JP2014146474A - Organic el display device and tape-like structure used for the same - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an organic EL display device and a tape-like structure used for the same, capable of displaying an image having a high definition and a high image quality, from a small size to an extra-large size such as an opposite angle of several hundreds inches.SOLUTION: An organic EL display device 100 has such a hierarchical structure that a pixel light-emission part 101 and a pixel drive circuit part 102 in a screen vertical direction are separated, and then laminated and bonded. The pixel light-emission part 101 has such a structure that an organic EL film 12 is sandwiched between a transparent plastic tape 10 to which a transparent electrode as a common anode is formed and a plastic tape 11 to which a cathode 25 separated into respective pixels is formed. In the pixel drive circuit part 102, signal lines 16-1 to 16-3, a power line 16-4, and a pixel connection bump 17-1 are formed on an upper surface of a plastic tape 14 having a width the same as or shorter than a plurality of screen horizontal pitches, and a chip 15 integrating the plurality of pixel drive circuits and a gate line connection bump 17-2 are formed on a lower surface.

Description

  The present invention relates to an organic EL display device and a tape-like structure used therefor, and more particularly to an active matrix organic EL (electroluminescence) display device and a tape-like structure used therefor.

  In recent years, attention has been paid to an organic EL display device which is a display device which is essentially superior to a liquid crystal display (LCD), such as self-light-emitting, high-speed response, and the like and capable of being ultra-thin. Similar to the inorganic light emitting diode, the organic EL light emitter used in this organic EL display device has a mechanism of formation of excitons by electrons and holes at the pn junction and light emission by this dissociation. Therefore, the light emitting portion has a structure in which an organic EL layer is sandwiched between two electrodes, an anode and a cathode, and the anode for extracting light is a transparent electrode. There are two types of organic EL materials used for this organic EL layer: low molecular weight materials and high molecular weight materials.

Low-molecular-weight materials achieve high efficiency and reliability through the formation of a multilayer structure in which charge injection, transport, and recombination are allotted to each layer of the organic thin film in vapor deposition, and become the mainstream for practical application. Yes. On the other hand, polymer materials are basically based on the idea that one molecule has a diode structure, and in principle, a single layer is sufficient. However, in reality, a pn junction structure is indispensable and multilayering is necessary. is there. However, since only a two- to three-layer film configuration can be realized due to the coating film formation, there are problems in terms of performance and reliability as a whole compared to low molecular weight materials. However, recently, high-performance polymer materials are gradually being developed, and organic EL applied to organic EL display devices (OLED: Organic Light Emissive Display, hereinafter referred to as OLED) having a luminance of 1000 cd / m ² or less. There is almost no problem as a material.

  In an OLED, a plurality of organic EL pixels are arranged in a two-dimensional matrix, and wiring and circuits for supplying voltage and current are mounted on each pixel to constitute a display panel. There are two types of display panels: a simple XY matrix and an active matrix with each pixel drive circuit attached. In terms of drive system, the former is called a multiplex system and the latter is called an active system. The multiplex method is only applied to a small display with a small number of pixels, and the active method is mainly used for the display panel of the OLED because of the light emission characteristics of the organic EL, and the present invention targets only the active method. The display panel of the active OLED has a wiring, a pixel driving circuit, a light emitting part electrode, and a light emitting layer formed on a single substrate within the range of one display cell (monochromatic part of the basic unit of display panel operation). Are formed as a repetitive pattern of only the number of pixels.

  The basis of the active OLED technology is a pixel configuration and a pixel driving circuit. There are two types of OLED pixel configurations. The first method uses the three primary colors of organic EL layers of red (R), green (G), and blue (B) for the pixels, and controls the self-light emission. The RGB organic EL layers are displayed. It is necessary to paint the cells separately. The second method is a method based on the entire surface of the organic EL white layer formed on the screen and the color filter technology established for the LCD, and controls the backlight intensity for each display cell. In this second method, relatively uniform light emission can be obtained, but it is inferior to the first method in terms of the image quality, which depends on the purity of white and the light use efficiency is low. Therefore, the first method is considered here.

  In this first method, the light emitting part formation method cannot apply normal lithography technology to pixel pattern formation due to the characteristics of the organic film. Thus, an organic layer having a width corresponding to the RGB vertical pixel column is formed. On the other hand, since it is difficult to separate the hues in the line-shaped coating, each pixel of RGB is surrounded by a bank structure, and a liquid is injected therein to form an organic film. .

In addition, in the OLED, three types of wiring, that is, a gate line, a signal line, and a common line are the same as those of the LCD, but in addition to this, a connection wiring to a current source is added. This is because the light emission of the OLED is due to current drive. For this reason, the pixel drive circuit of the OLED requires a current control switch circuit in addition to pixel selection, and unlike the configuration of one transistor for on / off voltage switch like the LCD, the configuration of at least two transistors It becomes. Further, in the case of LCD, the current consumption is 1 μA / cm ² by voltage driving, but in the case of OLED, the current value is 10 to 100 mA / cm ² , which is 4 to 5 orders of magnitude higher than that of LCD. For this reason, the pixel drive circuit of the OLED has a high drive current value, and the response speed becomes a problem with high definition. Therefore, the required circuit performance cannot be achieved with the a-Si thin film transistor (TFT), and p-Si or A TFT circuit configuration using an oxide film semiconductor (IGZO) is adopted.

  As described above, the OLED has a structure in which all cell configurations are formed on a single substrate, but is classified into two structures depending on which light is extracted from the substrate surface. The first structure is a form that is taken out from the back surface of the substrate (assuming that wiring, circuits, etc. are formed on the front surface), and is called a bottom emission type. In this bottom emission type, the substrate is transparent, and a transparent electrode (anode) such as ITO separated for each display cell is formed on the substrate. The second structure is called the top emission type. This top emission type has a structure in which an insulating layer is provided on the top of a wiring, a pixel driving circuit, etc., and a metal electrode (cathode) such as aluminum (Al) separated for each display cell is formed. The transparent electrode as the anode is formed on the entire screen. In the bottom emission type, when the size of the display cell is reduced by downsizing or high definition, the aperture ratio is reduced, that is, the ratio of the area occupied by the organic EL layer to the cell area is reduced. On the other hand, in the top emission type, the aperture ratio can be increased, but a transparent electrode (anode) must be formed on the organic EL layer, and a transparent electrode having a low resistance value cannot be obtained due to problems such as damage. It can be applied only to other display devices.

  As described above, OLED is a display device that is essentially superior to LCD. However, the larger the screen area, the higher the cost than LCD. In addition, there are problems with performance such as display non-uniformity. It becomes. Conventionally, there has been proposed an organic EL display device for solving the problem of joints and yield when a large OLED panel is produced by “tiling” a normal display panel. (For example, see Patent Documents 1 to 5).

  Each of the organic EL display devices described in Patent Documents 1 to 5 is configured to form an OLED using a fiber as a substrate, and the substrate fiber is a transparent glass or plastic wire having an arbitrary cross-sectional shape. A bottom emission type OLED pixel is formed, and wiring or the like is provided on the other surface. The organic EL display device has a configuration in which these fibers are arranged on a transparent face plate. The organic EL display device described in Patent Document 1 is an active OLED in which each pixel on one fiber is provided with a pixel driving circuit, a pixel address circuit (shift register, decoder, etc.) and wiring by a thin film process. .

  In addition, each organic EL display device described in Patent Documents 2 and 3 divides a display screen in which OLED fibers are arranged on a transparent surface into a lattice shape, and is a flexible printed circuit board (FPC) or printed circuit board. This is a device that operates as a collection of partial simple matrices using (PCB; Printed Circuit Board). Furthermore, each organic EL display device described in Patent Documents 4 and 5 has the same essential configuration as each organic EL display device described in Patent Documents 2 and 3, but with a simple matrix configuration in a bundle of fibers. These are arranged as a display screen. In each of the organic EL display devices described in Patent Documents 1 to 5, the joint problem is solved by arranging lines, and the yield problem is solved by discarding only the defective fiber.

US Pat. No. 6,259,838 US Pat. No. 6,259,846 US Pat. No. 6,274,978 US Pat. No. 6,560,398 US Patent Application Publication No. 2002/0008463

  However, each of the organic EL display devices described in Patent Documents 2 to 5 has a configuration specialized for a multiplex system and cannot be applied to an active OLED targeted by the present invention. On the other hand, the organic EL display device described in Patent Document 1 is an active OLED, and has a signal and pixel selection signal wiring on a fiber, and a decoder circuit and a drive circuit for a selected pixel in each pixel. In other words, in the organic EL display device described in Patent Document 1, not only the pixel drive circuit but also the part corresponding to the external circuit is incorporated in the panel on the fiber substrate, and the configuration of the current panel technology is not limited to the realization. It is just a shape built into the board. Further, the productivity which is an essential problem of the OLED is considered to be lower than that of the flat substrate in the configuration described in Patent Document 1.

  Here, when the current OLED is compared with the LCD, two problems can be considered. The first problem is a problem related to the current drive of the OLED, and the second problem is a problem related to the organic EL material. The first problem related to current driving is that the ratio of the wiring and pixel driving circuit occupied in the display cell by current driving is considerably larger than that of the LCD. From this point, the bottom emission type having the light emitting portion on the same plane has to go to a large panel. However, it is essential to reduce the wiring resistance with the increase in size, particularly to reduce the wiring resistance with the current source, the wiring width increases and the aperture ratio is considerably lower than that of the LCD. On the other hand, in the top emission type, this problem can be solved by forming a wiring and a circuit portion in a multilayer structure. That is, in an extreme case, the wiring problem can be solved in principle by wiring one layer for each layer with the required film thickness. However, in the configuration in which ITO is formed on the organic EL layer, it is difficult to reduce the resistance due to the reduction of film formation damage, and the present invention is limited to application to a small display device. Further, the manufacturing process of such a multilayer structure and the high-definition mask vapor deposition described later necessarily inevitably cost more than the LCD.

Further, the first problem related to current driving includes the problem of the pixel driving circuit. That is, the pixel drive circuit is composed of a plurality of transistors, and since the current value is particularly large, an a-Si TFT cannot be used, and a p-Si TFT is used. In comparison with the a-Si TFT manufacturing process, the p-Si TFT manufacturing process includes steps of dehydrogenation and laser annealing crystallization after a-Si: H film formation. The essential problem is that in the case of p-Si TFT, the grain structure causes variations in characteristics within the screen. An example of using amorphous IGZO for the uniformity of characteristics is increasing recently, but it is about 10 cm ² / Vs in terms of electric field mobility, and it is difficult to cope with large size and high definition.

  The second problem related to the organic EL material is a problem of the pixel formation process. There are two fundamental problems in mask vapor deposition in pixel formation of low molecular weight materials that are currently mainstream. The first problem is the problem of the mask itself. The larger the screen and the higher the definition, the more difficult it is to manufacture and handle the mask. The second problem is that of vapor deposition. This is directly related to productivity = cost. In order to increase productivity, the deposition rate may be increased, but generally there is a reciprocal relationship between the deposition rate and the film quality. With the current materials, the deposition rate is limited to about 1 nm / second at most. Therefore, there is no other way to increase the substrate size, but in that case, many problems occur such as control of film uniformity and large investment.

  As described above, the pixel formation process of the polymer material is difficult to separate pixels when applied at a pixel pitch, and thus an ink jet has been used. However, it is difficult to form a uniform film in the bank structure, and in addition, it has been found that the throughput is low. Originally, a high-speed process called coating is a characteristic of polymer materials, and recently, high-brightness materials have been manufactured. However, at present, this has not led to improvement in productivity.

  The OLED as described above has a small difference in cost from the LCD in the field of small screens (1.3 times the cost of the LCD for the 4 type), but the difference in cost from the LCD increases when the screen is large (55 The report “AMOLED Process Roadmap Report” published by Display Search Inc., a US technology research company, was published on the Internet on August 8, 2012. Have been). The reason for this is low yield and material costs, but at the same time, this solution is difficult with the development of the current technology, and it is speculated that it requires some other technological innovation and therefore requires a considerable period of time.

  As described above, the problem with OLEDs using low molecular weight materials, which are currently mainstream, is that the display performance and productivity decrease as the screen becomes larger and the definition becomes higher. In particular, the low productivity of mask vapor deposition in the organic EL layer forming process and the performance variation of p-Si TFT are the fundamental problems of the thin film process of a planar substrate. The solution to organic EL layer productivity is high-speed roll coating or die coating coating using a polymer material, but the problem is how to separate the RGB organic EL layers. . Uniformity and high performance of the pixel drive circuit over the entire screen are single crystal Si or a high performance amorphous semiconductor film close to single crystal Si, but none of them is expected in the current state of the art. That is, these problems cannot be solved as long as a flat substrate and a thin film process are used, and a technique for configuring an organic EL display device by a method other than this is required.

  The present invention has been made in view of the above points, and an organic EL display device capable of displaying a high-definition and high-quality image from a small screen size to an ultra-large screen size such as several hundred inches diagonal, and a tape used therefor An object is to provide a shaped structure.

  Another object of the present invention is that the manufacturing apparatus can be miniaturized, and the product cost can be significantly reduced due to high throughput. Moreover, the same manufacturing apparatus can be used to manufacture organic EL display devices of all screen sizes. An object of the present invention is to provide a tape-like structure capable of high reliability.

  In order to achieve the above object, an organic EL display device according to a first invention includes a first flexible tape having an anode formed on a surface thereof, and a cathode of each pixel in a pixel column in a screen vertical direction on the surface. A pixel light emitting portion having a structure in which an organic EL film is laminated and bonded to a second flexible tape having a connection electrode connected to the cathode on the back surface, and a signal line and a power line on one surface And pixel connection bumps are formed, and pixel driving by a third flexible tape in which at least the pixel driving circuit for a plurality of pixels is integrated on the other surface and at least pixel selection gate line connection bumps are formed. A circuit unit, and a pixel light emitting unit and a pixel drive circuit unit are stacked and joined in a state of being electrically connected to each other, and a plurality of units are arranged in the horizontal direction of the screen as a unit to form a full screen. That features To.

  In order to achieve the above object, the organic EL display device of the second invention is a transparent electrode in which the pixel light emitting portion of the first invention has a width of one horizontal pixel pitch or less of the display screen and is an anode on the surface. And a one-dimensional anode substrate made of a transparent first plastic tape, which is the first flexible tape, having a reinforcing metal film formed on the side surface, and a width equal to or less than one horizontal pixel pitch of the display screen The second flexible tape is a second flexible tape in which a cathode electrode row of each pixel of a pixel row in a vertical direction on the screen is formed on the front surface, and a connection electrode that is electrically connected to the cathode through a through hole is formed on the back surface. A cathode one-dimensional substrate composed of two plastic tapes, and an organic EL film continuously formed on the upper surface of the anode of the anode one-dimensional substrate or the upper surface of the cathode of the cathode one-dimensional substrate. Original substrate and organic Wherein the L film, a cathode dimensional substrate is hierarchical stacked.

  In order to achieve the above object, in the organic EL display device of the third invention, the pixel drive circuit unit of the first invention supplies a signal line for supplying a signal from the outside to the surface and a current. An integrated circuit in which at least a power supply line and a pixel connection bump arranged at a position corresponding to the cathode are formed, and a pixel drive circuit of a plurality of pixels in a vertical pixel column is integrated on the back surface, and a pixel selection gate line connection The third flexible board having a width equal to or less than a plurality of horizontal pixel pitches of the display screen, wherein a bump and a wiring for connecting the integrated circuit to the power supply line and the signal line through the through hole are formed at least including a terminal portion. It is characterized by comprising a third plastic tape that is a tape.

  In order to achieve the above object, an organic EL display device according to a fourth aspect of the present invention is the first aspect of the invention, wherein the width is equal to or less than one horizontal pixel pitch of the display screen, and the total pixel pitch of all pixels in the vertical direction of the screen A pixel light emitting section having a structure in which the organic EL film is laminated and bonded between the first and second flexible tapes having a long length, and a width equal to or less than a plurality of horizontal pixel pitches of the display screen Thus, the unit is a layered structure in which the pixel driving circuit unit using the third flexible tape having a length longer than the total pixel pitch of all the pixels in the vertical direction of the screen is stacked and joined in a state of being electrically connected. A black matrix extending in the vertical direction of the screen, which is arranged in each gap between pixels in the horizontal direction of the screen of the one-dimensional display unit, using a one-dimensional display unit arranged in a plurality of units in the horizontal direction of the screen as warp threads A first black insulating plastic fiber for a black matrix extending in the horizontal direction of the screen and arranged in a part of each pixel of the one-dimensional display unit at a pixel pitch in the vertical direction of the screen. The black insulating plastic fiber is regarded as a woven fabric structure with weft.

  In order to achieve the above object, according to a fifth aspect of the organic EL display device according to any one of the first to fourth aspects, the pixel light emitting section emits red light. The green pixel portion emitting green light and the blue pixel portion emitting blue light are separately formed for each primary color pixel portion unit.

  In order to achieve the above object, an organic EL display device according to a sixth invention includes a one-dimensional display unit corresponding to one display panel cut out from the fabric structure according to the fourth invention, and the first and second black insulating plastics. It is characterized by comprising a screen constituent part made of fiber, a peripheral circuit part connected to the screen constituent part, and a passivation film laminated on both front surfaces of the structure of the screen constituent part and the peripheral circuit part.

  In order to achieve the above object, the tape-like structure used in the organic EL display device of the seventh invention has a width equal to or less than one horizontal pixel pitch of the display screen of the organic EL display device and all pixels in the vertical direction of the screen. Among the first and second flexible tapes having a length longer than the total pixel pitch, a first flexible tape having an anode formed on the surface and a cathode of each pixel in the pixel column in the screen vertical direction are formed on the surface. A pixel light-emitting unit having a structure in which an organic EL film is sandwiched and bonded so that the anode and the cathode face each other between the second flexible tape having a connection electrode connected to the cathode on the back surface; At least a signal line, a power supply line, and a pixel connection bump are formed on one surface, and an integrated circuit in which pixel drive circuits of a plurality of pixels are integrated and at least a gate line connection bump for pixel selection are formed on the other surface. Was A pixel driving circuit unit using a third flexible tape having a width equal to or smaller than a plurality of horizontal pixel pitches of the display screen and a length longer than the total pixel pitch of all the pixels in the screen vertical direction of the display screen, and electrically connected pixels The screen vertical direction of the display screen and the screen are filled continuously between the light emitting portion and the pixel driving circuit portion, and the adhesive layer having a hierarchical structure by joining the pixel light emitting portion and the pixel driving circuit portion as a unit. It is formed in a horizontal direction.

  In order to achieve the above object, a tape-like structure according to an eighth aspect of the present invention is the pixel light emitting portion according to the seventh aspect, wherein a transparent electrode which is an anode is formed on the surface, and a reinforcing metal film is formed on the side surface. A formed one-dimensional anode substrate made of a transparent first plastic tape, which is a first flexible tape, and a cathode electrode column of each pixel in a pixel column in the vertical direction on the screen are formed on the back surface, A cathode one-dimensional substrate composed of a second plastic tape, which is a second flexible tape, formed with a connection electrode that is electrically connected to the cathode through a through hole, and the upper surface of the anode of the anode one-dimensional substrate or the cathode primary It has an organic EL film continuously formed on the upper surface of the cathode of the original substrate, and has a hierarchical structure in which an anode one-dimensional substrate, an organic EL film, and a cathode one-dimensional substrate are laminated.

  In order to achieve the above object, the tape-like structure of the ninth invention is laminated in a state where the pixel light emitting unit and the pixel driving circuit unit of the seventh or eighth invention are electrically connected. In a one-dimensional display unit having a length equal to or greater than the total pixel pitch of all the pixels in the vertical direction of the screen of the display device, in which a plurality of units are arranged in the horizontal direction of the screen with the hierarchical structure joined together as a unit, the one-dimensional display unit is a warp thread In addition, the first black insulating plastic fiber for black matrix, which is arranged in each gap between pixels in the horizontal direction of the screen of the one-dimensional display unit and extends in the vertical direction of the screen, is used as the warp, and the one-dimensional display unit A second black insulating plastic fiber for black matrix extending in the horizontal direction of the screen, which is arranged at a pixel pitch in the vertical direction of the screen in a part of each of the pixels, is a weft. Characterized by being configured to ascribe structure.

  According to the present invention, the pixel light emitting unit can maintain a high aperture ratio with a substantially pixel size, while the pixel driving circuit unit can use a high-performance pixel driving circuit based on a chip, and the resistance of wiring can be reduced. This makes it easy to realize a high-definition, high-quality organic EL display device ranging from a small screen size to a super-large screen size such as several hundred inches diagonal. Further, according to the tape-like structure of the present invention, the manufacturing apparatus can be reduced in size, and the product cost can be significantly reduced due to high throughput. Moreover, the same manufacturing apparatus enables organic EL display devices of all screen sizes. Can be manufactured with high reliability.

It is an equivalent circuit diagram of an example explaining one display cell of one embodiment of the organic EL display device according to the present invention. It is sectional drawing per pixel of one Embodiment of the organic electroluminescence display which concerns on this invention. It is a top view of the pixel drive circuit part in one Embodiment of the organic electroluminescence display which concerns on this invention. It is a layered structure and sectional view of a one-dimensional OLED which is a pixel light emission part. It is explanatory drawing of an example of the coating method of an organic electroluminescent film | membrane. It is a principal part sectional view of the manufacturing process of the cathode one-dimensional substrate and the manufactured cathode one-dimensional substrate. It is explanatory drawing of an example of the mask vapor deposition method of the metal electrode to an anode one-dimensional board | substrate or a cathode one-dimensional board | substrate, and the positional relationship figure of a tape and a SUS vapor deposition mask. An arrangement of one embodiment of the BM black insulating plastic fiber warp and weft one-dimensional display unit with respect to the light emitting portion, and one structure of the BM black insulating plastic fiber warp and weft and one-dimensional display unit light emitting portion. It is sectional drawing of embodiment. It is a figure which shows an example of the connection system to the external circuit of a one-dimensional display unit. It is explanatory drawing of an example of the joining method of two board | substrates. It is a figure which shows typically an example of the relative size of a chip | tip, a pixel, and a circuit tape, and the position of a chip | tip.

  A display panel according to the current manufacturing technology has a planar structure in which a pixel light emitting unit and a pixel driving circuit unit are integrated on the same surface of a flat substrate, but in the present invention, a pixel light emitting unit and a pixel driving circuit unit of a vertical pixel column are combined. A unit of screen structure is formed by separating and forming them on separate flexible tapes with a width equal to or shorter than one horizontal pixel pitch of the display screen, including the terminal portion, and then laminating and bonding them together And That is, in the present invention, a so-called tape-like structure composed of at least one set of three primary color vertical pixel columns (hereinafter referred to as a main structure) is cut from the screen including the vertical pixel columns up to the terminal portion. In the specification, it is manufactured by being disassembled into one-dimensional units (also referred to as “one-dimensional display units”), and these are arranged in a horizontal direction on a plurality of screens to constitute a full-screen display panel of the organic EL display device.

  The concept of “one-dimensional” as an element of the present invention is similar to the concept of a pixel array formed on a fiber according to the inventions described in Patent Documents 1 to 5. However, the essence of the present invention is that the pixel light emitting unit and the pixel driving circuit unit are completely separated, and are separately manufactured and stacked and joined to each other as a unit of the screen configuration, which is a one-dimensional display unit. This is fundamentally different from the “one-dimensional” concept of OLEDs described in Patent Documents 1-5.

  Next, embodiments of the present invention will be described with reference to the drawings. FIG. 1 is an equivalent circuit diagram illustrating an example of a display cell of an embodiment of an organic EL display device according to the present invention. In the figure, the pixel drive circuit 1 is separated from the pixel light emitting section 7 surrounded by a one-dot chain line including the organic EL light emitter 2 and is connected at a connection point 8. One display cell corresponds to one primary color pixel among the three primary color pixels constituting one pixel. The pixel driving circuit 1 includes MOS transistors Tr1 and Tr2 in which a pixel selection gate line 3 is connected to a gate and a signal line 4 is connected to a drain, and a MOS transistor Tr3 in which a source and a gate are connected to a power supply line 5. A MOS transistor Tr4 having a gate connected to the source of the MOS transistor Tr2 and a drain connected to the drain of the MOS transistor Tr3, and a capacitor C1 connected between the power supply line 5 and a connection point between the MOS transistors Tr2 and Tr4. It consists of. The source of the MOS transistor Tr4 is connected to the organic EL light emitter 2.

  The organic EL light emitter 2 has a known diode structure. Since the configuration of the pixel driving circuit 1 is known per se, a detailed description of its operation is omitted. However, a pixel column in the horizontal direction of the screen is selected by a pixel selection signal supplied to the gate line 3, and at the same time, each signal line 4 A display signal is supplied to the pixel. Therefore, the display signal supplied via the signal line 4 is supplied to the organic EL light emitting element 2 of the pixel driving circuit 1 of the pixel (display cell) selected by the pixel selection signal through the pixel driving circuit 1, and the organic EL The light emitter 2 is caused to emit light with a luminance corresponding to the display signal level. The current flows through the common electrode line 6 to the common electrode biased to a constant voltage.

  The pixel driving circuit 1 includes a gate line 3, a signal line 4, a power supply line 5, and a common electrode line 6 to constitute a pixel driving circuit unit. In the present invention, the pixel driving circuit unit and the pixel light emitting unit 7 are separately manufactured separately, and then both are stacked and joined. The two are electrically connected at a connection point 8. The configuration of the pixel drive circuit 1 is an example, and other configurations are known. However, since the configuration is not directly related to the present invention, the description of the pixel drive circuit having other configurations is omitted.

Next, the structure of the organic EL display device according to the present invention will be described.
FIG. 2 is a cross-sectional view of one embodiment of the organic EL display device according to the present invention per pixel, and FIG. 3 is a plan view of a pixel driving circuit unit in the embodiment of the organic EL display device according to the present invention. . In both drawings, the same components are denoted by the same reference numerals. As shown in FIG. 2, in the organic EL display device 100 according to an embodiment of the present invention, one pixel emits red light, an R pixel that emits red light, a G pixel that emits green light, and blue light. The B pixel portion has a hierarchical structure in which a pixel light emitting portion 101 and a pixel drive circuit portion 102 are stacked in the vertical direction of the screen.

  In FIG. 2, the R pixel portion is a cross-sectional portion below the symbol R, the G pixel portion is a cross-sectional portion below the symbol G, the B pixel portion is a cross-sectional portion below the symbol B, the R pixel portion, the G pixel portion, and For the B pixel unit, the pixel light emitting units 101 are provided independently of each other, and the pixel driving circuit unit 102 is provided in common. In FIG. 2, as an example, a structure in which the RGB pixel light emitting units 101 are integrated with a set of RGB one-dimensional FPCs is shown. In FIG. 2, the pixel light emitting unit 101 includes a flexible transparent plastic tape 10 on which a transparent electrode as a common anode is formed, and a flexible plastic tape 11 on which a cathode 26 separated into each pixel unit is formed. The organic EL film 12 (corresponding to the organic EL light emitter 2 in FIG. 1) is sandwiched between them. The structure having the function of the pixel light emitting unit 101 is referred to as a one-dimensional OLED in this specification. The transparent plastic tape 10 and the plastic tape 11, which are flexible tapes, have the same width and the width equal to or shorter than one horizontal pixel pitch of the display screen. The length in the vertical direction of the screen is the vertical pixel column of the display screen. Is set to a value that is significantly longer than the total pixel pitch of all pixels.

  On the other hand, the pixel drive circuit unit 102 supplies current to the signal lines 16-1 to 16-3 (corresponding to the signal line 4 in FIG. 1) to which signals are supplied from the outside, on the upper surface of the flexible plastic tape 14. Power supply line 16-4 (corresponding to power supply line 5 in FIG. 1) and pixel connection bumps 17-1 (corresponding to connection point 8 in FIG. 1) connected to the cathode are formed. An integrated circuit (hereinafter referred to as a chip) 15 in which a plurality of pixel driving circuits are integrated, a gate line connecting bump 17-2, and a wiring (not shown) are formed on the lower surface. In this specification, the structure having the function of the pixel driver circuit portion 102 is referred to as a one-dimensional FPC. The plastic tape 14 which is a flexible tape has a width of an arbitrary plurality of horizontal pixel pitches on the display screen. The plastic tape 11 of the pixel light emitting unit 101 and the plastic tape 14 of the pixel driving circuit unit 102 are filled and bonded with a flexible adhesive layer (underfill) 19 simultaneously with bump connection.

  Further, on the upper surface of the one-dimensional FPC plastic tape 14 constituting the pixel driving circuit unit 102, as shown in FIG. Nine pixel connection bumps 17-1 and signal lines 30 to 33 are formed. Further, on the upper surface of the one-dimensional FPC, a chip 15 and a plurality (three in FIG. 3) of gate line connecting bumps 17-2 are formed. The pixel connection bump 17-1 is connected to the chip 15 through the signal line 30. The bump 17-2 for connecting the gate line connects the gate line 18 (corresponding to the gate line 3 in FIG. 1) to the chip 15 via the signal line 31 formed on the lower surface of the plastic tape 14. The pixel connection bump 17-1, the signal line 16-1, and the power supply line 16-4 are connected to the chip 15 via through holes (not shown) formed in the plastic tape 14 and signal lines 33 and 32 on the lower surface. Connected with.

  The one-dimensional FPC that constitutes the pixel drive circuit unit 102 has the same structure as the FPC, TAB (Tape Automated Board), and COF (Chip on FPC) that are currently in practical use, except that the width is narrow. The copper foil tape and pattern forming technology used in the above can be used. The signal lines, power lines, etc. can have any film thickness in the above configuration and can be multi-layered, so that the problem of wiring resistance is completely solved for all screen sizes. Since the pixel driving circuit is manufactured by a large scale integrated circuit (LSI) process using an Si substrate, uniform and high-performance pixel driving is realized.

  Next, the structure of the pixel light emitting unit 101 will be described in more detail. 4A shows a layered structure of a one-dimensional OLED that is the pixel light emitting unit 101, and FIG. 4B shows a cross-sectional view taken along a cross-section A of FIG. In the figure, the same components as those in FIGS. 2 and 3 are denoted by the same reference numerals. Note that the cross-sectional view of FIG. 4B is a cross-sectional view of one primary color pixel portion among the R pixel portion, the G pixel portion, and the B pixel portion. As shown in FIG. 4A, the one-dimensional OLED as the pixel light emitting unit 101 has a cathode and an anode facing each other between a total of two substrates, an anode one-dimensional substrate 20 and a cathode one-dimensional substrate 22. The organic EL film 12 is laminated and bonded (that is, a so-called sandwiched structure). As shown in FIGS. 4A and 4B, the anode one-dimensional substrate 20 has a transparent electrode 23 as an anode on the surface of a transparent plastic tape 10 having a width equal to or shorter than one horizontal pixel pitch of the display screen. The reinforcing metal film 24 made of a metal such as copper for reducing the resistance of the common electrode is formed on the side surface of the tape.

  The organic EL film 12 is a continuous film formed on the transparent electrode 23 by coating. The cathodes 25 are formed on the organic EL film 12 at intervals corresponding to one pixel pitch in the vertical direction of the screen by mask vapor deposition by the method shown in FIG. The cathode one-dimensional substrate 22 has a cathode connection electrode 13 connected to the cathode 25 formed on the surface of the plastic tape 11 having the same width as the anode one-dimensional substrate 20, and an electrode 26 formed on the back surface of the plastic tape 11. In this structure, the electrodes 13 and 26 are electrically connected through a through hole 27 formed in the plastic tape 11. Since the cathode connection electrode 13 is electrically connected to the cathode 25, the cathode 25 is electrically connected to the electrode 26 through the cathode connection electrode 13. The anode one-dimensional substrate 20 and the cathode one-dimensional substrate 22 are described later with reference to the method of FIG. 10 so that a good electrical connection can be obtained with the organic EL film 12 sandwiched so that the transparent electrode 23 and the cathode 25 face each other. Glued with. The organic EL film 12 is electrically connected to pixel connection bumps and wirings on a one-dimensional FPC, which is a relatively large metal mass, via a cathode 25, and is mounted with a good heat sink.

  Next, a method for applying the organic EL film 12 will be described. FIG. 5 illustrates an example of a method for applying the organic EL film 12. The anode one-dimensional substrate 20 having the transparent electrode 23 as the anode formed on the surface of the transparent plastic tape 10 is fed in a certain direction by a roller 41 that rotates at a constant speed. On the other hand, the coating liquid 43 for the organic EL film is fed to the die head 44 by a liquid feeding device 42 such as a dispenser. Thereby, the organic EL film by the coating liquid 43 is continuously formed on the transparent electrode of the anode one-dimensional substrate 20 by the die head 44 by a coating method called die coating. The organic EL film can be formed on the cathode 25 by a similar method, not on the transparent electrode.

  Next, a manufacturing process of the cathode one-dimensional substrate will be described. FIG. 6 shows a cross-sectional view of the main steps of the cathode one-dimensional substrate manufactured and the cathode one-dimensional substrate manufactured. In the figure, the same components as those in FIGS. 2 to 4 are denoted by the same reference numerals. First, as shown in FIG. 6A, the copper film 50 formed on the entire surface of the plastic tape 11 is intermittently removed by applying a photolithographic technique, as shown in FIG. Electrodes 26 made of a copper film are formed at a pixel pitch in the vertical direction of the screen of the target display device.

  Subsequently, as shown in FIG. 6C, a predetermined through hole 27 is formed in the center position of the electrode 26 by a predetermined method to establish conduction between the front surface and the back surface of the plastic tape 11. Then, as shown in FIG. 6D, a cathode connection electrode 13 for cathode conduction is formed on the back surface of the plastic tape 11 by applying, for example, a mask vapor deposition method shown in FIG. 7 described later, and the through holes 27 and the bumps are formed. Conduct. FIG. 6E shows a cross-sectional view taken along the line A-A 'of the cathode one-dimensional substrate of FIG. The electrode 26 can also be formed by mask vapor deposition without using a photolithography technique.

  Next, a mask vapor deposition method for metal electrodes (mainly Al) will be described. FIG. 7A shows an explanatory view of an example of a mask deposition method of a metal electrode on an anode one-dimensional substrate or a cathode one-dimensional substrate. In FIG. 2A, a tape 60 such as a plastic tape 11 fed out from a tape feeding portion (not shown) runs on the surface of a roll 63 and is taken up by a tape winding portion (not shown). On the other hand, the endless SUS deposition mask 61 is brought into close contact with the tape 60 by the rolls 65-1 and 65-2 on the surface of the roll 63. In this state, the vapor deposition particles of the metal evaporated from the evaporation source 62 are vapor deposited so as to transfer the mask pattern of the SUS vapor deposition mask 61 onto the tape 60 through the SUS vapor deposition mask 61 to form a metal film. The rolls 64-1, 66-1, 66-2, 66-3, and 64-2 are rotation and tension mechanisms for the tape 60 and the SUS vapor deposition mask 61, respectively. FIG. 7B shows the positional relationship between the tape 60 and the SUS vapor deposition mask 61 when mask vapor deposition is performed on a large number of tapes 60.

  By the way, in general, in an image display device, in order to perform high-quality image display using pixel signals from a plurality of light-shielded pixels in the screen vertical direction and the screen horizontal direction as black tone reference signals, an optical device having a predetermined width is used. As is well known, a black matrix (BM), which is a light blocking area, is provided at each predetermined position in the vertical direction and horizontal direction of the screen. In view of this, the present invention configures the entire screen by arranging a plurality of hierarchical structures (that is, one-dimensional display units) in which the pixel light emitting units 101 and the pixel driving circuit units 102 in the pixel column in the vertical direction of the screen are stacked and joined in the horizontal direction of the screen. In order to provide the BM also in the organic EL display device according to the above, the tape-like structure used in the organic EL display device according to the present invention has black insulating plastic fibers arranged as a warp and a weft in a lattice pattern as the BM. Further, in addition to this arrangement, a woven fabric structure in which a continuous tape of a one-dimensional display unit is used as a warp is regarded as a continuous long “fabric”.

  This will be further described with reference to FIG. FIG. 8A shows the arrangement of one embodiment of the BM black insulating plastic fiber warp and weft one-dimensional display unit with respect to the light emitting portion, and FIG. 8B shows the BM black insulating plastic fiber warp and FIG. 3 shows a cross-sectional view of an embodiment of a structure comprising a weft and a light emitting part of a one-dimensional display unit.

  In FIG. 8A, an R display surface 70, a G display surface 71, and a B display surface 72 extending in the vertical direction of the screen are one-dimensional display units periodically provided in the horizontal direction of the screen. This is the structure of the R pixel portion, G pixel portion, and B pixel portion shown in the figure. Further, the black insulating plastic fiber for BM extending in the vertical direction of the screen, which can be regarded as the warp yarn 73 of the fabric, is in the gap between the pixels adjacent to the horizontal direction of the screen of the R display surface 70, the G display surface 71 and the B display surface 72. The black insulating plastic fiber for BM extending in the horizontal direction of the screen, which can be regarded as the weft 74 of the fabric, is arranged on a part of the R display surface 70, the G display surface 71 and the B display surface 72 at a vertical pixel pitch. Has been. As a result, a set of RGB one-dimensional display units composed of one R display surface 70, one G display surface 71, and one B display surface 72 adjacent in the horizontal direction of the screen, and two adjacent wefts 74, A region surrounded by a circle constitutes one pixel 78. This region includes three adjacent warp threads 73.

  That is, the tape-like structure of the present embodiment has a one-dimensional display in which an R display surface 70, a G display surface 71, and a B display surface 72 are periodically provided in the horizontal direction of the screen as shown in FIG. The continuous tape of the unit is a warp, and the black insulating plastic fiber for BM extending in the vertical direction of the screen arranged in a lattice shape is the vertical thread 73, and the black insulating plastic fiber for BM extending in the horizontal direction of the screen is used. It can be regarded as a woven fabric structure with a weft thread 74. Further, in this fabric structure, a large number of the one pixels 78 are arranged in an arbitrary length significantly longer than the number of screen vertical pixels (lines) of the display device, and a predetermined horizontal pixel pitch of the display device is set. It can be regarded as a long “fabric” having a width in which a number of pixels 78 are arranged.

  Further, as shown in the cross-sectional view of FIG. 8 (b), this tape-like structure has a plain weave with a pixel pitch of only BM, a one-dimensional display unit 75 (in this case, a set of RGB light emitting portions), and It is a structure in which a plain weave of weft 74 as BM is doubled. FIG. 8 (b) shows a structure in which both sides are further laminated with flexible passivation films 76 and 77. FIG.

  Next, a method for connecting the one-dimensional display unit to an external circuit will be described. FIG. 9 shows an example of a connection method of the one-dimensional display unit to an external circuit. In the figure, the same components as those in FIGS. 2 and 3 are denoted by the same reference numerals. In FIG. 9, the one-dimensional display unit 80 has a hierarchical structure in which pixel light emitting units and pixel drive circuit units in a pixel column in the vertical direction of the screen are stacked and joined, and a plurality of (only three of them are shown in FIG. 9) in the horizontal direction of the screen. (Shown) All screens are arranged. The one-dimensional display unit 80 is a screen constituent unit composed of a one-dimensional display unit for one display panel cut out from the fabric structure and black insulating plastic fibers for BM of warp yarns 73 and wefts 74. The terminal connection is made with the peripheral circuit portion composed of the common electrodes FPC 82 and FPC 83.

  In other words, the one-dimensional display unit 80 of the screen configuration unit is connected to the FPC 81 and the common electrode FPC 82 each equipped with a display signal driver and a power source (not shown) in the vertical direction of the screen, and to the line in the horizontal direction of the screen. The selection gate line 18 is connected to the chip 15 of the pixel driving circuit portion through wiring, and the terminal portion is connected to the FPC 83 on which a gate driver is mounted. The flexible passivation films 76 and 77 shown in FIG. 8B are laminated when the connection shown in FIG. 9 is completed.

  As described above, in the organic EL display device according to the present embodiment, the display panel is separated into the pixel light emitting unit (one-dimensional OLED) and the pixel driving circuit unit (one-dimensional FPC) in the vertical pixel column, and these are displayed on the display screen. A layered structure (one-dimensional display) that is formed separately on a flexible tape with a width equal to or shorter than one horizontal pixel pitch, including terminal parts, and then stacked and joined together in an electrically connected state. Unit) is the unit of the screen configuration, so that the pixel light-emitting portion of the display device can maintain a high aperture ratio with a substantially pixel size, while the pixel drive circuit portion uses a high-performance pixel drive circuit based on an Si chip. In addition, the resistance of the wiring can be easily reduced, and a high-definition and high-quality OLED can be realized from a small screen size to an ultra-large screen size such as a few hundred inches diagonal.

  For example, in a quad-4K 16: 9 aspect type 20 (a slightly narrow A3 size), the horizontal pixel pitch is 20 μm (423 ppi), and in a type 10 (˜A4), 10 μm (850 ppi). With the current organic EL technology, a high-performance pixel drive circuit cannot be mounted in terms of area at such a horizontal pixel pitch. On the other hand, in the present embodiment, the pixel drive circuit unit and the pixel light emitting unit are separated, and in principle, the pixel aperture ratio is 100% with the high-performance pixel drive circuit based on the Si LSI technology. Excellent display performance can be realized.

  Further, since the cathode 25 of each pixel is connected to the low-resistance wiring via the pixel connection bump 17-1 disposed at a position corresponding to the cathode position, it serves as a heat sink for the organic EL film 12, Deterioration can be prevented. Further, since the organic EL film 12 is a kind of “package structure” sandwiched between the one-dimensional anode substrate 20 and the one-dimensional cathode substrate 22 which have been subjected to passivation, high reliability is maintained while maintaining flexibility. realizable.

  In terms of manufacturing technology, the present embodiment has a configuration in which two one-dimensional substrates of a one-dimensional OLED and a one-dimensional FPC are stacked and bonded, so that the manufacturing apparatus is significantly reduced in size compared to the conventional one and has high throughput. Significant reduction in product cost is realized. Miniaturization of manufacturing equipment not only saves energy, but also eliminates the difference between production machines and experimental machines, and can speed up technological innovation. Further, since the primary color pixel portions of the three primary colors of red (R), green (G), and blue (B) are separately formed on the independent anode one-dimensional substrate 20, when a low molecular weight material is used. No mask vapor deposition is required, and when a polymer material is used, high-speed coating can be performed. Therefore, the manufacturing problem of color coating can be solved, and high productivity can be realized.

  Further, in this embodiment, the definition of the display device is determined only by the width of the flexible tape (transparent plastic tape 10 and plastic tape 11) constituting the one-dimensional OLED, and the enlargement of the screen is determined by the width and length of the flexible tape. Therefore, an organic EL display device having an arbitrary definition and screen size can be manufactured using the same manufacturing apparatus. The ability to produce organic EL display devices of all screen sizes with the same manufacturing device is a particularly important effect. For example, the width of the “substrate” of a general household HD-TV 52 type is 0.2 mm. Even for super large displays such as the 260 type and the 520 type, the substrate width is at most about 1 mm or 2 mm, and a simple jig replacement level is sufficient.

  Next, Example 1 of the present invention will be described. This embodiment is an example of manufacturing an OLED for 60-inch HD-TV. The horizontal pixel pitch of this OLED display screen is 0.23 mm. In this embodiment, as the transparent plastic tape 10 of the anode one-dimensional substrate 20, a tape-like fiber by spinning PEN (polyethylene naphthalate) having a width of 0.2 mm, which is slightly shorter than the horizontal pixel pitch, and a thickness of 20 μm. Using. As passivation for moisture and oxygen, polyurea and SiOx (x = 1.6) films were alternately laminated on the entire surface of the tape-like fiber. Next, a copper film having a thickness of 5 μm is formed as a reinforcing metal film 24 by plating on both sides of the tape-like fiber at 20 μm, and then a transparent electrode 23 having a film thickness of 100 nm at a substrate temperature of 110 ° C. by an RtR magnetron sputtering apparatus. ITO was deposited. The resistance value is 30Ω / □. The length in the vertical direction of the screen is 75 cm, the resistance value of the ITO part at both ends of the tape-like fiber is 113 kΩ, that of the copper film part is 70 Ω, and the tape-like fiber is connected to the common electrode having substantially zero resistance at both ends. The maximum resistance difference in the fiber is 35Ω.

The red (R), green (G), and blue (B) light-emitting films have a three-layer structure consisting of a hole transport layer, a light-emitting layer, and an electron transport layer. The layer is common to all emission colors. The hole transport layer is made of PEDOT-PSS or PVK (poly (N-vinylcarbazole)) matrix with TPD (N, N7-diphenyl-N, N'-bis (3 methylphenyl) -1,1'-biphenyl-4,4 '-diamine) doped, the electron transport layer is PBD (2- (4-biphenyl) -5- (4-tert-butylphenyl) 1,3,4-oxadiazole) PMMA (poly (methyl methacrylate)) Is doped. PVK is used as the matrix material of the light emitting layer, R is Ir (piq) (iridium bis (1-phenylisoquinoline) (acetylacetonato)), G is Ir (mppy) ₃ (iridium tris (2- (4-tolyl) pyridinato-N , C ^{2 ′} )) and B are doped with FIpic (iridium bis (2- (4,6-difluorophenyl) -pyridinato-N, C ^{2 ′} ) picolinate).

  These organic EL materials are applied by a die coater whose principle is shown in FIG. PEDOT-PSS is applied to the one-dimensional substrate of the light emitting part, and the light emitting layer and the electron transport layer are applied in this order after drying each film. The coater is a 100-unit multi-head die that individually controls the gap, and the coating speed is 180 m / min. After the coating, 100 fibers were simultaneously formed with LiF and Al at a film forming rate of 180 m / min using a mask vapor deposition machine of the principle shown in FIG.

  The plastic tape 11 for the cathode one-dimensional substrate 22 is a tape-like fiber formed by spinning with the same PEN width 0.2 mm and thickness 20 μm as the transparent plastic tape 10 of the anode one-dimensional substrate 20, and has through holes at intervals of 0.69 mm. A copper film was formed as an electrode 26 on one side by sputtering using the same endless mask in principle as in FIG. 7, and an electrode for connection with the circuit portion was formed. Subsequently, an Al electrode electrically connected to the cathode 25 of the anode one-dimensional substrate 22 through the copper film and the through hole was formed on the other surface in the same manner as shown in FIG.

  The anode one-dimensional substrate 20 and the cathode one-dimensional substrate 22 are joined by the method shown in FIG. That is, in FIG. 10, the anode one-dimensional substrate 90 (corresponding to the anode one-dimensional substrate 20) and the cathode one-dimensional substrate 91 (corresponding to the cathode one-dimensional substrate 22) are joined by microplasmas 92a and 92b, respectively. It is cleaned and introduced into the vacuum chamber 94 through the differential exhaust systems 93a and 93b. Here, after positioning both the substrates 90 and 91, the one-dimensional OLED 97 is completed by being joined by the crimping portion in the vacuum chamber 94 schematically shown by the rollers 95 and 96. Thereafter, the one-dimensional OLED 97 exits from the vacuum chamber 94 and is wound around the winder 99 through the differential exhaust system 98. For example, an organic EL film is formed on the transparent electrode of the anode one-dimensional substrate 90.

  As the one-dimensional FPC plastic tape 14, an existing FPC is used. In this example, a material in which a copper foil having a thickness of 18 μm was laminated on both surfaces of a 25 μm-thick Kapton tape (hereinafter referred to as “circuit tape”) was used. The width of the circuit tape is 2.04 mm, and three sets of RGB, that is, nine one-dimensional OLED tape circuit portions are used. Gold bumps (corresponding to the pixel connecting bumps 17-1 in FIGS. 2 and 3) are formed on one side of the circuit tape to connect the wirings and the pixels in the pixel light emitting section. The wiring consists of three signal lines (corresponding to the signal lines 16-1 to 16-3 in FIG. 3) and nine power sets (corresponding to the power lines 16-4 in FIG. 3). A total of three sets of one power supply line and three signal lines are arranged at a distance of 170 μm from a position 25 μm from the edge along the longitudinal direction of the plastic tape 14 (circuit tape) with a width of 100 μm. The resistance value of each wiring is about 7Ω. A total of 9720 lines consisting of 1080 lines with a length of 40 μm and a length of 100 μm are formed in a 70 μm width between wirings in a longitudinal direction with a total of 1080 lines, and through holes and gold bumps are formed here. Form.

  Further, the Si chip (corresponding to the chip 15 in FIGS. 2 and 3) of the pixel driving circuit formed on the other surface of the circuit tape has a thickness of 0.3 mm and a thickness of 0.1 mm, and 36 primary color pixel portions. These pixel drive circuits are integrated. Further, the size of the terminal bump is 20 μmφ, the pitch between the bumps is 40 μm, and 50 bumps per chip.

  FIG. 11 schematically shows an example of the relative size of the chip, the pixel and the circuit tape and the position of the chip. As shown in the figure, the width of the circuit tape 111 corresponding to the plus chip tape 14 constituting a part of the above-described one-dimensional FPC is such that each of the R pixel portion, the G pixel portion, and the B pixel portion of the display device. A set of pixels is set to a width corresponding to a horizontal pixel pitch in which three pixels are arranged in the horizontal direction of the screen. For example, when used in a 60-inch full HD organic EL display device, since there are 1080 vertical pixels and 1920 horizontal pixels, 5760 (= 1920 × 3) primary color pixel portions are arranged in the horizontal direction of the screen. Assuming that the horizontal width of one primary color pixel portion is 0.2 mm and this is arranged in the horizontal direction at a dot pitch of 0.23 mm, the width of the circuit tape 111 is 9 primary color pixel portions at a dot pitch of 0.23 mm. It is 2.04 mm (= 0.23 mm × 8 + 0.2 mm), which is the width arranged in (1). The circuit tape 111 is arranged with a total of 640 (= 5760/9) sheets in the horizontal direction with a horizontal gap of 30 μm between the tapes.

  On the other hand, as described above, the plus chip tape 14 constituting a part of the one-dimensional FPC has a length significantly longer than the total pixel pitch of all the pixels in the vertical direction of the screen of the display device. The circuit tape 111 is cut by cutting it into a length slightly longer than the length corresponding to the total pixel pitch of the pixels. Further, as shown in FIG. 11, the circuit tape 111 has a chip (corresponding to the chip 15 in FIGS. 2 and 3) 113 in which pixel driving circuits of a total of 36 primary color pixel portions 112 in 4 rows and 9 columns are integrated. Are arranged at the center of the arrangement region of the 36 primary color pixel portions 112. Accordingly, 270 (= 1080/4) chips 113 are mounted on the circuit tape 111 as one vertical pixel column. The chip 113 is flip-chip mounted on the surface opposite to the power supply line, the signal line, and the pixel connection bump. Wiring from the chip 113 to the power supply line, the signal line, and the bump is as described with reference to FIG. That is, the chip 113 is electrically connected to a power supply line, a signal line, and a pixel connection bump on the opposite surface of the chip 113 through a through-hole through a wiring on the same surface as the chip 113. As an example, in the same screen vertical column, the primary color pixel portions are arranged in the same primary color pixel portion.

  Similar to the formation of the one-dimensional OLED, the one-dimensional OLED and the one-dimensional FPC are connected by the method shown in FIG. That is, in FIG. 10, a one-dimensional OLED is used instead of the anode one-dimensional substrate 90 and a one-dimensional FPC is used instead of the cathode one-dimensional substrate 91, so that the pressure bonding is performed by the rollers 95 and 96 in the vacuum chamber 94. A one-dimensional display unit (tape-like structure) of a hierarchical structure of one-dimensional OLED and one-dimensional FPC is taken out from the vacuum chamber 94 and taken up by a winder 99. The gap between the RGB pixel lines in the wound one-dimensional display unit is 30 μm.

  In this example, 40 μmφ black insulating plastic fiber was used as the warp and weft for BM. As described above, the tape-like structure of the present embodiment has a one-dimensional display unit 75 including a plain weave with a pixel pitch of only BM and a set of RGB pixels, as shown in the cross-sectional view of FIG. And a plain weave of BM weft 74 and a double woven fabric structure. In this example, this was produced by a loom. This fabric is woven so that 640 circuit tapes 111 in a tape-like structure (one-dimensional display unit) are arranged in the horizontal direction of the screen at a pitch of 2.07 mm as “warp threads”. The width is 1324.8 mm. A long “fabric” with this width, ie, an array of display screens, was continuously produced.

  Then, after cutting this "fabric" into a length of 760 mm including a vertical height of the display screen (total pixel pitch in the vertical direction of the screen) of 745.2 mm and a terminal portion of about 15 mm at both ends, an external drive circuit, a control circuit Are connected as shown in FIG. 9, and a protective film is laminated on both sides of the tape-like structure (one-dimensional display unit). Was completed.

  In the present invention, since an organic EL display device can be easily manufactured from a small screen size of several tens of ultra-thin and flexible to an ultra-large screen size of several hundreds, it is called a full-scale large wall-mounted TV. In addition to the original display applications, it is possible to create new concepts such as “active” elements of living space such as displays as interiors, integration with buildings such as walls, and fusion of lighting and displays. In addition, in the present invention, since a pixel aperture ratio of 100% can be obtained in principle, excellent display performance can be realized at high resolution, and the resolution far exceeds the resolution of printing and photography, and nature is reproduced as it is. The amazing electronic paper that can be realized.

DESCRIPTION OF SYMBOLS 1 Pixel drive circuit 2 Organic EL light-emitting body 3, 18 Gate line 4, 16-1 to 16-3, 30-33 Signal line 5, 16-4 Power supply line 6 Common electrode line 7 Pixel light emission part 8 Connection point 10 Transparent plastic Tapes 11 and 14 Plastic tape 12 Organic EL film 13 Cathode connection electrodes 15 and 113 Integrated circuit (chip)
17-1 Pixel connection bump 17-2 Gate line connection bump 19 Adhesive layer 20, 90 Cathode one-dimensional substrate 22, 91 Anode one-dimensional substrate 23 Transparent electrode 24 Reinforcing metal film 25 Cathode 26 Electrode 27 Through hole 44 Die head 50 Copper film 60 Tape 61 SUS vapor deposition mask 62 Evaporation source 70 R display surface 71 G display surface 72 B display surface 73 Warp yarn 74 Weft yarn 75, 80 One-dimensional display unit 76, 77 Flexible passivation film 78 One pixel 81, 83 FPC
82 Common electrode FPC
92a, 92b Microplasma 93a, 93b, 98 Differential exhaust system 94 Vacuum chamber 95, 96 Roller 97 One-dimensional OLED
99 Winder 100 Organic EL Display Device 101 Pixel Light Emitting Unit 102 Pixel Drive Circuit Unit 111 Circuit Tape 112 Primary Color Pixel Unit

Claims (9)

A first flexible tape having an anode formed on the front surface, and a second flexible tape having a cathode formed for each pixel in a pixel column in the screen vertical direction on the surface and a connection electrode connected to the cathode formed on the back surface A pixel light emitting unit having a structure in which an organic EL film is laminated and bonded between
At least a signal line, a power supply line, and a pixel connection bump are formed on one surface, and at least an integrated circuit in which pixel drive circuits for a plurality of pixels are integrated and a pixel selection gate line connection bump are formed on the other surface. A third flexible tape pixel drive circuit unit;
And the pixel light emitting unit and the pixel driving circuit unit are stacked in an electrically connected state and joined together to form a whole screen by arranging a plurality of units in the horizontal direction of the screen as a unit. A characteristic organic EL display device. The pixel light emitting unit includes:
A transparent first plastic tape, which is the first flexible tape, having a width less than one horizontal pixel pitch of the display screen, the transparent electrode as the anode formed on the surface, and the reinforcing metal film formed on the side surface An anode one-dimensional substrate constituted by:
The cathode electrode column of each pixel of the pixel column in the vertical direction of the screen is formed on the front surface with a width equal to or less than one horizontal pixel pitch of the display screen, and a connection electrode connected to the cathode through a through hole on the back surface A cathode one-dimensional substrate formed of a second plastic tape that is the second flexible tape formed;
The organic EL film continuously formed on the upper surface of the anode of the one-dimensional anode substrate or the upper surface of the cathode of the one-dimensional cathode substrate, and the one-dimensional anode substrate, the organic EL film, 2. The organic EL display device according to claim 1, wherein the organic EL display device has a hierarchical structure in which the one-dimensional cathode substrate is laminated. The pixel drive circuit unit includes:
The signal lines for supplying signals from the outside to the front surface, the power supply lines for supplying current, and the pixel connection bumps disposed at positions corresponding to the cathodes are formed, and a vertical pixel column is formed on the back surface. The integrated circuit in which the pixel driving circuits of the plurality of pixels are integrated, the pixel selection gate line connection bump, and the wiring that connects the integrated circuit to the power supply line and the signal line through a through hole. 2. The third plastic tape as the third flexible tape, wherein the third flexible tape has a width equal to or smaller than a plurality of horizontal pixel pitches of the display screen, which is formed at least including a portion. Organic EL display device.   The organic EL film is sandwiched between the first and second flexible tapes having a width equal to or less than one horizontal pixel pitch of the display screen and longer than the total pixel pitch of all pixels in the vertical direction of the screen. The pixel by the third flexible tape having a width equal to or smaller than a plurality of horizontal pixel pitches of the display screen and a length longer than the total pixel pitch of all the pixels in the vertical direction of the screen. A one-dimensional display unit in which a plurality of units are arranged in the horizontal direction of the screen as a unit with a hierarchical structure in which the drive circuit unit is electrically connected and stacked and joined is used as a warp, and the horizontal direction of the screen of the one-dimensional display unit A first black insulating plastic fiber for black matrix extending in the vertical direction of the screen disposed in each gap between the pixels of the one-dimensional display unit. A configuration in which a second black insulating plastic fiber for black matrix extending in the horizontal direction of the screen, which is arranged at a pixel pitch in the vertical direction of the screen in a part of the pixel, is regarded as a woven structure having a weft as a weft. Item 10. An organic EL display device according to Item 1.   The pixel light emitting unit is formed separately for each primary color pixel unit of a red pixel unit that emits red light, a green pixel unit that emits green light, and a blue pixel unit that emits blue light. The organic EL display device according to any one of claims 1 to 4. The one-dimensional display unit for one display panel cut out from the fabric structure and the screen constituent part comprising the first and second black insulating plastic fibers;
A peripheral circuit unit connected to the screen configuration unit;
The organic EL display device according to claim 4, further comprising: a passivation film laminated on both front surfaces of the structure of the screen configuration unit and the peripheral circuit unit. An anode was formed on the surface of the first and second flexible tapes having a width equal to or less than one horizontal pixel pitch of the display screen of the organic EL display device and longer than the total pixel pitch of all pixels in the vertical direction of the screen. Between the first flexible tape and the second flexible tape in which the cathode of each pixel of the pixel column in the vertical direction of the screen is formed on the front surface and the connection electrode connected to the cathode is formed on the back surface, A pixel light emitting unit having a structure in which an organic EL film is laminated and bonded so that the anode and the cathode face each other;
At least a signal line, a power supply line, and a pixel connection bump are formed on one surface, and at least an integrated circuit in which pixel drive circuits for a plurality of pixels are integrated and a pixel selection gate line connection bump are formed on the other surface. A pixel driving circuit unit using a third flexible tape having a width equal to or smaller than a plurality of horizontal pixel pitches of the display screen and a length longer than the total pixel pitch of all pixels in the screen vertical direction of the display screen;
An adhesive layer that is filled between the pixel light emitting unit and the pixel driving circuit unit that are electrically connected to form a hierarchical structure by joining the pixel light emitting unit and the pixel driving circuit unit. A tape-like structure used for an organic EL display device, which is continuously formed in a screen vertical direction and a screen horizontal direction of the display screen. The pixel light emitting unit includes:
A one-dimensional anode substrate composed of a transparent first plastic tape as the first flexible tape, the transparent electrode as the anode formed on the surface, and a reinforcing metal film formed on the side surface;
The second flexible tape, wherein the cathode electrode row of each pixel in the pixel row in the vertical direction of the screen is formed on the front surface, and the connection electrode connected to the cathode through the through hole is formed on the back surface. A cathode one-dimensional substrate composed of plastic tape of
The organic EL film continuously formed on the upper surface of the anode of the one-dimensional anode substrate or the upper surface of the cathode of the one-dimensional cathode substrate, and the one-dimensional anode substrate, the organic EL film, 8. The tape-like structure according to claim 7, wherein the tape-like structure has a hierarchical structure in which the cathode one-dimensional substrate is laminated.   A total of all the pixels in the vertical direction of the screen of the display device, in which a plurality of units are arranged in the horizontal direction of the screen with a hierarchical structure in which the pixel light emitting unit and the pixel driving circuit unit are stacked and joined in an electrically connected state as a unit. A one-dimensional display unit having a length equal to or greater than the pixel pitch is used as a warp thread, and the first one for a black matrix extending in the vertical direction of the screen arranged in each gap between pixels in the horizontal direction of the screen of the one-dimensional display unit. Second black insulating plastic for black matrix extending in the horizontal direction of the screen, wherein the black insulating plastic fiber is a vertical thread, and is arranged at a pixel pitch in the vertical direction of the screen in a part of each pixel of the one-dimensional display unit The tape-like structure according to claim 7 or 8, wherein the structure is regarded as a woven fabric structure using fibers as weft yarns.

Images