Display device and method of manufacturing the same, method of repairing display device, and electronic apparatus

Patent metadata

Field	Value
Publication number	US-9716251-B2
Application number	US-201514863589-A
Country	US
Kind code	B2
Filing date	Sep 24, 2015
Priority date	Mar 27, 2012
Publication date	Jul 25, 2017
Grant date	Jul 25, 2017

Abstract

A display device includes light emitting elements that are arranged in a two-dimensional matrix, in which the light emitting elements include a drive circuit which is provided on a substrate, a first insulating layer which covers the drive circuit and the substrate, a light emitting portion in which a first electrode, an organic layer having a light emitting layer, and a second electrode are laminated, and a second insulating layer which covers the first electrode.

First claim

What is claimed is:

1. A method of manufacturing a display device, comprising:
the display device including light emitting elements that are arranged in a two-dimensional matrix, in which the light emitting elements include a drive circuit and a light emitting portion in which a first electrode, an organic layer having a light emitting layer, and a second electrode are laminated, the method comprising:
providing the drive circuit and a contact portion on a substrate;
forming a first insulating layer that covers the drive circuit, the contact portion, and the substrate;
forming a first opening, through which a part of the drive circuit is exposed in a bottom of the first opening, on a first portion of the first insulating layer which is located above the drive circuit;
forming a second opening, through which the contact portion is exposed in a bottom of a first concave portion of the first insulating layer, on a second portion of the first insulating layer which is located above the contact portion;
forming a conductive material layer on a first entire surface of the first insulating layer, the exposed contact portion, and the exposed part of the drive circuit, and patterning the conductive material layer to form the first electrode on the first insulating layer, to form a first electrode extending portion in the first opening, to form an auxiliary electrode layer, which is distant from the first electrode, over a range from an upper area of the first insulating layer to an internal area of the second opening, and to remove the conductive material layer on at least a part of a bottom of a second concave portion of the first insulating layer;
removing a third portion of the first insulating layer, which is located on an exposed portion in the bottom of the second concave portion, to expose the contact portion, forming a second insulating layer on a second entire surface of the first electrode, the first electrode extending portion, the auxiliary electrode layer, and a first exposed portion of the first insulating layer, forming a third opening, through which the first electrode is exposed in a bottom of the third opening, on the second insulating layer, forming a fourth opening, which reaches an exposed portion of the contact portion in the bottom of the second concave portion, on the second insulating layer, or
forming the second insulating layer on a third entire surface of the first electrode, the first electrode extending portion, the auxiliary electrode layer, and a second exposed portion of the first insulating layer, removing a fourth portion of the second insulating layer which is located above the second concave portion, removing a fifth portion of the first insulating layer which is located on a fourth portion of a bottom of the second concave portion, forming the third opening, through which the first electrode is exposed in a bottom of the third opening, on the second insulating layer, and forming the fourth opening, which reaches the exposed portion of the contact portion in the bottom of the second concave portion, on the second insulating layer and the first insulating layer;
forming the organic layer over a range from the exposed portion of the first electrode in the bottom of the third opening to a part of an upper area of the second insulating layer; and
forming the second electrode over a range from an upper area of the organic layer to the upper area of the second insulating layer and furthermore to an internal area of the fourth opening.

2. The method of manufacturing the display device according to claim 1 ,
wherein at least the second concave portion, the first opening, and the second opening are formed on the first insulating layer based on a photolithographic technique, and
one of a half-tone mask or a grey-tone mask is used in the photolithographic technique.

3. A method of repairing a display device, comprising
the display device including
light emitting elements that are arranged in a two-dimensional matrix,
in which the light emitting elements include a drive circuit which is on a substrate, a first insulating layer which covers the drive circuit and the substrate, a light emitting portion which includes a first electrode, an organic layer having a light emitting layer, and a second electrode, and a second insulating layer which covers the first electrode,
the first electrode on the first insulating layer is electrically connected to the drive circuit,
the light emitting elements further include a window layer on the first electrode,
the light emitting portion is divided into a plurality of window portions by the window layer,
the organic layer is at least on the first electrode, and
the second electrode is on the organic layer, the method comprising:
irradiating, based on a presence of foreign material in a window portion of the light emitting portion, a first portion of the first electrode surrounding the window portion with laser light to separate the first portion of the first electrode from remaining portions of the first electrode.

4. The method of repairing the display device according to claim 3 ,
wherein the first portion of the first electrode which is located below the window layer surrounding the window portion, or the first portion of the first electrode which is located below the window layer surrounding the window portion and a second portion of the first electrode which is located below the window layer and the second insulating layer surrounding the window portion are separated from remaining portions of the first electrode.

5. A method of repairing a display device, comprising:
the display device including
light emitting elements that are arranged in a two-dimensional matrix,
in which the light emitting elements include a drive circuit which is on a substrate, a first insulating layer which covers the drive circuit and the substrate, a light emitting portion which includes a first electrode, an organic layer having a light emitting layer, and a second electrode, and a second insulating layer which covers the first electrode,
the first electrode on the first insulating layer is electrically connected to the drive circuit,
the first electrode includes a plurality of first electrode pieces which are at a distance from each other, first electrode branched portions which extend from the plurality of first electrode pieces, and a first electrode main portion which collects the first electrode branched portions and extends toward the drive circuit,
the organic layer is at least on each of the plurality of first electrode pieces, and
the second electrode is on the organic layer, the method including:

irradiating, based on a presence of a foreign material on a first electrode piece, of the plurality of first electrode pieces, of the light emitting portion, a first electrode branched portion extending from the first electrode piece with laser light to cut the first electrode branched portion.

Assignees

• Sony Corp

Inventors

• Uesugi Masanao
• Yamada Jiro
• Morooka Mitsuo
• Hiromasu Yasunobu

Classifications

• H01L2251/568

  Electricity · mapped topic

• H01L51/5228

  Electricity · mapped topic

• H01L51/5203

  Electricity · mapped topic

• H01L51/0023

  Electricity · mapped topic

• H01L27/3276

  Electricity · mapped topic