Abstract:
An organic light-emitting display device preventing edge defects between a pixel define layer and a pixel electrode, and a method of manufacturing the same. The organic light-emitting display device, comprises: a substrate; a pixel electrode disposed on the substrate and comprising a first pattern unit and a second pattern unit which are electrically disconnected; a pixel define unit disposed on the substrate and exposing the pixel electrode; an intermediate layer disposed on the pixel electrode and emitting light; and a counter electrode disposed on the intermediate layer and the pixel define layer.

Description:
CLAIM OF PRIORITY 
       [0001]    This application makes reference to, incorporates the same herein, and claims all benefits accruing under 35 U.S.C. §119 from an application earlier filed in the Korean Intellectual Property Office on May 11, 2010 and there duly assigned Serial No. 10-2010-0044049. 
       BACKGROUND OF THE INVENTION 
       [0002]    1. Field of the Invention 
         [0003]    The present invention relates to an organic light-emitting display device and a method of manufacturing the same, and more particularly, to an organic light-emitting display device preventing edge defects between a pixel define layer and a pixel electrode, and a method of manufacturing the organic light-emitting display device. 
         [0004]    2. Description of the Related Art 
         [0005]    In general, flat display devices are largely classified into a light-emitting type and a light-receiving type. Examples of a light-emitting type include a flat cathode ray tube, a plasma display panel, an electroluminescent device, and a light-emitting diode. Examples of a light-receiving type include a liquid crystal display. Electroluminescent devices have a wide viewing angle, excellent contrast, and quick response speeds, and thus they have come into the spotlight as next generation display devices. The electroluminescent devices are classified into inorganic electroluminescent devices and organic light-emitting display devices based on the material used to form an emission layer (EML). 
         [0006]    The organic light-emitting display device, which is a self-emitting display apparatus in which light is emitted by excitation of a fluorescent organic material, is driven at a low voltage, is thin, and has a wide viewing angle and quick response speeds, and thus it may be used as next generation display devices. 
         [0007]    An organic light-emitting display device includes an anode, a cathode, and an EML formed of an organic material and disposed between the anode and the cathode. When an anode voltage and a cathode voltage are applied to the anode and the cathode, respectively, holes are transported from the anode to an EML through a hole transport layer (HTL), and electrons are transported from the cathode to the EML through an electron transport layer (ETL). The holes and the electrons are combined in the EML, and thus excitons are generated. 
         [0008]    When the exciton is changed from an excited state to a ground state, fluorescent molecules of the EML emit light, thereby forming an image. A full color type organic light-emitting display device may realize full color by using pixels emitting red®, green (G), and blue (B) lights. 
         [0009]    The organic light-emitting display devices include a pixel define layer at each end of the anode. A predetermined opening is formed in the pixel define layer, and then the EML and the cathode are sequentially formed on top of the anode exposed through the opening in the pixel define layer. 
       SUMMARY OF THE INVENTION 
       [0010]    The present invention provides an organic light-emitting display device preventing edge defects between a pixel define layer and a pixel electrode and a method of manufacturing the same. 
         [0011]    According to an aspect of the present invention, an organic light-emitting display device comprises: a substrate; a pixel electrode disposed on the substrate and including a first pattern unit and a second pattern unit which are electrically disconnected; a pixel define unit disposed on the substrate and exposing the pixel electrode; an intermediate layer disposed on the pixel electrode and emitting light; and a counter electrode disposed on the intermediate layer and the pixel define layer. 
         [0012]    The first pattern unit may be spaced apart from the second pattern unit so as to be electrically disconnected from the second pattern unit. 
         [0013]    The second pattern unit may be disposed at outer sides of the first pattern unit. 
         [0014]    The second pattern unit may be disposed so as to be spaced apart from the first pattern unit and to surround the first pattern unit. 
         [0015]    The second pattern unit may be disposed at an edge of the first pattern unit so as to be spaced apart from the first pattern unit. 
         [0016]    The second pattern unit may be disposed at opposing sides of the first pattern unit so as to be spaced apart from the first pattern unit. 
         [0017]    The intermediate layer disposed on the first pattern unit emits light, and the intermediate layer disposed on the second pattern unit does not emit light. 
         [0018]    The intermediate layer may be formed by inkjet printing. 
         [0019]    The organic light-emitting display device may further include: a pixel circuit unit disposed between the substrate and the pixel electrode and electrically connected to the pixel electrode; and an insulating layer disposed between the pixel circuit unit and the pixel electrode. 
         [0020]    The pixel circuit unit may be a thin-film transistor. 
         [0021]    The pixel circuit unit may be disposed on the substrate so as to correspond to the pixel define layer. 
         [0022]    The pixel circuit unit may be disposed on the substrate so as to correspond to the pixel electrode. 
         [0023]    According to another aspect of the present invention, a method of manufacturing an organic light-emitting display device comprises: forming a pixel electrode on a substrate; patterning the pixel electrode into a first pattern unit and a second pattern unit which are electrically disconnected; forming a pixel define layer so as to expose a portion of the pixel electrode; forming an intermediate layer on the pixel electrode; and forming a counter electrode on the pixel define layer and the pixel electrode. 
         [0024]    The first pattern unit and the second pattern unit may be formed by photolithography. 
         [0025]    The first pattern unit may be spaced apart from the second pattern unit so as to be electrically disconnected from the second pattern unit. 
         [0026]    The second pattern unit may be disposed at outer sides of the first pattern unit. 
         [0027]    The second pattern unit may be disposed so as to be spaced apart from the first pattern unit and so surround the first pattern unit. 
         [0028]    The second pattern unit may be disposed at an edge of the first pattern unit so as to be spaced apart from the first pattern unit. 
         [0029]    The second pattern unit may be disposed at opposing sides of the first pattern unit so as to be spaced apart from the first pattern unit. 
         [0030]    The intermediate layer disposed on the first pattern unit emits light, and the intermediate layer disposed on the second pattern unit does not emit light. 
         [0031]    The intermediate layer may be formed by inkjet printing. 
         [0032]    The method may further include: forming a pixel circuit unit on the substrate; forming an insulating layer so as to cover the pixel circuit unit; and forming a contact hole in the insulating layer so as to expose a portion of the pixel circuit unit before forming the pixel electrode; wherein the pixel electrode is electrically connected to the pixel circuit unit via the contact hole. 
         [0033]    The pixel circuit unit may be a thin-film transistor. 
         [0034]    The pixel circuit unit may be disposed on the substrate so as to correspond to the pixel define layer. 
         [0035]    The pixel circuit unit may be disposed on the substrate so as to correspond to the pixel electrode. 
     
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         [0036]    A more complete appreciation of the invention, and many of the attendant advantages thereof, will be readily apparent as the same becomes better understood by reference to the following detailed description when considered in conjunction with the accompanying drawings, in which like reference symbols indicate the same or similar components, wherein: 
           [0037]      FIG. 1  is a cross-sectional view of a pixel circuit unit according to an embodiment of the present invention; 
           [0038]      FIG. 2  is a plan view of an organic light-emitting display device according to an embodiment of the present invention; 
           [0039]      FIG. 3  is a plan view of a sub-pixel of the organic light-emitting display device of  FIG. 2 ; 
           [0040]      FIG. 4  is a cross-sectional view taken along line I-I of  FIG. 3 ; 
           [0041]      FIG. 5  is a cross-sectional view taken along line II-II of  FIG. 3 ; 
           [0042]      FIGS. 6  thru  9  are plan views of sub-pixels according to embodiments of the present invention; 
           [0043]      FIG. 10  is a plan view of an organic light-emitting display device according to another embodiment of the present invention; and 
           [0044]      FIG. 11  is a cross-sectional view taken along line III-III of  FIG. 10 . 
       
    
    
     DETAILED DESCRIPTION OF THE INVENTION 
       [0045]    Hereinafter, the present invention will be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the invention are shown. 
         [0046]      FIG. 1  is a cross-sectional view of a pixel circuit unit according to an embodiment of the present invention. 
         [0047]    Referring to  FIG. 1 , the pixel circuit unit may be a thin-film transistor (TFT)  10 . The TFT  10  may be disposed on a substrate  20 . The substrate  20  may be a glass substrate or a plastic substrate. 
         [0048]    A buffer layer  21  is disposed on the substrate  20 , an active layer  22 , including a semiconductor material, is disposed on the buffer layer  21 , and a gate insulating layer  23  is disposed so as to cover the active layer  22 . A gate electrode  24  is disposed on the gate insulating layer  23 , an interlayer insulating layer  25  is disposed so as to cover the gate electrode  24 , and source and drain electrodes  26  and  27 , respectively, are disposed on the interlayer insulating layer  25 . The source and drain electrodes  26  and  27 , respectively, are formed so as to contact source and drain regions  22   b  and  22   c , respectively, of the active layer  22  via contact holes  28  formed in the gate insulating layer  23  and the interlayer insulating layer  25 . 
         [0049]    The active layer  22  disposed on the substrate  20  may be formed of an inorganic semiconductor or an organic semiconductor. The source and drain regions  22   b  and  22   c , respectively, are doped with n-type or p-type impurities, and a channel region  22   a  is formed between the source region  22   b  and the drain region  22   c  so as to connect the source region  22   b  and the drain region  22   c.    
         [0050]    The inorganic semiconductor used to form the active layer  22  may include CdS, GaS, ZnS, CdSe, CaSe, ZnSe, CdTe, SiC, or Si. 
         [0051]    In addition, the organic semiconductor used to form the active layer  22  may include polymers such as polythiophene and derivatives thereof, polyparaphenylenevinylene and derivatives thereof, polyparaphenylene and derivatives thereof, polyfluorene and derivatives thereof, polythiophenevinylene and derivatives thereof, and polythiophene-hereto ring aromatic copolymer and derivatives thereof, and small molecules such as oligoacene of pentacene, tetracene, and naphthalene and derivatives thereof, oligothiophene of alpha-6-thiophene and alpha-5-thiophene and derivatives thereof, phthalocyanine containing or not containing a metal and derivatives thereof, pyromellitic dianhydride or pyromellitic diimide and derivatives thereof, and perylenetetracarboxylate dianhydride or perylenetetracarboxylic diimide and derivatives thereof. 
         [0052]    The active layer  22  is covered with the gate insulating layer  23 , and the gate electrode  24  is disposed on the gate insulating layer  23 . The gate electrode  24  may be a conductive metal layer such as MoW, Al, Cr or Al/Cu, but is not limited thereto. Various conductive materials, such as a conductive polymer, may be used to form the gate electrode  24 . The gate electrode  24  is formed so as to cover a region corresponding to the channel region  22   a  of the active layer  22 . 
         [0053]      FIG. 2  is a plan view of an organic light-emitting display device according to an embodiment of the present invention. 
         [0054]    Referring to  FIG. 2 , the organic light-emitting display device  100  includes a pixel region  30  and circuit regions  40  formed at edges of the pixel region  30 . The pixel region  30  includes a plurality of pixels, and each of the pixels includes an emission unit which emits light so as to realize an image. 
         [0055]    According to the current embodiment, the emission unit includes a plurality of sub-pixels respectively including an organic light emitting device. In a full color organic light-emitting display device, red (R), green (G), and blue (B) sub-pixels are arranged in various patterns, including a line pattern, a mosaic pattern, a lattice pattern, etc., to constitute pixels. Also, the full color organic light-emitting display device  100  may be a mono color flat panel display device or not a full color flat panel display device. 
         [0056]    The circuit regions  40  control, for example, an image signal which is input to the pixel region  30 . 
         [0057]    In the organic light-emitting display device  100  according to the current embodiment, at least one TFT may be installed in each of the pixel region  30  and the circuit regions  40 . 
         [0058]    The TFT installed in the pixel region  30  may include a pixel TFT, such as a switching TFT which transmits a data signal to an organic light-emitting device according to a gate line signal so as to control the operation of the organic light emitting device, and a driving TFT which drives the organic light-emitting device by supplying current according to the data signal. The TFT installed in the circuit region  40  may include a circuit TFT constituted so as to implement a predetermined circuit. 
         [0059]    The number and alignment of the TFT may vary according to characteristics of a display and driving methods thereof. 
         [0060]      FIG. 3  is a plan view of a sub-pixel of the organic light-emitting display device of  FIG. 2 ,  FIG. 4  is a cross-sectional view taken along line I-I of  FIG. 3 , and  FIG. 5  is a cross-sectional view taken along line II-II of  FIG. 3 . 
         [0061]    Referring to  FIGS. 3  thru  5 , a buffer layer  51  ( FIGS. 4 and 5 ) is disposed on a glass or plastic substrate  101 , and a pixel circuit unit  50  ( FIGS. 3 and 4 ) and an organic light-emitting device are disposed thereon. The pixel circuit unit  50  may be various TFTs, such as a top gate TFT and a bottom gate TFT. 
         [0062]    An active layer  52  ( FIG. 4 ) having a predetermined pattern is formed on the buffer layer  51 . A gate insulating layer  53  is formed on the active layer  52 , and a gate electrode  54  is formed in a predetermined region of the gate insulating layer  53 . The gate electrode  54  is connected to a gate line (not shown) through which a signal for turning on and/or off the TFT is applied. An interlayer insulating layer  55  is disposed on the gate electrode  54 . Source and drain electrodes  56  and  57 , respectively, are disposed on the interlayer insulating layer  55  so as to contact source and drain regions  52   b  and  52   c , respectively, of the active layer  52  through contact holes  56   a  and  57   a , respectively. An insulating layer may be disposed on the source and drain electrodes  56  and  57 , respectively. The insulating layer may include a passivation layer  58  formed of SiO2, SiNx, or the like, or a planarization layer  59  disposed on the passivation layer  58  and formed of an organic material, such as acryl, polyimide, and benzocyclobutene (BCB). 
         [0063]    A pixel electrode  161  ( FIGS. 3  thru  5 ), which functions as an anode of the organic light-emitting display device, is disposed on the planarization layer  59 . A pixel define layer  160  covers the pixel electrode  161 , and may be formed of an organic material. The pixel circuit unit  50  may be disposed on the substrate  101  in correspondence to the pixel define layer  160 . 
         [0064]    An opening is formed in the pixel define layer  160 , and an intermediate layer  162  is formed on the pixel define layer  160  and on the pixel electrode  161  exposed through the opening of the pixel define layer  160 . The intermediate layer  162  includes an emission layer (EML). The structure of the organic light-emitting display device is not limited to that described above, and various structures of organic light-emitting display devices may be used. 
         [0065]    The organic light-emitting device displays predetermined image information by emitting red, green and blue light as current flows. The organic light-emitting device includes: the pixel electrode  161 , which is connected to the drain electrode  57  of the TFT, and to which a positive power voltage is applied; a counter electrode  163 , which is formed so as to cover the entire pixel, and to which a negative power voltage is applied; and the intermediate layer  162  which is disposed between the pixel electrode  161  and the counter electrode  163  so as to emit light. 
         [0066]    The pixel electrode  161  and the counter electrode  163  are insulated from each other by the intermediate layer  162 , and respectively apply voltages of opposite polarities to the intermediate layer  162  so as to induce light emission in the intermediate layer  162 . 
         [0067]    The intermediate layer  162  may comprise a low-molecular weight organic layer or a high-molecular weight organic layer. When a low-molecular weight organic layer is used as the intermediate layer  162 , the intermediate layer  162  may have a single or multi-layer structure including at least one selected from the group consisting of a hole injection layer (HIL), a hole transport layer (HTL), an emission layer (EML), an electron transport layer (ETL), and an electron injection layer (EIL). The low-molecular weight organic layer may be formed of an organic material. Examples of available organic materials include copper phthalocyanine (CuPc), N,N′-di(naphthalene-1-yl)-N,N′-diphenyl-benzidine (NPB), and tris-8-hydroxyquinoline aluminum (Alq3). The low-molecular weight organic layer may be formed by vacuum deposition. 
         [0068]    When a high-molecular weight organic layer is used as the intermediate layer  162 , the intermediate layer  162  may mostly have a structure including an HTL and an EML. In this case, the HTL may be formed of poly(ethylenedioxythiophene) (PEDOT), and the EML may be formed of polyphenylenevinylenes (PPVs) or polyfluorenes. The HTL and the EML may be formed by screen printing, inkjet printing, or the like. 
         [0069]    The intermediate  162  is not limited thereto, and thus, various types of intermediate layers may be applied. 
         [0070]    The intermediate layer  162  may be formed by inkjet printing. The intermediate layer  162  may also be formed by spin coating. 
         [0071]    The pixel electrode  161  functions as an anode, and the counter electrode  163  functions as a cathode. Alternatively, the pixel electrode  161  may function as a cathode, and the counter electrode  163  may function as an anode. 
         [0072]    The pixel electrode  161  may be formed as a transparent electrode or a reflective electrode. The transparent electrode may be formed of indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO), or indium oxide (In 2 O 3 ). The reflective electrode may be formed by forming a reflective layer of silver (Ag), magnesium (Mg), aluminum (Al), platinum (Pt), palladium (Pd), gold (Au), nickel (Ni), neodymium (Nd), iridium (Ir), chromium (Cr) or a compound thereof, and forming a layer of ITO, IZO, ZnO, or In 2 O 3  on the reflective layer. 
         [0073]    The pixel electrode  161  may include a first pattern unit  161   a  and a second pattern unit  161   b  which are electrically disconnected. A gap g is formed between the first pattern unit  161   a  and the second pattern unit  161   b , and the first pattern unit  161   a  is electrically disconnected from the second pattern unit  161   b  by the gap g. As shown in  FIG. 3 , the, second pattern unit  161   b  may be disposed at outer sides of the first pattern unit  161   a  so as to surround the first pattern unit  161   a . The gap g shown in  FIG. 3  has a tetragonal shale “□”, but the shape is not limited thereto. The gap g may also have any shape such as a circular shape “◯” such that the second pattern unit  161   b  surrounds the first pattern unit  161   a.    
         [0074]    The first pattern unit  161   a  and the second pattern unit  161   b  may be formed using a photolithography process. That is, a metal layer used to form the pixel electrode  161  is deposited on the planarization layer  59 , and the first pattern unit  161   a  and the second pattern unit  161   b  may be patterned using a photolithography process. 
         [0075]    The first pattern unit  161   a  is connected to the pixel circuit unit  50  via the contact hole  59   a  ( FIG. 4 ). In other words, the first pattern unit  161   a  is connected to the drain electrode  57  of the TFT which is the pixel circuit unit  50  so that a positive power voltage is applied to the first pattern unit  161   a . However, the second pattern unit  161   b  is electrically disconnected from the first pattern unit  161   a  so that a power voltage is not applied to the second pattern unit  161   b . Accordingly, while the intermediate layer  162  disposed on the first pattern unit  161   a  emits light, the intermediate layer  162  disposed on the second pattern unit  161   b  does not emit light. Particularly, the intermediate layer  162  may be disposed on the pixel electrode  161 , i.e., on the first pattern unit  161   a  and the second pattern unit  161   b . However, since the first pattern unit  161   a  is electrically disconnected from the second pattern unit  161   b , and the power voltage is applied only to the first pattern unit  161   a , the intermediate layer  162  disposed on the first pattern unit  161   a  emits light, and the intermediate layer  162  disposed on the second pattern unit  161   b  does not emit light. 
         [0076]    The intermediate layer  162 , including the EML, is disposed on the pixel electrode  161  which is exposed by the pixel define layer  160 . Due to a surface energy difference between the pixel define layer  160  and the pixel electrode  161 , the intermediate layer  162  disposed at a boundary A ( FIGS. 4 and 5 ) between the pixel define layer  160  and the pixel electrode  161  may be thinner than the intermediate layer  162  disposed at the center of the pixel electrode  161 , or the intermediate layer  162  may not be formed at the boundary A. As such, if the intermediate layer  162  disposed at the boundary A is thinner than the intermediate layer  162  disposed at the center of the pixel electrode  161 , or the intermediate layer  162  is not formed, edge defects occur so that the boundary A emits weak light or does not emit light. According to the present embodiment, the edge defects may be inhibited by electrically disconnecting the outer sides of the pixel electrode  161  (i.e., the second pattern unit  161   b  which is adjacent to pixel define layer  160 ) from the first pattern unit  161   a  disposed at the center of the pixel electrode  161 . Unlike the boundary A, there is no surface energy difference in the first pattern unit  161   a , and thus the thickness of the intermediate layer  162  disposed on the first pattern unit  161   a  may be uniform, and thus the sub-pixel may emit light having uniform brightness. 
         [0077]    Also, the counter electrode  163  may be a transparent electrode or a reflective electrode. If the counter electrode  63  is a transparent electrode, the counter electrode  163  may be used as a cathode. Thus, a metal having a low work function (i.e., Li, Ca, LiF/Ca, LiF/Al, Al, Ag, Mg, or a compound thereof) may be deposited so as to face the intermediate layer  162 . Then, an auxiliary electrode layer or a bus electrode line may be formed of a material for forming a transparent electrode, such as ITO, IZO, ZnO, or In 2 O 3 , on the metal in order to form the counter electrode  163 . Otherwise, if the counter electrode  63  is a reflective electrode, the counter electrode  163  may be formed by depositing Li, Ca, LiF/Ca, LiF/Al, Al, Ag, Mg, or a compound thereof on the entire surface of the intermediate layer  162 . 
         [0078]      FIGS. 6  thru  9  are plan views of sub-pixels according to embodiments of the present invention. 
         [0079]    That is,  FIGS. 6  thru  9  show modifications in which the second pattern unit  161   b  is disposed at outer sides of the first pattern unit  161   a.    
         [0080]    Referring to  FIG. 6 , a “         ”-shaped gap g is formed between the second pattern unit  161   b  and the first pattern unit  161   a.    
         [0081]    Referring to  FIG. 7 , the second pattern unit  161   b  is disposed at an edge of the pixel electrode  161 , and a gap g is formed between the second pattern unit  161   b  and the first pattern unit  161   a.    
         [0082]    Referring to  FIGS. 8 and 9 , the second pattern units  161   b  may be disposed at opposing sides of the pixel electrode  161 . In other words, as shown in  FIG. 8 , the second pattern units  161   b  may be disposed at right and left sides of the first pattern unit  161   a  so as to be spaced apart from the first pattern unit  161   a  by a gap g. As shown in  FIG. 9 , the second pattern units  161   b  may be disposed at upper and lower sides of the first pattern unit  161   a  so as to be spaced apart from the first pattern unit  161   a  by a gap g. 
         [0083]      FIG. 10  is a plan view of an organic light-emitting display device according to another embodiment of the present invention, and  FIG. 11  is a cross-sectional view taken along line III-III of  FIG. 10 . 
         [0084]    The position of the pixel circuit unit  50  of the organic light-emitting display device shown in  FIGS. 10 and 11  is different from that in the organic light-emitting display device shown in  FIG. 3 . In other words, referring to  FIGS. 10 and 11 , the pixel circuit unit  50  is disposed on the substrate  101  so as to correspond to the pixel electrode  161 . 
         [0085]    According to the present invention, edge defects occurring at a boundary between a pixel electrode and a pixel define layer may be prevented. 
         [0086]    While the present invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those of ordinary skill in the art that various changes in form and detail may be made therein without departing from the spirit and scope of the present invention as defined by the following claims.