Patent Publication Number: US-2021167314-A1

Title: Display device

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     The present application claims priority from Japanese application JP2017-074160 filed on Apr. 4, 2017, the content of which is hereby incorporated by reference into this application. 
     BACKGROUND OF THE INVENTION 
     1. Field of the Invention 
     This pertains to a display device. 
     2. Description of the Related Art 
     An organic electroluminescence display device is configured to emit light by a current through an organic film between an anode and a cathode (JP 2011-216778A and JP 2013-058322A). The organic film, in addition to a light-emitting layer, includes a layer for improving carrier implantation efficiency and carrier mobility, with at least one layer thereof being continuous all over a display area. The current flows in a thickness direction of the light-emitting layer to emit light in each pixel, accompanied by a phenomenon where a leakage current flows through the organic film in a lateral direction to emit light in an adjacent pixel. This phenomenon has a larger impact on higher definition, leading to degradation in image quality. 
     The current leakage in the lateral direction can be prevented by patterning every layer constituting the organic film. Due to a limit to high-definition patterning, however, multiple vapor deposition processes are required, necessitating use of multiple fine metal masks. For example, JP 2011-216778A discloses a structure where layers have different thicknesses from color to color. JP 2013-058322A discloses that the light-emitting layers are separated from color to color, without referring to other layers being patterned. 
     SUMMARY OF THE INVENTION 
     This aims to suppress a phenomenon of emitting light in an adjacent pixel by a current leaking in a lateral direction. 
     A display device may include a plurality or pixel electrodes arranged in a matrix along a first direction and a second direction perpendicular to each other. A plurality of light-emitting layers may overlap with the respective plurality of pixel electrodes. A plurality of carrier generation layers may be separated from one another. Each of the plurality of carrier generation layers may continuously overlap with two of the plurality of light-emitting layers. The two are next to each other in a direction oblique to both the first direction and the second direction. A common electrode is opposed to the plurality of pixel electrodes. 
     The two light-emitting layers, with which each carrier generation layer continuously overlaps, are arranged in the direction oblique to both the first direction and the second direction and are further away from each other than other two light-emitting layers arranged in the first direction or second direction, suppressing the phenomena where the current leaking in a lateral direction to emit light in the adjacent pixel. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG. 1  is a perspective view of a display device in accordance with an embodiment. 
         FIG. 2  is an enlarged view of a portion of a II-II line cross section of the display device in  FIG. 1 . 
         FIG. 3  is an enlarged view of a portion pointed by III of the display device in  FIG. 2 . 
         FIG. 4  is an enlarged partial view of an area pointed by IV of the display device in  FIG. 1 . 
         FIG. 5  is a diagram of illustrating some pixel electrodes exposed from an insulation layer. 
         FIG. 6  is a diagram of explaining a process of forming first carrier generation layers. 
         FIG. 7  is a diagram of illustrating a first mask for forming first carrier generation layers. 
         FIG. 8  is a diagram of explaining a process of forming second carrier generation layers. 
         FIG. 9  is a diagram of illustrating a second mask for forming second carrier generation layers. 
         FIG. 10  a diagram of illustrating a variation 1 of the embodiment. 
         FIG. 11  is a diagram of illustrating a variation 2 of the embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
     Hereinafter, embodiments will be described with reference to the drawings. Here, the invention can be embodied according to various aspects within the scope of the invention without departing from the gist of the invention and is not construed as being limited to content described in the embodiments exemplified below. 
     The drawings are further schematically illustrated in widths, thickness, shapes, and the like of units than actual forms to further clarify description in some cases, but are merely examples and do not limit interpretation of the invention. In the present specification and the drawings, the same reference numerals are given to elements having the same functions described in the previously described drawings and the repeated description will be omitted. 
     Further, in the detailed description, “on” or “under” in definition of positional relations of certain constituents and other constituents includes not only a case in which a constituent is located just on or just under a certain constituent but also a case in which another constituent is interposed between constituents unless otherwise mentioned. 
       FIG. 1  is a perspective view of a display device in accordance with an embodiment. The display device is an organic electroluminescence display device. The display device is configured to display a full-color image in full-color pixels, each of which consists of combination of unit pixels (subpixels) of colors such as red, green, and blue. The display device incudes a first substrate  10 . The first substrate  10  has a rectangular planar shape with a side S 1  parallel to a first direction D 1  and a side S 2  parallel to a second direction D 2 . The first direction D 1  and the second direction D 2  are perpendicular to each other. The first substrate  10  may have an integrated circuit chip  12  mounted thereon for driving an element to display the image and an unillustrated flexible printed circuit board connected thereto for external electrical connection. 
       FIG. 2  is an enlarged view of a portion of a II-II line cross section of the display device in  FIG. 1 . The first substrate  10  has an undercoat layer  14  formed thereon for a barrier against impurities contained therein. On the undercoat layer  14  is a semiconductor layer  16 . A source electrode  18  and a drain electrode  20  are electrically connected to the semiconductor layer  16 ; a gate insulating layer  22  is formed to cover the semiconductor layer  16 . On the gate insulating layer  22  sits a gate electrode  24 , which is covered with an interlayer dielectric  26 . The source electrode  18  and the drain electrode  20  penetrate the gate insulating layer  22  and the interlayer dielectric  26 . The semiconductor layer  16 , the source electrode  18 , the drain electrode  20 , and the gate electrode  24  constitute at least part of a thin film transistor TFT, which is covered with a passivation film  28 . 
     A planarization film  30  formed over the passivation film  28 . On the planarization film  30  are a plurality of electrodes  32  (e.g. anode) configured to correspond to the respective unit pixels. The planarization film  30  is formed to be flat on a surface where at least the pixel electrodes  32  are disposed. The pixel electrode  32  is electrically connected to one of the source electrode  18  and the drain electrode  20  on the semiconductor layer  16  through a contact hole  34  penetrating the planarization film  30  and passivation film  28 . 
     On the planarization film  30  and the pixel electrode  32  is an insulation layer  36 , which is formed to sit on a periphery of the pixel electrode  32  and to have an opening to expose a portion (e.g. central portion) of the pixel electrode  32 . The insulation layer  36  constitutes a bank around the portion of the pixel electrode  32 . The pixel electrode  32  is part of the light-emitting element  38 . The light-emitting element  38  further includes a common electrode  40  (e.g. cathode) and an organic electroluminescence layer  42 . The common electrode  40  is opposed to the plurality of pixel electrodes  32 . 
       FIG. 3  is an enlarged view of a portion pointed by III of the display device in  FIG. 2 . The organic electroluminescence layer  42  includes light-emitting layers EML. The light-emitting layers EML are disposed (separately) on the respective pixel electrodes  32  and sit on the insulation layer  36  as well. In this case, the light-emitting layer EML emits light in blue, red, or green in accordance with the corresponding pixel. The color in accordance with each pixel is not limited thereto and may be yellow or white. The light-emitting layer EML may be formed by vapor deposition or may be formed to entirely cover the display area over the plurality of pixels. The light-emitting layer EML may be formed to be continuous over the insulation layer  36 . In this case, the light-emitting layer EML is formed by a coating method using solvent dispersion. The light-emitting layer EML over the plurality of pixels is configured to emit white light at every subpixel, with intended color wavelengths extracted through a color filter unillustrated. 
     Between the pixel electrode  32  and the light-emitting layer EML is interposed a hole injection layer HIL and a hole transport layer HTL. Additionally, between the hole transport layer HTL and the light-emitting layer EML is an electron block layer EBL. The hole injection layer HIL is contact with the pixel electrode  32 . Between the common electrode  40  and the light-emitting layer EML is an electron injection layer EIL and an electron transport layer ETL. Additionally, between the electron transport layer ETL and the light-emitting layer EML is a hole block layer HBL. 
     The light-emitting layer EML is between the pixel electrode  32  and the common electrode  40  to emit light, with brightness controlled by a current flowing therebetween. The common electrode  40  may be made from a metallic thin film with light transmission properties, displaying an image by transmitting light generated in the light-emitting layer EML. The pixel electrode  32  includes a reflective film for reflecting the light generated in the light-emitting layer EML toward the common electrode  40 . 
     As shown in  FIG. 2 , the light-emitting element  38  is blocked from moisture by being sealed with a sealing film  44 . The sealing film  44  includes an inorganic layer formed from an inorganic material such as silicon nitride and may have a structure where an organic layer is interposed between a pair of inorganic layers. A second substrate  48  is attached to the sealing film  44  with an adhesive layer  46  interposed therebetween. 
       FIG. 4  is an enlarged partial view of an area pointed by IV of the display device in  FIG. 1 . The plurality of pixel electrodes  32  are arranged in a matrix along a first direction D 1  and a second direction D 2  perpendicular to each other. The plurality of light-emitting layers EML (E 1 , E 2 , E 3 , E 4 ) are separated from one another. The plurality of light-emitting layers EML overlap with the respective plurality of pixel electrodes  32 . 
     The plurality of light-emitting layers EML fall into some groups G. Each group G includes a first light-emitting layer E 1 , a second light-emitting layer E 2 , a third light-emitting layer E 3 , and a fourth light-emitting layer E 4 , arranged in a clockwise direction. The first light-emitting layer E 1  and the second light-emitting layer E 2  are next to each other in the first direction D 1 . The second light-emitting layer E 2  and the third light-emitting layer E 3  are next to each other in the second direction D 2 . The third light-emitting layer and the fourth light-emitting layer E 4  are next to each other in the first direction D 1 . The fourth light-emitting layer E 4  and the first light-emitting layer E 1  are next to each other in the second direction D 2 . The first light-emitting layer E 1  and the third light-emitting layer E 3  are next to each other in third direction D 3 , which is oblique to both the first direction D 1  and second direction D 2 . The second light-emitting layer E 2  and the fourth light-emitting layer E 4  are next to each other in a fourth direction D 4 , which is oblique to both the first direction D 1  and second direction D 2 . The third direction D 3  and the fourth direction D 4  are perpendicular to each other. At least three of the first light-emitting layer E 1 , the second light-emitting layer E 2 , the third light-emitting layer E 3 , and the fourth light-emitting layer E 4  are configured to emit light in colors different from one another for forming the full-color pixel. 
     In the embodiment, the hole in layer HIL, which is in close contact with each pixel electrode  32 , is a carrier generation layer  50 . The carrier generation layer  50  is formed from an organic material with acceptors doped therein for serving to accept electrons. The acceptors turn into acceptor ions upon acceptance of the electrons, generating holes. The acceptors serve to accept the electrons from the organic material. 
     The carrier generation layers  50  are separated from one another. Each carrier generation layer  50  continuously of with two light-emitting layers EML, which are next to each other in a direction (e.g. third direction D 3  or fourth direction D 4 ) oblique to both the first direction D 1  and the second direction D 2 . 
     The plurality of carrier generation layers  50  include first carrier generation layers  50   a.  Each first carrier generation layer  50   a  overlaps with the first light-emitting layer E 1  and the third light-emitting layer E 3  included in a corresponding group G. Specifically, the first carrier generation layer  50   a  continuously overlaps with two adjacent light-emitting layers EML next to each other in the third direction D 3 . 
     The plurality of carrier generation layers  50  include second carrier generation layers  50   b.  Each second carrier generation layer  50   b  overlaps with the second light-emitting layer E 2  and the fourth light-emitting layer E 4  included in a corresponding pair of groups G next to each other in the fourth direction D 4 . Specifically, the second carrier generation layer  50   b  continuously overlaps with two adjacent light-emitting layers EML next to each other in the fourth direction D 4 . 
     The two light-emitting layers EML, with which each carrier generation layer  50  continuously overlaps, are arranged in the direction (third direction D 3  or fourth direction D 4 ) oblique to both the first direction D 1  and the second direction D 2  and are further away from each other than other two light-emitting layers EML arranged in the first direction D 1  or second direction D 2 , suppressing the phenomena where the current leaking in a lateral direction to emit the light in the adjacent pixel. 
       FIGS. 5-9  are diagrams to explain a manufacturing method of the display device in accordance with the embodiment.  FIG. 5  is a diagram of illustrating some pixel electrodes  32  exposed from an insulation layer  36 . Any processes leading to the illustration may be obvious from the foregoing disclosure, their explanations omitted. 
     The plurality of pixel electrodes  32  fall into some groups. Each group includes a first pixel electrode  32   a , a second pixel electrode  32   b,  a third pixel electrode  32   c,  and a fourth pixel electrode  32   d,  arranged in a clockwise direction. The first pixel electrode  32   a  and the second pixel electrode  32   b  are next to each other in the first direction D 1 . The second pixel electrode  32   b  and the third pixel electrode  32   c  are next to each other in the second direction D 2 . The third pixel electrode  32   c  and the fourth pixel electrode  32   d  are next to each other in the first direction D 1 . The fourth pixel electrode  32   d  and the first pixel electrode  32   a  are next to each other in the second direction D 2 . The first pixel electrode  32   a  and the third pixel electrode  32   c  are next to each other in the third direction D 3 . The second pixel electrode  32   b  and the fourth pixel electrode  32   d  are next to each other in the fourth direction D 4 . 
       FIG. 6  is a diagram of explaining a process of forming first carrier generation layers  50   a.  As shown in  FIG. 6 , the first carrier generation layers  50   a  (hole injection layer HIL) are formed on the pixel electrodes  32  and insulation layer  36 . Each first carrier generation layer  50   a  overlaps with the first pixel electrode  32   a  and the third pixel electrode  32   c,  included in corresponding one of the groups. The first pixel electrode  32   a  and the third pixel electrode  32   c  are next to each other in the direction (e.g. third direction D 3 ) oblique to both the first direction D 1  and the second direction D 2 . 
       FIG. 7  is a diagram of illustrating a first mask  52  for forming first carrier generation layers  50   a.  The first mask  52  has a plurality of openings  52   a  corresponding to the respective first carrier generation layers  50   a.  The first carrier generation layers  50   a  are formed by vapor deposition using the first mask  52 . 
       FIG. 8  is a diagram of explaining a process of forming second carrier generation layers  50   b.  As shown in  FIG. 8 , the second carrier generation layers  50   b  (hole injection layer HIL) are formed on the pixel electrodes and the insulation layer  36 . Each second carrier generation layer  50   b  overlaps with the second pixel electrode  32   b  and the fourth pixel electrode  32   d  included in a corresponding pair of the groups next to each other in the fourth direction D 4 . 
       FIG. 9  is a diagram of illustrating a second mask  54  for forming second carrier generation layers  50   b.  The second mask  54  has a plurality of openings  54   a  corresponding to the respective second carrier generation layers  50   b.  The second carrier generation layers  50   b  are formed by vapor deposition using the second mask  54 . Alternatively, the first mask  52  in  FIG. 7 , with 90-degree rotation, may be substituted for the second mask  54 . 
       FIG. 10  is a diagram of illustrating a variation 1 of the embodiment. In this variation, the carrier generation layer  150  includes a hole injection layer HIL and a hole transport layer HTL. The acceptors serve to accept electrons from the hole transport layer HTL. The invention includes such an example. 
       FIG. 11  is a diagram of illustrating a variation 2 of the embodiment. The variation differs from the above embodiment in that the pixel electrode  232  has a planar shape (specifically an area exposed from the insulation layer  236 ) formed in a circle. The pixel electrodes  232  are arranged in a matrix along the first direction D 1  and the second direction D 2 . The first substrate  210  has a third side S 3  parallel to the third direction D 3  and a fourth side S 4  parallel to the fourth direction D 4 . The invention includes such an example. 
     The display device is not limited to the organic electroluminescence display device but may be a display device with light-emitting elements disposed in respective pixels, such as a quantum-dot light-emitting diode (QLED). 
     While there have been described what are at present considered to be certain embodiments, it will be understood that various modifications may be made thereto, and it is intended that the appended claims cover all such modifications as fall within the true spirit and scope of the invention.