transistor) in which a metal oxide (hereinafter also called an oxide semiconductor) is used as the semiconductor in which the channel is formed. OS transistors have extremely high field-effect mobility compared to amorphous silicon. In addition, OS transistors have a remarkably small source-drain leakage current (hereinafter also called an off-current) in the off state, and can retain the charge stored in a capacitor connected in series with the transistor for a long period of time. Moreover, by applying OS transistors, the power consumption of the display device can be reduced.

[0510] By using LTPS transistors for some of the transistors in the pixel circuit and OS transistors for others, a display device with low power consumption and high driving capability can be realized. A more preferable example is to apply OS transistors to transistors that function as switches to control conduction and non-conductivity between wiring, and to apply LTPS transistors to transistors that control current.

[0511] For example, one of the transistors provided in the pixel circuit functions as a transistor for controlling the current flowing to the light-emitting device, and can also be called a drive transistor. One of the source and drain of the drive transistor is electrically connected to the pixel electrode of the light-emitting device. It is preferable to use an LTPS transistor for this drive transistor. This makes it possible to increase the current flowing to the light-emitting device in the pixel circuit.

[0512] On the other hand, another transistor provided in the pixel circuit functions as a switch to control the selection and deselection of pixels, and can also be called a selection transistor. The gate of the selection transistor is electrically connected to the gate line, and one of the source and drain is electrically connected to the source line (signal line). It is preferable to use an OS transistor for the selection transistor. This makes it possible to maintain the gradation of pixels even when the frame frequency is significantly reduced (e.g., 1 fps or less), and thus power consumption can be reduced by stopping the driver when displaying still images.

[0513] Below, we will explain more specific configuration examples with reference to the drawings.

[0514] [Example of display device configuration 2] Figure 29A shows a block diagram of the display device 10. The display device 10 includes a display unit 11, a drive circuit unit 12, a drive circuit unit 13, and the like.

[0515] The display unit 11 has a plurality of pixels 30 arranged in a matrix. Each pixel 30 has sub-pixels 21R, 21G, and 21B. Each of the sub-pixels 21R, 21G, and 21B has a light-emitting device that functions as a display device and a coloring layer.

[0516] Pixel 30 is electrically connected to wiring GL, wiring SLR, wiring SLG, and wiring SLB. Wiring SLR, wiring SLG, and wiring SLB are each electrically connected to the drive circuit unit 12. Wiring GL is electrically connected to the drive circuit unit 13. The drive circuit unit 12 functions as a source line drive circuit (also called a source driver), and the drive circuit unit 13 functions as a gate line drive circuit (also called a gate driver). Wiring GL functions as a gate line, and wiring SLR, wiring SLG, and wiring SLB each function as source lines.

[0517] Sub-pixel 21R has a light-emitting device that emits white light and a colored layer that transmits red light. Sub-pixel 21G has a light-emitting device that emits white light and a colored layer that transmits green light. Sub-pixel 21B has a light-emitting device that emits white light and a colored layer that transmits blue light. As a result, the display device 10 can display in full color. Note that pixel 30 may have sub-pixels that emit light of other colors. For example, in addition to the three sub-pixels described above, pixel 30 may have a sub-pixel with a light-emitting device that emits white light, or a sub-pixel that emits yellow light, etc.

[0518] Wiring GL is electrically connected to sub-pixels 21R, 21G, and 21B, which are arranged in the row direction (the direction in which wiring GL extends). Wirings SLR, SLG, and SLB are electrically connected to sub-pixels 21R, 21G, or 21B (not shown), which are arranged in the column direction (the direction in which wiring SLR, etc. extends).

[0519] [Example of pixel circuit configuration] Figure 29B shows an example of a circuit diagram for a pixel 21 that can be applied to the sub-pixels 21R, 21G, and 21B described above. Pixel 21 has transistors M1, M2, M3, capacitor C1, and light-emitting device EL. Wiring GL and wiring SL are electrically connected to pixel 21. Wiring SL corresponds to one of the wirings SLR, SLG, and SLB shown in Figure 29A.

[0520] Transistor M1 has its gate electrically connected to wiring GL, one of its source and drain electrically connected to wiring SL, and the other of its source and drain electrically connected to one electrode of capacitor C1 and the gate of transistor M2. Transistor M2 has one of its source and drain electrically connected to wiring AL, and the other of its source and drain electrically connected to one electrode of light-emitting device EL, the other electrode of capacitor C1, and one of its source and drain. Transistor M3 has its gate electrically connected to wiring GL, and the other of its source and drain electrically connected to wiring RL. Light-emitting device EL has its other electrode electrically connected to wiring CL.

[0521] A data potential D is applied to wiring SL. A selection signal is applied to wiring GL. This selection signal includes a potential that makes the transistor conduct and a potential that makes it non-conductive.

[0522] A reset potential is applied to wiring RL. An anode potential is applied to wiring AL. A cathode potential is applied to wiring CL. In pixel 21, the anode potential is set to a potential higher than the cathode potential. The reset potential applied to wiring RL can be set to a potential such that the potential difference between the reset potential and the cathode potential is smaller than the threshold voltage of the light-emitting device EL. The reset potential can be set to a potential higher than the cathode potential, the same as the cathode potential, or lower than the cathode potential.

[0523] Transistors M1 and M3 function as switches. Transistor M2 functions as a transistor for controlling the current flowing to the light-emitting device EL. For example, it can be said that transistor M1 functions as a selector transistor and transistor M2 functions as a drive transistor.

[0524] Here, it is preferable to apply LTPS transistors to all of transistors M1 through M3. Alternatively, it is preferable to apply OS transistors to transistors M1 and M3 and an LTPS transistor to transistor M2.

[0525] Alternatively, OS transistors may be applied to all of transistors M1 through M3. In this case, one or more of the transistors in the drive circuit unit 12 and the drive circuit unit 13 may be LTPS transistors, and the other transistors may be OS transistors. For example, OS transistors may be applied to the transistors provided in the display unit 11, and LTPS transistors may be applied to the transistors provided in the drive circuit unit 12 and the drive circuit unit 13.

[0526] As an OS transistor, a transistor using an oxide semiconductor in the semiconductor layer where the channel is formed can be used. The semiconductor layer preferably contains, for example, indium, M (where M is one or more selected from gallium, aluminum, silicon, boron, yttrium, tin, copper, vanadium, beryllium, titanium, iron, nickel, germanium, zirconium, molybdenum, lanthanum, cerium, neodymium, hafnium, tantalum, tungsten, and magnesium), and zinc. In particular, it is preferable that M is one or more selected from aluminum, gallium, yttrium, and tin. In particular, it is preferable to use an oxide containing indium, gallium, and zinc (also written as IGZO) as the semiconductor layer of the OS transistor. Alternatively, it is preferable to use an oxide containing indium, tin, and zinc. Alternatively, it is preferable to use an oxide containing indium, gallium, tin, and zinc.

[0527] Transistors using oxide semiconductors, which have a wider bandgap and lower carrier density than silicon, can achieve extremely low off-currents. Therefore, this low off-current allows the charge stored in a capacitor connected in series with the transistor to be retained for extended periods. For this reason, it is preferable to use transistors made of oxide semiconductors for transistors M1 and M3, which are connected in series with capacitor C1. By using transistors with oxide semiconductors as transistors M1 and M3, it is possible to prevent the charge held in capacitor C1 from leaking through transistor M1 or M3. Furthermore, because the charge held in capacitor C1 can be retained for extended periods, it becomes possible to display still images for extended periods without rewriting the data in pixel 21.

[0528] Note that in Figure 29B, the transistor is shown as an n-channel type transistor, but a p-channel type transistor can also be used.

[0529] Furthermore, it is preferable that each transistor in the pixel 21 be formed in a row on the same substrate.

[0530] As the transistor in pixel 21, a transistor having a pair of gates that overlap across a semiconductor layer can be applied.

[0531] In a transistor having a pair of gates, configuring the pair of gates to be electrically connected to each other and given the same potential offers advantages such as increased on-current and improved saturation characteristics. Alternatively, one of the pair of gates may be given a potential that controls the transistor's threshold voltage. Furthermore, providing a constant potential to one of the pair of gates can improve the stability of the transistor's electrical characteristics. For example, one of the transistor's gates may be electrically connected to a wiring to which a constant potential is provided, or it may be electrically connected to its own source or drain.

[0532] The pixel 21 shown in Figure 29C is an example where transistors M1 and M3 each have a pair of gates. The pair of gates of transistors M1 and M3 are electrically connected. This configuration shortens the data writing time to the pixel 21.

[0533] The pixel 21 shown in Figure 29D is an example in which a transistor with a pair of gates is applied to transistor M2, in addition to transistors M1 and M3. In transistor M2, the pair of gates are electrically connected. By applying such a transistor to transistor M2, the saturation characteristics are improved, making it easier to control the luminescence brightness of the light-emitting device EL and improving the display quality.

[0534] [Example of transistor configuration] The following describes examples of transistor cross-sectional configurations that can be applied to the above-mentioned display device.

[0535] [Configuration Example 1] Figure 30A is a cross-sectional view including transistor 410.

[0536] Transistor 410 is provided on substrate 401 and is a transistor in which polycrystalline silicon is applied as the semiconductor layer. For example, transistor 410 corresponds to transistor M2 of pixel 21. That is, Figure 30A is an example in which one of the source and drain of transistor 410 is electrically connected to the conductive layer 431 of the light-emitting device.

[0537] The transistor 410 has a semiconductor layer 411, an insulating layer 412, a conductive layer 413, etc. The semiconductor layer 411 has a channel-forming region 411i and a low-resistance region 411n. The semiconductor layer 411 is made of silicon. Preferably, the semiconductor layer 411 is made of polycrystalline silicon. A portion of the insulating layer 412 functions as a gate insulating layer. A portion of the conductive layer 413 functions as a gate electrode.

[0538] Furthermore, the semiconductor layer 411 may also be configured to include a metal oxide (also called an oxide semiconductor) that exhibits semiconductor properties. In this case, the transistor 410 can be called an OS transistor.

[0539] The low-resistance region 411n is a region containing impurity elements. For example, if transistor 410 is an n-channel type transistor, phosphorus, arsenic, etc., can be added to the low-resistance region 411n. On the other hand, if it is a p-channel type transistor, boron, aluminum, etc., can be added to the low-resistance region 411n. Furthermore, in order to control the threshold voltage of transistor 410, the aforementioned impurities may also be added to the channel formation region 411i.

[0540] An insulating layer 421 is provided on the substrate 401. The semiconductor layer 411 is provided on the insulating layer 421. The insulating layer 412 is provided covering the semiconductor layer 411 and the insulating layer 421. The conductive layer 413 is provided on the insulating layer 412 in a position overlapping with the semiconductor layer 411.

[0541] Furthermore, an insulating layer 422 is provided covering the conductive layer 413 and the insulating layer 412. Conductive layers 414a and 414b are provided on the insulating layer 422. Conductive layers 414a and 414b are electrically connected to the low-resistance region 411n at openings provided in the insulating layers 422 and 412. A portion of the conductive layer 414a functions as one of the source electrode and drain electrode, and a portion of the conductive layer 414b functions as the other of the source electrode and drain electrode. In addition, an insulating layer 423 is provided covering the conductive layer 414a, conductive layer 414b, and insulating layer 422.

[0542] A conductive layer 431, which functions as a pixel electrode, is provided on the insulating layer 423. The conductive layer 431 is provided on the insulating layer 423 and is electrically connected to the conductive layer 414b at an opening provided in the insulating layer 423. Although not shown here, an EL layer and a common electrode can be laminated on the conductive layer 431.

[0543] [Configuration Example 2] Figure 30B shows a transistor 410a having a pair of gate electrodes. The transistor 410a shown in Figure 30B differs from that in Figure 30A mainly in that it has a conductive layer 415 and an insulating layer 416.

[0544] The conductive layer 415 is provided on the insulating layer 421. Furthermore, an insulating layer 416 is provided covering the conductive layer 415 and the insulating layer 421. The semiconductor layer 411 is provided such that at least the channel-forming region 411i overlaps with the conductive layer 415 via the insulating layer 416.

[0545] In the transistor 410a shown in Figure 30B, a portion of the conductive layer 413 functions as a first gate electrode, and a portion of the conductive layer 415 functions as a second gate electrode. At the same time, a portion of the insulating layer 412 functions as a first gate insulating layer, and a portion of the insulating layer 416 functions as a second gate insulating layer.

[0546] Here, when electrically connecting the first gate electrode and the second gate electrode, the conductive layer 413 and the conductive layer 415 may be electrically connected through openings provided in the insulating layer 412 and the insulating layer 416 in a region not shown. Also, when electrically connecting the second gate electrode to the source or drain, the conductive layer 414a or conductive layer 414b and the conductive layer 415 may be electrically connected through openings provided in the insulating layer 422, the insulating layer 412, and the insulating layer 416 in a region not shown.

[0547] When LTPS transistors are applied to all transistors constituting pixel 21, transistor 410 as exemplified in Figure 30A, or transistor 410a as exemplified in Figure 30B, can be applied. In this case, transistor 410a may be used for all transistors constituting pixel 21, transistor 410 may be applied to all transistors, or transistor 410a and transistor 410 may be used in combination.

[0548] [Configuration Example 3] The following describes an example of a configuration that includes both transistors with silicon semiconductor layers and transistors with metal oxide semiconductor layers.

[0549] Figure 30C shows a schematic cross-sectional view including transistors 410a and 450.

[0550] For transistor 410a, the above configuration example 1 can be used. Although an example using transistor 410a is shown here, a configuration with transistor 410 and transistor 450 is also possible, or a configuration with all of transistors 410, 410a, and 450 is also possible.

[0551] Transistor 450 is a transistor in which a metal oxide is applied to the semiconductor layer. The configuration shown in Figure 30C is an example in which, for example, transistor 450 corresponds to transistor M1 of pixel 21 and transistor 410a corresponds to transistor M2. That is, Figure 30C is an example in which one of the source and drain of transistor 410a is electrically connected to the conductive layer 431.

[0552] Figure 30C also shows an example where transistor 450 has a pair of gates.

[0553] The transistor 450 has a conductive layer 455, an insulating layer 422, a semiconductor layer 451, an insulating layer 452, a conductive layer 453, etc. A portion of the conductive layer 453 functions as the first gate of the transistor 450, and a portion of the conductive layer 455 functions as the second gate of the transistor 450. At this time, a portion of the insulating layer 452 functions as the first gate insulating layer of the transistor 450, and a portion of the insulating layer 422 functions as the second gate insulating layer of the transistor 450.

[0554] The conductive layer 455 is provided on the insulating layer 412. The insulating layer 422 covers the conductive layer 455. The semiconductor layer 451 is provided on the insulating layer 422. The insulating layer 452 covers the semiconductor layer 451 and the insulating layer 422. The conductive layer 453 is provided on the insulating layer 452 and has a region that overlaps with the semiconductor layer 451 and the conductive layer 455.

[0555] Furthermore, an insulating layer 426 is provided covering the insulating layer 452 and the conductive layer 453. Conductive layers 454a and 454b are provided on the insulating layer 426. Conductive layers 454a and 454b are electrically connected to the semiconductor layer 451 at openings provided in the insulating layer 426 and the insulating layer 452. A portion of the conductive layer 454a functions as one of the source electrode and drain electrode, and a portion of the conductive layer 454b functions as the other of the source electrode and drain electrode. In addition, an insulating layer 423 is provided covering the conductive layer 454a, the conductive layer 454b, and the insulating layer 426.

[0556] Here, it is preferable that the conductive layers 414a and 414b, which are electrically connected to the transistor 410a, are formed by processing the same conductive film as conductive layers 454a and 454b. Figure 30C shows a configuration in which conductive layers 414a, 414b, 454a, and 454b are formed on the same plane (i.e., in contact with the upper surface of the insulating layer 426) and contain the same metal element. In this case, conductive layers 414a and 414b are electrically connected to the low-resistance region 411n through openings provided in the insulating layer 426, insulating layer 452, insulating layer 422, and insulating layer 412. This is preferable because it simplifies the manufacturing process.

[0557] Furthermore, it is preferable that the conductive layer 413, which functions as the first gate electrode of transistor 410a, and the conductive layer 455, which functions as the second gate electrode of transistor 450, are formed by processing the same conductive film. Figure 30C shows a configuration in which the conductive layer 413 and the conductive layer 455 are formed on the same plane (i.e., in contact with the upper surface of the insulating layer 412) and contain the same metal element. This is preferable because it simplifies the manufacturing process.

[0558] In Figure 30C, the insulating layer 452, which functions as the first gate insulating layer of the transistor 450, is configured to cover the edge of the semiconductor layer 451. However, as shown in Figure 30D, the insulating layer 452 may be processed so that its upper surface shape matches or is approximately the same as that of the conductive layer 453.

[0559] In this specification, "approximately matching top surface shapes" means that at least a portion of the contours overlap between stacked layers. For example, this includes cases where the upper and lower layers are processed with the same mask pattern, or partially with the same mask pattern. However, strictly speaking, the contours may not overlap, and the upper layer may be located inside the lower layer, or the upper layer may be located outside the lower layer; in this case, too, it is said that the "top surface shapes are approximately matching."

[0560] In this example, transistor 410a corresponds to transistor M2 and is electrically connected to the pixel electrode, but this is not the only example. For example, transistor 450 or transistor 450a may correspond to transistor M2. In this case, transistor 410a corresponds to transistor M1, transistor M3, or another transistor.

[0561] This embodiment can be combined with other embodiments as appropriate.

[0562] (Embodiment 6) This embodiment describes metal oxides (also called oxide semiconductors) that can be used in the OS transistor described in the above embodiment.

[0563] The metal oxide preferably contains at least indium or zinc. It is particularly preferable that it contains indium and zinc. In addition, it is preferable that it contains aluminum, gallium, yttrium, tin, etc. It may also contain one or more selected from boron, silicon, titanium, iron, nickel, germanium, zirconium, molybdenum, lanthanum, cerium, neodymium, hafnium, tantalum, tungsten, magnesium, cobalt, etc.

[0564] Furthermore, metal oxides can be formed by methods such as sputtering, chemical vapor deposition (CVD) methods including metal-organic chemical vapor deposition (MOCVD), or atomic layer deposition (ALD).

[0565] <Classification of crystal structures> Examples of crystalline structures for oxide semiconductors include amorphous (including completely amorphous), CAAC (c-axis-aligned crystalline), nc (nanocrystalline), CAC (cloud-aligned composite), single crystal, and polycrystal.

[0566] The crystal structure of a film or substrate can be evaluated using X-ray diffraction (XRD) spectroscopy. For example, it can be evaluated using the XRD spectrum obtained by GIXD (Grazing-Incidence XRD) measurement. The GIXD method is also known as the thin-film method or the Seemann-Bohlin method.

[0567] For example, in a quartz glass substrate, the peak shape of the XRD spectrum is nearly symmetrical. On the other hand, in an IGZO film with a crystalline structure, the peak shape of the XRD spectrum is asymmetrical. The asymmetrical shape of the XRD spectrum peak clearly indicates the presence of crystals in the film or substrate. In other words, if the peak shape of the XRD spectrum is not symmetrical, the film or substrate cannot be said to be in an amorphous state.

[0568] Furthermore, the crystalline structure of a film or substrate can be evaluated by the diffraction pattern (also called the nano-beam electron diffraction pattern) observed using nano-beam electron diffraction (NBED). For example, a halo is observed in the diffraction pattern of a quartz glass substrate, confirming that the quartz glass is in an amorphous state. However, in the diffraction pattern of an IGZO film deposited at room temperature, a spot-like pattern is observed instead of a halo. Therefore, it is presumed that an IGZO film deposited at room temperature is in an intermediate state, neither crystalline nor amorphous, and cannot be concluded to be in an amorphous state.

[0569] <<Oxide semiconductor structure>> It should be noted that oxide semiconductors may be classified differently from those described above when considering their structure. For example, oxide semiconductors can be divided into single-crystal oxide semiconductors and other non-single-crystal oxide semiconductors. Examples of non-single-crystal oxide semiconductors include the aforementioned CAAC-OS and nc-OS. Non-single-crystal oxide semiconductors also include polycrystalline oxide semiconductors, pseudo-amorphous oxide semiconductors (a-like OS), and amorphous oxide semiconductors.

[0570] Here, we will explain the details of the CAAC-OS, nc-OS, and a-like OS mentioned above.

[0571] [CAAC-OS] CAAC-OS is an oxide semiconductor having multiple crystalline regions, the c-axis of which is oriented in a specific direction. This specific direction is the thickness direction of the CAAC-OS film, the normal direction to the surface on which the CAAC-OS film is formed, or the normal direction to the surface of the CAAC-OS film. A crystalline region is a region with periodic atomic arrangement. If we consider the atomic arrangement as a lattice arrangement, then a crystalline region is also a region with a aligned lattice arrangement. Furthermore, CAAC-OS has regions where multiple crystalline regions are connected in the ab-plane direction, and these regions may exhibit distortion. Distortion refers to a point in the connected region where the orientation of the lattice arrangement changes between a region with a aligned lattice arrangement and another region with a aligned lattice arrangement. In short, CAAC-OS is an oxide semiconductor that is c-axis oriented and does not exhibit clear orientation in the ab-plane direction.

[0572] Each of the multiple crystalline regions described above is composed of one or more minute crystals (crystals with a maximum diameter of less than 10 nm). When a crystalline region is composed of a single minute crystal, the maximum diameter of that crystalline region is less than 10 nm. When a crystalline region is composed of many minute crystals, the size of that crystalline region may be around several tens of nanometers.

[0573] Furthermore, in In-M-Zn oxides (where element M is one or more elements selected from aluminum, gallium, yttrium, tin, titanium, etc.), CAAC-OS tends to have a layered crystalline structure (also called a layered structure) consisting of layers containing indium (In) and oxygen (hereinafter referred to as the In layer) and layers containing element M, zinc (Zn), and oxygen (hereinafter referred to as the (M,Zn) layer). Note that indium and element M are mutually substitutable. Therefore, the (M,Zn) layer may contain indium. Also, the In layer may contain element M. Also, the In layer may contain Zn. This layered structure can be observed, for example, as a lattice image in high-resolution TEM (Transmission Electron Microscope) images.

[0574] When structural analysis of a CAAC-OS film is performed using an XRD instrument, for example, out-of-plane XRD measurements using θ / 2θ scanning show a peak indicating c-axis orientation at 2θ = 31° or nearby. Note that the position of the c-axis orientation peak (value of 2θ) may vary depending on the type and composition of the metal elements constituting the CAAC-OS.

[0575] Furthermore, for example, multiple bright spots are observed in the electron diffraction pattern of a CAAC-OS film. These spots are observed at point-symmetric positions with respect to the incident electron beam spot (also called the direct spot) that passed through the sample.

[0576] When the crystal region is observed from the specific direction described above, the lattice arrangement within that crystal region is based on a hexagonal lattice, but the unit cell is not necessarily a regular hexagon and may be non-regular hexagonal. Furthermore, the strain may have lattice arrangements such as pentagons or heptagons. Moreover, in CAAC-OS, clear grain boundaries cannot be observed even near the strain. In other words, it can be seen that the formation of grain boundaries is suppressed by the strain in the lattice arrangement. This is thought to be because CAAC-OS can tolerate strain due to the fact that the arrangement of oxygen atoms is not dense in the ab-plane direction, and the bond distance between atoms changes due to the substitution of metal atoms.

[0577] A crystal structure in which clear grain boundaries are observed is called a polycrystal. Grain boundaries act as recombination centers, trapping carriers and potentially causing a decrease in transistor on-current and field-effect mobility. Therefore, CAAC-OS, in which clear grain boundaries are not observed, is one of the crystalline oxides with a suitable crystal structure for the semiconductor layer of a transistor. In addition, a structure containing Zn is preferred for the composition of CAAC-OS. For example, In-Zn oxide and In-Ga-Zn oxide are preferred because they suppress the generation of grain boundaries more than In oxide.

[0578] CAAC-OS is an oxide semiconductor with high crystallinity and no clearly defined grain boundaries. Therefore, CAAC-OS is less susceptible to the decrease in electron mobility caused by grain boundaries. Furthermore, since the crystallinity of oxide semiconductors can decrease due to the inclusion of impurities and the generation of defects, CAAC-OS can be said to be an oxide semiconductor with few impurities and defects (such as oxygen vacancies). Consequently, oxide semiconductors containing CAAC-OS have stable physical properties. Therefore, oxide semiconductors containing CAAC-OS are heat resistant and highly reliable. In addition, CAAC-OS is stable even at high temperatures (so-called thermal budget) during the manufacturing process. Therefore, using CAAC-OS in OS transistors allows for greater flexibility in the manufacturing process.

[0579] [nc-OS] nc-OS exhibits periodicity in atomic arrangement in minute regions (e.g., regions between 1 nm and 10 nm, particularly between 1 nm and 3 nm). In other words, nc-OS contains minute crystals. These minute crystals are also called nanocrystals because their size is, for example, between 1 nm and 10 nm, particularly between 1 nm and 3 nm. Furthermore, nc-OS shows no regularity in crystal orientation between different nanocrystals. Therefore, no orientation is observed throughout the film. Consequently, depending on the analytical method, nc-OS may be indistinguishable from a-like OS or amorphous oxide semiconductors. For example, when structural analysis of an nc-OS film is performed using an XRD instrument, no peaks indicating crystallinity are detected in out-of-plane XRD measurements using θ / 2θ scanning. Also, when electron diffraction (also called limited-field electron diffraction) is performed on an nc-OS film using an electron beam with a probe diameter larger than that of the nanocrystals (e.g., 50 nm or larger), a diffraction pattern resembling a halo pattern is observed. On the other hand, when electron diffraction (also called nanobeam electron diffraction) is performed on an nc-OS film using an electron beam with a probe diameter close to or smaller than the size of the nanocrystal (for example, 1 nm to 30 nm), an electron diffraction pattern may be obtained in which multiple spots are observed within a ring-shaped region centered on a direct spot.

[0580] [a-like OS] a-like OS is an oxide semiconductor having a structure between nc-OS and amorphous oxide semiconductors. a-like OS has porous or low-density regions. That is, a-like OS has lower crystallinity compared to nc-OS and CAAC-OS. Also, a-like OS has a higher hydrogen concentration in the film compared to nc-OS and CAAC-OS.

[0581] <<Oxide Semiconductor Composition>> Next, we will explain the details of CAC-OS mentioned above. Note that CAC-OS refers to the material composition.

[0582] [CAC-OS] CAC-OS is a material composition in which, for example, the elements constituting the metal oxide are unevenly distributed in sizes of 0.5 nm to 10 nm, preferably 1 nm to 3 nm, or close to that size. In the following, a state in which one or more metal elements are unevenly distributed in a metal oxide, and the regions containing these metal elements are mixed in sizes of 0.5 nm to 10 nm, preferably 1 nm to 3 nm, or close to that size, is also referred to as a mosaic or patchy state.

[0583] Furthermore, CAC-OS is a composite metal oxide having a mosaic-like structure formed by the separation of the material into a first region and a second region, with the first region distributed within the film (hereinafter also referred to as a cloud-like structure). In other words, CAC-OS is a composite metal oxide having a structure in which the first region and the second region are mixed.

[0584] Here, the atomic ratios of In, Ga, and Zn to the metal elements constituting the CAC-OS in In-Ga-Zn oxide are denoted as [In], [Ga], and [Zn], respectively. For example, in the CAC-OS of In-Ga-Zn oxide, the first region is the region where [In] is greater than the [In] in the composition of the CAC-OS film. The second region is the region where [Ga] is greater than the [Ga] in the composition of the CAC-OS film. Alternatively, for example, the first region is the region where [In] is greater than the [In] in the second region, and [Ga] is smaller than the [Ga] in the second region. The second region is the region where [Ga] is greater than the [Ga] in the first region, and [In] is smaller than the [In] in the first region.

[0585] Specifically, the first region described above is a region whose main components are indium oxide, indium zinc oxide, etc. The second region described above is a region whose main components are gallium oxide, gallium zinc oxide, etc. In other words, the first region can be rephrased as a region whose main component is In. Similarly, the second region can be rephrased as a region whose main component is Ga.

[0586] Furthermore, a clear boundary may not be observed between the first region and the second region described above.

[0587] Furthermore, CAC-OS in In-Ga-Zn oxide refers to a material composition containing In, Ga, Zn, and O, in which regions with Ga as the main component and regions with In as the main component are arranged in a mosaic-like manner, with these regions existing randomly. Therefore, it is presumed that CAC-OS has a structure in which metal elements are unevenly distributed.

[0588] CAC-OS can be formed, for example, by sputtering under conditions where the substrate is not heated. When forming CAC-OS by sputtering, one or more gases selected from inert gases (typically argon), oxygen gas, and nitrogen gas may be used as the film-forming gas. Furthermore, it is preferable that the ratio of the oxygen gas flow rate to the total flow rate of the film-forming gas during film formation be as low as possible. For example, it is preferable that the ratio of the oxygen gas flow rate to the total flow rate of the film-forming gas during film formation be 0% or more and less than 30%, preferably 0% or more and 10% or less.

[0589] Furthermore, for example, in the case of CAC-OS in In-Ga-Zn oxide, EDX mapping obtained using energy dispersive X-ray spectroscopy (EDX) confirms that it has a structure in which regions mainly composed of In (first region) and regions mainly composed of Ga (second region) are unevenly distributed and mixed.

[0590] Here, the first region is a region with higher conductivity compared to the second region. In other words, the conductivity of the metal oxide is exhibited when carriers flow through the first region. Therefore, a high field-effect mobility (μ) can be achieved when the first region is distributed in a cloud-like manner within the metal oxide.

[0591] On the other hand, the second region is a region with higher insulating properties compared to the first region. In other words, the distribution of the second region within the metal oxide can suppress leakage current.

[0592] Therefore, when CAC-OS is used in a transistor, the conductivity due to the first region and the insulation due to the second region work complementaryly to give CAC-OS a switching function (on / off function). In other words, CAC-OS has conductive function in part of the material, insulating function in part of the material, and semiconductor function as a whole. By separating the conductive function and the insulating function, both functions can be maximized. Therefore, by using CAC-OS in a transistor, a high on-current (I on ), high field-effect mobility (μ), and good switching operation can be achieved.

[0593] Furthermore, transistors using CAC-OS offer high reliability. Therefore, CAC-OS is ideal for various semiconductor devices, including display devices.

[0594] Oxide semiconductors can take on diverse structures, each possessing different properties. One embodiment of the present invention may include two or more of the following: amorphous oxide semiconductors, polycrystalline oxide semiconductors, a-like OS, CAC-OS, nc-OS, and CAAC-OS.

[0595] <Transistors containing oxide semiconductors> Next, we will explain the case where the above oxide semiconductor is used in a transistor.

[0596] By using the above-mentioned oxide semiconductor in transistors, it is possible to realize transistors with high field-effect mobility. Furthermore, it is possible to realize highly reliable transistors.

[0597] It is preferable to use an oxide semiconductor with a low carrier concentration for the transistor. For example, the carrier concentration of an oxide semiconductor is 1 × 10⁻⁶. 17 cm -3 The following is preferably 1 × 10 15 cm -3 More preferably 1 × 10 13 cm -3More preferably 1 × 10 11 cm -3 More preferably 1 × 10 10 cm -3 It is less than 1 × 10 -9 cm -3 This concludes the explanation. Furthermore, when lowering the carrier concentration of an oxide semiconductor film, the impurity concentration in the oxide semiconductor film should be lowered to reduce the defect level density. In this specification, a low impurity concentration and low defect level density are referred to as high-purity intrinsic or substantially high-purity intrinsic. Note that oxide semiconductors with low carrier concentrations are sometimes referred to as high-purity intrinsic or substantially high-purity intrinsic oxide semiconductors.

[0598] Furthermore, oxide semiconductor films that are highly intrinsic or substantially highly intrinsic may have a low trap level density due to their low defect level density.

[0599] Furthermore, charges trapped in the trap levels of oxide semiconductors can take a long time to disappear, sometimes behaving like fixed charges. Therefore, transistors in which channel formation regions are formed in oxide semiconductors with a high trap level density may exhibit unstable electrical properties.

[0600] Therefore, reducing the impurity concentration in the oxide semiconductor is effective in stabilizing the electrical characteristics of the transistor. Furthermore, in order to reduce the impurity concentration in the oxide semiconductor, it is preferable to also reduce the impurity concentration in adjacent films. Examples of impurities include hydrogen, nitrogen, alkali metals, alkaline earth metals, iron, nickel, and silicon.

[0601] <Impurities> Here, we will explain the effects of various impurities in oxide semiconductors.

[0602] In oxide semiconductors, the presence of silicon or carbon, which are Group 14 elements, leads to the formation of defect levels in the oxide semiconductor. Therefore, the concentration of silicon or carbon in the oxide semiconductor and the concentration of silicon or carbon near the interface with the oxide semiconductor (concentration obtained by secondary ion mass spectrometry (SIMS)) are compared by 2 × 10⁻⁶. 18 atoms / cm 3 The following is preferably 2 × 10 17 atoms / cm 3 The following applies:

[0603] Furthermore, if an oxide semiconductor contains alkali metals or alkaline earth metals, it may form defect levels and generate carriers. Therefore, transistors using oxide semiconductors containing alkali metals or alkaline earth metals tend to exhibit normally-on characteristics. For this reason, the concentration of alkali metals or alkaline earth metals in the oxide semiconductor obtained by SIMS should be set to 1 × 10⁻⁶. 18 atoms / cm 3 The following is preferably 2 × 10 16 atoms / cm 3 Do the following:

[0604] Furthermore, in oxide semiconductors, the presence of nitrogen generates electrons, which act as carriers, increasing the carrier concentration and making it easier for the semiconductor to become n-type. As a result, transistors using oxide semiconductors containing nitrogen tend to exhibit normally-on characteristics. Alternatively, the presence of nitrogen in oxide semiconductors can lead to the formation of trap levels. As a result, the electrical properties of the transistor may become unstable. For this reason, the nitrogen concentration in oxide semiconductors obtained by SIMS should be set to 5 × 10⁻⁶. 19 atoms / cm 3 Less than 5 × 10 18 atoms / cm 3 More preferably 1 × 10 18 atoms / cm 3 More preferably 5 × 10 17 atoms / cm 3 Do the following:

[0605] Furthermore, hydrogen contained in oxide semiconductors can react with oxygen bonded to metal atoms to form water, potentially creating oxygen vacancies. Hydrogen can then fill these vacancies, generating electrons, which act as carriers. Additionally, some of the hydrogen can combine with oxygen bonded to metal atoms to generate electrons. Therefore, transistors using oxide semiconductors containing hydrogen tend to exhibit normally-on characteristics. For this reason, it is preferable to reduce the hydrogen content in oxide semiconductors as much as possible. Specifically, in oxide semiconductors, the hydrogen concentration obtained by SIMS should be 1 × 10⁻⁶. 20 atoms / cm 3 Less than 1 × 10 19 atoms / cm 3 Less than 5x10 18 atoms / cm 3 Less than 1 × 10 18 atoms / cm 3 Make it less than.

[0606] By using an oxide semiconductor with sufficiently reduced impurities in the channel formation region of a transistor, stable electrical characteristics can be provided.

[0607] This embodiment can be combined with other embodiments as appropriate.

[0608] (Embodiment 7) In this embodiment, an electronic device according to one aspect of the present invention will be described with reference to Figures 31 to 35.

[0609] The electronic device of this embodiment has a display device according to one aspect of the present invention in its display unit. The display device according to one aspect of the present invention is easily made high-definition and high-resolution. Therefore, it can be used in the display units of various electronic devices.

[0610] Examples of electronic devices include television sets, desktop or notebook personal computers, computer monitors, digital signage, and large game machines such as pachinko machines, as well as other electronic devices with relatively large screens, digital cameras, digital video cameras, digital photo frames, mobile phones, portable game consoles, personal digital assistants, and audio playback devices.

[0611] In particular, a display device according to one aspect of the present invention can be used suitably in electronic devices having a relatively small display area because it can increase the resolution. Examples of such electronic devices include wristwatch-type and bracelet-type information terminals (wearable devices), as well as wearable devices that can be worn on the head, such as head-mounted displays for VR, glasses-type devices for AR, and devices for MR (Mixed Reality).

[0612] A display device according to one aspect of the present invention preferably has an extremely high resolution such as HD (1280 x 720 pixels), FHD (1920 x 1080 pixels), WQHD (2560 x 1440 pixels), WQXGA (2560 x 1600 pixels), 4K (3840 x 2160 pixels), or 8K (7680 x 4320 pixels). In particular, a resolution of 4K, 8K, or higher is preferred. Furthermore, the pixel density (resolution) of the display device according to one aspect of the present invention is preferably 100 ppi or more, preferably 300 ppi or more, more preferably 500 ppi or more, more preferably 1000 ppi or more, more preferably 2000 ppi or more, more preferably 3000 ppi or more, more preferably 5000 ppi or more, and even more preferably 7000 ppi or more. By using a display device that has either high resolution or high detail, or both, it becomes possible to further enhance the sense of presence and depth in personal electronic devices such as portable or home-use devices. Furthermore, there are no particular limitations on the screen ratio (aspect ratio) of the display device according to one embodiment of the present invention. For example, the display device can support various screen ratios such as 1:1 (square), 4:3, 16:9, and 16:10.

[0613] The electronic device of this embodiment may have sensors (including those with the function of measuring force, displacement, position, velocity, acceleration, angular velocity, rotational speed, distance, light, liquid, magnetism, temperature, chemical substances, sound, time, hardness, electric field, current, voltage, power, radiation, flow rate, humidity, gradient, vibration, odor, or infrared radiation).

[0614] The electronic device of this embodiment can have a variety of functions. For example, it can have a function to display various information (still images, videos, text images, etc.) on the display unit, a touch panel function, a function to display a calendar, date or time, a function to execute various software (programs), a wireless communication function, a function to read programs or data recorded on a recording medium, and so on.

[0615] Figures 31A, 31B, 32A, and 32B illustrate an example of a wearable device that can be worn on the head. These wearable devices have either or both the function of displaying AR content and / or the function of displaying VR content. In addition to AR and VR, these wearable devices may also have the function of displaying SR or MR content. By having electronic devices that can display AR, VR, SR (Substitutional Reality), MR, etc., it is possible to enhance the user's sense of immersion.

[0616] The electronic device 700A shown in Figure 31A and the electronic device 700B shown in Figure 31B each include a pair of display panels 751, a pair of housings 721, a communication unit (not shown), a pair of mounting units 723, a control unit (not shown), an imaging unit (not shown), a pair of optical members 753, a frame 757, and a pair of nose pads 758.

[0617] A display device according to one aspect of the present invention can be applied to the display panel 751. Therefore, an electronic device capable of displaying extremely high resolution can be created.

[0618] Electronic devices 700A and 700B can project an image displayed on the display panel 751 onto the display area 756 of the optical element 753. Because the optical element 753 is translucent, the user can see the image displayed on the display area superimposed on the transmitted image visible through the optical element 753. Therefore, electronic devices 700A and 700B are electronic devices capable of AR display.

[0619] Electronic devices 700A and 700B may be equipped with cameras capable of capturing images of the area in front of them as imaging units. Furthermore, electronic devices 700A and 700B may each be equipped with acceleration sensors such as gyro sensors to detect the orientation of the user's head and display an image corresponding to that orientation in the display area 756.

[0620] The communications unit has a wireless communication device, which can supply video signals and the like. Alternatively, instead of the wireless communication device, or in addition to the wireless communication device, it may be equipped with a connector to which a cable supplying video signals and power potential can be connected.

[0621] Furthermore, electronic devices 700A and 700B are equipped with batteries that can be charged wirelessly, wired, or both.

[0622] The housing 721 may be equipped with a touch sensor module. The touch sensor module has the function of detecting when the outer surface of the housing 721 is touched. The touch sensor module can detect the user's tap or slide operations and perform various processes. For example, a tap operation can be used to pause or resume the video, and a slide operation can be used to fast forward or rewind. Furthermore, by providing a touch sensor module in each of the two housings 721, the range of operations can be expanded.

[0623] Various types of touch sensors can be applied to the touch sensor module. For example, various methods such as capacitive, resistive, infrared, electromagnetic induction, surface acoustic wave, and optical sensors can be used. In particular, it is preferable to apply a capacitive or optical sensor to the touch sensor module.

[0624] When using an optical touch sensor, a photoelectric conversion device (also called a photoelectric element) can be used as the light-receiving device (also called a photoelectric element). The active layer of the photoelectric conversion device can be made of either an inorganic semiconductor or an organic semiconductor, or both.

[0625] The electronic device 800A shown in Figure 32A and the electronic device 800B shown in Figure 32B each include a pair of display units 820, a housing 821, a communication unit 822, a pair of mounting units 823, a control unit 824, a pair of imaging units 825, and a pair of lenses 832.

[0626] A display device according to one embodiment of the present invention can be applied to the display unit 820. Therefore, an electronic device capable of displaying extremely high resolution can be created. This allows the user to experience a high level of immersion.

[0627] The display unit 820 is located inside the housing 821, in a position where it can be seen through the lens 832. Furthermore, by displaying different images on a pair of display units 820, a three-dimensional display using parallax can also be performed.

[0628] Electronic devices 800A and 800B can be described as electronic devices for VR. A user wearing either electronic device 800A or electronic device 800B can view the image displayed on the display unit 820 through the lens 832.

[0629] It is preferable that electronic devices 800A and 800B each have a mechanism that allows adjustment of the left and right positions of the lens 832 and the display unit 820 so that they are in the optimal position according to the user's eye position. It is also preferable that they have a mechanism that adjusts the focus by changing the distance between the lens 832 and the display unit 820.

[0630] The attachment portion 823 allows the user to attach the electronic device 800A or 800B to their head. While Figure 32A and other figures illustrate the attachment portion as resembling the temples (or joints) of eyeglasses, it is not limited to this shape. The attachment portion 823 only needs to be wearable by the user; for example, it may be helmet-shaped or band-shaped.

[0631] The imaging unit 825 has the function of acquiring external information. The data acquired by the imaging unit 825 can be output to the display unit 820. An image sensor can be used in the imaging unit 825. In addition, multiple cameras may be provided to accommodate multiple angles of view, such as telephoto and wide-angle.

[0632] Although an example with an imaging unit 825 is shown here, any distance measuring sensor (hereinafter also referred to as a detection unit) capable of measuring the distance to an object can be provided. In other words, the imaging unit 825 is one form of a detection unit. As the detection unit, for example, an image sensor or a distance image sensor such as LiDAR (Light Detection and Ranging) can be used. By using the image obtained by the camera and the image obtained by the distance image sensor, more information can be acquired, enabling more accurate gesture control.

[0633] The electronic device 800A may have a vibration mechanism that functions as a bone conduction earphone. For example, a configuration having such a vibration mechanism can be applied to one or more of the display unit 820, housing 821, and mounting unit 823. This allows users to enjoy video and audio simply by wearing the electronic device 800A, without needing separate audio equipment such as headphones, earphones, or speakers.

[0634] Electronic devices 800A and 800B may each have input terminals. Cables can be connected to the input terminals to supply video signals from video output devices, etc., and power for charging batteries provided within the electronic devices.

[0635] An electronic device according to one aspect of the present invention may have a function for wireless communication with an earphone 750. The earphone 750 has a communication unit (not shown) and has a wireless communication function. The earphone 750 can receive information (e.g., voice data) from the electronic device through its wireless communication function. For example, the electronic device 700A shown in Figure 31A has a function for transmitting information to the earphone 750 through its wireless communication function. Also, for example, the electronic device 800A shown in Figure 32A has a function for transmitting information to the earphone 750 through its wireless communication function.

[0636] Furthermore, the electronic device may have an earphone section. The electronic device 700B shown in Figure 31B has an earphone section 727. For example, the earphone section 727 and the control section can be connected to each other by a wire. Some of the wiring connecting the earphone section 727 and the control section may be located inside the housing 721 or the mounting section 723.

[0637] Similarly, the electronic device 800B shown in Figure 32B has an earphone unit 827. For example, the earphone unit 827 and the control unit 824 can be connected to each other by a wire. Part of the wiring connecting the earphone unit 827 and the control unit 824 may be located inside the housing 821 or the mounting unit 823. Also, the earphone unit 827 and the mounting unit 823 may have magnets. This allows the earphone unit 827 to be fixed to the mounting unit 823 by magnetic force, which is preferable as it facilitates storage.

[0638] Furthermore, the electronic device may have an audio output terminal to which earphones or headphones can be connected. The electronic device may also have an audio input terminal and / or an audio input mechanism. For example, a sound-collecting device such as a microphone can be used as the audio input mechanism. By having an audio input mechanism, the electronic device may be given the function of a so-called headset.

[0639] Thus, as one embodiment of the present invention, both eyeglass-type (electronic devices 700A and 700B, etc.) and goggle-type (electronic devices 800A and 800B, etc.) are preferred as electronic devices.

[0640] Furthermore, an electronic device according to one aspect of the present invention can transmit information to earphones via wired or wireless means.

[0641] The electronic device 6500 shown in Figure 33A is a portable information terminal that can be used as a smartphone.

[0642] The electronic device 6500 includes a housing 6501, a display unit 6502, a power button 6503, a button 6504, a speaker 6505, a microphone 6506, a camera 6507, and a light source 6508, etc. The display unit 6502 has a touch panel function.

[0643] A display device according to one aspect of the present invention can be applied to the display unit 6502.

[0644] Figure 33B is a schematic cross-sectional view of the housing 6501, including the end on the microphone 6506 side.

[0645] A light-transmitting protective member 6510 is provided on the display side of the housing 6501, and the display panel 6511, optical member 6512, touch sensor panel 6513, printed circuit board 6517, battery 6518, etc. are arranged in the space enclosed by the housing 6501 and the protective member 6510.

[0646] The protective member 6510 is fixed to the display panel 6511, the optical member 6512, and the touch sensor panel 6513 by an adhesive layer (not shown).

[0647] In the area outside the display unit 6502, a portion of the display panel 6511 is folded back, and the FPC 6515 is connected to this folded portion. IC 6516 is mounted on the FPC 6515. The FPC 6515 is connected to terminals provided on the printed circuit board 6517.

[0648] A flexible display according to one embodiment of the present invention can be applied to the display panel 6511. This makes it possible to realize an extremely lightweight electronic device. Furthermore, because the display panel 6511 is extremely thin, it is possible to incorporate a large-capacity battery 6518 while kee...

Claims

1. It comprises a first light-emitting device, a second light-emitting device, a first insulating layer, a second insulating layer, a first colored layer, and a second colored layer. The first light-emitting device comprises a first pixel electrode, a first light-emitting layer having a region disposed on the first pixel electrode, and a common electrode having a region disposed on the first light-emitting layer. The second light-emitting device comprises a second pixel electrode, a second light-emitting layer having a region disposed on the second pixel electrode, and the common electrode having a region disposed on the second light-emitting layer. The ends of the first pixel electrode and the ends of the second pixel electrode each have a region that overlaps with the first insulating layer. The aforementioned second insulating layer has an inorganic material, The second insulating layer has a recess and a region that is disposed on the first insulating layer, The second insulating layer has regions that are in contact with the sides of the first light-emitting layer and the second light-emitting layer, The first colored layer has a region that overlaps with the first light-emitting device. The second colored layer has a region that overlaps with the second light-emitting device. The first light-emitting device and the second light-emitting device each have the function of emitting white light. The first colored layer has the function of transmitting visible light of a different color from the second colored layer. Display device.

2. In claim 1, Having a third insulating layer, The third insulating layer is provided within the recess of the second insulating layer. The third insulating layer comprises an organic material, The third insulating layer has a region that overlaps with the side surface of the first light-emitting layer via the second insulating layer. The third insulating layer has a region that overlaps with the side surface of the second light-emitting layer via the second insulating layer. The third insulating layer has a region that overlaps with the first insulating layer via the second insulating layer. Display device.

3. In claim 1 or claim 2, The first light-emitting device has a common layer between the first light-emitting layer and the common electrode. The second light-emitting device has the common layer between the second light-emitting layer and the common electrode, The common layer comprises at least one of a hole injection layer, a hole suppression layer, a hole transport layer, an electron transport layer, an electron suppression layer, and an electron injection layer. Display device.

4. In any one of claims 1 to 3, The first light-emitting layer is made of the same material as the second light-emitting layer. Display device.

5. It comprises a first light-emitting device, a second light-emitting device, a first insulating layer, a second insulating layer, a first colored layer, and a second colored layer. The first light-emitting device comprises a first pixel electrode, a first light-emitting unit having a region disposed on the first pixel electrode, a first charge generation layer having a region disposed on the first light-emitting unit, a second light-emitting unit having a region disposed on the first charge generation layer, and a common electrode having a region disposed on the second light-emitting unit. The second light-emitting device comprises a second pixel electrode, a third light-emitting unit having a region disposed on the second pixel electrode, a second charge generation layer having a region disposed on the third light-emitting unit, a fourth light-emitting unit having a region disposed on the second charge generation layer, and the common electrode having a region disposed on the fourth light-emitting unit. The ends of the first pixel electrode and the ends of the second pixel electrode each have a region that overlaps with the first insulating layer. The aforementioned second insulating layer has an inorganic material, The second insulating layer has a recess and a region that is disposed on the first insulating layer, The second insulating layer has regions that are in contact with the first pixel electrode, the second pixel electrode, the first charge generation layer, and the respective sides of the second charge generation layer. The first colored layer has a region that overlaps with the first light-emitting device. The second colored layer has a region that overlaps with the second light-emitting device. The first light-emitting device and the second light-emitting device each have the function of emitting white light. The first colored layer has the function of transmitting visible light of a different color from the second colored layer. Display device.

6. In claim 5, Having a third insulating layer, The third insulating layer is provided within the recess of the second insulating layer. The third insulating layer comprises an organic material, The third insulating layer has a region that overlaps with the side surface of the first charge generation layer via the second insulating layer. The third insulating layer has a region that overlaps with the side surface of the second charge generation layer via the second insulating layer. The third insulating layer has a region that overlaps with the first insulating layer via the second insulating layer. Display device.

7. In claim 5 or claim 6, The first light-emitting device has a common layer between the second light-emitting unit and the common electrode. The second light-emitting device has the common layer between the fourth light-emitting unit and the common electrode, The common layer comprises at least one of a hole injection layer, a hole suppression layer, a hole transport layer, an electron transport layer, an electron suppression layer, and an electron injection layer. Display device.

8. In any one of claims 5 to 7, The first light-emitting unit has the same material as the third light-emitting unit, The first charge generation layer has the same material as the second charge generation layer. The second light-emitting unit is made of the same material as the fourth light-emitting unit. Display device.

9. A display device according to any one of claims 1 to 8, Having at least one of a connector and an integrated circuit, Display module.

10. The display module according to claim 9, A device comprising at least one of the following: housing, battery, camera, speaker, and microphone, electronic equipment.

11. A first pixel electrode and a second pixel electrode are formed on an insulating surface. A first insulating layer is formed to cover the ends of the first pixel electrode and the ends of the second pixel electrode. A first layer is formed on the first pixel electrode and the second pixel electrode. A first sacrificial layer is formed on the first layer described above. The first layer and the first sacrificial layer are processed to form a second layer on the first pixel electrode, a second sacrificial layer on the second layer, a third layer on the second pixel electrode, and a third sacrificial layer on the third layer. A first insulating film is formed that covers at least the upper surface of the first insulating layer, the side surfaces of the second layer, the side surfaces of the third layer, the side surfaces and upper surface of the second sacrificial layer, and the side surfaces and upper surface of the third sacrificial layer. By processing the first insulating film, a second insulating layer is formed that covers at least the upper surface of the first insulating layer, the side surface of the second layer, and the side surface of the third layer. Remove the second sacrificial layer and the third sacrificial layer, A common electrode is formed on the second layer and the third layer. A first colored layer having a region overlapping with the second layer, and a second colored layer having a region overlapping with the third layer are formed on the common electrode. Method for manufacturing a display device.

12. A first pixel electrode and a second pixel electrode are formed on an insulating surface. A first insulating layer is formed to cover the ends of the first pixel electrode and the ends of the second pixel electrode. A first layer is formed on the first pixel electrode and the second pixel electrode. A first sacrificial layer is formed on the first layer described above. The first layer and the first sacrificial layer are processed to form a second layer on the first pixel electrode, a second sacrificial layer on the second layer, a third layer on the second pixel electrode, and a third sacrificial layer on the third layer. Using an inorganic material, a first insulating film is formed that covers at least the upper surface of the first insulating layer, the side surfaces of the second layer, the side surfaces of the third layer, the side surfaces and upper surface of the second sacrificial layer, and the side surfaces and upper surface of the third sacrificial layer. Using an organic material, a second insulating film is formed on the first insulating film. By processing the first insulating film and the second insulating film, a second insulating layer is formed that covers at least the upper surface of the first insulating layer, the side surfaces of the second layer, and the side surfaces of the third layer, and a third insulating layer is formed on the second insulating layer. Remove the second sacrificial layer and the third sacrificial layer, A common electrode is formed on the second layer and the third layer. A first colored layer having a region overlapping with the second layer, and a second colored layer having a region overlapping with the third layer are formed on the common electrode. Method for manufacturing a display device.

13. In claim 12, A photosensitive resin is used as the organic material to form the second insulating film. Method for manufacturing a display device.

14. In any one of claims 11 to 13, As the first sacrificial layer, a first sacrificial film and a second sacrificial film on the first sacrificial film are formed. After forming the first resist mask on the second sacrificial film, the second sacrificial film is processed using the first resist mask. Remove the first resist mask, The first sacrificial film is processed using the processed second sacrificial film as a mask. The first layer is processed using the processed first sacrificial film as a mask. Method for manufacturing a display device.

15. In any one of claims 11 to 14, After removing the second and third sacrificial layers, a fourth layer is formed on the second and third layers. The common electrode is formed on the fourth layer. Method for manufacturing a display device.

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