Light emitting device

A first side surface (312) is positioned at a light emitting region (142) side. The first side surface (312) is inclined toward the light emitting region (142) with distance from the first surface (102) of the substrate (100). A second side surface (314) is positioned opposite to the first side surface (312). The second side surface (314) is inclined away from the light emitting region (142) with distance from the first surface (102) of the substrate (100). A first upper surface (316) is positioned between the first side surface (312) and the second side surface (314), and is substantially parallel to the first surface (102) of the substrate (100).

CROSS-REFERENCE TO RELATED APPLICATIONS

This application is a U.S. National Stage entry of PCT Application No: PCT/JP2020/033594 filed Sep. 4, 2020, which claims priority to Japanese Patent Application No. 2019-165939 filed Sep. 12, 2019, the contents of which are incorporated herein by reference.

TECHNICAL FIELD

The present invention relates to a light emitting device.

BACKGROUND ART

In recent years, a light emitting device having an organic electroluminescence (EL) element has been developed. Such a light emitting device has a sealing structure for sealing the organic EL element (light emitting portion). Examples of the sealing structure include a sealing layer covering the light emitting portion, or a sealing member (for example, a sealing can) adhered to a substrate through an adhesive layer.

Patent Document 1 discloses an example of a sealing structure of a light emitting device. The light emitting device includes a resin structure. The structure surrounds the light emitting portion. The structure is treated with liquid repellent. The light emitting portion is covered with a resin layer. An end portion of the resin layer is dammed by the structure. Accordingly, a position of the end portion of the resin layer can be adjusted by a position of the structure.

RELATED DOCUMENT

Patent Document

SUMMARY OF THE INVENTION

Technical Problem

For example, as disclosed in Patent Document 1, the position of the end portion of the resin layer may be adjusted by the position of the structure. The present inventor has studied to adjust the position of the end portion of the resin layer in accordance with the position of the structure by a structure different from the structure disclosed in Patent Document 1.

Examples of the problem to be solved by the present invention include adjustment of the position of the end portion of the resin layer by the position of the structure.

Solution to Problem

The invention according to claim1relates to a light emitting device including a substrate, a light emitting portion positioned over the substrate, a structure surrounding a light emitting region including the light emitting portion, a sealing layer covering the light emitting portion and the structure, and a resin layer covering at least a portion of the sealing layer overlapping with the light emitting region, in which the structure includes a first side surface positioned at the light emitting region side, and a second side surface positioned opposite to the first side surface and inclined away from the light emitting region with distance from the substrate.

DESCRIPTION OF EMBODIMENTS

An expression “A is positioned over B” in the present specification may mean that A is directly positioned on B with no different element (for example, a layer) positioned between A and B or may mean that a different element (for example, a layer) is partially or fully positioned between A and B. Furthermore, expressions indicating orientations, such as “up”, “down”, “left”, “right”, “front”, and “back” are basically used in accordance with orientations in the drawings and are not interpreted to be limited to, for example, orientations in which an invented product described in the present specification is used.

In the present specification, the expression “convex” means, unless otherwise noted, an aspect protruding from a certain surface, and is not used to limit the aspect. For example, one aspect of the convex simply protrudes straight from a surface. Another aspect curvedly protrudes from a certain surface.

In the present specification, the term “angle” may be defined for the intersection of two lines. The expression “angle formed by A and B” means one angle formed by the intersection of one tangent line that passes through one point of A and one tangent line that passes through one point of B. A and B may be spaced from each other. An example of the “angle formed by a surface A and a surface B” is one angle formed by the intersection of a first tangent line to the line indicating the surface A and a second tangent line to the line indicating the surface B in the cross-sectional view including the surface A and the surface B.

In the present specification, the expression “A and B overlap with each other” means that at least a part of A is positioned at the same place as at least a part of B on a projection image from a certain direction, unless otherwise noted. In this case, a plurality of elements may be directly in contact with each other or may be spaced from each other.

In the present specification, the expression “outside A” means a portion at a side where A is not positioned with respect to an edge of A, unless otherwise noted.

An anode in the present specification refers to an electrode from which a hole is injected into a layer containing a light emitting material (for example, an organic layer) and a cathode refers to an electrode from which an electron is injected into the layer containing the light emitting material. In addition, expressions “anode” and “cathode” may also mean different terms such as “hole injection electrode” and “electron injection electrode” or “positive electrode” and “negative electrode”.

In the present specification, the expression “end of A” means a boundary between A and other elements when viewed from one direction, the expression “end portion of A” is a part of regions of A including the boundary, and the expression “end point of A” means one point on the boundary.

“Light emitting device” in the present specification includes devices having a light emitting element such as a display, lighting, or the like. In addition, “light emitting device” may include wires, integrated circuits (ICs), casing, or the like that are directly, indirectly, or electrically connected to the light emitting element.

The expression “connect” in the present specification refers to a state in which a plurality of elements are directly or indirectly connected. For example, a case where a plurality of elements are connected through an adhesive or a joining member may also be simply expressed as “a plurality of elements are connected”. In addition, a case where a member capable of supplying or transmitting a current, a voltage, or a potential is present between a plurality of elements and “a plurality of elements are electrically connected” may also be simply expressed as “a plurality of elements are connected”.

In the present specification, unless otherwise noted, expressions such as “first, second, A, B, (a), and (b)” and the like are expressions for differentiating elements, and the essence, sequence, order, number, or the like of the corresponding element is not limited by the expression.

In the present specification, each member and each element may be singular or plural, unless the context clarifies whether a member or element is “singular” or “plural”.

In the present specification, unless otherwise noted, the expression “A includes B” does not necessarily mean that A consists of B and possibly means that A may consist of element other than B.

Unless otherwise noted, “cross section” in the present specification means a surface that appears at the time of cutting the light emitting device in a direction in which pixels, light emitting materials, or the like are laminated.

In the present specification, the expressions “not have”, “not include”, “not positioned”, and the like may mean that a certain element is completely excluded, or may mean that an element is present to the extent that it does not have a technical effect.

In the present specification, expressions that describe anteroposterior relations in time such as “after”, “subsequent to”, “next”, and “before” indicate relative time relations, and individual elements for which an anteroposterior relation in time is used are not necessarily continuous from each other. In the case of expressing individual elements that are continuous from each other, an expression “immediately”, “directly”, or the like may be used.

In the present specification, the expression “substantially parallel” also includes a state of being inclined to the extent that it has a technical effect, unless otherwise noted. For example, when the two elements A and B are positioned at an angle of equal to or more than −10° and equal to or less than 10° and have no critical technical effect at an angle of equal to or more than −10° and equal to or less than 10°, it is expressed as “A and B are substantially parallel”. A state where two elements A and B are positioned at an angle of equal to or more than −10° and equal to or less than 10° due to a manufacturing error is also expressed as “substantially parallel”. The expression “parallel” means that two elements are mathematically parallel.

Unless otherwise noted, the expression “A covers B” in the present specification may mean, for example, that A contacts with B with no other elements (for example, a layer) positioned between A and B or may mean that other elements (for example, a layer) are partially or fully positioned between A and B.

In the following, embodiments of the present invention will be described below with reference to the drawings. In all drawings, similar components are designated by the similar reference numerals, and the description thereof will not be repeated.

FIG.1is a plan view of a light emitting device10according to Embodiment 1.FIG.2is a cross-sectional view taken along line A-A ofFIG.1. InFIG.1, a A-A direction is a direction perpendicular to an extension direction of a first structure310or a second structure320extending along an outer edge on a left side of a light emitting portion140(light emitting region142) inFIG.1. For the sake of description, a sealing layer210(FIG.2) is not shown inFIG.1.

The light emitting device10includes a substrate100, the light emitting portion140(light emitting region142), the sealing layer210, a resin layer220, the first structure310, the second structure320.

The substrate100may be a single layer or a plurality of layers. A thickness of the substrate100is, for example, equal to or more than 10 μm and equal to or less than 1000 μm. The substrate100has a first surface102and a second surface104. The light emitting portion140, the sealing layer210, the resin layer220, the first structure310, and the second structure320are positioned over the first surface102of the substrate100. The second surface104is positioned opposite to the first surface102. The substrate100is a glass substrate, for example. The substrate100may be a resin substrate containing an organic material (for example, polyethylene naphthalate (PEN), polyethersulfone (PES), polyethylene terephthalate (PET), or polyimide). When the substrate100is the resin substrate, an inorganic barrier layer (for example, SiN or SiON) may be positioned over at least one of the first surface102and the second surface104of the substrate100.

In the present embodiment, the light emitting device10emits light from the second surface104side of the substrate100. That is, the light emitting device10is a bottom emission. In this case, the substrate100has translucency. A transmittance of the visible light of the substrate100is, for example, equal to or more than 75% and equal to or less than 100%. The light emitting device10, however, may emit the light from the first surface102side of the light emitting device10. That is, the light emitting device10may be a top emission. Alternatively, the light emitting device10may emit the light from both the second surface104side and the first surface102side of the substrate100.

The light emitting region142includes the light emitting portion140. The light emitting region142is a region where the light is emitted by the light emitting portion140. The light emitting portion140has an organic electroluminescence (EL) element. The organic EL element has an organic layer including an emissive layer. In the present embodiment, the light emitting portion140is a surface light source extending over the entire light emitting region142. In other words, the light emitting device10is a light emitting panel. It should be noted that the shapes of the substrate100and the light emitting portion140(light emitting region142) of the light emitting device10are not limited to the example (rectangle) shown inFIG.1.

The sealing layer210covers the first surface102of the substrate100, the light emitting portion140, the first structure310, and the second structure320. The sealing layer210includes one or a plurality of inorganic layers. The inorganic layer contains an inorganic material, such as at least one of silicon nitride (SiNx), silicon oxide (SiO2), silicon oxynitride (SiON), aluminum oxide (Al2O3), and titanium oxide (TiO2). The sealing layer210is excellent in step coverage. Accordingly, as shown inFIG.3, in one cross section, the sealing layer210extends along the unevenness formed by the light emitting portion140, the first structure310, and the second structure320over the first surface102of the substrate100.

When viewed from a direction perpendicular to the first surface102of the substrate100(FIG.1), the resin layer220covers at least a portion of the sealing layer210overlapping with the light emitting region142(portion covering the light emitting portion140). When viewed from the direction perpendicular to the first surface102of the substrate100(FIG.1), the resin layer220overlaps with a portion of the sealing layer210positioned outside the light emitting region142, as well as the portion of the sealing layer210overlapping with the light emitting region142. The resin layer220and the sealing layer210function as a sealing structure for sealing the light emitting portion140. The resin layer220functions as a protective layer for protecting the light emitting portion140and the sealing layer210. The resin layer220contains an acrylic resin, an epoxy resin, or a silicone resin, for example. An upper surface222of the resin layer220is substantially parallel to the first surface102of the substrate100at a region overlapping with the light emitting region142and its periphery. In other words, in the region overlapping with the light emitting region142and its periphery, a height of the upper surface222of the resin layer220with respect to the first surface102of the substrate100is substantially constant regardless of the position in the region and the periphery. In this case, when the light emitting device10is a light emitting device having translucency, the distortion of a transmitted image of the light emitting device10can be reduced. In order to make the upper surface222of the resin layer220substantially parallel to the first surface102of the substrate100in the region overlapping with the light emitting region142and its periphery, it is necessary to adjust the extending of the resin layer220, that is, a position of an end portion of the resin layer220with high accuracy. In the present embodiment, as will be described below, the position of the end portion of the resin layer220can be adjusted with high accuracy by the first structure310or the second structure320.

When viewed from the direction perpendicular to the first surface102of the substrate100(FIG.1), the resin layer220overlaps with the light emitting region142and the first structure310, and an outer end of the resin layer220extends along an outer end of the first structure310(second side surface314described below). The shape of the outer end of the resin layer220, however, is not limited to the example shown inFIG.1. For example, a part of the outer end of the resin layer220may extend along an inner end of the first structure310(first side surface312described below), an outer end of the second structure320(fourth side surface324described below), or an inner end of the second structure320(third side surface322described below). As will be described below, in the present embodiment, the position of the outer end of the resin layer220can be positioned between the inner end of the first structure310(first side surface312described below) or its periphery and the outer end of the second structure320(fourth side surface324described below) or its periphery.

When viewed from the direction perpendicular to the first surface102of the substrate100(FIG.1), the first structure310continuously surrounds the light emitting region142. In other words, the first structure310continuously extends along the outer edge of the light emitting region142, and is not broken at any portion around the light emitting region142. When viewed from the direction perpendicular to the first surface102of the substrate100(FIG.1), the second structure320is positioned outside the first structure310with respect to the light emitting region142, and continuously surrounds the light emitting region142. In other words, the second structure320continuously extends along the outer edge of the first structure310, and is not broken at any portion around the first structure310.

In the cross section perpendicular to the substrate100, specifically, in the cross section (for example, the cross section shown inFIG.2) perpendicular to the first surface102of the substrate100and perpendicular to the extension direction of the first structure310or the second structure320(inFIG.1, the direction in which the first structure310or the second structure320extends along the outer edge of the light emitting region142), the first structure310has the first side surface312, the second side surface314, and a first upper surface316. The first side surface312is positioned at the light emitting region142side. The first side surface312is inclined toward the light emitting region142with distance from the first surface102of the substrate100. The second side surface314is positioned opposite to the first side surface312. The second side surface314is inclined away from the light emitting region142with distance from the first surface102of the substrate100. The first upper surface316is positioned between the first side surface312and the second side surface314, and is substantially parallel to the first surface102of the substrate100. In other words, the shape of the first structure310in one cross section (for example, the cross section shown inFIG.2) is a trapezoid with a lower base (base in contact with the first surface102of the substrate100) shorter than an upper base (base away from the first surface102of the substrate100: the first upper surface316).

In the cross section perpendicular to the substrate100, specifically, in the cross section (for example, the cross section shown inFIG.2) perpendicular to the first surface102of the substrate100and perpendicular to the extension direction of the first structure310or the second structure320(inFIG.1, the direction in which the first structure310or the second structure320extends along the outer edge of the light emitting region142), the second structure320has the third side surface322, the fourth side surface324, and a second upper surface326. The third side surface322is positioned at the first structure310side. The third side surface322is inclined toward the first structure310with distance from the first surface102of the substrate100. The fourth side surface324is positioned opposite to the third side surface322. The fourth side surface324is inclined away from the first structure310with distance from the first surface102of the substrate100. The second upper surface326is positioned between the third side surface322and the fourth side surface324, and is substantially parallel to the first surface102of the substrate100. In other words, the shape of the second structure320in one cross section (for example, the cross section shown inFIG.2) is a trapezoid with a lower base (base in contact with the first surface102of the substrate100) shorter than an upper base (base away from the first surface102of the substrate100: the second upper surface326).

The first structure310and the second structure320contain, for example, a resin, such as the acrylic resin, the epoxy resin, and the silicone resin. In other words, the first structure310and the second structure320may be made of the resin. The first structure310and the second structure320may contain the same material, or may contain different materials from each other. The first structure310and the second structure320have electrical insulation.

In the present embodiment, the position of the end portion of the resin layer220can be adjusted by the position of the first structure310or the second structure320. The reason for this is as follows.

In the present embodiment, the sealing layer210is bent at an angle θ1of an acute angle between the portion of the sealing layer210covering the first upper surface316of the first structure310and the portion of the sealing layer210covering the second side surface314of the first structure310. The resin layer220is formed by curing an uncured resin layer having a relatively low viscosity. When the uncured resin layer is formed in the region surrounded by the first structure310and the uncured resin layer extends toward outside the light emitting portion140in a manufacturing process of the light emitting device10, the uncured resin layer wetting and extending on the portion of the sealing layer210covering the first upper surface316of the first structure310is less likely to wet and extend on the portion of the sealing layer210covering the second side surface314of the first structure310, as compared when the angle θ1is a right angle or an obtuse angle. Accordingly, the position of the end portion of the resin layer220can be adjusted by the position of the first structure310. Even if the end portion of the resin layer220extends to outside the first structure310with respect to the light emitting region142, the second structure320has the same structure as the structure of the first structure310. Accordingly, the position of the end portion of the resin layer220can be adjusted by the position of the second structure320.

In the present embodiment, the upper surface222of the resin layer220over the light emitting portion140is positioned higher than the first upper surface316of the first structure310and the second upper surface326of the second structure320with respect to the first surface102of the substrate100. In other words, the distance between the upper surface222of the resin layer220and the first surface102of the substrate100over the light emitting portion140in the direction perpendicular to the first surface102of the substrate100is larger than the distance between the first upper surface316of the first structure310and the first surface102of the substrate100in the direction perpendicular to the first surface102of the substrate100or the distance between the second upper surface326of the second structure320and the first surface102of the substrate100in the direction perpendicular to the first surface102of the substrate100. In this case, when the uncured resin layer is formed in the region surrounded by the first structure310and the uncured resin layer extends toward outside the light emitting portion140in the manufacturing process of the light emitting device10, the uncured resin layer easily covers the first upper surface316of the first structure310or the second upper surface326of the second structure320. In the present embodiment, however, as described above, the position of the end portion of the resin layer220can be adjusted by the position of the first structure310or the second structure320.

In the present embodiment, the position of the end portion of the resin layer220is adjusted by the shapes of the sealing layer210and the first structure310or the second structure320. In other words, the position of the end portion of the resin layer220can be adjusted without surface treatment on the sealing layer210or the first structure310(for example, liquid repellent treatment). Thus, the manufacturing process of the light emitting device10is easy. The portion of the sealing layer210covering the first structure310or the second structure320, however, may be treated with the liquid repellent.

Next, an example of the method of manufacturing the light emitting device10will be described.

First, the light emitting portion140, the first structure310, and the second structure320are formed over the first surface102of the substrate100. The first structure310and the second structure320may be formed in a step of forming the light emitting portion140, or may be formed before or after the step of forming the light emitting portion140. In an example, the first structure310and the second structure320are formed by photolithography of resist to be the first structure310and the second structure320. For example, exposure and development of a negative resist enables to leave the exposed portion of the resist as the first structure310and the second structure320. In this case, the first structure310and the second structure320are formed by the same step. The steps of forming the first structure310and the step of forming the second structure320, however, may be different from each other.

Next, the sealing layer210is formed over the first surface102of the substrate100. The sealing layer210is formed by, for example, atomic layer deposition (ALD). The sealing layer210, however, may be formed by a method different from the ALD, such as chemical vapor deposition (CVD) or sputtering.

Next, the resin layer220is formed over the first surface102of the substrate100. Specifically, first, the uncured resin layer to be the resin layer220is formed in the region surrounded by the first structure310. The uncured resin layer is formed by, for example, an application process such as inkjet or a deposition process such as vapor deposition. The uncured resin layer has a relatively low viscosity. Accordingly, the uncured resin layer easily extends over the first surface102of the substrate100. In the present embodiment, however, the extending of the uncured resin layer can be limited by the first structure310or the second structure320. That is, the position of the end portion of the uncured resin layer can be adjusted by the position of the first structure310or the second structure320. Next, the uncured resin layer is cured to form the uncured resin layer on the resin layer220. For example, photo-curing or thermosetting is used for curing the uncured resin layer.

In the present embodiment, the light emitting device10includes two structures (first structure310and second structure320). The number of structures in the light emitting device10, however, may be only one. Alternatively, the light emitting device10may include three or more structures.

In the present embodiment, the first side surface312of the first structure310is inclined toward the light emitting region142side (right side inFIG.2) with respect to the direction perpendicular to the first surface102of the substrate100(vertical direction inFIG.2). The first side surface312of the first structure310, however, may be along the direction perpendicular to the first surface102of the substrate100(vertical direction inFIG.2), or may be inclined toward opposite (left side inFIG.2) to the light emitting region142with respect to the direction perpendicular to the first surface102of the substrate100. Similarly, the third side surface322of the second structure320may be along the direction perpendicular to the first surface102of the substrate100(vertical direction inFIG.2), or may be inclined toward opposite (left side inFIG.2) to the light emitting region142with respect to the direction perpendicular to the first surface102of the substrate100.

In the present embodiment, the light emitting portion140includes the organic EL element. The light emitting portion140, however, may have a light emitting portion different from the organic EL element, such as an inorganic EL element or a semiconductor LED (light-emitting diode).

FIG.3is a view showing a modification example ofFIG.2. The example shown inFIG.3is the same as the example shown inFIG.2except for the position of the end portion of the resin layer220. Also in the present modification example, the position of the end portion of the resin layer220can be adjusted by the position of the first structure310or the second structure320. The reason for this is as follows.

In the present modification example, the sealing layer210is bent at an angle θ2of an acute angle between the portion of the sealing layer210covering the first side surface312of the first structure310and the portion of the sealing layer210covering the first upper surface316of the first structure310. The resin layer220is formed by curing an uncured resin layer having a relatively low viscosity. When the uncured resin layer is formed in the region surrounded by the first structure310and the uncured resin layer extends toward outside the light emitting portion140in a manufacturing process of the light emitting device10, the uncured resin layer wetting and extending on the portion of the sealing layer210covering the first side surface312of the first structure310is less likely to wet and extend on the portion of the sealing layer210covering the first upper surface316of the first structure310, as compared with when the angle θ2is a right angle or an obtuse angle. Accordingly, the position of the end portion of the resin layer220can be adjusted by the position of the first structure310. Even if the end portion of the resin layer220extends to outside the first structure310with respect to the light emitting region142, the second structure320has the same structure as the structure of the first structure310. Accordingly, the position of the end portion of the resin layer220can be adjusted by the position of the second structure320.

In the present modification example, the second side surface314of the first structure310is inclined toward opposite to the light emitting region142(left side inFIG.2) with respect to the direction perpendicular to the first surface102of the substrate100(vertical direction inFIG.3). The second side surface314of the first structure310, however, may be along the direction perpendicular to the first surface102of the substrate100(vertical direction inFIG.3), or may be inclined toward the light emitting region142side (right side inFIG.3) with respect to the direction perpendicular to the first surface102of the substrate100. Similarly, the fourth side surface324of the second structure320may be along the direction perpendicular to the first surface102of the substrate100(vertical direction inFIG.3), or may be inclined toward the light emitting region142side (right side inFIG.3) with respect to the direction perpendicular to the first surface102of the substrate100.

FIG.4is a view showing a modification example ofFIG.1.

When viewed from the direction perpendicular to the first surface102of the substrate100(FIG.4), the first structure310discontinuously surrounds the light emitting region142. In other words, the first structure310discontinuously extends along the outer edge of the light emitting region142, and is broken at least one portion around the light emitting region142. When viewed from the direction perpendicular to the first surface102of the substrate100(FIG.4), the second structure320is positioned outside the first structure310with respect to the light emitting region142, and discontinuously surrounds the light emitting region142. In other words, the second structure320discontinuously extends along the outer edge of the first structure310, and is broken at least one portion around the first structure310.

A plurality of portions of the first structure310spaced apart from each other along the outer edge of the light emitting region142and a plurality of portions of the second structure320spaced apart from each other along the outer edge of the light emitting region142are alternately arranged along the outer edge of the light emitting region142. Accordingly, even if a part of the resin layer220extends toward outside the light emitting region142from the region between adjacent portions of the first structure310along the outer edge of the light emitting region142, the extension of a part of the resin layer220can be limited by the second structure320. The plurality of portions of the first structure310spaced apart from each other along the outer edge of the light emitting region142and the plurality of portions of the second structure320spaced apart from each other along the outer edge of the light emitting region142, however, may be aligned along the outer edge of the light emitting region142.

FIG.5is a plan view of the light emitting device10according to Embodiment 2.FIG.6is a view with a plurality of second electrodes130removed fromFIG.5.FIG.7is a view with an insulating layer150and a plurality of partition walls160removed fromFIG.6.FIG.8is a cross-sectional view taken along line B-B ofFIG.5. InFIGS.5to8, an X direction indicates an extension direction of each first electrode110(longitudinal direction of each first electrode110), and a Y direction indicates a direction intersecting the X direction, specifically, a direction orthogonal to the X direction, and indicates an extension direction of each second electrode130(longitudinal direction of each second electrode130). InFIG.5, the B-B direction is along the X direction. For the sake of description,FIGS.5to7do not show the organic layer120and the sealing layer210(FIG.8). The light emitting device10according to Embodiment 2 is the same as the light emitting device10according to Embodiment 1 except the following points.

The light emitting device10includes a substrate100, a plurality of first electrodes110, a plurality of first wires112, a plurality of organic layers120, the plurality of second electrodes130, a plurality of second wires132, an insulating layer150, the plurality of partition walls160, the sealing layer210, the resin layer220, the first structure310, and the second structure320.

The light emitting device10is a light emitting display. Specifically, the light emitting device10includes a plurality of light emitting portions140arranged in a matrix along the X direction and the Y direction. In the example shown inFIGS.5to7, the plurality of light emitting portions140are arranged in four rows in the X direction and seven columns in the Y direction. The layouts of the plurality of light emitting portions140, however, are not limited to the examples shown inFIGS.5to7. Each light emitting portion140is a pixel of the light emitting display.

The light emitting region142of the light emitting device10includes the plurality of light emitting portions140. The light emitting region142is defined as follows. A shape of the light emitting region142is a rectangle having two sides extending along the X direction and two sides extending along the Y direction. The two sides of the light emitting region142extending along the X direction overlap with one side of the light emitting portion140positioned at the outermost side in the Y direction (one side at the outer side in the Y direction of two sides of the light emitting portion140extending along the X direction) among the plurality of light emitting portions140. The two sides of the light emitting region142extending along the Y direction overlap with one side of the light emitting portion140positioned at the outermost side in the X direction (one side at the outer side in the X direction of two sides of the light emitting portion140extending along the Y direction) among the plurality of light emitting portions140.

In the present embodiment, the light emitting device10emits light from the second surface104side of the substrate100. That is, the light emitting device10is a bottom emission. The light emitting device10, however, may emit the light from the first surface102side of the light emitting device10. That is, the light emitting device10may be a top emission. Alternatively, the light emitting device10may emit the light from both the second surface104side and the first surface102side of the substrate100.

The plurality of first electrodes110are positioned over the first surface102of the substrate100. The plurality of first electrodes110extend along the X direction, and are arranged along the Y direction. Each first electrode110has translucency. A transmittance of the visible light of each first electrode110is, for example, equal to or more than 75% and equal to or less than 100%. Each first electrode110can function as the anode. In an example, the first electrode110contains an oxide semiconductor. Examples of the oxide semiconductor include indium tin oxide (ITO), indium zinc oxide (IZO), indium tungsten zinc oxide (IWZO), zinc oxide (ZnO), and indium gallium zinc oxide (IGZO).

The plurality of organic layers120are positioned over the first surface102of the substrate100and over the plurality of first electrodes110to intersect the plurality of first electrodes110. The plurality of organic layers120extend along the Y direction, and are arranged along the X direction. Each organic layer120may include, for example, a hole injection layer (HIL), a hole transport layer (HTL), an emissive layer (EML), an electron transport layer (ETL), and an electron injection layer (EIL) in order from the first electrode110to the second electrode130. Examples of the layers included in each organic layer120, however, are not limited to the example described here.

The plurality of second electrodes130are positioned over the first surface102of the substrate100, over the plurality of first electrodes110, and over the plurality of organic layers120to intersect the plurality of first electrodes110. The plurality of second electrodes130extend along the Y direction, and are arranged along the X direction. Each second electrode130can function as the cathode. In an example, each second electrode130may contain metal or alloy. The metal or alloy is, for example, at least one metal selected from the group consisting of Al, Au, Ag, Pt, Mg, Sn, Zn, and In, or an alloy of the metal selected from the group described above.

The insulating layer150has a plurality of first openings152. The insulating layer150contains, for example, an organic insulating material, such as polyimide. The insulating layer150is positioned over the first surface102of the substrate100and over the plurality of first electrodes110such that a part of each of the plurality of first electrodes110is exposed from each first opening152. Each of the plurality of first openings152defines each of the plurality of light emitting portions140. Specifically, in each first opening152, a part of each first electrode110, a part of each organic layer120, and a part of each second electrode130are arranged in order from the first surface102of the substrate100, and overlap with each other. In other words, each light emitting portion140has a portion of each first electrode110overlapping with the first opening152, a portion of each organic layer120overlapping with the first opening152, and a portion of each second electrode130overlapping with the first opening152.

Each of the plurality of first electrodes110is connected to each of the plurality of first wires112. In the present embodiment, each first electrode110and each first wire112are a common conductive layer. Each first wire112is, for example, a portion of the common conductive layer outside the outer edge of the insulating layer150. Each first electrode110and each first wire112, however, may be different conductive layers. A part of the first wires112is positioned outside the first structure310and the second structure320with respect to the light emitting region142. Accordingly, the voltage can be supplied to the first electrode110from the outside of the light emitting device10through the first wire112.

Each of the plurality of second electrodes130is connected to each of the plurality of second wires132. Each second wire132contains the material described for the first electrode110, for example. One end portion of each second wire132is covered with the insulating layer150. The insulating layer150has a plurality of second openings154. A part of the one end portion of each second wire132is exposed from each second opening154of the insulating layer150, and is in contact with each second electrode130. The other end portion of the second wire132is positioned outside the first structure310and the second structure320with respect to the light emitting region142. Accordingly, the voltage can be supplied to the second electrode130from the outside of the light emitting device10through the second wire132.

The plurality of partition walls160are positioned over the insulating layer150. The plurality of partition walls160extend along the Y direction, and are arranged alternately with the plurality of second electrodes130along the X direction. In other words, each partition wall160is positioned between adjacent second electrodes130. The partition wall160contains, for example, a resin, such as an acrylic resin, an epoxy resin, or a silicone resin. In other words, the partition wall160may be a resin body.

In the cross section perpendicular to the substrate100, specifically, in the cross section perpendicular to the first surface102of the substrate100and perpendicular to the extension direction (Y direction) of the partition wall160(for example, the cross section shown inFIG.8), the partition wall160has a fifth side surface162, a sixth side surface164, and a third upper surface166. The fifth side surface162and the sixth side surface164are opposite to each other. The fifth side surface162is inclined away from the sixth side surface164with distance from the first surface102of the substrate100. The sixth side surface164is inclined away from the fifth side surface162with distance from the first surface102of the substrate100. The third upper surface166is positioned between the fifth side surface162and the sixth side surface164, and is substantially parallel to the first surface102of the substrate100.

A height T3of the partition wall160(length of the partition wall160in the direction perpendicular to the first surface102of the substrate100) is substantially equal to a height T1of the first structure310(length of the first structure310in the direction perpendicular to the first surface102of the substrate100) or a height T2of the second structure320(length of the second structure320in the direction perpendicular to the first surface102of the substrate100). For example, the height T3of the partition wall160is equal to or more than 90% and equal to or less than 110% of the height T1of the first structure310, or is equal to or more than 90% and equal to or less than 100% of the height T2of the second structure320. The height T3of the partition wall160, however, may be different from the height T1of the first structure310or the height T2of the second structure320.

An organic layer120aand a conductive layer130aare positioned over the third upper surface166of the partition wall160. The organic layer120acontains the same material as the organic layer120, and the conductive layer130acontains the same material as the second electrode130.

The sealing layer210covers a first surface102of the substrate100, the plurality of first electrodes no, the plurality of second electrodes130, the insulating layer150, the partition wall160(including the organic layer120aand the conductive layer130aover the third upper surface166of the partition wall160), the first structure310, and the second structure320. The sealing layer210is excellent in step coverage. Accordingly, as shown inFIG.8, in one cross section, the sealing layer210extends along the unevenness formed by the light emitting portion140, the insulating layer150, the partition wall160(including the organic layer120aand the conductive layer130aover the third upper surface166of the partition wall160), the first structure310, and the second structure320over the first surface102of the substrate100.

The resin layer220covers the sealing layer210in the light emitting region142in the same manner as in Embodiment 1. Also in the present embodiment, the position of the end portion of the resin layer220can be adjusted by the position of the first structure310or the second structure320in the same manner as in Embodiment 1.

Next, an example of the method of manufacturing the light emitting device10will be described.

First, the plurality of first electrodes110(including the plurality of first wires112) and the plurality of second wires132are formed over the first surface102of the substrate100. The plurality of first electrodes110and the plurality of second wires132are formed, for example, by patterning the conductive layer. When the plurality of first electrodes110, the plurality of first wires112, and the plurality of second wires132are formed from a common conductive layer, the plurality of first electrodes110, the plurality of first wires112, and the plurality of second wires132contain the same material.

Next, an insulating layer to be the insulating layer150is formed over the first surface102of the substrate100, and the insulating layer is exposed and developed to form the insulating layer150, the plurality of first openings152, and the plurality of second openings154.

Next, the plurality of partition walls160, the first structure310, and the second structure320are formed over the first surface102of the substrate100and over the insulating layer150. Specifically, each partition wall160, the first structure310, and the second structure320are formed by photolithography of resist to be each partition wall160, the first structure310, and the second structure320. For example, exposure and development of a negative resist enables to leave the exposed portion of the resist as each partition wall160, the first structure310, and the second structure320. In this case, the plurality of partition walls160, the first structure310, and the second structure320are formed by the same step. Accordingly, the manufacturing process of the light emitting device10can be simplified. In this case, the plurality of partition walls160, the first structure310, and the second structure320contain the same material (for example, the same resin). The height T3of the partition wall160is almost equal to the height T1of the first structure310or the height T2of the second structure320. A step of forming the plurality of partition walls160and a step of forming the first structure310or the second structure320, however, may be different steps. The material contained in each partition wall160and the material contained in the first structure310or the second structure320may be different from each other.

Next, an organic layer to be the organic layer120is formed over the first surface102of the substrate100by vapor deposition. In this case, the organic layer is divided from each other by each partition wall160to form the plurality of organic layers120, and the organic layer120aremains over each partition wall160. The organic layer120, however, may be formed by a method different from vapor deposition, such as a coating process such as inkjet. In this case, the organic layer is not divided by the plurality of partition walls160, and the organic layer120adoes not remain over each partition wall160.

Next, a conductive layer to be the second electrode130is formed over the first surface102of the substrate100by vapor deposition. In this case, the conductive layer is divided from each other by each partition wall160to form the plurality of second electrodes130, and the conductive layer130aremains over each partition wall160.

Next, the sealing layer210is formed over the substrate100. A forming method of the sealing layer210is the same as the method described in Embodiment 1.

Next, the resin layer220is formed over the first surface102of the substrate100. A forming method of the resin layer220is the same as the method described in Embodiment 1.

FIGS.9to12are cross-sectional views for describing an example of the manufacturing method of the light emitting device10according to Embodiment 3. The light emitting device10according to Embodiment 3 is different from the light emitting device10according to Embodiment 1 or Embodiment 2 except the following points.

First, as shown inFIG.9, the first structure310and two adjacent resist films400are formed over the first surface102of the substrate100. In the example shown inFIG.9, the first structure310and each resist film400extend along the direction perpendicular to the paper, for example, in the same manner as the first structure310shown inFIG.2. In an example, the first structure310and each resist film400are formed by photolithography of resist to be the first structure310and each resist film400. For example, exposure and development of a negative resist enables to leave the exposed portion of the resist as the first structure310and each resist film400. In this case, the first structure310and each resist film400are formed by the same step. In this case, the first structure310and each resist film400contain the same material. The step of forming the first structure310and a step of forming each resist film400, however, may be different steps.

Next, as shown inFIG.10, the conductive layer to be the first wire112and a conductive layer112a(conductive layer112awill be described below) is deposited over the two adjacent resist films400and over the portion of the first surface102of the substrate100positioned between the two adjacent resist films400. The conductive layer is deposited, for example, by vapor deposition. With the resist film400, the conductive layer is separated into the conductive layer (first wire112) over the portion of the first surface102of the substrate100positioned between the two adjacent resist films400, and the conductive layer (conductive layer112a) over each of the two adjacent resist films400.

Next, as shown inFIG.11, the first structure310is covered with a protective layer410, whereas the two adjacent resist films400are not covered with the protective layer410. The protective layer410is, for example, a resist containing a material different from the materials contained in the first structure310and the resist film400.

Next, as shown inFIG.12, the resist film400is removed from the first surface102of the substrate100together with the conductive layer112awhile leaving the first structure310over the first surface102of the substrate100. In other words, the resist film400is lifted off. Specifically, the resist film400can be removed by a solvent that dissolves the resist film400. In this case, even if the first structure310and the resist film400contain the same material, the first structure310is protected from the solvent by the protective layer410. Thus, the first wire112can be patterned while forming the first structure310over the first surface102of the substrate100.

Next, the protective layer410is removed from the first surface102of the substrate100.

In the present embodiment, the light emitting portion140(light emitting region142) is formed over the first surface102of the substrate100before or after the steps shown inFIGS.9to12or in the steps shown inFIGS.9to12. After the light emitting portion140and the first structure310are formed, the sealing layer210and the resin layer220are formed in the same manner as in Embodiments 1 and 2. The first structure310surrounds the light emitting region142when viewed from the direction perpendicular to the first surface102of the substrate100. When viewed from the direction perpendicular to the first surface102of the substrate100, the first wire112may be positioned between the light emitting region142and the first structure310, or may be positioned outside the first structure310with respect to the light emitting region142. Also in the present embodiment, the position of the end portion of the resin layer220can be adjusted by the position of the first structure310.

In the present embodiment, the first wire112is patterned by the lift-off of the resist film400. The conductive layer patterned by the lift-off of the resist film400, however, may be a conductive layer different from the first wire112, or may be, for example, the second wire132.

In the above, the embodiments have been described above with reference to the drawings, these are examples of the present invention, and various configurations other than the above can be adopted.

This application claims priority based on Japanese Patent Application No. 2019-165939 filed on Sep. 12, 2019, the entire disclosure of which is incorporated herein by reference.

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