Source: http://www.freepatentsonline.com/7728326.html
Timestamp: 2019-11-20 05:08:48
Document Index: 255774357

Matched Legal Cases: ['art 2003', 'art 2', 'art 12', 'art 40', 'art 314', 'art 304']

Light emitting device and electronic apparatus - Semiconductor Energy Laboratory Co., Ltd.
United States Patent 7728326
11/723437
257/79, 257/99, 257/E51.018, 257/E51.019, 257/E51.02, 257/E51.021, 257/E51.022
H01L35/24; H01L51/52
257/99, 257/40, 257/79, 257/E51.018- 22
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Bryant, Kiesha R.
1. A light emitting device comprising: a substrate; a first insulating film over the substrate; a light emitting element over the first insulating film, the light emitting element having a cathode, an organic compound layer in contact with the cathode, and an anode in contact with the organic compound layer; a layer comprising Al, N and O over the light emitting element; a conductive film adhering a flexible print circuit in a terminal portion over the first insulating film; and a second insulating film over the layer comprising Al, N and O and the conductive film, wherein the light emitting element is covered by the layer comprising Al, N and O.
8. A light emitting device comprising: a substrate; a first layer comprising Al, N and O on the substrate; a first insulating film over the first layer comprising Al, N and O; a light emitting element over the first insulating film, the light emitting element having a cathode, an organic compound layer in contact with the cathode, and an anode in contact with the organic compound layer; a second layer comprising Al, N and O over the light emitting element; a conductive film adhering a flexible print circuit in a terminal portion over the first insulating film; and a second insulating film over the second layer comprising Al, N and O and the conductive film, wherein the light emitting element is covered by the second layer comprising Al, N and O.
15. A light emitting device comprising: a substrate; a first layer comprising Al, N and O on the substrate; a layer comprising organic resin on the first layer comprising Al, N and O; a second layer comprising Al, N and O on the layer comprising organic resin; a first insulating film over the second layer comprising Al, N and O; a light emitting element over the first insulating film, the light emitting element having a cathode, an organic compound layer in contact with the cathode, and an anode in contact with the organic compound layer; a third layer comprising Al, N and O over the light emitting element; a conductive film adhering a flexible print circuit in a terminal portion over the first insulating film; and a second insulating film over the third layer comprising Al, N and O and the conductive film, wherein the light emitting element is covered by the third layer comprising Al, N and O.
24. A light emitting device comprising: a plastic substrate; a first insulating film over the plastic substrate; a light emitting element over the first insulating film, the light emitting element having a cathode, an organic compound layer in contact with the cathode, and an anode in contact with the organic compound layer; a layer comprising Al, N and O over the light emitting element; a conductive film adhering a flexible print circuit in a terminal portion over the first insulating film; and a second insulating film over the layer comprising Al, N and O and the conductive film, wherein the light emitting element is covered by the layer comprising Al, N and O.
32. A light emitting device comprising: a plastic substrate; a first layer comprising Al, N and O on the plastic substrate; a first insulating film over the first layer comprising Al, N and O; a light emitting element over the first insulating film, the light emitting element having a cathode, an organic compound layer in contact with the cathode, and an anode in contact with the organic compound layer; a second layer comprising Al, N and O over the light emitting element; a conductive film adhering a flexible print circuit in a terminal portion over the first insulating film; and a second insulating film over the second layer comprising Al, N and O and the conductive film, wherein the light emitting element is covered by the second layer comprising Al, N and O.
40. A light emitting device comprising: a plastic substrate; a first layer comprising Al, N and O on the plastic substrate; a layer comprising organic resin on the first layer comprising Al, N and O; a second layer comprising Al, N and O on the layer comprising organic resin; a first insulating film over the second layer comprising Al, N and O; a light emitting element over the first insulating film, the light emitting element having a cathode, an organic compound layer in contact with the cathode, and an anode in contact with the organic compound layer; a third layer comprising Al, N and O over the light emitting element; a conductive film adhering a flexible print circuit in a terminal portion over the first insulating film; and a second insulating film over the third layer comprising Al, N and O and the conductive film, wherein the light emitting element is covered by the third layer comprising Al, N and O.
FIG. 1A is a top view which shows an EL module, and FIG. 1B is a sectional view cut along the line of A-A′ of FIG. 1A. In FIG. 1B, a film substrate 10a (for example, a plastic substrate) having flexibility on which surface, disposed is a lamination layer of a layer 10b which functions as a barrier film and is represented by AlNxOy (called also as an AlNxOy film) and a stress relaxation film (organic resin) 10c and an AlNxOy film 10d, is adhered to an insulating film 11 by an adhesive layer 33. In addition, a material which stress is smaller than that of the barrier film may be used as the adhesive layer 33 and it may be made to function as a stress relaxation film. As just described, by layering a plurality of barrier films 10b and 10d, even in case that the barrier film suffers some cracks, other barrier film effectively prevents impurities such as moisture and oxygen from getting into the light emitting layer. In addition, by disposing the stress relaxation film between a plurality of barrier films, obtained is a light emitting device which is more flexible and cracks may be prevented when it is bent.
Moreover, the pixel part 12 and the driving circuits 13 and 14 are sealed by a covering member 30a by use of adhesive. The covering member 30a is adhered as a supporting body before peeling. In addition, in case that the peeling is carried out after the covering member 30a as the supporting body is adhered, there exist only insulating films 20 and 11 at a portion of a wiring lead-out terminal (connecting portion) and mechanical strength is weakened and therefore, before peeling, the FPC 19 is affixed and further, fixed by an organic resin 32.
Here, it is preferable that in order to resist against transformation due to heat or external force, as the covering member 30a, one which is the same material as the film substrate 10a, for example, a plastic substrate may be used. In addition, in order to block intrusion of impurities such as moisture and oxygen, an AlNxOy film 30b is formed in advance on the covering member 30a. Here, in order to transmit emitting light through the covering member, a barrier layer (AlNxOy film 30b) as a single layer was used, but in the same manner as in the film substrate 10a, a plurality of barrier layers and a layer (stress relaxation film) which is disposed between the barrier layers and has smaller stress than that of the barrier layer may be used. In that case, as a stress relaxation film, one that has high translucency is used.
By sealing the light emitting element by the barrier films 10b and 10d represented by AlNxOy and the protective film 29 represented by AlNxOy by use of the above-described structure, the light emitting element can be completely blocked from an ambient air and it is possible to block intrusion of a material for inducing deterioration of which main cause is oxidization of the organic compound layer by moisture and oxygen from outside of the device. In addition, heat developed can be exhaled by AlNxOy film having a thermal conduction characteristic. Accordingly, it is possible to obtain a light emitting device which has high reliability.
Further, FIG. 2 shows an outline view of a flexible light emitting device 45 to which an external force is applied. In FIG. 2, 40 represents a pixel part, and 41 represents an FPC, and 42a and 42b represent integrated circuits, and 43a and 43b represent gate side driving circuits, and 44 represents a source side driving circuit, and 45a and 45b represent film substrates. A lamination layer of a layer which is represented by AlNxOy and a layer which comprises an organic resin is disposed on one side or both sides of film substrates 45a and 45b, and blocks intrusion of impurities such as moisture, oxygen and alkaline metal from outside to protect the light emitting element and TFT.
In addition, on the film substrate 45a, the pixel part 40, the driving circuit and the light emitting element are disposed and these elements are sandwiched together with the film substrate 45b. It is possible to form complex integrated circuits (such as a memory, a CPU, a controller and a D/A converter) 42a and 42b on the same substrate as that on which these pixel part and the driving circuit are formed, but it is difficult to manufacture it by use of small number of masks. Accordingly, it is preferable to carry out mounting one IC chip which has the memory, the CPU, the controller and the D/A converter by a COG (chip on glass) system, a TAB (tape automated bonding) system and a wire bonding method. It should be appreciated that the IC chip may be mounted after the film substrate 45a and the film substrate 45b are adhered, and the IC chip may be sealed by the film substrate 45b after the IC chip is mounted on the film substrate 45a.
Next, as shown in FIG. 3C, masks 109 is formed by a light exposure step, and a first etching process for forming gate electrodes and wirings is performed. An ICP (Inductively Coupled Plasma) etching method may be preferably used for the etching process. The ICP etching method is used, and the etching conditions (an electric energy applied to a coil-shape electrode, an electric energy applied to an electrode on a substrate side, a temperature of the electrode on the substrate side, and the like) are appropriately adjusted, whereby a film can be etched to have a desired taper shape. Note that chlorine-based gases typified by Cl2, BCl3, SiCl4, CCl4 or the like, fluorine-based gases typified by CF4, SF6, NF3, or the like and O2 can be appropriately used as etching gases. In the first etching process, the edges of the films can be tapered owing to the shape of the resist mask and the effect of the bias voltage applied to the substrate side. The angle of the tapered portion is set to 15 to 45°. In order to etch the films without leaving any residue on the gate insulating film, the etching time is prolonged by about 10 to 20%. The selective ratio of the silicon oxynitride film to the W film is 2 to 4 (typically, 3), and hence the exposed surface of the silicon oxynitride film is etched by about 20 to 50 nm through the over-etching treatment. Through the first etching treatment, the first shape conductive layers 110 and 111 (first conductive layers 110a and 111a and second conductive layers 110b and 111b) are formed from the first conductive film and the second conductive film. Denoted by 112 is a gate insulating film and a region of the gate insulating film which is not covered with the first shape conductive layers is etched and thinned by about 20 to 50 nm.
Then, the second doping treatment is carried out as shown in FIG. 4A. The film is doped with an n-type impurity (donor) in a dose smaller than in the first doping treatment at a high acceleration voltage. For example, the acceleration voltage is set to 70 to 120 keV and the dose is set to 1×1013/cm2. As a result, impurity regions are formed inside the first impurity regions that have been formed in the semiconductor layer in FIG. 3D. In the second doping treatment, the second conductive films 110b and 111b are used as masks against the impurity element and the impurity element reaches regions below the first conductive films 110a and 111a. Thus formed are impurity regions (n− region) 115 and 116 that overlap the first conductive films 110a and 111a, respectively. Since the remaining first conductive layers 110a and 111a have almost the uniform thickness, the concentration difference along the first conductive layers is small and the concentration in the impurity regions is 1×1017 to 1×1019/cm3.
The second etching treatment is then conducted as shown in FIG. 4B. In this etching treatment, ICP etching is employed, CF4, Cl2 and O2 are mixed as etching gas, and plasma is generated by giving RF (13.56 MHz) power of 500 W to a coiled electrode at a pressure of 1 Pa. RF (13.56 MHz) power of 50 W is also given to the substrate side (sample stage) so that a self-bias voltage lower than that of the first etching treatment can be applied. The tungsten film is subjected to anisotropic etching under these conditions so that the tantalum nitride film or the titanium film serving as the first conductive layers is remained. In this way, second shape conductive layers 117 and 118 (first conductive films 117a and 118a and second conductive films 117b and 118b) are formed. Denoted by 119 is a gate insulating film and a region of the gate insulating film which is not covered with the second shape conductive layers 117 and 118 is further etched and thinned by about 20 to 50 nm.
An n-channel TFT has a channel formation region 131; an impurity region 116a (Gate Overlapped Drain: GOLD region) overlapping the gate electrode 118 that is formed of the second shape conductive layer; an impurity region 116b (LDD region) formed outside the gate electrode; and an impurity region 119 functioning as a source region or a drain region.
In FIG. 6A, 300 represents a substrate, and 301 represents a nitride layer, and 302 represents an oxide layer, and 303 represents a furring insulating layer, and 304a-304c represent TFTs, and 305 represents a light emitting element, and 306 represents an interlayer insulating film.
Then, on the second material layer 302, a layer to be peeled off is formed. The layer to be peeled off may be a layer which contains various elements as represented by TFT (a thin film diode, a photoelectric conversion element having a PIN bonding with silicon and a silicon resistance element). Further, thermal processing can be carried out within a range that the substrate 300 can resist. In addition, in the invention, even when film stress of the second material layer 302 is different from film stress of the first material layer 301, peeling does not occur by thermal processing in a process for forming the layer to be peeled off. Here, as the layer to be peeled off, on the base insulating layer 303, an element 304a of the driving circuit 313 and elements 304b and 304c of the pixel part 314 are formed, and a light emitting element 305 for electrically connecting to the element 304c of the pixel part 304 is formed, and in order to cover the light emitting element, an interlayer insulating film (organic resin having translucency) 306 with film thickness of 10 nm to 1000 nm is formed (FIG. 6A).
Then, the second material layer 302 is attached to a transferring body 309a by the adhesive layer 308 such as epoxy resin. In the preferred embodiment, shown was an example which has the air gap between the covering member and the protective film, but in this embodiment, shown is an example in which the adhesive layer is adhered to the protective film 307.
Further, here, weight saving is carried out by use of a plastic film substrate as the transferring body 309a. Furthermore, by disposing a lamination layer of a layer which functions as a barrier film and is represented by AlNxOy (called as AlNxOy film) 309b and a stress relaxation film (organic resin) 309c and an AlNxOy film 309d on the transferring body 309a, the barrier film effectively prevents intrusion of impurities such as moisture and oxygen in a light emitting layer and a penetration of impurities such as moisture and oxygen into a light emitting layer is prevented effectively by the barrier film. At the same time, a light emitting device having more flexibility can be obtained by providing a stress relaxing film between a plurality of barrier film, and an occurrence of crack can be prevented.
The cross-sectional structure shown in FIG. 8 is described. The film substrate 1000a provided with the lamination layer composed of the AlNxOy film 1000b and the stress relaxation film 1000c is bonded to the insulating film 1001 with a bonding layer 1023. The insulating film 1010 is formed on the insulating film 1001. The pixel portion 1002 and the gate driving circuit 1003 are formed above the insulating film 1010. The pixel portion 1002 is composed of the current control TFT 1011 and plural pixels including the pixel electrode 1012 that is connected electrically to the drain of the current control TFT 1011. The current control TFT 1011 is possible to use an n-channel TFT, however, it is prefer to use a p-channel TFT. In addition, the gate driving circuit 1003 is formed by using a CMOS circuit that is combined with the n-channel TFT 1013 and the p-channel TFT 1014.
The cathode 1017 also functions as a common wiring element connected to all the pixels and is electrically connected to a FPC 1009 via connection wiring 1008. All the elements included in the pixel portion 1002 and the gate driving circuit 1003 are covered with the cathode 1017, an organic resin 1018 and a protective film 1019. It is possible to apply the AlNxOy film the same as the AlNxOy film 1000b as the protective film 1019 and it is bonded by a cover member 1020 and a bonding layer. A recess portion is formed in the cover member and a desiccant 1021 is set therein.
In FIG. 9 is illustrated a flexible film substrate 1100a (e.g., a plastic substrate), an AlNxOy film 1100b, an AlNxOy film 1100d, a stress easing film (organic resin) 1100c, an insulating film as the second material layer (e.g. a silicon oxide film), a pixel portion 1102, a gate driving circuit 1103, an insulating film 1110, a pixel electrode (cathode) 1112, a bank 1115, an organic compound layer 1116, an anode 1117, an organic resin 1118, a protective film (AlNxOy film) 1119, a cover member 1120, a desiccant 1121, an organic resin 1122, and a bonding layer 1123.
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