Abstract:
The invention relates to a matrix display screen which includes, in sequence: a mounting ( 50 ); at least one first metal portion ( 156 ); a stack of layers ( 52, 72, 86, 104 ) including transistors (TFT 1 , TFT 2 ); and organic light-emitting diodes ( 32 ).

Description:
CROSS-REFERENCE TO RELATED APPLICATIONS 
       [0001]    The present application is a National Stage of PCT International Application Serial Number PCT/FR2013/052887, filed Nov. 28, 2013, which claims priority under 35 U.S.C. §119 of French patent Application Serial Number 12/61460, filed Nov. 30, 2012, the disclosures of which are incorporated by reference herein. 
     
    
     BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present disclosure relates to a display screen comprising organic light-emitting diodes, particularly a display screen for a head-up display. 
         [0004]    2. Description of the Related Art 
         [0005]    Head-up displays, also known as HUDs, are augmented reality display systems which enable to integrate visual information in a real scene seen by an observer. In practice, such systems may be placed in a helmet visor, in the cockpit of a plane, or in the interior of a vehicle. They are thus positioned at a short distance from the user&#39;s eyes, for example, a few centimeters or tens of centimeters away. 
         [0006]    The visual information is provided by a display screen. Conventionally, it is a cathode-ray tube screen. The current tendency is to replace the cathode-ray tube screens of head-up displays with matrix display screens of smaller bulk. It would be desirable to be able to use organic light-emitting diode matrix display screens which comprise display pixels arranged in rows and in columns. 
         [0007]    However, in a head-up display, the display screen should be capable of providing a luminance of at least 70,000 candelas per square meter. This may correspond to currents having excessive intensities, incompatible with the proper operation of conventional organic light-emitting diode display screens. 
       SUMMARY 
       [0008]    Thus, an embodiment provides a matrix display system successively comprising: 
         [0009]    a support; 
         [0010]    at least a first metal portion; 
         [0011]    a stack of layers including transistors; and 
         [0012]    organic light-emitting diodes. 
         [0013]    According to an embodiment, the first metal portion is connected to at least one of the transistors. 
         [0014]    According to an embodiment, the first metal portion extends opposite a plurality of display pixels. 
         [0015]    According to an embodiment, the first metal portion extends opposite all the display pixels. 
         [0016]    According to an embodiment, each display pixel comprises at least one of said transistors, the first metal portion being connected to said transistor for each display pixel. 
         [0017]    According to an embodiment, the metal portion is solid. 
         [0018]    According to an embodiment, the metal portion comprises through openings. 
         [0019]    According to an embodiment, the screen further comprises an electrode connected to the cathode of each light-emitting diode, and at least a second metal portion, at the same level as the first metal portion, connected to the electrode. 
         [0020]    According to an embodiment, the second metal portion extends along an edge of the first metal portion. 
         [0021]    According to an embodiment, the screen comprises a plurality of second metal portions, each second metal portion extending along an edge of the first metal portion and being connected to the electrode. 
         [0022]    According to an embodiment, the stack comprises third metal portions, the thickness of the third metal portions being strictly smaller than the thickness of the first metal portion. 
         [0023]    According to an embodiment, the transistors comprise thin-layer transistors. 
         [0024]    An embodiment also provides a head-up display comprising a display screen such as previously defined. 
         [0025]    An embodiment also provides a method of forming a matrix display screen, comprising the successive steps of:
       providing a support;   forming on the support at least one first metal portion;   forming, on the first metal portion, a stack of layers including transistors; and   forming organic light-emitting diodes on the stack.       
 
         [0030]    According to an embodiment, the method comprises, after the step of forming the stack and before the step of forming the organic light-emitting diodes, the step of depositing a planarization layer on the stack. 
         [0031]    According to an embodiment, the transistors are made of polysilicon deposited at low temperature or LTPS technology. 
         [0032]    According to an embodiment, the first metal portion is formed by a damascene method. 
         [0033]    According to an embodiment, the method comprises forming at least one contacting area between one of the transistors and the first metal portion. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0034]    The foregoing and other features and advantages will be discussed in detail in the following non-limiting description of specific embodiments in connection with the accompanying drawings, among which: 
           [0035]      FIG. 1  shows in the form of a block diagram an example of head-up display; 
           [0036]      FIG. 2  partially and schematically shows the equivalent circuit of an example of display pixel of an organic light-emitting diode matrix display screen; 
           [0037]      FIG. 3  shows a partial simplified transverse cross-section view of the display pixel of  FIG. 2  according to an example where the display pixel is formed with thin-layer transistors; 
           [0038]      FIG. 4  is a partial simplified transverse cross-section view of an embodiment of a matrix display screen comprising light-emitting diodes; 
           [0039]      FIG. 5  is a cross-section view of  FIG. 4  along line V-V; 
           [0040]      FIG. 6  is a cross-section view similar to  FIG. 3  of a display pixel of the screen of  FIG. 4 ; 
           [0041]      FIG. 7  is a partial enlarged cross-section view similar to  FIG. 5  of a variation of the display screen of  FIG. 4 ; and 
           [0042]      FIGS. 8A to 8D  are partial simplified cross-section views of the structures obtained at steps of an embodiment of a method of manufacturing the matrix display shown in  FIG. 4 . 
       
    
    
       [0043]    For clarity, the same elements have been designated with the same reference numerals in the various drawings and, further, as usual in the representation of circuits, the various drawings are not to scale. 
       DETAILED DESCRIPTION 
       [0044]    In the following description, unless otherwise indicated, terms “almost”, “substantially”, “approximately”, and “in the order of” mean “to within 10%”. 
         [0045]      FIG. 1  schematically illustrates the operation of a head-up display  5 . 
         [0046]    A beam splitter  10  is placed between the eye of a user  12  and a scene to be observed  14 . The objects of scene  14  to be observed are generally located at infinity or at a long distance from observer  12 . Beam splitter  10  is inclined according to a 45° angle relative to an axis connecting scene  14  and observer  12 . Beam splitter  10  enables to transmit the information originating from scene  14  to observer  12  without altering this information. 
         [0047]    A projection system  15  is provided to project an image seen by observer  12  at the same distance as the real image of scene  14  and to overlay it thereon. This system comprises a display screen  16  located at the primary focal point of an optical system  18 . Display screen  16  is controlled by a display screen control unit  20  which determines the images to be displayed, for example, from signals provided by sensors, not shown. 
         [0048]    Projection system  15  is placed perpendicularly to the axis connecting scene  14  and observer  12  so that the beam originating from optical system  18  reaches beam splitter  10  perpendicularly to this axis. The beam originating from optical system  18  thus reaches beam splitter  10  with a 45° angle relative to its surface and is reflected towards observer  12 . The image displayed on screen  16  is collimated at infinity by optical system  18 . Observer  12  does not have to make any effort of accommodation, which limits his/her visual fatigue. Beam splitter  10  combines the image of scene  14  and the image originating from projection system  15 , whereby observer  12  visualizes an image comprising the projected image overlaid on the image of scene  14 . 
         [0049]    Display screen  16  generally is a cathode ray tube display screen. It would be desirable to be able to use a matrix display screen instead of a cathode ray tube screen, particularly to decrease the screen bulk. The smallest element of a digital image capable of being displayed by matrix display screen  16  is called image pixel. The smallest element of screen  16  for displaying an image is called display pixel. For a color screen, the displaying of one image pixel may require a plurality of display pixels, for example, red, green, and blue pixels. The display pixels of a matrix display screen are evenly distributed in rows and in columns. As an example, a monochrome display screen  16 , used in a head-up display, may typically comprise from 300 to 1,500 rows and from 300 to 1,500 columns, for example 640 columns and 480 rows. As an example, all display screens adapted to the VGA (Video Graphics Array) display standard may be envisaged. 
         [0050]    It would be desirable to be able to use an organic light-emitting diode or OLED matrix display screen as a display screen  16  of a head-up display. 
         [0051]      FIG. 2  partially and schematically shows an example of a display pixel  22  of an OLED matrix display screen. Each display pixel  22  comprises an organic light-emitting diode  32 , two P-type field-effect transistors TFT 1  and TFT 2 , and a capacitor C S . The cathode of diode  32  is connected to a cathode electrode V C  which may be common to all the display pixels  22  of the screen. For each row of the screen, a selection line V SELECTION  is connected to the gate of transistor TFT 1  of all the display pixels in the row. For each column of the screen, a line of transmission of a data signal V DATA  is connected to one of the conduction terminals of transistor TFT 1  of each display pixel in the column. The other conduction terminal of transistor TFT 1  is connected to an armature of capacitor C S  and to the gate of transistor TFT 2 . For each screen column, a power supply line V DD  is connected, for each display pixel  22  in the column, to the other armature of capacitor C S  and to a conduction terminal of transistor TFT 2 , the other conduction terminal of transistor TFT 2  being connected to the anode of diode  32 . 
         [0052]    The activation of display pixel  22  comprises a selection phase and an emission phase. During the selection phase, transistor TFT 1  is conductive. Capacitor C S  is charged with the voltage applied to line V DATA , which depends on the light emission intensity desired for diode  32 . During the emission phase, line V DD  is set to a high reference potential and cathode electrode V C  is set to a low reference potential. A current flows through diode  32 , the intensity thereof being controlled by transistor TFT 2  and depending on the voltage across capacitor C S . 
         [0053]      FIG. 3  shows pixel  22 , seen along a transverse cross-section, in the case where transistors TFT 1  and TFT 2  are thin-layer transistors. 
         [0054]    Each display pixel  22  successively comprises from bottom to top: 
         [0055]    an area  40  which is especially used as a support for the entire screen; 
         [0056]    an area  42  comprising transistors TFT 1  and TFT 2  and conductive lines V DATA , V SELECTION , and V DD ; 
         [0057]    an area  44  comprising diode  32  and cathode electrode V C ; and 
         [0058]    an area  46  which is especially used as a protection coating. 
         [0059]    A substrate  50  is conventionally used to form area  40 . In the present example, the light radiation emitted by diodes  32  is intended to be seen from above in  FIG. 3 . Substrate  50  may be made of an insulating or conductive material. Preferably, substrate  50  is made of a material having a good heat conductivity, for example, a semiconductor material to help dissipating the heat generated by the transistors and the diodes, particularly silicon, or a metallic material. 
         [0060]    As an example, the transistors of area  42  are thin-layer transistors. The source, drain, and channel regions of the transistors are then formed in thin layers of a semiconductor material having a thickness in the order of or smaller than some hundred nanometers, for example, amorphous silicon, microcrystalline silicon, polysilicon, single-crystal silicon, cadmium selenide, or zinc oxide. Any type of thin-layer transistor manufacturing method may be implemented. As an example, when the semiconductor material is polysilicon, the thin layer transistor manufacturing method may be a method based on low temperature polysilicon or LTPS method. 
         [0061]    More specifically, area  42  comprises: 
         [0062]    an insulating layer  52 , for example, made of silicon oxide, covering substrate  50 ; 
         [0063]    portions  54 ,  56  of a semiconductor material, particularly polysilicon or amorphous silicon, formed on layer  52 . Portion  54  comprises portions  58 ,  60  corresponding to the source or drain regions of transistor TFT 1 , a portion  62  corresponding to the channel region of transistor TFT 1 , and a portion  64  forming a lower electrode of capacitor C S . Portion  56  comprises portions  66 ,  68  corresponding to the source or drain regions of transistor TFT 2  and a portion  70  corresponding to the channel region of transistor TFT 2 ; 
         [0064]    a dielectric layer  72 , for example, made of silicon oxide, covering the portions of semiconductor material  54 ,  56  and layer  52 , and used as a gate insulator  74  for transistor TFT 1 , as a dielectric layer  76  for capacitor C S , and as a gate insulator  78  for transistor TFT 2 ; 
         [0065]    metal portions, formed on dielectric layer  72 , particularly a metal portion  80  forming the metal gate of transistor TFT 1 , a metal track, not shown, forming selection line V SELECTION , a metal portion forming upper electrode  82  of capacitor C S , and a metal portion  84  forming the metal gate of transistor TFT 2 ; 
         [0066]    a dielectric layer  86 , for example, made of silicon oxide, covering dielectric layer  72  and metal portions  80 ,  82 ,  84 ; 
         [0067]    metal vias, only four vias  88 ,  90 ,  92 , and  94  being shown in  FIG. 3 , crossing dielectric layers  86  and  72  and coming into contact with source and drain regions  58 ,  60  of transistor TFT 1 , with upper electrode  82  of storage capacitor C S , with metal gate  84  of transistor TFT 2 , with source and drain regions  66  and  68  of transistor TFT 2 ; 
         [0068]    metal tracks or portions  96 ,  98 ,  100 , and  102 , formed on dielectric layer  86  in contact with vias  88 ,  90 ,  92 ,  94 , metal track  102  forming, in particular, line V DD , and metal track  96  forming line V DATA ; 
         [0069]    an insulating layer  104 , also called smoothing layer or planarization layer, covering insulating layer  86  and metal tracks  96 ,  98 ,  100 , and  102  and used to obtain a planar surface  105  having light-emitting diode  32  formed thereon. 
         [0070]    As an example, the tracks, the vias, and the metal portions of area  42  are made of molybdenum, titanium, tungsten, of a tungsten and molybdenum alloy, or of aluminum. 
         [0071]    As an example, area  42  shown in  FIG. 3  is manufactured by the forming of successive layers on substrate  50 . As a variation, area  42  is formed on an intermediate support and is then placed on substrate  50 , the intermediate support being then removed. 
         [0072]    An opening  106  is formed in layer  104  and exposes metal portion  100 . 
         [0073]    Area  44  comprises: 
         [0074]    an anode electrode  108  of light-emitting diode  32  covering layer  104  and extending in opening  106  so that electrode  108  is electrically connected to drain region  66  of transistor TFT 2 ; 
         [0075]    an insulating layer  110  formed on layer  104  and a portion of electrode  108 ; 
         [0076]    a light-emitting diode  112  formed on electrode  108 , which may itself comprise a stack of a plurality of layers; and 
         [0077]    a cathode electrode  114  of the light-emitting diode covering diode  112  and insulating layer  110  and extending all over the display screen. Cathode  114  is made of an at least partly transparent conductive material, for example, a silver layer having a thickness in the range from 10 to 25 nm. 
         [0078]    Area  46  may comprise: 
         [0079]    a color filter  116  covering cathode  114 ; and 
         [0080]    a protection layer  118  covering color filter  116 . 
         [0081]    Further, a metal track covering insulating layer  86  is provided at the periphery of the matrix display screen and is connected to cathode electrode  114 . 
         [0082]    The thickness of the metal tracks provided on insulating layer  86  is, for a conventional light-emitting diode screen, generally in the order of a few tens of micrometers. Conventionally, power supply line V DD  has a 10-μm width for a display pixel having a 40-μm width and the metal track connected to cathode electrode  104  has a 2-mm width. 
         [0083]    For a head-up display application, power supply line V DD  should be able to transmit several milliamperes and the current collected by the cathode electrode may reach several amperes. For a conventional matrix display screen comprising light-emitting diodes, with the metal track dimensions used to form power supply line V DD , significant voltage drops would be obtained on line V DD , which might adversely affect the proper operation of the screen, particularly due to the crosstalk phenomenon. 
         [0084]    Further, the metal track connected to the cathode electrode should have a thickness of several micrometers, or even than more than 10 μm to have a sufficiently low resistance, which cannot be envisaged. Indeed, it is not possible to form an organic light-emitting diode on too uneven a surface induced by the thickness of the underlying metal tracks since the organic layers of the diode are very thin and are generally deposited by evaporation. Too uneven a surface may generate discontinuities at the level of the deposited organic layers and thus induce short-circuits between the anode and the cathode. It is thus necessary, if the surface is too uneven, to deposit a smoothing layer, for example, made of polyimide, particularly deposited by spin deposition, before the forming of the diodes. But the greater the surface unevennesses, the thicker this smoothing layer should be. In such conditions, the heat removal towards the substrate may be altered. Further, the contact via towards the electrode through this smoothing layer should be all the larger as the layer to be crossed is thick, since it is difficult to form a steep edge of small dimension in a large thickness of organic material. This generates a loss of useful surface area at the pixel. 
         [0085]    It is thus difficult to use conventional matrix display screen structures comprising organic light-emitting diodes for a head-up display application. 
         [0086]    Thus, an object of an embodiment is to provide a matrix display screen comprising organic light-emitting diodes, which at least partly overcomes some of the disadvantages of existing screens. 
         [0087]    Another object is to increase the luminance of the light-emitting diode matrix display screen with respect to a conventional light-emitting diode matrix display screen. 
         [0088]    Another object is to decrease the thickness of smoothing layer  104  with respect to a conventional light-emitting diode matrix display screen. 
         [0089]    Another object is to decrease the thickness of the metal tracks located on insulating layer  86  with respect to a conventional organic light-emitting diode matrix display screen. 
         [0090]    The present invention comprises forming the power supply lines V DD  of the display pixels and/or the metal tracks connected to the cathode electrode with conductive tracks, preferably metal tracks, different from those formed on insulating layer  86 . 
         [0091]      FIGS. 4 to 6  are cross-section views of a display screen  150  according to an embodiment. In  FIG. 4 , area  46  is not shown. 
         [0092]    As compared with the display screen shown in  FIG. 3 , display screen  150  according to the present embodiment further comprises an additional area  152  between area  42  having transistors TFT 1  and TFT 2  and substrate  50  formed therein. Area  152  comprises an insulating layer  154  and metal portions  155  formed at the surface of insulating layer  154 . According to an embodiment, an additional layer may be provided between these metal portions and insulating layer  154 . 
         [0093]    As an example, metal portions  155  are advantageously made of copper, but they may be made of other materials, for example, of aluminum. 
         [0094]    As an example, if metal portions  155  are made of copper, the additional underlying layer is made of Ti/TiN or Ta/TaN, conventionally used as a copper diffusion barrier. 
         [0095]    As an example, the thickness of metal portions  155  is in the range from 1 to 10 μm, for example, 2 μm, and the thickness of the portion of insulating layer  154  interposed between metal portions  155  and substrate  50  is in the range from 100 to 1,000 nm. The portion of insulating layer  154  interposed between metal portions  155  and substrate  50  electrically insulates metal portions  155  from substrate  50  in the case where the substrate is made of an electrically-conductive material. In the case where substrate  50  is made of an electrically-insulating material, conductive portions  155  may be directly formed on substrate  50 . 
         [0096]    Metal portions  155  comprise a metal portion  156  comprising a central area  157 , shown in  FIG. 5 , substantially extending under the entire area  42  having the transistors formed therein and extending in connection pads  158 . As an example, central area  157  has, in the cross-section plane of  FIG. 5 , a square cross-section having a side length for example in the range from 10 mm to 200 mm, for example approximately 70 mm, extending, at two opposite corners, in two connection pads  158 . Each connection portion  158  is intended, in operation, to be connected to a reference voltage source. In the present embodiment, central area  157  is a continuous metal area. 
         [0097]    Metal portions  155  further comprise two metal tracks  160 ,  162  which extend along two contiguous sides of central area  157  and join at the level of a connection pad  164 . Metal portions  155  further comprise two metal tracks  166 ,  168  which extend along the two other contiguous sides of central area  157  and join at the level of a connection pad  170 . As an example, each metal track  160 ,  162 ,  166 ,  168  has a wavelength in the order of the side length of the screen, that is, from 10 mm to 200 mm, for example, approximately 70 mm, and a width in the range from 1 mm to 10 mm, for example, approximately 2 mm. As shown in  FIG. 4 , cathode electrode  114  laterally extends to be connected, at its periphery, to metal tracks  160 ,  162 ,  166 ,  168 . 
         [0098]    Metal portion  156  plays the role of previously-described power supply line V DD . As shown in  FIG. 6 , area  42  is formed similarly to what has been previously described in relation with  FIG. 3 , but for the fact that previously-described power supply line V DD  is no longer formed by a metal track formed on insulating layer  86  and that each display pixel comprises a conductive via  172  crossing insulating layer  52  to connect source region  56  of control transistor TFT 2  to metal portion  156 , as shown in  FIG. 4 , or crossing insulating layers  52  and  86  to connect the upper electrode of capacitor C S  to metal portion  156 . 
         [0099]    According to an embodiment, particularly when metal portions  155  are made of copper, metal portions  155  are formed according to an etch method similar to the damascene-type etch method implemented, in particular, in the manufacturing of integrated circuits. According to such a method, insulating layer  154  is deposited on substrate  50 . Openings are then formed in insulating layer  154  at the provided locations of metal portions  155 , and the openings do not extend across the entire thickness of insulating layer  154 . A Ti/TiN or Ta/TaN layer may at this stage possibly be deposited over the entire surface. Then, a copper layer is deposited over the entire obtained structure and penetrates, in particular, into the recesses. A step of chemical mechanical planarization (CMP) is formed to remove the copper layer surface portion to reach the surface of insulating layer  154  and delimit metal portions  155  in the recesses. 
         [0100]    According to another embodiment, in the case where metal portions  155  are made of a material which may be etched by chemical etching, the forming of portions  155  may comprise depositing a metal layer on an insulating layer and etching the metal layer to define metal portions  155 . Layer  52  can then be formed on top of and between metal portions  155 . 
         [0101]    The metal tracks of the display screen conducting the currents having the highest intensities are formed by metal portions  155  in the present embodiment, and not by metal portions of area  42  having the transistors of the display pixels formed therein. The dimensions of portions  155  are provided to enable such currents to flow. In particular, according to an embodiment, the thickness of metal portions  96 ,  98 ,  100 ,  102  of area  42  is low, below one micrometer, typically in the order of 0.1 or 0.2 μm, which does not induce too uneven a surface. It is then not necessary to deposit too thick a smoothing layer  104 , which would adversely affect the heat dissipation through the substrate. Risks of short-circuits at the light-emitting diode are thus also limited. Thus, the thickness of metal portions  96 ,  98 ,  100 ,  102  of area  42  is at least twice, preferably at least 5 times, more preferably at least 10 times, more preferably still at least 20 times, smaller than the thickness of metal portions  155 . The thickness is for example 2 μm for area  155  and 0.1 μm for the tracks of area  42 . 
         [0102]      FIG. 7  shows another embodiment of metal portion  156  where central area  157  is crossed by openings  174  filled with an insulating material  176  and separate from one another. As an example, openings  174  are distributed in rows and in columns. Advantageously, the embodiment shown in  FIG. 7  makes the forming of metal portions  155  easier. Indeed, in the case where a damascene-type etch method is implemented, it is generally preferable to have a substantially uniform density of metal and insulating portions over the entire surface to be treated, to decrease surface unevennesses, and particularly a dishing during the chem.-mech. polishing step, due to the difference in polishing speed between the metallic and insulating portions. 
         [0103]      FIGS. 8A to 8D  are cross-section views of structures obtained at steps of an embodiment of a method of manufacturing display screen  150  shown in  FIG. 4 , where the source and drain regions of transistors TFT 1  and TFT 2  are formed in a silicon layer, particularly made of single-crystal silicon, which is placed on a multilayer structure comprising metal portions  155 . 
         [0104]      FIG. 8A  shows a multilayer structure successively comprising substrate  50 , insulating layer  154 , metal portions  155 , and an insulating layer  180 . 
         [0105]      FIG. 8B  shows a multilayer structure  182  of SOI type (Silicon On Insulator) successively comprising a substrate  184 , an insulating layer  186 , a semiconductor layer  188 , for example, single-crystal silicon, and an insulating layer  190 . 
         [0106]      FIG. 8C  show the structure obtained after having bonded insulating layers  180  and  190 . 
         [0107]      FIG. 8D  shows the structure obtained after having removed substrate  184  and insulating layer  186 , for example, by etching. 
         [0108]    The next steps of the method particularly comprise forming previously-described areas  42 ,  44 , and  46 . In particular, the source and drain regions of transistors TFT 1  and TFT 2  may be formed in semiconductor layer  188 . 
         [0109]    As a variation, insulating layer  186  of multilayer structure  182  may be replaced with an embrittled area of the semiconductor material forming substrate  184  and semiconductor layer  188 . Thereby, after the step of bonding multilayer structure  182 , multilayer structure  182  is divided in two portions at the level of the embrittled area. 
         [0110]    Specific embodiments have been described. Various alterations and modifications will occur to those skilled in the art. In particular, each display pixel may have a structure different from that shown in  FIG. 3  and comprise a larger number of transistors.