JP2015232933A - Display device manufacturing method - Google Patents

Abstract

PROBLEM TO BE SOLVED: To provide an encapsulation structure having high reliability in a display device.SOLUTION: A display device comprises: a flexible substrate having a first part and a second part arranged at a distance from each other so as to overlap each other, and a third part which is bent and links the first part and the second part in a continuously integrated manner; a light emitting element layer laminated on the first part so as to be arranged in a range surrounded by the first part, the second part and the third part; and a filling material layer sandwiched between the second part and the light emitting element layer.

Description

  The present invention relates to a method for manufacturing a display device.

  A display panel using an element that is sensitive to moisture, such as an organic electroluminescence display device, needs to block moisture entering from the atmosphere, and thus requires a structure for sealing the element. In order to realize a highly reliable sealing method at low cost, it is conceivable to apply a roll-to-roll method as disclosed in Patent Document 1.

JP 2012-113916 A JP 2012-220636 A

  In Patent Document 1, since a lighting fixture is assumed, accurate alignment is not required. On the other hand, in the display device, it is necessary to align the thin film transistor substrate and the counter substrate with high accuracy, which is difficult in the roll-to-roll method. Further, the roll-to-roll method has a problem that the apparatus becomes large-scale because a large area is collectively attached. Note that Patent Document 2 discloses that a wiring board is formed so as to be integrated with a flexible board on which display elements are laminated, but sealing is not mentioned.

  An object of the present invention is to provide a highly reliable sealing structure in a display device.

  The above and other objects and novel features of the present invention will become apparent from the description of this specification and the accompanying drawings.

  In the display device according to the present invention, the first portion and the second portion that are arranged so as to overlap each other with a space therebetween, and the third portion that is bent by connecting the first portion and the second portion are continuous. An integrated flexible substrate; a light emitting element layer stacked on the first portion so as to be disposed in a region surrounded by the first portion, the second portion, and the third portion; And a filler layer interposed between the two portions and the light emitting element layer.

  The display device in the present invention may further include a color filter layer. The color filter layer may be between the filler layer and the second portion. The color filter layer may be between the light emitting element layer and the filler layer.

  The display device according to the present invention may further include a touch sensor layer. The touch sensor layer may include a vertically extending electrode and a horizontally extending electrode. The touch sensor layer may be between the filler layer and the second portion.

  The display device according to the present invention may further include a desiccant at an end portion of the region surrounded by the first portion, the second portion, and the third portion that is closer to the third portion. Good. The desiccant may be inside the filler layer.

  The display device according to the present invention further includes a sealing material that seals an end portion exposed from the third portion of the region surrounded by the first portion, the second portion, and the third portion. It is good.

  The first portion may include an extension that protrudes from the second portion in a direction opposite to the third portion. The second portion may have an extension that protrudes from the first portion in a direction opposite to the third portion.

  The first portion includes a first extension protruding from the second portion in a direction opposite to the third portion, and the second portion includes the first portion in a direction opposite to the third portion. It is good also as having the 2nd extension part projected from a portion. Further, the first extension part and the second extension part may be provided so as to be shifted in the opposite direction orthogonal to the protruding direction so as not to face each other.

  The second portion has a third extension protruding from the first portion, and the third extension protrudes from an end portion of the first portion excluding a connection portion with the third portion. And it is good also as bending toward the periphery of the said 1st part so that the said area | region may be sealed.

  According to the present invention, a highly reliable sealing structure is provided in a display device.

It is a figure which shows typically an example in which the OLED display device which is 1st Embodiment of this invention is manufactured. It is a figure which shows typically an example in which the OLED display device which is 1st Embodiment of this invention is manufactured. It is a top view which shows the sheet | seat comprised with a some flexible substrate after a cutting process. It is a top view which shows the state bent in the bending position shown by the dashed-dotted line (alpha) in FIG. 1C. It is a top view which shows the state by which the filler layer etc. were laminated | stacked on the flexible substrate which comprises the display apparatus which concerns on 1st Embodiment of this invention. FIG. 2B is a cross-sectional view taken along section line IIB-IIB in FIG. 2A. 1 is a plan view of a display device according to a first embodiment. FIG. 3B is a cross-sectional view taken along section line IIIB-IIIB in FIG. 3A. FIG. 4 is a cross-sectional view taken along a cutting line IIIB-IIIB in FIG. FIG. 4B is a cross-sectional view taken along section line IIIB-IIIB in FIG. 3A, showing another modification of the display device according to the first embodiment. It is a partially expanded plan view which shows typically arrangement | positioning of the detection electrode contained in the touch sensor layer with which a display apparatus is equipped. It is a top view of the flexible substrate which constitutes the display concerning a 2nd embodiment. FIG. 5B is a cross-sectional view taken along a cutting line VB-VB in FIG. 5A. It is a top view of the flexible substrate which comprises the display apparatus which concerns on 3rd Embodiment. FIG. 6B is a cross-sectional view taken along section line VIB-VIB in FIG. 6A. It is a top view of the flexible substrate which constitutes the display concerning a 4th embodiment. It is sectional drawing in the cutting line VIIB-VIIB of FIG. 7A. It is a top view of the flexible substrate which constitutes the display concerning a 5th embodiment. It is sectional drawing in the cutting line VIIIB-VIIIB of FIG. 8A. It is a top view of the display apparatus which concerns on 5th Embodiment. It is sectional drawing in the cutting | disconnection line VIIID-VIIID of FIG. 8C.

[First Embodiment]
The display device according to the first exemplary embodiment of the present invention includes a first part and a second part, which are arranged so as to overlap each other with a gap therebetween, and a first part that bends by connecting the first part and the second part. A flexible substrate having three parts continuously and light emission laminated on the first part so as to be disposed in a region surrounded by the first part, the second part and the third part. It has an element layer and a filler layer interposed between the second portion and the light emitting element layer.

  The display device according to the first embodiment of the present invention may be applied to, for example, an OLED (Organic Light-Emitting Diode) display device. Hereinafter, the display device according to the first embodiment of the present invention will be described based on an example applied to an OLED display device.

  1A and 1B are diagrams schematically showing an example in which the OLED display device according to the first embodiment of the present invention is manufactured. The OLED display device according to the first embodiment of the present invention may be manufactured by applying a flexographic printing technique as shown in FIGS. 1A and 1B, for example.

  A sheet 200 that can be obtained by a plurality of flexible substrates constituting an OLED display device by being conveyed and cut by a conveyance roll 300 shown in FIG. 1A is conveyed. In other words, a plurality of flexible substrates constituting the OLED display device are formed on the sheet 200 conveyed by the conveyance roll 300.

  The first portion of each flexible substrate provided on the sheet 200 conveyed by the conveying roll 300 is provided with an OLED including a TFT (Thin Film Transistor) and a light emitting element layer. The second portion of the flexible substrate is provided with a color filter, for example.

  Further, on the first portion and / or the second portion of the flexible substrate, for example, a material for forming a filler layer stored in the ink tank 301 and supplied from the ink chamber 302, the first portion and the second portion of the flexible substrate 20 are formed. When the third part that is bent by connecting the two parts is bent, a sealing material for sealing the region surrounded by the first part, the second part, and the third part is applied via the anilox roll 303. The

  Specifically, as shown in FIG. 1B, a material for forming the filler layer and a sealing material are applied to the resin relief plate 305 provided on the surface of the plate cylinder 304, and the resin relief plate 305 and the transport roll 300 The sheet 200 is transferred to a sheet 200 including a plurality of flexible substrates passing between the two.

  Thereafter, the sheet 200 is rolled again and cut into a sheet (200b in FIG. 1C) composed of a smaller number of flexible substrates, for example, using a cutter 306 (this process is referred to as a cutting process). .

  FIG. 1C is a plan view showing a sheet composed of a plurality of flexible substrates after the cutting step. FIG. 2A is a plan view showing a state in which a filler layer or the like is laminated on the flexible substrate constituting the display device according to the first embodiment of the present invention. 2B is a cross-sectional view taken along section line IIB-IIB in FIG. 2A.

  1C, 2A, and 2B indicate a position where the first portion and the second portion are connected and bent. FIG. 1D is a plan view showing a state of being bent at a bending position indicated by a one-dot broken line α in FIG. 1C. And 1 unit of the flexible substrate 20 which comprises the display apparatus which concerns on 1st Embodiment will be obtained by cut | disconnecting by the dashed-dotted line (beta) in FIG. 1C and 1D.

  FIG. 2A is a plan view of a flexible substrate constituting the display device according to the first embodiment. 2B is a cross-sectional view taken along section line IIB-IIB in FIG. 2A.

  As shown in FIGS. 2A and 2B, the first portion, the second portion, and the bent third portion of the flexible substrate constituting the display device according to the first embodiment are continuously and integrally formed. Yes. When the flexible substrate is bent at the third portion, the first portion and the second portion are disposed so as to overlap each other in plan view with a space therebetween.

  In addition, the flexible substrate has excellent flexibility and flexibility. The flexible substrate may be made of, for example, polyimide or polyethylene terephthalate (PET).

  The thickness of the flexible substrate may be, for example, 0.1 mm or less, or 0.05 mm or less. Further, in order to give the third portion of the flexible substrate a characteristic that is more easily bent than the other portions, for example, the thickness of the third portion of the flexible substrate is the thickness of the first portion and the second portion. It is good also as small compared with the thickness of a part.

  In addition, the third portion of the flexible substrate has a thickness that is parallel to the direction of bending, for example, in order to give the third portion of the flexible substrate a characteristic that is more easily bent than the other portions. A plurality of different muscles may be provided. In addition, the third portion of the flexible substrate may be provided with a plurality of different stripes having a small thickness in parallel with the bending direction.

  In addition, the first portion of the flexible substrate is provided with a light emitting element layer laminated thereon, and the upper surface of the light emitting element layer (the opposite side of the light emitting element layer from the side facing the first portion of the flexible substrate). The surface) is provided with a filler layer. As a result, when the flexible substrate is bent at the third portion, the light emitting element layer and the filler layer are disposed in a region surrounded by the first portion, the second portion, and the three portions of the flexible substrate. It will be. The filler layer is interposed between the second portion and the light emitting element layer.

  Moreover, it is good also as having the functional layer 50 in the 2nd part of the flexible substrate which comprises the display apparatus which concerns on 1st Embodiment, as FIG. 2B shows. For example, the functional layer 50 may be a color filter layer or a touch sensor layer.

  FIG. 3A is a plan view of the display device according to the first embodiment. 3B is a cross-sectional view taken along section line IIIB-IIIB in FIG. 3A. In the present embodiment, a color filter layer 50 a is provided as the functional layer 50.

  As shown in FIG. 3B, the display device 10 is bent by connecting the first portion 21 and the second portion 22, which are arranged so as to overlap each other at an interval, and the first portion 21 and the second portion 22. The flexible substrate 20 which has the 3rd part 23 to carry out continuously integrally.

  The display device 10 includes a light emitting element layer 30 stacked on the first portion 21 and a thin film transistor (a thin film transistor) so as to be disposed in a region surrounded by the first portion 21, the second portion 22, and the third portion 23. TFT) layer 210. In addition, the light emitting element layer 30 provided in the display device 10 according to the present embodiment includes an anode 31, an OLED 32, a cathode 32, and a sealing film 34 as shown in FIG. 3B.

  In the display device 10, the color filter layer 50a may be disposed between the filler layer 40 and the second portion 22 as shown in FIG. 3B.

  FIG. 3D shows a modification of the display device 10 according to the first embodiment, and is a cross-sectional view taken along a cutting line IIIB-IIIB in FIG. 3A. In the display device 10, the color filter layer 50a may be disposed between the light emitting element layer 30 and the filler layer 40 as shown in FIG. 3C.

  3C shows another modification of the display device 10 according to the first embodiment, and is a cross-sectional view taken along the cutting line IIIB-IIIB in FIG. 3A. In the display device 10 illustrated in FIG. 3C, a touch sensor layer 50 b is provided as the functional layer 50. In the display device 10, the touch sensor layer 50b may be disposed between the filler layer 40 and the second portion 22 as illustrated in FIG. 3B.

  FIG. 4 is a partially enlarged plan view schematically showing the arrangement of the detection electrodes 51 and 52 included in the touch sensor layer 50 b provided in the display device 10.

  As shown in FIG. 4, the first detection electrode 51 and the second detection electrode 52 included in the touch sensor layer 50 b included in the display device 10 have a shape in which rhombus (diamond) shapes are arranged side by side, The electrodes may extend in the X and Y directions (vertically extending electrodes and horizontally extending electrodes). Although it has a complicated shape as compared with the solid electrode or the like used in the capacitance surface type, a touch sensor can be obtained by using the detection electrodes 51 and 52 having such a shape in which diamonds are continuously arranged. This is preferable because the detection sensitivity can be improved. These detection electrodes, interlayer films, protective films, and the like can be easily realized by forming them in the same process using the same materials as the electrodes constituting the TFT circuit or OLED structure.

  A display panel using elements that are sensitive to moisture, such as the organic electroluminescence display device 10, needs to block moisture that enters from the atmosphere, and thus requires a structure for sealing the elements. The display device 10 according to the first embodiment includes an end on the side that intersects the third portion 23 of the first portion 21 of the flexible substrate 20 in the vertical direction, and a third portion 23 of the second portion 22 of the flexible substrate 20. The end portion on the side intersecting the vertical direction is sealed with a sealing material (not shown) conventionally used.

  In addition, the end of the first portion 21 of the flexible substrate 20 opposite to the third portion 23 (or the region adjacent to the end) and the third portion 23 of the second portion 22 of the flexible substrate 20. The opposite end portion (or the region adjacent to the end portion) of the opposite side is sealed with a conventionally used sealing material.

  Here, the sealing in the third portion 23 of the flexible substrate 20 does not require the use of a separate sealing material because the flexible substrate 20 is continuously formed integrally, and simply bending the third portion 23. Simple and reliable sealing is realized.

  Sealing with a sealing material eliminates the risk of moisture entering the inside of the display device 10 from the outside due to the sealing method and the material of the sealing material, such as when the sealing material is not properly applied. Although difficult, sealing in the third portion 23 of the display device 10 according to the first embodiment can remove such risks, and as a result, the sealing of the display device 10 is more reliable. Become.

  Further, as shown in FIG. 3B, the display device 10 is provided on the third portion 23 (bent portion) in the region surrounded by the first portion 21, the second portion 22, and the third portion 23 of the flexible substrate 20. It is good also as having the desiccant 60 in the edge part of the near side. Thus, by providing the desiccant 60, even if moisture invades from the atmosphere of the display device 10, the influence on the light emitting element layer 30 is reduced, and the reliability of the display device 10 is further increased. It will be.

  When the desiccant 60 is disposed on the display device 10, the desiccant 60 may be disposed inside the filler layer 40. As described above, by arranging the desiccant 60 inside the filler, the position where the desiccant 60 is provided is fixed, and the risk of the moisture-containing desiccant 60 affecting the light emitting element layer 30 is reduced. As a result, the reliability of the display device 10 is further increased.

  In addition, the display device 10 further includes a sealing material that seals an end portion exposed from the third portion 23 in a region surrounded by the first portion 21, the second portion 22, and the third portion 23 of the flexible substrate 20. It is good as well. Thus, by further providing a sealing material that seals the end portion exposed from the third portion 23 of the region surrounded by the first portion 21, the second portion 22 and the third portion 23 of the flexible substrate 20, The reliability of the display device 10 is further increased.

  Next, another embodiment of the display device 10 according to the present invention will be described. Each of the other embodiments described below is different from the above-described embodiment in the shape of the flexible substrate 20, and the configuration other than each flexible substrate 20 in the other embodiments has been described above. The configuration of the embodiment can be applied.

  Moreover, the display device 10 according to each embodiment described below may be applied to the OLED display device 10, for example. Hereinafter, the display device 10 according to each embodiment of the present invention will be described based on examples applied to the OLED display device 10.

[Second Embodiment]
FIG. 5A is a plan view of the flexible substrate 20 constituting the display device 10 according to the second embodiment. 5B is a cross-sectional view taken along a cutting line VB-VB in FIG. 5A.

  When the flexible substrate 20 used in the display device 10 of the present embodiment shown in FIG. 5A or the like is bent at a position indicated by a dashed line α corresponding to the bending position of the third portion 23, The 1 part 21 has the extension part 21a which protrudes from the 2nd part 22 in the opposite direction to the 3rd part 23 which is a bending part.

  In the display device 10 provided with the extension, for example, a semiconductor chip (driver IC) or the like is mounted on the extension 21a, and a COF (Chip on Film) technology can be applied.

[Third Embodiment]
FIG. 6A is a plan view of the flexible substrate 20 constituting the display device 10 according to the third embodiment. 6B is a cross-sectional view taken along section line VIB-VIB in FIG. 6A.

  When the flexible substrate 20 used in the display device 10 of the present embodiment shown in FIG. 6A or the like is bent at a position indicated by a dashed line α corresponding to the bending position of the third portion 23, the flexible substrate 20 The 2 part 22 has the extension part 22a which protrudes from the 1st part 21 in the opposite direction to the 3rd part 23 which is a bending part.

  In the display device 10 provided with the extension, for example, a semiconductor chip (driver IC) or the like is mounted on the extension 22a, and the COF technology can be applied.

[Fourth Embodiment]
FIG. 7A is a plan view of the flexible substrate 20 constituting the display device 10 according to the third embodiment. FIG. 7B is a cross-sectional view taken along section line VIIB-VIIB in FIG. 7A.

  When the flexible substrate 20 used in the display device 10 of the present embodiment shown in FIG. 7A or the like is bent at a position indicated by a dashed line α corresponding to the position where the third portion 23 is bent, the flexible substrate 20 The 1 part 21 has the 1st extension part 21b which protrudes from the 2nd part 22 in the opposite direction to the 3rd part 23 which is a bending part, and the 2nd part 22 of the flexible substrate 20 is the 3rd which is a bending part. It has the 2nd extension part 22b which protrudes from the 1st part 21 in the direction opposite to the part 23. As shown in FIG.

  Moreover, as FIG. 7A etc. show, the 1st extension part 21b and the 2nd extension part 22b are good also as being shifted and provided in the opposite direction orthogonal to a protrusion direction so that it may not mutually oppose.

  For example, when the light emitting element layer 30 is disposed on the first portion 21 of the flexible substrate 20 and the touch sensor layer is disposed on the second portion 22 of the flexible substrate 20, a driver IC for controlling the light emitting element is mounted on the first extension portion 21b. In addition, by mounting a driver IC for controlling the touch sensor on the second extension 22b, it is possible to consolidate the wiring on the flexible substrate 20 and to realize space saving of the entire display device 10 and simplification of the manufacturing process. Will be.

[Fifth Embodiment]
FIG. 8A is a plan view of the flexible substrate 20 constituting the display device 10 according to the fifth embodiment. 8B is a cross-sectional view taken along section line VIIIB-VIIIB in FIG. 8A.

  When the flexible substrate 20 used in the display device 10 of the present embodiment shown in FIG. 8A or the like is bent at a position indicated by a one-dot broken line α1 corresponding to the bending position of the third portion 23, the flexible substrate 20 The second portion 22 has a third extension 21c that protrudes from the first portion 21, and the third extension protrudes from the end portion of the first portion 21 excluding the connection portion with the third portion 23. Bending toward the periphery of the first portion 21 so as to seal the region surrounded by the first portion 21, the second portion 22, and the third portion 23 (location indicated by the dashed line α2 in FIGS. 8A and 8B) Bend at).

  FIG. 8C is a plan view of the display device 10 according to the fifth embodiment. 8D is a cross-sectional view taken along section line VIIID-VIIID in FIG. 8C.

  One side (S1 in FIG. 8C) among the three sides (sides S1, S2, and S3 in FIG. 8C) of the display device 10 according to the present embodiment is sealed by bending the third portion 23. Has been. Then, two sides (S2, S3 in FIG. 8C) among the three sides (sides S1, S2, and S3 in FIG. 8C) of the peripheral edge of the display device 10 according to the present embodiment are as shown in FIG. 8D. The third extension 22c of the second portion 22 is bent toward the periphery of the first portion 21 so as to seal the region surrounded by the first portion 21, the second portion 22, and the third portion 23. It is sealed by.

  Therefore, sealing is performed on three sides among the four sides of the peripheral edge of the display device 10 in the present embodiment without using a sealing material, and the sealing of the display device 10 is more reliable.

  As a modification of the fifth embodiment, when the first portion 21 of the flexible substrate 20 is bent from the second portion 22 when it is bent at a position indicated by a dashed line α1 corresponding to the position where the third portion 23 bends. A third extension projecting from the end of the second portion 22 excluding the connecting portion with the third portion 23, the first portion 21, the second portion 22 and the third portion; It is good also as bending toward the periphery of the 2nd part 22 so that the area | region enclosed by the part 23 may be sealed.

  DESCRIPTION OF SYMBOLS 10 Display apparatus (OLED display apparatus), 20 Flexible substrate, 30 Light emitting element layer, 40 Filler layer, 50 Functional layer, 50a Color filter layer, 50b Touch sensor layer, 60 Drying material.

Claims (15)

A flexible substrate having a first part and a second part arranged so as to overlap each other with a gap therebetween, and a third part which connects and bends the first part and the second part, and is continuously integrated; ,
A light emitting device layer stacked on the first portion so as to be disposed in a region surrounded by the first portion, the second portion, and the third portion;
A filler layer interposed between the second portion and the light emitting element layer;
A display device comprising: A color filter layer;
The display device according to claim 1. The color filter layer is between the filler layer and the second portion;
The display device according to claim 2. The color filter layer is between the light emitting element layer and the filler layer,
The display device according to claim 2. A touch sensor layer;
The display device according to claim 1. The touch sensor layer includes vertically extending electrodes and horizontally extending electrodes.
The display device according to claim 5. The touch sensor layer is between the filler layer and the second portion;
The display device according to claim 5 or 6. A desiccant is further provided at an end of the region surrounded by the first portion, the second portion, and the third portion, on the side close to the third portion;
The display device according to claim 1, wherein the display device is a display device. The desiccant is inside the filler layer;
The display device according to claim 8. A sealant for sealing an end portion exposed from the third portion of the region surrounded by the first portion, the second portion, and the third portion;
The display device according to claim 1, wherein the display device is a display device. The first portion has an extension protruding from the second portion in a direction opposite to the third portion.
The display device according to claim 1, wherein the display device is a display device. The second part has an extension protruding from the first part in a direction opposite to the third part,
The display device according to claim 1, wherein the display device is a display device. The first portion has a first extension protruding from the second portion in a direction opposite to the third portion;
The second part has a second extension projecting from the first part in a direction opposite to the third part,
The display device according to claim 1, wherein the display device is a display device. The first extension part and the second extension part are provided to be shifted in opposite directions perpendicular to the protruding direction so as not to face each other.
The display device according to claim 13. The second part has a third extension protruding from the first part,
The third extension protrudes from an end portion of the first portion excluding a connection portion with the third portion, and is bent toward the periphery of the first portion so as to seal the region. Yes,
The display device according to claim 1, wherein the display device is a display device.

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