GB2404073A - Method of manufacturing organic EL display panel,and method of manufacturing colour-converting filter substrate - Google Patents
Method of manufacturing organic EL display panel,and method of manufacturing colour-converting filter substrate Download PDFInfo
- Publication number
- GB2404073A GB2404073A GB0316644A GB0316644A GB2404073A GB 2404073 A GB2404073 A GB 2404073A GB 0316644 A GB0316644 A GB 0316644A GB 0316644 A GB0316644 A GB 0316644A GB 2404073 A GB2404073 A GB 2404073A
- Authority
- GB
- United Kingdom
- Prior art keywords
- color
- substrate
- organic
- converting filter
- overcoat layer
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
- Granted
Links
- 239000000758 substrate Substances 0.000 title claims abstract description 123
- 238000004519 manufacturing process Methods 0.000 title claims abstract description 32
- 239000000463 material Substances 0.000 claims description 21
- 239000010409 thin film Substances 0.000 claims description 12
- 230000004888 barrier function Effects 0.000 claims description 11
- 230000006835 compression Effects 0.000 claims description 5
- 238000007906 compression Methods 0.000 claims description 5
- 238000000034 method Methods 0.000 abstract description 58
- 238000012546 transfer Methods 0.000 abstract description 8
- 125000006850 spacer group Chemical group 0.000 abstract description 4
- 239000010410 layer Substances 0.000 description 224
- 239000003086 colorant Substances 0.000 description 51
- 229920005989 resin Polymers 0.000 description 24
- 239000011347 resin Substances 0.000 description 24
- 238000002347 injection Methods 0.000 description 15
- 239000007924 injection Substances 0.000 description 15
- 230000015572 biosynthetic process Effects 0.000 description 10
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 8
- 238000006243 chemical reaction Methods 0.000 description 8
- ZUOUZKKEUPVFJK-UHFFFAOYSA-N diphenyl Chemical compound C1=CC=CC=C1C1=CC=CC=C1 ZUOUZKKEUPVFJK-UHFFFAOYSA-N 0.000 description 8
- 239000007789 gas Substances 0.000 description 8
- 239000011159 matrix material Substances 0.000 description 8
- 238000000206 photolithography Methods 0.000 description 8
- 238000004528 spin coating Methods 0.000 description 8
- 239000010408 film Substances 0.000 description 7
- 238000000059 patterning Methods 0.000 description 7
- 238000004544 sputter deposition Methods 0.000 description 7
- -1 aromatic sulfonamide Chemical class 0.000 description 6
- 239000011248 coating agent Substances 0.000 description 6
- 238000000576 coating method Methods 0.000 description 6
- 238000007789 sealing Methods 0.000 description 6
- 239000000975 dye Substances 0.000 description 5
- 238000010438 heat treatment Methods 0.000 description 5
- 239000000203 mixture Substances 0.000 description 5
- 230000003287 optical effect Effects 0.000 description 5
- 239000000049 pigment Substances 0.000 description 5
- VEXZGXHMUGYJMC-UHFFFAOYSA-N Hydrochloric acid Chemical compound Cl VEXZGXHMUGYJMC-UHFFFAOYSA-N 0.000 description 4
- 239000000853 adhesive Substances 0.000 description 4
- 230000001070 adhesive effect Effects 0.000 description 4
- 235000010290 biphenyl Nutrition 0.000 description 4
- 239000004305 biphenyl Substances 0.000 description 4
- 230000008859 change Effects 0.000 description 4
- ZYGHJZDHTFUPRJ-UHFFFAOYSA-N coumarin Chemical compound C1=CC=C2OC(=O)C=CC2=C1 ZYGHJZDHTFUPRJ-UHFFFAOYSA-N 0.000 description 4
- 239000011521 glass Substances 0.000 description 4
- 230000005525 hole transport Effects 0.000 description 4
- 239000007788 liquid Substances 0.000 description 4
- 235000012239 silicon dioxide Nutrition 0.000 description 4
- 239000000243 solution Substances 0.000 description 4
- NIXOWILDQLNWCW-UHFFFAOYSA-N acrylic acid group Chemical group C(C=C)(=O)O NIXOWILDQLNWCW-UHFFFAOYSA-N 0.000 description 3
- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 3
- 230000008901 benefit Effects 0.000 description 3
- 238000004132 cross linking Methods 0.000 description 3
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- 238000005530 etching Methods 0.000 description 3
- 239000000178 monomer Substances 0.000 description 3
- 230000002035 prolonged effect Effects 0.000 description 3
- 239000000377 silicon dioxide Substances 0.000 description 3
- 239000002904 solvent Substances 0.000 description 3
- KRHYYFGTRYWZRS-UHFFFAOYSA-N Fluorane Chemical compound F KRHYYFGTRYWZRS-UHFFFAOYSA-N 0.000 description 2
- PXHVJJICTQNCMI-UHFFFAOYSA-N Nickel Chemical compound [Ni] PXHVJJICTQNCMI-UHFFFAOYSA-N 0.000 description 2
- SJEYSFABYSGQBG-UHFFFAOYSA-M Patent blue Chemical compound [Na+].C1=CC(N(CC)CC)=CC=C1C(C=1C(=CC(=CC=1)S([O-])(=O)=O)S([O-])(=O)=O)=C1C=CC(=[N+](CC)CC)C=C1 SJEYSFABYSGQBG-UHFFFAOYSA-M 0.000 description 2
- NBIIXXVUZAFLBC-UHFFFAOYSA-N Phosphoric acid Chemical compound OP(O)(O)=O NBIIXXVUZAFLBC-UHFFFAOYSA-N 0.000 description 2
- JUJWROOIHBZHMG-UHFFFAOYSA-N Pyridine Chemical compound C1=CC=NC=C1 JUJWROOIHBZHMG-UHFFFAOYSA-N 0.000 description 2
- 229910000831 Steel Inorganic materials 0.000 description 2
- 239000000980 acid dye Substances 0.000 description 2
- 229910052782 aluminium Inorganic materials 0.000 description 2
- XAGFODPZIPBFFR-UHFFFAOYSA-N aluminium Chemical compound [Al] XAGFODPZIPBFFR-UHFFFAOYSA-N 0.000 description 2
- 125000002490 anilino group Chemical group [H]N(*)C1=C([H])C([H])=C([H])C([H])=C1[H] 0.000 description 2
- 239000000981 basic dye Substances 0.000 description 2
- IOJUPLGTWVMSFF-UHFFFAOYSA-N benzothiazole Chemical compound C1=CC=C2SC=NC2=C1 IOJUPLGTWVMSFF-UHFFFAOYSA-N 0.000 description 2
- 150000001875 compounds Chemical class 0.000 description 2
- 235000001671 coumarin Nutrition 0.000 description 2
- 229960000956 coumarin Drugs 0.000 description 2
- VBVAVBCYMYWNOU-UHFFFAOYSA-N coumarin 6 Chemical compound C1=CC=C2SC(C3=CC4=CC=C(C=C4OC3=O)N(CC)CC)=NC2=C1 VBVAVBCYMYWNOU-UHFFFAOYSA-N 0.000 description 2
- 230000007547 defect Effects 0.000 description 2
- 239000000982 direct dye Substances 0.000 description 2
- 239000000986 disperse dye Substances 0.000 description 2
- 238000009826 distribution Methods 0.000 description 2
- 230000000694 effects Effects 0.000 description 2
- CNEKKZXYBHKSDC-UHFFFAOYSA-N ethyl acetate;propane-1,2-diol Chemical compound CC(O)CO.CCOC(C)=O CNEKKZXYBHKSDC-UHFFFAOYSA-N 0.000 description 2
- RBTKNAXYKSUFRK-UHFFFAOYSA-N heliogen blue Chemical compound [Cu].[N-]1C2=C(C=CC=C3)C3=C1N=C([N-]1)C3=CC=CC=C3C1=NC([N-]1)=C(C=CC=C3)C3=C1N=C([N-]1)C3=CC=CC=C3C1=N2 RBTKNAXYKSUFRK-UHFFFAOYSA-N 0.000 description 2
- 239000004973 liquid crystal related substance Substances 0.000 description 2
- 229910052751 metal Inorganic materials 0.000 description 2
- 239000002184 metal Substances 0.000 description 2
- 239000007769 metal material Substances 0.000 description 2
- JRZJOMJEPLMPRA-UHFFFAOYSA-N olefin Natural products CCCCCCCC=C JRZJOMJEPLMPRA-UHFFFAOYSA-N 0.000 description 2
- 239000003960 organic solvent Substances 0.000 description 2
- 238000006116 polymerization reaction Methods 0.000 description 2
- 150000003254 radicals Chemical class 0.000 description 2
- 230000004044 response Effects 0.000 description 2
- 229920002050 silicone resin Polymers 0.000 description 2
- 239000002356 single layer Substances 0.000 description 2
- 239000010959 steel Substances 0.000 description 2
- 238000002834 transmittance Methods 0.000 description 2
- WBYWAXJHAXSJNI-VOTSOKGWSA-M .beta-Phenylacrylic acid Natural products [O-]C(=O)\C=C\C1=CC=CC=C1 WBYWAXJHAXSJNI-VOTSOKGWSA-M 0.000 description 1
- BCMCBBGGLRIHSE-UHFFFAOYSA-N 1,3-benzoxazole Chemical compound C1=CC=C2OC=NC2=C1 BCMCBBGGLRIHSE-UHFFFAOYSA-N 0.000 description 1
- HYZJCKYKOHLVJF-UHFFFAOYSA-N 1H-benzimidazole Chemical compound C1=CC=C2NC=NC2=C1 HYZJCKYKOHLVJF-UHFFFAOYSA-N 0.000 description 1
- PCGDWIWUQDHQLK-UHFFFAOYSA-N 2-morpholin-4-yl-5-nitrobenzaldehyde Chemical compound O=CC1=CC([N+](=O)[O-])=CC=C1N1CCOCC1 PCGDWIWUQDHQLK-UHFFFAOYSA-N 0.000 description 1
- BCHZICNRHXRCHY-UHFFFAOYSA-N 2h-oxazine Chemical compound N1OC=CC=C1 BCHZICNRHXRCHY-UHFFFAOYSA-N 0.000 description 1
- GZVHEAJQGPRDLQ-UHFFFAOYSA-N 6-phenyl-1,3,5-triazine-2,4-diamine Chemical compound NC1=NC(N)=NC(C=2C=CC=CC=2)=N1 GZVHEAJQGPRDLQ-UHFFFAOYSA-N 0.000 description 1
- NIXOWILDQLNWCW-UHFFFAOYSA-M Acrylate Chemical compound [O-]C(=O)C=C NIXOWILDQLNWCW-UHFFFAOYSA-M 0.000 description 1
- 229920000178 Acrylic resin Polymers 0.000 description 1
- VYZAMTAEIAYCRO-UHFFFAOYSA-N Chromium Chemical compound [Cr] VYZAMTAEIAYCRO-UHFFFAOYSA-N 0.000 description 1
- 229920000877 Melamine resin Polymers 0.000 description 1
- 239000004640 Melamine resin Substances 0.000 description 1
- 229920002845 Poly(methacrylic acid) Polymers 0.000 description 1
- 239000004642 Polyimide Substances 0.000 description 1
- 229910052581 Si3N4 Inorganic materials 0.000 description 1
- 229910004205 SiNX Inorganic materials 0.000 description 1
- 229910003070 TaOx Inorganic materials 0.000 description 1
- 229910003087 TiOx Inorganic materials 0.000 description 1
- 239000007983 Tris buffer Substances 0.000 description 1
- 229920001807 Urea-formaldehyde Polymers 0.000 description 1
- 229920002433 Vinyl chloride-vinyl acetate copolymer Polymers 0.000 description 1
- 229910007667 ZnOx Inorganic materials 0.000 description 1
- 239000002253 acid Substances 0.000 description 1
- 150000001252 acrylic acid derivatives Chemical class 0.000 description 1
- 125000003647 acryloyl group Chemical group O=C([*])C([H])=C([H])[H] 0.000 description 1
- 150000001336 alkenes Chemical class 0.000 description 1
- 229920000180 alkyd Polymers 0.000 description 1
- 229910000147 aluminium phosphate Inorganic materials 0.000 description 1
- 125000003118 aryl group Chemical group 0.000 description 1
- QVGXLLKOCUKJST-UHFFFAOYSA-N atomic oxygen Chemical compound [O] QVGXLLKOCUKJST-UHFFFAOYSA-N 0.000 description 1
- XJHABGPPCLHLLV-UHFFFAOYSA-N benzo[de]isoquinoline-1,3-dione Chemical compound C1=CC(C(=O)NC2=O)=C3C2=CC=CC3=C1 XJHABGPPCLHLLV-UHFFFAOYSA-N 0.000 description 1
- 239000011230 binding agent Substances 0.000 description 1
- 239000001045 blue dye Substances 0.000 description 1
- 238000009125 cardiac resynchronization therapy Methods 0.000 description 1
- 238000005266 casting Methods 0.000 description 1
- 150000001768 cations Chemical class 0.000 description 1
- 239000000919 ceramic Substances 0.000 description 1
- 239000013522 chelant Substances 0.000 description 1
- VYXSBFYARXAAKO-WTKGSRSZSA-N chembl402140 Chemical compound Cl.C1=2C=C(C)C(NCC)=CC=2OC2=C\C(=N/CC)C(C)=CC2=C1C1=CC=CC=C1C(=O)OCC VYXSBFYARXAAKO-WTKGSRSZSA-N 0.000 description 1
- 229910052804 chromium Inorganic materials 0.000 description 1
- 239000011651 chromium Substances 0.000 description 1
- 229930016911 cinnamic acid Natural products 0.000 description 1
- 235000013985 cinnamic acid Nutrition 0.000 description 1
- 229910052681 coesite Inorganic materials 0.000 description 1
- 238000004891 communication Methods 0.000 description 1
- XCJYREBRNVKWGJ-UHFFFAOYSA-N copper(II) phthalocyanine Chemical compound [Cu+2].C12=CC=CC=C2C(N=C2[N-]C(C3=CC=CC=C32)=N2)=NC1=NC([C]1C=CC=CC1=1)=NC=1N=C1[C]3C=CC=CC3=C2[N-]1 XCJYREBRNVKWGJ-UHFFFAOYSA-N 0.000 description 1
- 229910052593 corundum Inorganic materials 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 230000008021 deposition Effects 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 238000006471 dimerization reaction Methods 0.000 description 1
- 238000005516 engineering process Methods 0.000 description 1
- 230000007613 environmental effect Effects 0.000 description 1
- 125000003700 epoxy group Chemical group 0.000 description 1
- 150000002148 esters Chemical class 0.000 description 1
- 238000011156 evaluation Methods 0.000 description 1
- 239000006081 fluorescent whitening agent Substances 0.000 description 1
- 239000001046 green dye Substances 0.000 description 1
- 239000003999 initiator Substances 0.000 description 1
- 150000002484 inorganic compounds Chemical class 0.000 description 1
- 229910010272 inorganic material Inorganic materials 0.000 description 1
- 229910052809 inorganic oxide Inorganic materials 0.000 description 1
- 239000011810 insulating material Substances 0.000 description 1
- 238000004020 luminiscence type Methods 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- WBYWAXJHAXSJNI-UHFFFAOYSA-N methyl p-hydroxycinnamate Natural products OC(=O)C=CC1=CC=CC=C1 WBYWAXJHAXSJNI-UHFFFAOYSA-N 0.000 description 1
- IBHBKWKFFTZAHE-UHFFFAOYSA-N n-[4-[4-(n-naphthalen-1-ylanilino)phenyl]phenyl]-n-phenylnaphthalen-1-amine Chemical group C1=CC=CC=C1N(C=1C2=CC=CC=C2C=CC=1)C1=CC=C(C=2C=CC(=CC=2)N(C=2C=CC=CC=2)C=2C3=CC=CC=C3C=CC=2)C=C1 IBHBKWKFFTZAHE-UHFFFAOYSA-N 0.000 description 1
- 125000001624 naphthyl group Chemical group 0.000 description 1
- 229910052759 nickel Inorganic materials 0.000 description 1
- 150000004767 nitrides Chemical class 0.000 description 1
- 239000012299 nitrogen atmosphere Substances 0.000 description 1
- 239000001301 oxygen Substances 0.000 description 1
- 229910052760 oxygen Inorganic materials 0.000 description 1
- 229920001721 polyimide Polymers 0.000 description 1
- 239000002952 polymeric resin Substances 0.000 description 1
- 230000000379 polymerizing effect Effects 0.000 description 1
- 229920000915 polyvinyl chloride Polymers 0.000 description 1
- 239000004800 polyvinyl chloride Substances 0.000 description 1
- UMJSCPRVCHMLSP-UHFFFAOYSA-N pyridine Natural products COC1=CC=CN=C1 UMJSCPRVCHMLSP-UHFFFAOYSA-N 0.000 description 1
- 239000010453 quartz Substances 0.000 description 1
- 238000010791 quenching Methods 0.000 description 1
- 230000000171 quenching effect Effects 0.000 description 1
- MCJGNVYPOGVAJF-UHFFFAOYSA-N quinolin-8-ol Chemical compound C1=CN=C2C(O)=CC=CC2=C1 MCJGNVYPOGVAJF-UHFFFAOYSA-N 0.000 description 1
- 239000001044 red dye Substances 0.000 description 1
- 238000012827 research and development Methods 0.000 description 1
- PYWVYCXTNDRMGF-UHFFFAOYSA-N rhodamine B Chemical compound [Cl-].C=12C=CC(=[N+](CC)CC)C=C2OC2=CC(N(CC)CC)=CC=C2C=1C1=CC=CC=C1C(O)=O PYWVYCXTNDRMGF-UHFFFAOYSA-N 0.000 description 1
- 238000000926 separation method Methods 0.000 description 1
- 229910052710 silicon Inorganic materials 0.000 description 1
- 239000010703 silicon Substances 0.000 description 1
- HQVNEWCFYHHQES-UHFFFAOYSA-N silicon nitride Chemical compound N12[Si]34N5[Si]62N3[Si]51N64 HQVNEWCFYHHQES-UHFFFAOYSA-N 0.000 description 1
- 229910052814 silicon oxide Inorganic materials 0.000 description 1
- 238000003980 solgel method Methods 0.000 description 1
- 229910052682 stishovite Inorganic materials 0.000 description 1
- 239000000126 substance Substances 0.000 description 1
- 229940124530 sulfonamide Drugs 0.000 description 1
- 229920003002 synthetic resin Polymers 0.000 description 1
- 229910052715 tantalum Inorganic materials 0.000 description 1
- GUVRBAGPIYLISA-UHFFFAOYSA-N tantalum atom Chemical compound [Ta] GUVRBAGPIYLISA-UHFFFAOYSA-N 0.000 description 1
- ANRHNWWPFJCPAZ-UHFFFAOYSA-M thionine Chemical compound [Cl-].C1=CC(N)=CC2=[S+]C3=CC(N)=CC=C3N=C21 ANRHNWWPFJCPAZ-UHFFFAOYSA-M 0.000 description 1
- HLLICFJUWSZHRJ-UHFFFAOYSA-N tioxidazole Chemical compound CCCOC1=CC=C2N=C(NC(=O)OC)SC2=C1 HLLICFJUWSZHRJ-UHFFFAOYSA-N 0.000 description 1
- OGIDPMRJRNCKJF-UHFFFAOYSA-N titanium oxide Inorganic materials [Ti]=O OGIDPMRJRNCKJF-UHFFFAOYSA-N 0.000 description 1
- 229910052905 tridymite Inorganic materials 0.000 description 1
- LENZDBCJOHFCAS-UHFFFAOYSA-N tris Chemical compound OCC(N)(CO)CO LENZDBCJOHFCAS-UHFFFAOYSA-N 0.000 description 1
- WFKWXMTUELFFGS-UHFFFAOYSA-N tungsten Chemical compound [W] WFKWXMTUELFFGS-UHFFFAOYSA-N 0.000 description 1
- 229910052721 tungsten Inorganic materials 0.000 description 1
- 239000010937 tungsten Substances 0.000 description 1
- 238000001771 vacuum deposition Methods 0.000 description 1
- 238000007740 vapor deposition Methods 0.000 description 1
- 238000001947 vapour-phase growth Methods 0.000 description 1
- 125000000391 vinyl group Chemical group [H]C([*])=C([H])[H] 0.000 description 1
- 229920002554 vinyl polymer Polymers 0.000 description 1
- 229910001845 yogo sapphire Inorganic materials 0.000 description 1
Classifications
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/30—Devices specially adapted for multicolour light emission
- H10K59/38—Devices specially adapted for multicolour light emission comprising colour filters or colour changing media [CCM]
-
- G—PHYSICS
- G02—OPTICS
- G02F—OPTICAL DEVICES OR ARRANGEMENTS FOR THE CONTROL OF LIGHT BY MODIFICATION OF THE OPTICAL PROPERTIES OF THE MEDIA OF THE ELEMENTS INVOLVED THEREIN; NON-LINEAR OPTICS; FREQUENCY-CHANGING OF LIGHT; OPTICAL LOGIC ELEMENTS; OPTICAL ANALOGUE/DIGITAL CONVERTERS
- G02F1/00—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics
- G02F1/01—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour
- G02F1/13—Devices or arrangements for the control of the intensity, colour, phase, polarisation or direction of light arriving from an independent light source, e.g. switching, gating or modulating; Non-linear optics for the control of the intensity, phase, polarisation or colour based on liquid crystals, e.g. single liquid crystal display cells
- G02F1/133—Constructional arrangements; Operation of liquid crystal cells; Circuit arrangements
- G02F1/1333—Constructional arrangements; Manufacturing methods
- G02F1/1339—Gaskets; Spacers; Sealing of cells
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/12—Light sources with substantially two-dimensional radiating surfaces
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/10—OLED displays
- H10K59/12—Active-matrix OLED [AMOLED] displays
- H10K59/1201—Manufacture or treatment
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/80—Constructional details
- H10K59/87—Passivation; Containers; Encapsulations
- H10K59/871—Self-supporting sealing arrangements
- H10K59/8723—Vertical spacers, e.g. arranged between the sealing arrangement and the OLED
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/80—Manufacture or treatment specially adapted for the organic devices covered by this subclass using temporary substrates
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K2102/00—Constructional details relating to the organic devices covered by this subclass
- H10K2102/301—Details of OLEDs
- H10K2102/302—Details of OLEDs of OLED structures
- H10K2102/3023—Direction of light emission
- H10K2102/3026—Top emission
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/10—OLED displays
- H10K59/12—Active-matrix OLED [AMOLED] displays
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K85/00—Organic materials used in the body or electrodes of devices covered by this subclass
- H10K85/30—Coordination compounds
- H10K85/311—Phthalocyanine
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K85/00—Organic materials used in the body or electrodes of devices covered by this subclass
- H10K85/30—Coordination compounds
- H10K85/321—Metal complexes comprising a group IIIA element, e.g. Tris (8-hydroxyquinoline) gallium [Gaq3]
- H10K85/324—Metal complexes comprising a group IIIA element, e.g. Tris (8-hydroxyquinoline) gallium [Gaq3] comprising aluminium, e.g. Alq3
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K85/00—Organic materials used in the body or electrodes of devices covered by this subclass
- H10K85/60—Organic compounds having low molecular weight
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K85/00—Organic materials used in the body or electrodes of devices covered by this subclass
- H10K85/60—Organic compounds having low molecular weight
- H10K85/631—Amine compounds having at least two aryl rest on at least one amine-nitrogen atom, e.g. triphenylamine
Landscapes
- Physics & Mathematics (AREA)
- Nonlinear Science (AREA)
- Engineering & Computer Science (AREA)
- Manufacturing & Machinery (AREA)
- Mathematical Physics (AREA)
- Chemical & Material Sciences (AREA)
- Crystallography & Structural Chemistry (AREA)
- General Physics & Mathematics (AREA)
- Optics & Photonics (AREA)
- Microelectronics & Electronic Packaging (AREA)
- Electroluminescent Light Sources (AREA)
Abstract
To provide a method of manufacturing an organic EL display panel that has an overcoat layer 5 having sufficient surface smoothness despite being kept thin and having projections 16 on some parts thereof that function as supporting pillars, and for which stable light emission characteristics are maintained. In the case of an organic EL display panel comprising an organic EL light emitter substrate and a color-converting filter substrate that has color-converting filter layers 2,3,4, an overcoat layer 5, and supporting pillars 16 that act as spacers, the overcoat layer and the supporting pillars are formed as a single body on the color-converting filter layers using a transfer method.
Description
Method of Manufacturing Organic EL Display Panel,_and Method of
Manufacturing Color-Convertina Filter Substrate The present invention relates to a method of manufacturing a color-converting filter substrate and a method of manufacturing an organic EL display panel, according to which multi-color display with high detail is possible, and environmental resistance and productivity are excellent. More specifically, the present invention relates to a method of manufacturing a color-converting filter substrate and a method of manufacturing an organic EL display panel, where the color-converting filter substrate and the organic EL display panel are for display use in image sensors, personal computers, word processors, televisions, facsimiles, audio equipment, video equipment, car navigation equipment, desk-top electronic calculators, telephones, mobile terminal equipment, industrial measuring equipment, and so on.
In recent years, there have been rapid advances in increasing the speed of, and expanding the range of application of, information communication. Amid this, there has been widespread development of high-detail display devices having low power consumption and fast response, able to answer to the requirements on display devices with regard to portability and moving picture display.
Ever since the report by Tang et al. of a laminated type EL light emitter that emits light with a high brightness of lOOOcd/m2 or more at an applied voltage of lOV, there has been anticipation of applying organic EL light emitters to flat panel displays, utilizing the characteristic features that are superior to liquid crystal display devices and the like such as high contrast, low- voltage driving, wide angle of visibility and fast response, and research and development toward practical implementation has been carried out vigorously. Green monochrome organic EL display panels have already been commercialized, and the attainment of high-detail fullcolor displays is awaited.
Moreover, regarding the constitution of EL light emitters, in addition to laminates of organic molecules, studies are also being carried out into light emitters that use organic polymeric materials.
As methods of making organic EL display panels be multi-color or fullcolor, three methods are being studied.
Firstly, there is a method in which light emitters of the three primary colors red, green and blue are arranged separated from one another in a matrix, and are each made to emit light (Japanese Patent Application Laidopen No. 57-157487, etc.). With this method, light-emitting materials of three types for red, green and blue light emission must be arranged with high precision in a matrix, and hence manufacture is technically difficult, and it is difficult to carry out manufacture cheaply. Moreover, there are drawbacks such as it being difficult to maintain good color reproduction over a prolonged period due to the brightness change characteristics and driving conditions being different for the three types of light-emitting material.
As the second method, a method has been proposed in which colored filters are used with a backlight that emits white light, thus transmitting the three primary colors separated from one another (Japanese Patent Application Laid-open No. 1-315988, etc.); however, it is difficult to obtain an organic EL light emitter that has a long lifetime and emits white light of high brightness and hence can be used as a backlight for obtaining red, green and blue light of sufficient brightness.
As the third method, a method has been disclosed in which fluorescent bodies that are arranged separated from one another in a plane are made to absorb light emitted from a light emitter, and hence fluorescence of a plurality of colors is emitted from the fluorescent bodies (Japanese Patent Application Laid-open No. 3-152897, etc.). This method of obtaining light of a plurality of colors from a single light emitter by using fluorescent bodies has been applied to CRTs, plasma displays, and so on. This method has an advantage that a light emitter having a high brightness can be used as the light source; for example, a color conversion method in which blue light is subjected to wavelength conversion into green light and red light has been proposed (Japanese Patent Application Laid-open No. 8- 286033, etc.). Here, if color-converting layers containing fluorescent colorants are patterned with high detail, then a full-color luminescent- type display panel becomes possible.
In recent years, for each of these methods of achieving full color, fullcolor display devices with a driving method that uses thin film transistors (TFTs) have been proposed. In this case, if the light is made to exit from the side of the substrate on which the TFTs are formed, then the wiring parts block the light and hence the aperture ratio is low; in recent years, a so-called top emission method in which the light is made to exit from the opposite side of the substrate to that on which the TFTs are formed has thus been proposed.
In the case of the top emission method, with the method in which light emitters of the three primary colors red, green and blue are arranged separated from one another in a matrix, light-emitting materials of the three types red, green and blue must again be arranged with high precision in a matrix, and hence it is difficult to carry out manufacture efficiently and cheaply; moreover, there are still unresolved drawbacks such as it being difficult to maintain good color reproduction over a prolonged period due to the brightness change characteristics and driving conditions being different for the three types of light emitting material.
Moreover, with the method in which colored filters are used with a backlight that emits white light, thus transmitting the three primary colors separated from one another, again the problem of making the backlight have high efficiency still remains.
Only with the color conversion method in which fluorescent bodies that are arranged separated from one another are made to absorb light and hence fluorescence of a plurality of colors is emitted from the fluorescent bodies, is it possible to provide an organic EL display panel having yet higher detail and brightness by adopting the top emission method using the TFT driving method.
Examples of a color display device of this type are disclosed in Japanese Patent Application Laid-open No. 11- 251059 and Japanese Patent Application Laid-open No. 2000- 77191.
An advantage of the top emission method using the TFT driving method with an organic EL light emitter is that, unlike in the case of an LCD (liquid crystal display) for which light must be transmitted from the rear face and hence the region of formation of the TFT parts, which will block this light, must be made as small as possible, the light-emitting part is above the TFTs and hence the region of formation of the TFT parts may extend over the whole of the substrate.
As a method of manufacturing such a top emission type multi-color organic EL display panel, a method in which a color-converting filter substrate and a TFT substrate in which an organic EL light emitter is formed are bonded together can be envisaged. In this case, it is preferable for the sealing space between the two substrates to be as small as possible. However, if the distance between the two substrates is made too small, then the two substrates may contact one another, leading to the organic EL light emitter being damaged. To resolve this problem, art in which supporting pillars that function as spacers are formed in parts where the organic EL light emitter is not formed has been disclosed in Japanese Patent Application Laid-open No. 11-297477.
With a conventional color-converting filter substrate, as shown in Fig. 9, red color-converting filter layers 2, green color-converting filter layers 3 and blue color-converting filter layers 4 are arranged on a transparent supporting substrate, and an overcoat layer 6 having a gas barrier ability is disposed thereon as a flattening layer. The color- converting filter layers 2 (red), 3 (green) and 4 (blue) are each patterned in independent rectangular parallelepipeds, and then the overcoat layer 6 is formed using a spin coating method or the like so as to cover the color- converting filter layers 2, 3 and 4. The overcoat layer should be thick so as to completely fill up gaps between the color-converting layers and thus make the surface sufficiently smooth. However, if the overcoat layer is made thick, then a problem arises in that there is a deterioration in viewing angle characteristics. It is thus important to obtain a sufficient degree of flatness while keeping the overcoat layer thin.
However, even if the overcoat layer is formed directly on the colorconverting filter layers using a spin coating method or the like, if one attempts to keep the overcoat layer thin, then due to a problem of coverage, there is a loss of surface smoothness, with undulations of amplitude several Am arising.
As shown in Fig. 8, a top emission type color conversion type multi-color organic EL display panel has a structure in which such a color-converting filter substrate and an organic EL light emitter substrate are bonded together facing one another. Here, as with the thickness of the overcoat layer, it is preferable for the sealing distance between the two substrates to be small, specifically 0.5 to 5pm, so that the optical path length can be made short and thus deterioration of the viewing angle characteristics can be prevented. However, because there are undulations on the surface of the overcoat layer, it is difficult to maintain the sealing distance between the two substrates at a small, constant value using supporting pillars 11 as spacers.
Moreover, if the supporting pillars are formed using a method in which application is carried out using a spin coating method and then patterning is carried out using a photolithography method, then because the area of formation of the supporting pillars is small, the material utilization rate is poor.
In view of the problems described above, it is an object of the present invention to provide a method of manufacturing a color-converting filter substrate that has an overcoat layer having sufficient surface smoothness despite being kept thin and having projections on some parts thereof that function as supporting pillars, and for which stable light emission characteristics are maintained over a prolonged period, and a method of manufacturing an organic EL display panel having such a color-converting filter substrate.
To attain the above object, according to the present invention, in the case of a method of manufacturing an organic EL display panel in which an organic EL light emitter substrate comprising a substrate, thin film transistors that are provided on the substrate and each have a source and a drain, and an organic EL light emitter that is driven by the thin film transistors and which is constituted by building up first electrodes that are made of an electrically conductive thin film material and are each formed on an upper part of a corresponding one of the thin film transistors and connected to the source or the drain of the corresponding one of the thin film transistors, at least an organic EL light-emitting layer, and second electrodes, and a color-converting filter substrate comprising at least a transparent supporting substrate, color-converting filter layers arranged on the supporting substrate, and a transparent overcoat layer that covers the color-converting filter layers to make the color-converting filter layers have a smooth surface, and has a gas barrier ability, are bonded together via supporting pillars for adjusting the gap between the organic EL light emitter substrate and the colorconverting filter substrate, such that the second electrodes of the organic EL light emitter and the overcoat layer face one another with a prescribed gap therebetween; the method is made to be such that the overcoat layer and the supporting pillars are formed as a single body by being transferred onto the color-converting filter layers through at least the steps of: temporarily disposing a single body comprising the overcoat layer and the supporting pillars on a stripping layer disposed on a temporary substrate having a supporting pillar female form formed therein, or on a stripping layer that is disposed on a temporary substrate and has a supporting pillar female form formed therein; compression bonding the single body comprising the À 20 overcoat layer and the supporting pillars onto the color- converting filter layers and the transparent supporting substrate and curing at a temperature of not more than 2000C; and eliminating the stripping layer and taking away the temporary substrate.
Moreover, according to another aspect of the present invention, in the case of a method of manufacturing a color-converting filter substrate comprising at least a transparent supporting substrate, color-converting filter layers arranged on the supporting substrate, and a transparent overcoat layer that has projecting supporting pillars, covers the colorconverting filter layers to make the color-converting filter layers have a smooth surface, and has a gas barrier ability.
The method is made to be such that the overcoat layer having the supporting pillars is formed as a single body by being transferred onto the color-converting filter layers through at least the steps of: temporarily disposing a single body comprising the overcoat layer and the supporting pillars on a stripping layer disposed on a temporary substrate that has a supporting pillar female form formed therein, or on a stripping layer that is disposed on a temporary substrate and has a supporting pillar female form formed therein; compression bonding the single body comprising the overcoat layer and the supporting pillars onto the color-converting filter layers and the transparent supporting substrate and curing at a temperature of not more than 200 C; and eliminating the stripping layer and taking away the temporary substrate.
Here, the overcoat layer can be made to comprise a laminate of a first overcoat layer that has the supporting pillars and makes the colorconverting filter layers have a smooth surface, and a second overcoat layer that has a gas barrier ability.
Note that the color-converting filter layers comprise fluorescent colorant layers of the three primary colors formed in a desired pattern, or fluorescent colorant layers of at least one of the three primary colors and colored filters of the remaining primary colors formed in a desired pattern, or colored filters of the three primary colors formed in a desired pattern, or colored filters of at least one of the three primary colors and laminates of fluorescent colorant layers and colored filters of the remaining primary colors formed in a desired pattern.
Moreover, a structure in which the fluorescent colorant layers or the colored filters or the laminates of fluorescent colorant layers and colored filters are connected together by black masks that are thinner than these layers is also included in the present invention. In short, the present invention is applied to a method of manufacturing a colorconverting filter substrate having a constitution in which there are "steps", albeit only slight, at the color-converting filter layer parts, and a method of manufacturing an organic EL display panel having such a color-converting filter substrate.
In the drawings: Fig. 1 is a schematic sectional view of a top emission type multi-color organic EL display panel that uses a color-converting filter substrate obtained using the manufacturing method of the present invention; Fig. 2 is a schematic sectional view showing the colorconverting filter substrate of the present invention; Fig. 3 is a schematic sectional view showing a temporary substrate having disposed thereon a stripping layer in which a supporting pillar female form is formed; Fig. 4 is a schematic sectional view showing a temporary substrate having a supporting pillar female form formed therein and a stripping layer disposed thereon; Fig. 5 is a schematic sectional view of a colorconverting filter substrate for showing a method of transferring an overcoat layer and supporting pillars (before adhesion); Fig. 6 is a schematic sectional view of the color converting filter substrate for showing the method of transferring the overcoat layer and the supporting pillars (after adhesion); Fig. 7 is a schematic sectional view of the color converting filter substrate for showing the method of transferring the overcoat layer and the supporting pillars (after transfer); Fig. 8 is a schematic sectional view of a top emission type multi-color organic EL display panel that uses a color-converting filter substrate obtained using a conventional manufacturing method; and Fig. 9 is a schematic sectional view showing a conventional color- converting filter substrate.
Fig. 2 is a sectional view of a color-converting filter substrate in which red, green and blue color converting filter layers 2, 3 and 4 that contain dye(s), pigment(s) or the like have been formed on a transparent supporting substrate 1, and then an overcoat layer 5 and supporting pillars 16 have been formed as a single body thereon. Moreover, Fig. 1 shows an example of a sectional view of a top emission type multi-color organic EL display panel obtained by bonding the color-converting filter substrate of the present invention and a monochrome organic EL light emitter substrate together.
According to the present invention, in the color- converting filter substrate, a transparent overcoat layer is formed on a transparent supporting substrate 1 and on À color-converting filter layers 2, 3 and 4 that contain dye(s), pigment(s) or the like and are disposed on an upper surface of the supporting substrate 1, and moreover there are supporting pillars 16 formed on the overcoat layer 5 that function as spacers when bonding the color-converting filter substrate to an organic EL light emitter substrate; the overcoat layer 5 and the supporting pillars 16 are formed as a single body by temporarily forming a single body comprising the overcoat layer 5 and the supporting pillars 16 on a stripping layer 13 that is disposed on a temporary substrate 12 and has a supporting pillar female form formed therein as shown in Fig. 3, or on a stripping layer 13 disposed on a temporary substrate 12 having a supporting pillar female form formed therein as shown in Fig. 4, and then making the single body comprising the À overcoat layer 5 and the supporting pillars 16 face the color- converting filter layers 2, 3 and 4 on the transparent supporting substrate 1 as shown in Fig. 5, bonding the single body comprising the overcoat layer 5 and the supporting pillars 16 to the color-converting filter layers as shown in Fig. 6, and then transferring the single body comprising the overcoat layer 5 and the supporting pillars 16 onto the color-converting filter layers by eliminating the stripping layer 13 as shown in Fig. 7.
Following is a description of the method of
manufacturing a color-converting filter substrate and the method of manufacturing an organic EL display panel according to the present invention.
Fig. 1 is a sectional view of the constitution of an organic EL display panel, showing an embodiment of the present invention.
1: Organic fluorescent colorants In the present invention, the organic fluorescent colorant(s) should be colorant(s) that absorb light in the near ultraviolet region or visible region, in particular light in the blue or blue/green region, emitted from a light emitter, and emit visible light of a different wavelength as fluorescence; preferably at least one or more fluorescent colorant(s) that emit(s) fluorescence in the red region is/are used, and this/these may be combined with one or more fluorescent colorant(s) that emit(s) fluorescence in the green region. Specifically, it is easy to obtain an organic EL light emitter that emits light in the blue or blue/green region, but if one attempts to convert this light into light in the red region merely by passing the light through a red filter, then due to there originally being little light of wavelengths in the red region, the outputted light will be extremely dim.
The light from the light emitter is thus converted into light in the red region using fluorescent colorant(s), whereby it becomes possible to output light in the red region of sufficient intensity. Moreover, regarding light in the green region, similarly to the light in the red region, the light from the light emitter may be converted into light in the green region using other organic fluorescent colorant(s) and then outputted; alternatively, if the light emitted by the light emitter contains sufficient light in the green region, then the light from the light emitter may be merely passed through a green filter and then outputted. Furthermore, regarding light in the blue region, the light from the organic EL light emitter can be merely passed through a blue filter and then outputted.
Examples of fluorescent colorants that absorb light from the blue to blue/green region emitted from a light emitter and emit fluorescence in the red region are rhodamine type colorants, cyanine type colorants, pyridine type colorants, oxazine type colorants, and so on.
Furthermore, various dyes (direct dyes, acid dyes, basic dyes, disperse dyes) can also be used if fluorescent.
Examples of fluorescent colorants that absorb light from the blue to blue/green region emitted from a light emitter and emit fluorescence in the green region are coumarin type colorants, coumarin colorant type dyes, naphthalimide type colorants, and so on. Furthermore, various dyes (direct dyes, acid dyes, basic dyes, disperse dyes) can also be used if fluorescent.
Note that organic fluorescent colorant(s) used in the present invention may be kneaded in advance with a polymethacrylic acid ester, polyvinyl chloride, a vinyl chloride-vinyl acetate copolymer resin, an alkyd resin, an aromatic sulfonamide resin, a urea resin, a melamine resin, a benzoguanamine resin, a mixture of such resins, or the like, to form an organic fluorescent pigment. Moreover, the above organic fluorescent colorants and organic fluorescent pigments (in the present specification, the two are grouped together and referred to generically as Organic fluorescent colorants') may be used singly, or two or more may be used in combination to adjust the color tone of the fluorescence. The organic fluorescent colorant(s) used in the present invention is/are contained in the fluorescent colorant layers (color-converting layers) in an amount of 0.01 to 5wt\, more preferably 0.1 to 2wt%, relative to the weight of the fluorescent colorant layer.
If the organic fluorescent colorant content is less than O.Olwt%, then it will not be possible to carry out sufficient wavelength conversion, whereas if this content exceeds 5wt%, then a drop in the color conversion efficiency will be brought about due to effects such as concentration quenching.
2: Matrix resin The matrix resin is the binder in the fluorescent colorant layers. That is, the matrix resin is a parent material resin in which the fluorescent colorant(s) is/are dispersed.
The matrix resin used in the fluorescent colorant layers in the present invention is one obtained by subjecting a light-curable or jointlight/heat-curable resin to light and/or heat treatment, thus generating radical species or ionic species and hence polymerizing or crosslinking the resin, thus making the resin insoluble and
unmeltable.
Specifically, examples of such light-curable or joint-light/heat-curable resins are (1) ones obtained by subjecting a film of a composition comprising an acrylic polyfunctional monomer or oligomer having a plurality of acryloyl groups or methacryloyl groups and a photopolymerization or thermopolymerization initiator to light or heat treatment, thus generating photo-radicals or thermal radicals and hence carrying out polymerization, (2) ones obtained by subjecting a composition comprising a polyvinyl cinnamic acid ester and a sensitizer to light or heat treatment, thus carrying out dimerization and crosslinking, (3) ones obtained by subjecting a film of a composition comprising a chain or cyclic olefin and a bisazide to light or heat treatment, thus generating a nitrene and crosslinking the olefin, (4) ones obtained by subjecting a film of a composition comprising a monomer having epoxy groups and a photoacid generator to light or heat treatment, thus generating an acid (cations) and carrying out polymerization, and so on. In particular, light-curable or joint-light/heat-curable resins of type (1) above are preferable, since high-detail patterning is possible, and the reliability in terms of solvent resistance, thermal resistance and so on is good.
3: Overcoat layer The overcoat layer used in the present invention, which has a gas barrier ability, is preferably made of a material that has high transparency in the visible region (a transmittance of at least 50\ in a range of 400 to 700nm), Tg of at least 100 C, and a surface hardness of at least pencil hardness 2H, for which a smooth coating film can be formed on the substrate, and that does not cause deterioration in the functions of the color-converting filter layers 2 to 4; examples are light-curable resins and/or heat-curable resins such as imide-modified silicone resins, materials obtained by dispersing an inorganic metal compound (TiO, Al203, SiO2, etc.) in an acrylic, polyimide or silicone resin, epoxy-modified acrylate resins, which are W -curable resins, acrylate monomer/oligomer/polymer resins having reactive vinyl groups, resist resins, inorganic compounds obtained using a sol-gel method, and fluororesins. Moreover, an inorganic oxide, an inorganic nitride or the like may be used as the overcoat layer. For example, as a material that is electrically insulating, acts as a barrier against gases and organic solvents, and has high transparency in the visible region (a transmittance of at least 50 in a range of 400 to 700nm), SiOx, SiNX, SiNXOy, AlOX, TiOX, TaOx, ZnOx, or the like can be used.
The overcoat layer may be a single layer, or may comprise a plurality of layers formed on top of one another. In the case of a single layer, this one layer must have both a function of flattening out steps caused by the pattern of the color-converting filter layers, and a function as a gas barrier layer toward the organic EL light emitter. In the case that a plurality of layers are formed on top of one another, functional separation is possible into a layer having the function of flattening out steps caused by the pattern of the color-converting filter layers, and a layer having the function as a gas barrier layer toward the organic EL light emitter.
When using such an overcoat layer in a color conversion type organic EL display panel, there are important factors that must be considered. That is, care must be taken over the effects of the thickness of the overcoat layer on the display performance, in particular the viewing angle characteristics. A particularly important viewing angle characteristic with a color conversion type organic EL display panel is changes in color that occur when the angle from which the display panel is viewed is changed.
If the overcoat layer is made to be too thick, then the optical path traveled by the exciting light emitted by the organic EL light-emitting layer to the color-converting filter layers via the overcoat layer will become long. As a result, when viewing on a slant, leakage of the exciting light to adjacent pixels of a different color (i.e. optical cross-talk) will occur. In terms of the display performance of the display panel, the ratios of the amount of light emission of the adjacent color due to this optical cross-talk to the amount of light emission of the original color is required to be sufficiently low.
This requirement can be restated as a restriction on the relationship between the thickness of the overcoat layer and the minimum pixel width. According to Journal of Technical Disclosure No. 2001-6083, it ispreferable for the thickness t of the overcoat layer to be in a range of O < t < 0.1W, where W is the minimum pixel width.
4: Supporting pillars Supporting pillars are formed between some of the pixels. Moreover, there are no particular limitations on sites of formation of supporting pillars outside the display region. There are no particular limitations on the shape of the supporting pillars, with it being possible to envisage a circular cylindrical shape, a rectangular shape running along edge parts of the pixels, or an IKEI shape.
The height of the supporting pillars corresponds to the gap between the organic EL light emitter substrate and the color-converting filter substrate when the two are bonded together; this height should be as low as possible so that good viewing angle characteristics can be secured and yet must be sufficiently high to prevent the substrates from contacting one another, and is thus preferably 0.5 to 5mm.
5: Transfer of overcoat layer and supporting pillars In the method of the present invention, an overcoat layer that has been formed using a dry method (sputtering, vapor deposition, CVD, etc.), a wet method (spin coating, roll coating, casting, etc.), or the like on a stripping layer that has been formed on a temporary substrate is bonded onto the colorconverting filter substrate using pressure or the like, and is then transferred onto the color-converting filter substrate by etching away the stripping layer; this is different to the method principally used in the past in which the overcoat layer is formed using a dry method or a wet method directly onto the color-converting filter substrate. Moreover, by using a temporary substrate or stripping layer in which a supporting pillar female form has been formed, it is possible to simultaneously form projections that act as supporting pillars. An advantage of the transfer method is that the scope of selection of the material of the overcoat layer and the formation conditions therefor is broadened since it is not necessary to consider the thermal stability, chemical resistance and so on of the color- converting filter layers. Moreover, the color-converting filter layers and the overcoat layer can be manufactured in parallel, and hence the lead time can be shortened, and thus productivity is good, and furthermore because the supporting pillars can be formed simultaneously, the material utilization efficiency is also good.
For the temporary substrate, a material such as silicon, silicon nitride, a glass, quartz, or a ceramic can be used. As methods of forming the supporting pillar female form in the temporary substrate, there are a method in which the temporary substrate is directly processed using a laser or the like, and a method in which a thin film of an easily processed metallic material or the like is disposed on the temporary substrate and then this is processed.
For the stripping layer, a metallic material such as chromium, nickel, tantalum or tungsten, an insulating material such as alumina or silicon dioxide, or InZnO or the like is used. Such a stripping layer can formed using vacuum deposition, vapor phase growth, sputtering or the like; in the case of forming the supporting pillar female form in the stripping layer, patterning is carried out using photolithography or the like.
The surface of the temporary substrate and the stripping layer must be sufficiently flat since this affects the degree of flatness of the surface of the overcoat layer; it is preferable for the maximum height difference over the surface of the temporary substrate and the stripping layer to be not more than 0.1pm.
The pressure when bonding the overcoat layer and the color-converting filter layers together is preferably at least 0.2kgW/cm2 but not more than 2.0kgW/cm2, this being to make it such that voids do not arise at the bonding interface and yet the shape of the color-converting filter layers is maintained. Moreover, the temperature when bonding the overcoat layer and the color-converting filter layers together is preferably at least 100 C so that moisture, organic solvent and so on will not remain behind, but must be not more than 200 C due to the problem of the thermal stability of the colorants.
The etching away of the stripping layer can be carried out using, for example, a solution having phosphoric acid as a principal component thereof in the case of alumina or the like, an etching solution containing hydrofluoric acid in the case of silicon dioxide, or hydrochloric acid in the case of InZnO.
In the case of forming an overcoat layer in which a plurality of layers are formed on top of one another as described earlier, it is possible either to form the plurality of layers on top of one another on the temporary substrate and then carry out the transfer, or to transfer some of the layers and then form the remainder of the layers thereupon.
Moreover, an adhesive having similar optical properties to the overcoat layer may be provided between the overcoat layer and the color-converting filter layers.
Such an adhesive is used in the case that adhesion of the overcoat layer to the color-converting filter layers is poor if an adhesive is not used, or the case that there are inconveniences such as the occurrence of voids between the overcoat layer and the color-converting filter layers. For example, in the case that the viscosity of the material constituting the overcoat layer is high and hence voids are prone to occurring between the overcoat layer and the color-converting filter layers, this problem can be avoided by providing a layer of an adhesive having low viscosity.
6: Organic EL light emitter substrate.
The organic EL display panel using the color- converting filter substrate comprises the color-converting filter substrate and an organic EL light emitter substrate.
The constitution is made to be such that light in the near ultraviolet to visible region, preferably light in the blue to blue/green region, emitted from the organic EL light emitter enters the color-converting filter layers including the fluorescent colorant layers, and visible light of a different wavelength is outputted from the color-converting filter layers including the fluorescent colorant layers.
Note that depending on the constitution of the color- converting filter layers, it is possible that the color converting filter layers do not include fluorescent colorant layers as described above, although such a constitution is rarely adopted since there are problems as described earlier under the second method of achieving full
color in the Prior Art section.
The organic EL light emitter has a structure in which an organic EL lightemitting layer is disposed between two sets of electrodes, and if necessary a hole injection layer, an electron injection layer and so on may be interposed. Specifically, an organic EL light emitter having a layer structure such as the following is adopted.
(1) Anodes / organic EL light-emitting layer / cathodes (2) Anodes / hole injection layer / organic EL light- emitting layer / cathodes (3) Anodes / organic EL light-emitting layer / electron injection layer / cathodes (4) Anodes / hole injection layer / organic EL light emitting layer / electron injection layer / cathodes (5) Anodes / hole injection layer / hole transport layer / organic EL light-emitting layer / electron injection layer / cathodes In the above layer structures, it is necessary for at least one of the anodes and the cathodes to be transparent in the wavelength region of the light emitted by the organic EL light-emitting layer; the light passes through these transparent electrodes, and is thus made to be incident on the color- converting filter layers.
Publicly-known materials are used as the materials of the above-mentioned layers. For example, as the organic EL light-emitting layer, to obtain luminescence from blue to blue/green in color, for example a fluorescent whitening agent of benzothiazole type, benzimidazole type, benzoxazole type or the like, a metal chelated oxonium compound, a styrylbenzene type compound, an aromatic dimethylidene type compound, or the like is preferably used.
An example of the case of applying the manufacturing method of the present invention to a top emission type multi-color organic EL display panel will now be described with reference to the drawings.
Fig. 2 is a sectional view of a color-converting À filter substrate in which color-converting filter layers 2, 3 and 4 each containing red, green or blue dye(s) or pigment(s) have been formed in a pattern on a transparent supporting substrate 1 by photolithography, and then an overcoat layer 5 and supporting pillars 16 have been formed thereon. Fig. 1 shows an example of a sectional view of a top emission type multi-color organic EL display panel to which the present invention has been applied.
1: Formation of blue color-converting filter layers A blue filter material (made by Fuji Hunt Electronics Technology; Color Mosaic CB-7001) was applied using a spin coating method onto a sheet of Corning glass as a transparent supporting substrate 1, and patterning was carried out using a photolithography method, thus obtaining a striped pattern of blue color-converting filter layers 4 with a thickness of loom, a line width of O.lmm and a pitch of 0.33mm.
2: Formation of green color-converting filter layers 0.7 parts by weight of Coumarin 6 as a fluorescent colorant was dissolved in 120 parts by weight of a propylene glycol monoethyl acetate (PGMEA) solvent. 100 parts by weight of a photopolymerizable resin "V259PA/P5" (trade name, Nippon Steel Chemical Co., Ltd.) was then added to the solution and dissolved, thus obtaining a coating liquid. The coating liquid was applied using a spin coating method onto the transparent supporting substrate 1 on which the striped pattern of the blue color converting filter layers 4 had been formed, and then patterning was carried out using a photolithography method, thus obtaining a striped pattern of green color-converting filter layers 3 with a thickness of loom, a line width of O.lmm and a pitch of 0.33mm.
3: Formation of red color-converting filter layers 0.6 parts by weight of Coumarin 6, 0.3 parts by weight of Rhodamine 6G and 0.3 parts by weight of Basic Violet 11 as fluorescent colorants were dissolved in 120 parts by weight of a propylene glycol monoethyl acetate (PGMEA) solvent. 100 parts by weight of a photopolymerizable resin "V259PA/P5" (trade name, Nippon Steel Chemical Co., Ltd.) was then added to the solution and dissolved, thus obtaining a coating liquid. The coating liquid was applied using a spin coating method onto the transparent supporting substrate 1 on which the striped patterns of the blue color-converting filter layers 4 and the green color-converting filter layers 3 had been formed, and then patterning was carried out using a photolithography method, thus obtaining a striped pattern of red color-converting filter layers 2 with a thickness of gym, a line width of 0.lmm and a pitch of 0.33mm.
4: Formation of overcoat layer InZnO was deposited as a stripping layer 13 using a sputtering method to a thickness of 2pm over the whole surface of a sheet of Corning 1737 glass (made by Corning, trade name) as a temporary substrate 12. A supporting pillar female form was patterned into the stripping layer 13 using a photolithography method, and then InZnO was further deposited to a thickness of 0.2m using a sputtering method, thus completing the formation of a stripping layer 13 having a supporting pillar female form therein on the temporary substrate 12 as shown in Fig. 3. An acrylic transparent resin (NN810, made by JSR) was applied as an overcoat layer 5 to a thickness of 10pm using a spin coating method onto the stripping layer 13, and patterning was carried out using a photolithography method so that the overcoat layer 5 would fit around the color-converting filter layers, i.e. cover the upper surfaces of the color- converting filter layers and also fit into the gaps between the color- converting filter layers. The temporary substrate 12 and the transparent supporting substrate 1 were then placed together such that the overcoat layer 5 on the temporary substrate 12 and the color-converting filter layers 2, 3 and 4 on the transparent supporting substrate 1 faced one another and fitted together as shown in Fig. 6, and in this state compression bonding was carried out under conditions of 80 C and 0. 5kgW/cm2. With the pressure kept as is, the temperature was then held at 160 C for 30 minutes, thus curing the overcoat layer 5. The stripping layer 13 was then etched away using hydrochloric acid, whereby the overcoat layer 5 was transferred onto the color-converting filter substrate as shown in Fig. 7. At this time, supporting pillars 16 were also formed simultaneously. After the transfer, although not shown separately in the drawings, SiOXNy was deposited to 300nm using a sputtering method to form a second overcoat layer.
Note that in the case that a second overcoat layer is formed on the overcoat layer on which the supporting pillars have been formed, there is potentially a risk of the supporting pillar parts becoming a smooth shape, but in the present example, the height of the supporting pillars was Him, and the thickness of the second overcoat layer was thin compared with this at 0.3m, and moreover the method of manufacturing the second overcoat layer was sputtering, and hence there was no change in the shape to the extent that the supporting pillars lost their function.
The thickness of the overcoat layers (laminate) obtained as described above was 5.2mm at the color converting filter layers, and the maximum height difference over the surface was 0.2mm. There was no deformation of the patterns of the color-converting filter layers upon forming the overcoat layers.
5: Organic EL light emitter substrate As shown in Fig. 1, a constitution was adopted in which bottom gate type TFTs 15 were formed on a sheet of Corning 1737 glass (made by Corning, trade name) as a substrate 14, and the sources of the TFTs were connected to anodes 17.
For each of the anodes 17, Al connected to the source of the corresponding TFT via a contact hole formed in an insulating film on the TFT, not shown, was formed as a lower part, and IZO (InZnO) was formed on the upper surface thereof.
The Al is provided to reflect light emitted from the light-emitting layer so that light is emitted efficiently from the top, and to reduce the electrical resistance. The thickness of the Al film was made to be 300nm. The upper part IZO has a high work function, and hence is provided to efficiently inject holes into the light-emitting layer.
The thickness of the IZO was made to be 200nm.
A hole injection layer 7, a hole transport layer 8, an organic EL lightemitting layer 9, and an electron injection layer 10 were deposited in this order on the anodes 17 without releasing the vacuum. The structural formulae of the materials used in the various layers are
shown in Table 1.
Layer Material Structural Formula Hole Injection Copper phthalocyanine Layer 4,4'-bis[N-(1- N- :W naphthyl)-N- 11 phenylamino]biphenyl Hole Transport 4,4'-bis[N-(1 Layer naphtyhl)-N phenylamino]biphenyl N Lightemitting 4,4'-bis(2,2' layer diphenylvinyl)biphenyl Electron Tris(8 Injection Layer hydroxyquinoline) aluminum complex ó$0 During the deposition, the pressure inside the vacuum chamber was reduced down to lxlO4Pa. Copper phthalocyanine (CuPc) was formed to a thickness of lOOnm as the hole injection layer 7. 4,4'-bis[N-(1-naphthyl)N-phenylamino]biphenyl (a-NPD) was formed to a thickness À of 2Onm as the hole transport layer 8. 4,4'-bis(2,2'- diphenylvinyl!biphenyl (DPVBi) was formed to a thickness of 30nm as the light-emitting layer 9. An aluminum chelate (Alq) was formed to a thickness of 20nm as the electron injection layer 10. After that, transparent cathodes 18 were formed using a metal mask without releasing the vacuum.
The transparent cathodes 18 were formed by depositing metallic Mg/Ag, which has a low work function as required for electron injection, to a thickness of 2nm using a codeposition method, and then depositing an IZO film thereon to a thickness of 200nm using a sputtering method.
6: Bonding together The color-converting filter substrate and the organic EL light emitter substrate obtained as described above were sealed together using a W -curing sealing resin 19 under a dry nitrogen atmosphere (oxygen and moisture concentration both not more than lOppm) in a glove box. The two substrates contacted one another only at the supporting pillars and the sealing resin, and the state of sealing was good.
The brightness distribution and the angle of visibility were evaluated for the display panel manufactured in the example described above. The brightness distribution was +2 over the panel, and the angle of visibility was approximately 160 in the horizontal direction, and approximately 150 in the vertical direction.
Moreover, the organic EL display panel was driven for 500 hours in a high-temperature environment at 85 C, and an evaluation of pixel defects was carried out, whereupon the occurrence of pixel defects was not observed. The change in dark spots on the light-emitting surface was also observed. The result was that with the organic EL display panel manufactured using the manufacturing method of the present invention, the occurrence and growth of dark spots was hardly seen at all.
Through the method according to the present invention in which supporting pillars and an overcoat layer are À formed as a single body on the color-converting filter layers by transfer, it is possible to efficiently manufacture a multi-color organic EL display panel having excellent display performance.
Claims (3)
1. A method of manufacturing an organic EL display panel in which an organic EL light emitter substrate comprising a substrate, thin film transistors that are provided on the substrate and each have a source and a drain, and an organic EL light emitter that is driven by said thin film transistors and which is constituted by building up first electrodes that are made of an electrically conductive thin film material and are each formed on an upper part of a corresponding one of said thin film transistors and connected to said source or said drain of said corresponding one of said thin film transistors, at least an organic EL light-emitting layer, and second electrodes, and a color-converting filter substrate comprising at least a transparent supporting substrate, color-converting filter layers arranged on said supporting substrate, and a transparent overcoat layer that covers said color converting filter layers to make said color-converting filter layers have a smooth surface, and has a gas barrier ability, are bonded together via supporting pillars for adjusting the gap between said organic EL light emitter substrate and said color-converting filter substrate, such that said second electrodes of said organic EL light emitter and said overcoat layer face one another with a prescribed gap therebetween; the method of manufacturing an organic EL display panel characterized in that said overcoat layer and said supporting pillars for gap adjusting are formed as a single body by being transferred onto said color-converting filter layers through at least the steps of: temporarily disposing a single body comprising said overcoat layer and said supporting pillars on a stripping layer disposed on a temporary substrate having a supporting pillar female form formed therein, or on a stripping layer that is disposed on a temporary substrate and has a supporting pillar female form formed therein; compression bonding said single body comprising said overcoat layer and said supporting pillars onto said color converting filter layers and said transparent supporting substrate and curing at a temperature of not more than 200 C; and eliminating said stripping layer and taking away said temporary substrate.
2. A method of manufacturing a color-converting filter substrate comprising at least a transparent supporting substrate, color-converting filter layers arranged on said supporting substrate, and a transparent overcoat layer that has projecting supporting pillars, covers said colorconverting filter layers to make said color-converting filter layers have a smooth surface, and has a gas barrier ability; the method of manufacturing a color-converting filter substrate characterized in that said overcoat layer having said supporting pillars is formed as a single body by being transferred onto said color-converting filter layers through at least the steps of: temporarily disposing a single body comprising said overcoat layer and said supporting pillars on a stripping layer disposed on a temporary substrate that has a supporting pillar female form formed therein, or on a stripping layer that is disposed on a temporary substrate and has a supporting pillar female form formed therein; compression bonding said single body comprising said overcoat layer and said supporting pillars onto said color converting filter layers and said transparent supporting substrate and curing at a temperature of not more than 200C; and eliminating said stripping layer and taking away said temporary substrate.
3. The method of manufacturing an organic EL display panel according to claim 1, wherein said overcoat layer comprises a laminate of a first overcoat layer that has said supporting pillars and makes said colorconverting filter layers have a smooth surface, and a second overcoat layer that has a gas barrier ability.
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| Publication number | Priority date | Publication date | Assignee | Title |
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| WO2010023603A2 (en) * | 2008-08-28 | 2010-03-04 | Philips Intellectual Property & Standards Gmbh | Phosphor converted oled illumination device |
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| WO2010023603A2 (en) * | 2008-08-28 | 2010-03-04 | Philips Intellectual Property & Standards Gmbh | Phosphor converted oled illumination device |
| WO2010023603A3 (en) * | 2008-08-28 | 2011-01-20 | Philips Intellectual Property & Standards Gmbh | Phosphor converted oled illumination device |
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| GB2404073B (en) | 2006-05-17 |
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