Display device and manufacturing method therefor

Abstract

Provided in the present disclosure is a display device. The display device comprises a substrate and pixel define layers. The pixel define layers are arranged on the substrate, and an upper surface and a side surface of each pixel define layer define an included angle.

Description

Display device and manufacturing method thereof Technical Field

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

[0002] Display devices containing optical component layers are widely used in most electronic devices, and in recent years, there has been a growing demand for larger displays. However, in the manufacturing process for these devices, some steps suffer from poor light extraction efficiency. Improving the light extraction efficiency of display devices is a widely recognized challenge in the field. Therefore, the display industry is seeking solutions to address this issue.

[0003] Summary of the Invention

[0004] A display device includes a substrate and a pixel definition layer. The pixel definition layer is disposed on the substrate, wherein the pixel definition layer has an upper surface and a side surface defining an angle.

[0005] A display device includes a substrate, a plurality of pixel definition layers, and a light-emitting structure. The plurality of pixel definition layers are disposed on the substrate. The light-emitting structure is disposed on the plurality of pixel definition layers. The upper surface of the light-emitting structure has a plurality of protrusions above one of the plurality of pixel definition layers. BRIEF DESCRIPTION OF THE DRAWINGS

[0006] FIG. 1 is a cross-sectional view of a display device according to some embodiments.

[0007] FIG. 2 is a partially enlarged view of the display device shown in FIG. 1 , according to some embodiments.

[0008] FIG3 is a cross-sectional view of a display device according to some embodiments.

[0009] 4A , 4B, 4C, and 4D illustrate a display device at different stages of fabrication according to methods of certain embodiments of the present disclosure. DETAILED DESCRIPTION

[0010] The following disclosure provides many different embodiments or examples for implementing different features of the present application. Specific examples of components and configurations are described below to simplify the disclosure of the present application. Of course, these are merely examples and are not intended to limit the present application. For example, the following description of forming a first feature on or above a second feature may include embodiments in which the first and second features are in direct contact, and may also include embodiments in which other features are formed between the first and second features, so that the first and second features are not in direct contact. In addition, the present application may repeat component symbols and / or letters in different examples. This repetition is for the purpose of simplicity and clarity, and does not dictate the relationship between the different embodiments and / or architectures discussed.

[0011] Furthermore, this application may use spatially corresponding terms, such as "below," "below," "lower," "above," "higher," and similar terms, to describe the relationship of one component or feature to another component or feature in the drawings. Spatially corresponding terms are intended to encompass different orientations of the device in use or operation in addition to the orientation depicted in the drawings. The device may be oriented (rotated 90 degrees or at other orientations), and the spatially corresponding descriptors used herein interpreted accordingly.

[0012] Although the numerical ranges and parameters disclosed throughout the broad scope of this disclosure are approximate, the numerical values ​​set forth in the specific examples are as precise as possible. However, any numerical value inherently contains certain errors due to the standard deviation found in individual test measurements. Furthermore, as used herein, "about" generally means within 10%, 5%, 1%, or 0.5% of a given value or range. Alternatively, the term "about" means within the acceptable standard error of the mean as considered by one of ordinary skill in the art. Except in the operating / working examples, or unless otherwise indicated, all numerical ranges, amounts, values, and ratios disclosed herein, such as amounts of materials, time periods, temperatures, operating conditions, quantitative ratios, and the like, are to be understood as being modified in all instances by the term "about." Therefore, unless otherwise indicated, the numerical parameters set forth in this disclosure and claims are approximate and may vary as necessary. Each numerical parameter should at least be interpreted in light of the number of reported significant digits and by applying ordinary rounding techniques. As used herein, ranges may be expressed from one endpoint to the other or between two endpoints. Unless otherwise stated, all ranges disclosed herein are inclusive of the endpoints.

[0013] FIG. 1 is a cross-sectional view of a display device 10 according to some embodiments.

[0014] In some embodiments, the display device 10 includes a substrate 110, an electrode 121, an electrode 122, a pixel definition layer 130, a light emitting structure 140, and a light guide layer 150. In some embodiments, the display device 10 may include a pixel or a portion of a pixel. In some embodiments, the display device 10 is configured to emit a first color, a second color, and a third color. In some embodiments, the first color includes green light (e.g., light with a wavelength between 500 nm and 580 nm), the second color includes red light (e.g., light with a wavelength between 620 nm and 780 nm), and the third color includes blue light (e.g., light with a wavelength between 400 nm and 500 nm). In some embodiments, the display device 10 is configured to emit white light, ultraviolet light, infrared light, or other suitable light.

[0015] FIG. 2 is a partially enlarged view of the display device shown in FIG. 1 , according to some embodiments.

[0016] In some embodiments, the substrate 110 includes a substrate (not shown), a dielectric layer (not shown), and one or more circuits (not shown) provided on or within the substrate. In some embodiments, the substrate is a transparent substrate, or at least a portion is transparent. In some embodiments, the substrate is a non-flexible substrate, and the material of the substrate may include glass, quartz, low temperature polysilicon (LTPS) or other suitable materials. In some embodiments, the substrate is a flexible substrate, and the material of the substrate may include transparent epoxy resin, polyimide, polyvinyl chloride, methyl methacrylate or other suitable materials. The dielectric layer may be provided on the substrate as needed. In some embodiments, the dielectric layer may include silicon oxide, silicon nitride, silicon oxynitride or other suitable materials.

[0017] In some embodiments, the circuit may include a complementary metal-oxide-semiconductor (CMOS) circuit, or include a plurality of transistors and a plurality of capacitors adjacent to the transistors, wherein the transistors and the capacitors are formed on a dielectric layer. In some embodiments, the transistors are thin-film transistors (TFTs). Each transistor includes a source / drain region (including at least one source region and a drain region), a channel region between the source / drain regions, a gate electrode disposed above the channel region, and a gate insulator between the channel region and the gate electrode. The channel region of the transistor may be made of a semiconductor material, such as silicon or other elements selected from Group IV or Group III and Group V.

[0018] In some embodiments, the substrate 110 includes components such as an interlayer dielectric structure and a metal layer (eg, a first metal layer and a second metal layer). The interlayer dielectric structure is disposed on a circuit or a transistor.

[0019] Electrodes 121 are disposed on the surface of substrate 110. Each electrode 121 is configured such that one side is connected to circuitry embedded in or electrically connected to substrate 110, and the other side contacts light-emitting structure 140. Electrodes 121 comprise a metal material such as Ag or Mg. In some embodiments, electrodes 121 comprise indium tin oxide (ITO), indium zinc oxide (IZO), or other suitable materials. In some embodiments, electrodes 121 define openings 121o.

[0020] The pixel definition layer 130 is disposed on the substrate 110. The pixel definition layer 130 covers a portion of the electrode 121. A portion of the pixel definition layer 130 is disposed in the opening 121o. The pixel definition layer 130 can be disposed between two pixels. The opening of the pixel definition layer 130 can be used to define the light-emitting area and / or profile of the above-mentioned pixel. The cross-section of the pixel definition layer 130 can have a trapezoidal profile. In some embodiments, the surface area of ​​the upper surface of the pixel definition layer 130 (the surface 130s1 facing the light-emitting structure 140) is smaller than the surface area of ​​the lower surface of the pixel definition layer 130 (the surface facing the substrate 110). In some embodiments, the pixel definition layer 130 includes a light-absorbing material whose absorbance can be greater than 85%, for example, 85%, 88%, 90%, 93%, 95%, 97%, 98%, or 99%. The pixel definition layer 130 can include a dielectric material. In some embodiments, the material of the pixel definition layer 130 includes an inorganic material. In some embodiments, the material of the pixel definition layer 130 includes nitride, oxide and / or other suitable materials. When the pixel definition layer 130 includes an inorganic material, it can define a smaller line width, which helps to miniaturize the display device 10. In addition, inorganic materials have better weather resistance than organic materials. In addition, the pixel definition layer formed by organic materials and the pixel definition layer formed by inorganic materials will define different surface profiles after the reflow step. For example, in the cross-sectional view, the pixel definition layer formed by the organic material presents a partially circular or elliptical profile; the upper surface of the pixel definition layer formed by the inorganic material basically presents a trapezoidal profile.

[0021] In some embodiments, the pixel definition layer 130 may include a surface 130s1 and a surface 130s2. Surface 130s1 may also be referred to as an upper surface, and surface 130s2 may also be referred to as a side surface, which is connected to surface 130s1. In some embodiments, surface 130s1 and surface 130s2 form an angle θ. In some embodiments, angle θ is in a range of approximately 95 degrees to 135 degrees, for example, 95 degrees, 100 degrees, 105 degrees, 110 degrees, 115 degrees, 120 degrees, 125 degrees, 130 degrees, or 135 degrees.

[0022] The light-emitting structure 140 is disposed on the electrode 121. The light-emitting structure 140 is disposed on the pixel definition layer 130. The light-emitting structure 140 covers the surface 130s1 and the surface 130s2 of the pixel definition layer 130. In some embodiments, the light-emitting structure 140 is a composite structure. The light-emitting structure 140 may include a carrier injection layer, a hole transportation layer (HTL), an electron transportation layer (ETL), an emissive layer (EML), and / or other suitable components. The carrier transportation layer and the hole transportation layer have the property of unidirectionally transporting electrons or holes. The light-emitting layer may include different materials in different pixels to emit light wavelengths in different bands, such as red light, green light, blue light, and / or white light.

[0023] In some embodiments, the light-emitting structure 140 may include a protrusion 141, a protrusion 142, and a protrusion 142'. The protrusion 141 may be located above the surface 130s1. In some embodiments, the protrusion 141 may overlap with the opening 121o of the electrode 121 in the vertical direction. In some embodiments, the protrusion 142 may be located above or adjacent to the intersection of the surfaces 130s1 and 130s2, for example, above or adjacent to the angle θ. In some embodiments, the surface (e.g., the upper surface) of the protrusion 141 and the surface (e.g., the upper surface) of the protrusion 142 may have different profiles.

[0024] In some embodiments, the maximum distance between protrusion 141 and substrate 110 can reach height H1, the maximum distance between protrusion 142 and substrate 110 can reach height H2, and the maximum distance between protrusion 142' and substrate 110 can reach height H3. In some embodiments, height H1 is not equal to height H2. Height H1 is not equal to height H3. Height H2 is not equal to height H3. In some embodiments, the two protrusions 142 and 142' shown in FIG. 2 can have asymmetrical profiles.

[0025] In some embodiments, the surface of the protrusion 141 is composed of continuous points, that is, its surface does not have saddle points and / or cusps. In some embodiments, the surface of the protrusion 142 has discontinuous points, that is, its surface has saddle points and / or cusps (e.g., the apex of the protrusion 142). In some embodiments, the surface of the light-emitting structure 140 located on the pixel definition layer 130 has a non-circular profile. In some embodiments, the surface of the light-emitting structure 140 located on the pixel definition layer 130 has a substantially trapezoidal profile. That is, the light-emitting structure 140 has a protrusion corresponding to the pixel definition layer 130. When viewed from above, this protrusion has a substantially quadrilateral profile, and the profile of this protrusion conforms to the profile of the pixel definition layer 130, presenting a shape that is wide at the top and narrow at the bottom.

[0026] Although not shown in Figures 1 and 2, the carrier injection layer, hole transport layer, electron transport layer and / or light-emitting layer of the light-emitting structure 140 each have a plurality of protrusions above the pixel definition layer 130. The contours and positions of the protrusions may correspond to the protrusions 141 and the protrusions 142.

[0027] The electrode 122 is disposed on the light emitting structure 140. The electrode 122 includes a metal material, such as Ag, Mg, etc. In some embodiments, the electrode 122 includes indium tin oxide (ITO), indium zinc oxide (IZO), or other suitable materials. In some embodiments, the electrode 122 has a protrusion 1221 and a protrusion 1222. In some embodiments, the protrusion 1221 may overlap with the opening 121o of the electrode 121 in the vertical direction. In some embodiments, the protrusion 1222 may be located above the intersection of the surface 130s1 and the surface 130s2, for example, above the angle θ. In some embodiments, the surfaces (e.g., the upper surface) of the protrusion 1221 and the protrusion 1222 may have different profiles.

[0028] The light guide layer 150 is disposed on the electrode 122. The light guide layer 150 is configured to guide the light emitted by the light emitting structure 140 to a desired location. In some embodiments, the light guide layer 150 may include a protrusion 151 and a protrusion 152. The protrusion 151 may be located above the surface 130s1. In some embodiments, the protrusion 151 may overlap with the opening 121o of the electrode 121 in the vertical direction. In some embodiments, the protrusion 152 may be located above the intersection of the surface 130s1 and the surface 130s2, for example, above the angle θ. In some embodiments, the surfaces (for example, the upper surfaces) of the protrusion 151 and the protrusion 152 may have different profiles. Although Figures 1 and 2 show the light guide layer 150 having the protrusion 151 and the protrusion 152, in other embodiments, the upper surface of the light guide layer 150 may include a partially circular or elliptical profile without a saddle point and / or a sharp point, and is not limited thereto.

[0029] FIG3 is a cross-sectional view of a display device 20 according to certain embodiments. Display device 20 is similar to display device 10 , except for the following differences: In some embodiments, display device 20 further includes a planarization layer 160 , a filler layer 170 , an optical component layer 181 , a filter layer 182 , and a cover plate 190 .

[0030] The planarization layer 160 is disposed on the light emitting structure 140. The planarization layer 160 covers the pixel definition layer 130. The planarization layer 160 covers the electrode 122. The planarization layer 160 is configured to provide a planar surface (eg, a planar upper surface). The planarization layer 160 may include oxide, nitride, or other dielectric materials.

[0031] Filling layer 170 is disposed on planar layer 160. Filling layer 170 comprises a substantially transparent material, such as a resin or other suitable material, and may include any filler. Filling layer 170 may have a light transmittance greater than 85%, such as 85%, 88%, 90%, 93%, 95%, 97%, 98%, or 99%.

[0032] In some embodiments, an optical component layer 181 is disposed within the filler layer 170 . The optical component layer 181 is vertically aligned with the space defined by two adjacent pixel definition layers 130 . In some embodiments, the optical component layer 181 is configured to alter the light path of light emitted by the pixels. In some embodiments, the optical component layer 181 includes a lens or other suitable component. In some embodiments, the optical component layer 181 may have a profile that protrudes toward the substrate 110 .

[0033] The filter layer 182 is disposed on the optical component layer 181 and is vertically aligned with the optical component layer 181. In some embodiments, the filter layer 182 can allow light of different wavelengths to pass through corresponding to different pixels. For example, the filter layer 182 can allow green light, red light, blue light, and / or white light to pass through. In some embodiments, the filter layer 182 can be removed.

[0034] The cover plate 190 is disposed on the filter layer 182. In some embodiments, the cover plate 190 comprises a substantially transparent member, such as glass or other suitable member.

[0035] 4A , 4B, 4C, and 4D illustrate a display device at different stages of fabrication according to methods of certain embodiments of the present disclosure.

[0036] Referring to FIG. 4A , a substrate 110 is provided or received. An electrode 121 is formed on the substrate 110. The electrode 121 defines an opening 121o to expose a portion of the upper surface of the substrate 110. The electrode 121 can be formed on the substrate 110 by vapor deposition, sputtering, atomic layer deposition (ALD), thermal evaporation, coating, or jetting, and patterned by lithography and etching techniques.

[0037] 4B , a dielectric layer 130 ′ is formed to cover the electrode 121 and the substrate 110 . The dielectric layer 130 ′ may fill the opening 121 o . The dielectric layer 130 ′ may be formed by a deposition process or other suitable process.

[0038] Referring to FIG. 4C , a patterning process is performed to pattern the dielectric layer 130′ to form the pixel definition layer 130. In some embodiments, the dielectric layer 130′ comprises an inorganic material, such as a nitride, an oxide, and / or other suitable materials. The patterning process may include forming a photoresist layer on the dielectric layer 130′, exposing the photoresist layer to light, and developing the photoresist layer to define a desired pattern. In this embodiment, the patterning process may include performing an etching process. In this embodiment, the patterning process may include performing a dry etching process. In this embodiment, the patterning process may include reactive-ion etching (RIE).

[0039] Referring to FIG4D , a light-emitting structure 140, an electrode 122, and a light-guiding layer 150 are formed on the pixel definition layer 130 to form a display device, such as the display device 10 shown in FIG1 . Forming the light-emitting structure 140 may include forming a carrier injection layer, a carrier transport layer, a light-emitting layer, and / or other suitable components. In addition, the light-emitting structure 140 may have at least one or more protrusions (e.g., protrusion 141 and protrusion 142) by varying the process conditions. The number of protrusions may be varied by varying process parameters such as temperature and time, and is not limited to the embodiment shown in FIG4D .

[0040] The foregoing description summarizes the features of some embodiments so that those skilled in the art can better understand various aspects of the present disclosure. Those skilled in the art will appreciate that this disclosure can be readily used as a basis for designing or modifying other processes and structures to achieve the same objectives and / or advantages as the embodiments of this application. Those skilled in the art will also appreciate that such equivalent structures do not depart from the spirit and scope of the present disclosure, and that those skilled in the art can make various changes, substitutions, and alterations without departing from the spirit and scope of the present disclosure.

[0041] Furthermore, the scope of this application is not limited to the specific embodiments of the processes, machines, manufacture, compositions of matter, means, methods, and steps described in the specification. Those skilled in the art will understand from the disclosure herein that existing or future developed processes, machines, manufacture, compositions of matter, means, methods, or steps that function the same as or achieve substantially the same results as the corresponding embodiments described herein may be used in accordance with this disclosure. Accordingly, such processes, machines, manufacture, compositions of matter, means, methods, or steps are intended to be within the scope of this application.

[0042] Description of the accompanying drawings

[0043] 10 Display devices

[0044] 110 substrate

[0045] 121 electrodes

[0046] 121o opening

[0047] 122 electrodes

[0048] 1221 salient

[0049] 1222 protrusion

[0050] 130 pixels definition layer

[0051] 130s1 surface

[0052] 130s2 surface

[0053] 130' dielectric layer

[0054] 140 luminous structure

[0055] 141 salient

[0056] 142 protrusion

[0057] 142' salient

[0058] 150 light guide layer

[0059] 151 salient

[0060] 152 protrusion

[0061] 160 flat layer

[0062] 170 filling layers

[0063] 181 optical component layer

[0064] 182 filter layer

[0065] 190 cover

[0066] 20 display devices

[0067] θ angle

[0068] H1 height

[0069] H2 height

[0070] H3 height

Claims

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

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

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

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

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

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

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

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