TW202002276A - Display device and manufacturing method thereof - Google Patents

Abstract

A display device including a plurality of sub-pixels is provided. The sub-pixels are disposed on a substrate. Each of the sub-pixels has an active element, a first electrode, a first bank layer, a second bank layer, an emissive layer and a second electrode. The first bank layer is disposed on the first electrode and has a first hole overlapping a portion of the first electrode. The second bank layer is disposed on the first bank layer and has a second hole overlapping the first hole. The first bank layer has a material region. A normal projection of the material region on the substrate is located between a normal projection of the first hole on the substrate and a normal projection of the second hole on the substrate. The material region has a first width in a first direction. The material region has a second width in a second direction interlaced with the first direction. A first width of a material region of a first sub-pixel of the sub-pixels is not equal to a second width of the material region of the first sub-pixel of the sub-pixels. Moreover, a manufacturing method of the display device is also provided.

Description

Display device and manufacturing method thereof

The invention relates to a display device and a manufacturing method thereof.

With the advancement of technology, in the process of organic light emitting diode (ORGANIC LIGHT EMITTING DIODE; OLED) display devices, an inkjet printing process (Ink Jet Printing; IJP) can be used to form a light emitting layer. The inkjet printing process is to spray or inject the liquefied organic light-emitting material into the opening defined by the bank to form a light-emitting layer. However, the thickness of the light-emitting layer formed in the opening of the organic light-emitting material is not uniform, which further affects the display quality of the display panel. For example, the film thickness of the light emitting layer at the edge of the opening is much larger than the film thickness of the light emitting layer at the center of the opening, that is, the film thickness of the light emitting layer at the edge of the opening is very different from the film thickness at the center of the opening.

The invention provides a display device with good performance.

The invention provides a method for manufacturing a display device, which can manufacture a display device with good performance.

A display device of the present invention includes multiple sub-pixels. A plurality of sub-pixels are arranged on the substrate. Each sub-pixel includes an active element, a first electrode, a first bank layer, a second bank layer, a light-emitting layer, and a second electrode. The first electrode is electrically connected to the active element. The first bank layer is disposed on the first electrode and has a first opening overlapping with a part of the first electrode. The second bank layer is disposed on the first bank layer and has a second opening overlapping with the first opening. The light emitting layer is disposed on part of the first electrode, and is located in the first opening of the first bank layer and the second opening of the second bank layer. The second electrode is disposed on the light emitting layer. The first bank layer has a material area, and the vertical projection of the material area on the substrate is between the vertical projection of the first opening on the substrate and the vertical projection of the second opening on the substrate. The material region has a first width in a first direction, and the material region has a second width in a second direction that intersects the first direction. The sub-pixel includes the first sub-pixel. The first width of the material area of the first sub-pixel is not equal to the second width of the material area of the first sub-pixel.

A manufacturing method of a display device of the present invention includes: providing a substrate; forming a plurality of active elements on the substrate; forming a plurality of first electrodes electrically connected to the active elements, the first electrodes being arranged in a plurality in the first direction A row of first electrodes, and arranged in a plurality of first electrode columns in a second direction, the first direction and the second direction are interleaved; a mask structure is provided, having a plurality of strip-shaped solid portions and a plurality of strips separated from each other Each of the strip-shaped openings separates adjacent strip-shaped solid portions; when the strip-shaped solid portions of the mask structure respectively shield the first electrode row, the source material passes through the strip-shaped structure of the mask structure An opening to form a first bank layer on the first electrode, wherein the first bank layer has a plurality of bank strips and a plurality of first strip-shaped openings, the bank strips are separated from each other in the first direction, each first strip The shape of the opening separates the adjacent bank strips, and the two adjacent bank strips are respectively disposed on opposite sides of each first electrode of the same first electrode row of the plurality of first electrode rows; A second bank layer, the second bank layer has a plurality of openings respectively overlapping with the first electrode; a plurality of droplets are injected into the first stripe opening of the first bank layer and the opening of the second bank layer, so that the first electrode, The first stripe opening of the first bank layer and the opening of the second bank layer form a plurality of light emitting layers; a second electrode is formed to cover the light emitting layer.

Based on the above, in the display device and the manufacturing method thereof according to an embodiment of the present invention, the vertical projection of the first bank layer on the substrate of at least one sub-pixel has a material area that does not overlap with the vertical projection of the second bank layer on the substrate The material area has a first width in the first direction, the material area has a second width in the second direction, and the first width is not equal to the second width. With this, the problem of uneven film thickness of the light-emitting layer of the display device can be improved.

In order to make the above-mentioned features and advantages of the present invention more obvious and understandable, the embodiments are specifically described below in conjunction with the accompanying drawings for detailed description as follows.

Hereinafter, the present invention will be described more fully with reference to the accompanying drawings, in which exemplary embodiments of the present invention are shown. As those skilled in the art would realize, the described embodiments may be modified in various different ways, all without departing from the spirit or scope of the present invention.

In the drawings, the thickness of layers, films, panels, regions, etc., are exaggerated for clarity. Throughout the specification, the same reference numerals denote the same elements. It should be understood that when an element such as a layer, film, region, or substrate is referred to as being "on" or "connected" to another element, it can be directly on or connected to the other element, or Intermediate elements may also be present. In contrast, when an element is referred to as being "directly on" or "directly connected to" another element, there are no intervening elements present. As used herein, "connected" may refer to physical and/or electrical connections. Furthermore, "electrical connection" or "coupling" can mean that there are other components between the two components.

In addition, relative terms such as "lower" or "bottom" and "upper" or "top" may be used herein to describe the relationship between one element and another element, as shown. It should be understood that relative terms are intended to include different orientations of the device than those shown in the figures. For example, if the device in one drawing is turned over, the element described as being on the "lower" side of the other element will be oriented on the "upper" side of the other element. Thus, the exemplary term "lower" may include "lower" and "upper" orientations, depending on the particular orientation of the drawings. Similarly, if the device in one drawing is turned over, elements described as "below" or "beneath" other elements would then be oriented "above" the other elements. Thus, the exemplary terms "above" or "below" can include an orientation of above and below.

As used herein, "about", "approximately", or "substantially" includes the stated value and the average value within the acceptable deviation range of the specific value determined by those of ordinary skill in the art, taking into account the measurements and A certain amount of measurement-related errors (ie, measurement system limitations). For example, "about" may mean within one or more standard deviations of the stated value, or within ±30%, ±20%, ±10%, ±5%. In addition, "about", "approximately" or "substantially" used in this article can select a more acceptable range of deviation or standard deviation according to optical properties, etching properties or other properties, instead of applying one standard deviation to all properties .

Exemplary embodiments are described herein with reference to cross-sectional views that are schematic diagrams of idealized embodiments. Therefore, a change in the shape of the graph as a result of, for example, manufacturing techniques and/or tolerances can be expected. Therefore, the embodiments described herein should not be construed as being limited to the specific shapes of the regions as shown herein, but include deviations in shapes caused by manufacturing, for example. For example, an area shown or described as flat may generally have rough and/or non-linear characteristics. In addition, the acute angle shown may be round. Therefore, the regions shown in the drawings are schematic in nature, and their shapes are not intended to show the precise shapes of the regions, and are not intended to limit the scope of the claims.

Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those of ordinary skill in the art to which this invention belongs. It will be further understood that terms such as those defined in commonly used dictionaries should be interpreted as having meanings consistent with their meanings in the context of the relevant technology and the present invention, and will not be interpreted as idealized or excessive Formal meaning unless explicitly defined as such in this article.

FIG. 1A is a schematic top view of some components of a display device according to an embodiment of the invention. FIG. 1B is a schematic cross-sectional view of the sub-pixels of the display device according to section line A-A' of FIG. 1A. FIG. 1A omits the drawing of the substrate 100, active device 110, flat layer 120, hole injection layer 160, hole transport layer 170, light emitting layer 180, electron transport layer 190, electron injection layer 200, and second electrode 210 of FIG. 1B. .

Please refer to FIGS. 1A and 1B. The display device 10 of this embodiment includes a plurality of sub-pixels 10A. The sub-pixel 10A is provided on the substrate 100. In the present embodiment, the substrate 100 is, for example, a rigid substrate. However, the present invention is not limited to this, and in other embodiments, the substrate 100 may also be a flexible substrate. For example, the material of the hard substrate can be glass, quartz or other suitable materials; the material of the flexible substrate can be plastic or other suitable materials.

Each sub-pixel 10A of this embodiment includes an active element 110, a first electrode 130, a first bank layer 140, a second bank layer 150, a light-emitting layer 180, and a second electrode 210. In this embodiment, each sub-pixel 10A may further include a flat layer 120, a hole injection layer 160, a hole transport layer 170, an electron transport layer 190, and an electron injection layer 200, but the invention is not limited thereto.

The active device 110 is disposed on the substrate 100. For example, in this embodiment, the active device 110 includes at least one thin film transistor with a gate, a semiconductor pattern, a drain and a source, wherein the drain and the first electrode 130 (or pixel electrode) are electrically connected Sexual connection, but the invention is not limited to this.

In this embodiment, the flat layer 120 is disposed on the substrate 100 and covers the active device 110. The flat layer 120 is an unpatterned film layer, but it is not limited thereto. The material of the flat layer 120 includes inorganic materials (for example: silicon oxide, silicon nitride, silicon oxynitride, other suitable materials or stacked layers of at least two of the above materials), organic materials (for example: polyester (PET), poly Olefins, polypropylenes, polycarbonates, polyalkylene oxides, polystyrenes, polyethers, polyketones, polyalcohols, polyaldehydes, other suitable materials or a combination of the above), other Suitable materials or combinations of the above.

In this embodiment, the first electrode 130 is disposed on the flat layer 120. The first electrode 130 is electrically connected to the active device 110. For example, the first electrode 130 in this embodiment is, for example, a pixel electrode, and is electrically connected to the drain of at least one thin film transistor of the active device 110.

The first bank layer 140 is disposed on the first electrode 130. The first bank layer 140 has a first opening 140a overlapping a portion of the first electrode 130. The material of the first bank layer 140 includes silicon oxide, silicon nitride, or other suitable materials.

The second bank layer 150 is disposed on the first bank layer 140. The second bank layer 150 has a second opening 150a overlapping the first opening 140a. In this embodiment, the material of the second bank layer 150 and the material of the first bank layer 140 may be different; for example, for the same organic light-emitting material (such as ink for short), the first bank layer 140 is, for example, The ink affinity, and the second bank layer 150 is, for example, ink repellent, but the invention is not limited thereto. In this embodiment, the material of the second bank layer 150 is, for example, photoresist, but the invention is not limited thereto. The first bank layer 140 has a material region 145. The vertical projection of the material region 145 on the substrate 100 is between the vertical projection of the first opening 140 a on the substrate 100 and the vertical projection of the second opening 150 a on the substrate 100. The material region 145 has a first width W1 in the first direction y, and the material region 145 has a second width W2 in the second direction x. Part of the first electrode 130 overlaps with the first opening 140a of the first bank layer 140 and the second opening 150a of the second bank layer 150, the first direction y means defined by the direction directly above the first electrode 130 of the part The side wall 150s of the second bank layer 150 of the second opening 150a, and the first direction y and the second direction x are staggered.

The plurality of sub-pixels 10A of the display device 10 include the first sub-pixel 10a. The first width W1 of the material region 145 of the first sub-pixel 10a is not equal to the second width W2 of the material region 145 of the first sub-pixel 10a. For example, in this embodiment, the width 140y of the first opening 140a of the first sub-pixel 10a in the first direction y is greater than the width of the first opening 140a of the first sub-pixel 10a in the second direction x 140x, and the first width W1 of the first sub-pixel 10a can be selectively greater than the second width W2 of the first sub-pixel 10a.

The light emitting layer 180 is disposed on part of the first electrode 130 and is located in the first opening 140 a of the first bank layer 140 and the second opening 150 a of the second bank layer 150. For example, in this embodiment, the hole injection layer 160, the hole transport layer 170, and the light emitting layer 180 are sequentially disposed on the portion of the first electrode 130. The hole injection layer 160, the hole transport layer 170 and the light emitting layer 180 are located in the first opening 140a of the first bank layer 140 and the second opening 150a of the second bank layer 150. For example, in this embodiment, the method in which the hole injection layer 160, the hole transport layer 170, and the light-emitting layer 180 are sequentially disposed on part of the first electrode 130 is, for example, an inkjet printing process (Ink Jet Printing; IJP), but the invention is not limited to this. In this embodiment, the material of the light-emitting layer 180 is, for example, an organic electroluminescent material, but the present invention is not limited thereto. In this embodiment, by designing that the first width W1 is not equal to the second width W2, the problem of uneven film thickness of the light-emitting layer 180 can be improved.

In the third direction z perpendicular to the substrate 100, the top surface 182 of the light emitting layer 180 has a point 182a overlapping the center of the second opening 150a. The distance from a point 182a on the top surface 182 of the light emitting layer 180 to the top surface 130t of the first electrode 130 is the first distance T1. The distance from the boundary edge 180a of the top surface 182 of the light emitting layer 180 and the second bank layer 150 to the top surface 140t of the first bank layer 140 is the second distance T2. In this embodiment, the first distance T1 is less than or equal to the second distance T2. For example, the second distance T2 is less than or equal to 20 times the first distance T1, that is, T1 ≤ T2 ≤ 20´T1, but the present invention is not limited to this.

In this embodiment, the electron transport layer 190 and the electron injection layer 200 are sequentially disposed on the light emitting layer 180 and the second bank layer 150. For example, in this embodiment, the electron transport layer 190 and the electron injection layer 200 are formed by, for example, a vapor deposition process, but the invention is not limited thereto.

The second electrode 210 is disposed on the light emitting layer 180. For example, in this embodiment, the second electrode 210 is disposed on the electron injection layer 200. In this embodiment, in the third direction z perpendicular to the substrate 100, the second electrode 210 may have substantially the same film thickness. That is, in the third direction z perpendicular to the substrate 100, the top surface 182 of the light-emitting layer 180 has a point 182a that overlaps with the center of the second opening 150a, and the top surface 212 of the second electrode 210 has a gap with the second opening 150a A point 212a overlapping in the center. A point 182a on the top surface 182 of the light-emitting layer 180 is located above the first electrode 130 in a portion overlapping the first opening 140a and the second opening 150a, and a point 212a on the top surface 212 of the second electrode 210 is located in front of the point 182a Above, the distance from the point 182a to the point 212a in the third direction z is the first distance H1. The distance between the top surface 150t of the second bank layer 150 and the top surface 212 of the second electrode 210 in the third direction z is the second distance H2, and the first distance H1 is approximately equal to the second distance H2. That is, in this embodiment, the composite layer composed of the electron transport layer 190, the electron injection layer 200, and the second electrode 210 has substantially the same film thickness, but the invention is not limited thereto.

Based on the above, in the display device 10 according to an embodiment of the invention, the width 140y of the first opening 140a of the first bank layer 140 in the first direction y is greater than the width 140x of the first opening 140a in the second direction x, and The first width W1 is greater than the second width W2. Thereby, the problem of uneven thickness of the light-emitting layer 180 can be improved, thereby improving the display quality of the display device 10.

2 is a schematic top view of some components of a display device according to another embodiment of the invention. It must be noted here that the embodiment of FIG. 2 uses the element numbers and partial contents of the embodiment of FIG. 1A, wherein the same or similar reference numerals are used to indicate the same or similar elements, and the description of the same technical content is omitted. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments will not be repeated.

The main difference between the embodiment of FIG. 2 and the embodiment of FIG. 1A is that the size relationship between the first width W1 and the second width W2 is different.

2, in the display device 20 of this embodiment, the width 140y of the first opening 140a of the first bank layer 140 of the first sub-pixel 20a of the first sub-pixel 20a of the sub-pixel 20A in the first direction y is greater than the first opening The width 140a of the 140a in the second direction x is 140x, and the first width W1 is smaller than the second width W2.

Similarly, in the display device 20 according to an embodiment of the invention, the first width W1 is smaller than the second width W2. Thereby, the problem of uneven thickness of the light emitting layer 180 can be improved, thereby improving the display quality of the display device 20.

3 is a schematic top view of some components of a display device according to another embodiment of the invention. It must be noted here that the embodiment of FIG. 3 uses the element numbers and partial contents of the embodiment of FIG. 1A, wherein the same or similar reference numerals are used to indicate the same or similar elements, and the description of the same technical content is omitted. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments will not be repeated.

The main difference between the embodiment of FIG. 3 and the embodiment of FIG. 1A is that the first opening 140a of the first bank layer 140 has a plurality of curved sections 140b.

Referring to FIG. 3, in the display device 30 of this embodiment, the first opening 140a of the first bank layer 140 of the first sub-pixel 30a of the sub-pixel 30A has a plurality of curved sections 140b. In the present embodiment, the plurality of curved sections 140b are arranged in the first direction y. A plurality of curved sections 140b are connected into a wavy line section 140b'. With this, the aperture ratio of the display device 30 can be increased.

In this embodiment, the first bank layer 140 has a material region 145, the material region 145 has a first width W1 in the first direction y, and the minimum width of the material region 145 in the second direction x is the second width W2, the material The maximum width of the region 145 in the second direction x is the width W2'. In this embodiment, the first opening 140a has a maximum width 140x in the second direction x, the width 140y of the first opening 140a in the first direction y is greater than the width 140x, and the first width W1 is greater than the second width W2. In this embodiment, the width W2' may be equal to the first width W1, but the present invention is not limited to this. For example, in this embodiment, the size relationship between the width W2' and the second width W2 may be 0.2"W2' ≤ W2 ≤ 0.8"W2', but the present invention is not limited thereto.

4 is a schematic top view of some components of a display device according to another embodiment of the invention. It must be noted here that the embodiment of FIG. 4 uses the element numbers and partial contents of the embodiment of FIG. 3, wherein the same or similar reference numerals are used to indicate the same or similar elements, and the description of the same technical content is omitted. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments will not be repeated.

The main difference between the embodiment of FIG. 4 and the embodiment of FIG. 3 is that the formation position of the wavy line segment 140b' is different.

Referring to FIG. 4, in the display device 40 of this embodiment, the plurality of curved sections 140b of the first opening 140a of the first bank layer 140 of the first sub-pixel 40a of the sub-pixel 40A are arranged in the second direction x . The plurality of curved sections 140b are connected as a wavy line section 140b'. With this, the aperture ratio of the display device 40 can be increased.

The first bank layer 140 has a material region 145. In this embodiment, the minimum width of the material region 145 in the first direction y is the first width W1, and the material region 145 has the second width W2 in the second direction x. In this embodiment, the first opening 140a has a maximum width 140y in the first direction y, the width 140y is larger than the width 140x of the first opening 140a in the second direction x, and the first width W1 is smaller than the second width W2. In this embodiment, the width W1' may be equal to the second width W2, but the present invention is not limited to this. For example, in this embodiment, the size relationship between the width W1' and the first width W1 may be 0.2"W1' ≤ W1 ≤ 0.8"W1', but the present invention is not limited thereto.

5A is a schematic top view of some components of a display device according to another embodiment of the invention. 5B is a schematic cross-sectional view of the sub-pixels of the display device according to the cross-sectional line B-B' of FIG. 5A. 6A to 6D are schematic cross-sectional views of manufacturing processes of some components of the display device of FIG. 5A. FIG. 5A omits the drawing of the substrate 100, active device 110, flat layer 120, hole injection layer 160, hole transport layer 170, light emitting layer 180, electron transport layer 190, electron injection layer 200, and second electrode 210 of FIG. 5B. . It must be noted here that the embodiments of FIGS. 5A-5B continue to use the element numbers and partial contents of the embodiments of FIGS. 1A-1B, wherein the same or similar reference numbers are used to indicate the same or similar elements, and the same technical content is omitted instruction of. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments will not be repeated.

The main difference between the embodiment of FIGS. 5A-5B and the embodiment of FIGS. 1A-1B is that the relationship between the size of the first width W1 and the second width W2 is different.

5A and 5B, in the display device 50 of this embodiment, the width 140y of the first opening 140a of the first bank layer 140 of the first sub-pixel 50a of the first sub-pixel 50a of the sub-pixel 50A in the first direction y is greater than The width 140x of the first opening 140a in the second direction x, the first width W1 is not zero, and the second width W2 is zero. With this, the aperture ratio of the display device 50 can be increased.

In this embodiment, since the second width W2 is zero, the manufacturing method of the display device 50 may be different from the manufacturing methods of the foregoing embodiments 10 to 40 of the display device. In the following, with reference to FIGS. 6A to 6D and FIGS. 7A to 7B, an example of a manufacturing process of a display device 50 according to another embodiment of the present invention is illustrated. 7A and 7B are schematic top views of manufacturing steps of the display device of FIGS. 6B and 6D, respectively. In particular, FIG. 6B corresponds to the section line C-C' of FIG. 7A, and FIG. 6D corresponds to the section line D-D' of FIG. 7B.

Please refer to FIG. 6A. First, the substrate 100 is provided. Next, a plurality of active devices 110 are formed on the substrate 100. Then, a plurality of first electrodes 130 electrically connected to the plurality of active elements 110 are formed. In this embodiment, before the first electrode 130 is formed, a flat layer 120 may be selectively formed on the active device 110. The flat layer 120 covers the active device 110 and the substrate 110, but the invention is not limited thereto. The plurality of first electrodes 130 are arranged in a plurality of first electrode rows 130y in the first direction y (as shown in FIG. 7A), and are arranged in a plurality of first electrode columns 130x in the second direction x (as shown in FIG. 7A) Show). The first direction y is staggered with the second direction x.

Please refer to FIGS. 6B and 7A, and then, a mask structure 300 is provided. The mask structure 300 has a plurality of strip-shaped solid portions 310 and a plurality of strip-shaped openings 320 spaced apart from each other. Each strip-shaped opening 320 separates adjacent strip-shaped solid portions 310. The plurality of strip-shaped solid portions 310 respectively shield the plurality of first electrode rows 130x. For example, each strip-shaped solid portion 310 shields a middle portion of each first electrode 130 of a corresponding one of the first electrode rows 130x, adjacent strips The opening 320 exposes opposite sides of each first electrode 130 corresponding to one first electrode row 130x in the first direction y.

Please refer to FIG. 6C, and then, when the strip-shaped solid portions 310 of the mask structure 300 respectively shield the first electrode rows 130x, the source material 410 passes through the strip-shaped opening portions 320 of the mask structure 300, so that the first A first bank layer 140 is formed on the electrode 130 (as shown in FIG. 6D). For example, in this embodiment, the component 400 is used to provide the source material 410, so that the source material 410 passes through the strip-shaped opening 320 of the mask structure 300 and is deposited in the strip-shaped opening 320, so as to be on the first electrode 130 The first bank layer 140 is formed. However, the present invention is not limited to this. In other embodiments, the first bank layer 140 may also be formed by physical vapor deposition processes such as evaporation.

It is worth mentioning that, since one of the first width W1 and the second width W2 is zero, the mask structure 300 can be used to perform a physical vapor deposition process to form the first bank layer 140. Compared with processes such as lithography and etching, the use of the physical vapor deposition process described above to form the first bank layer 140 is relatively simple and time-saving, which helps to reduce the manufacturing cost of the display device 50.

6D and FIG. 7B, the first bank layer 140 of this embodiment has a plurality of bank strips 140' and a plurality of first strip-shaped openings 140a'. In this embodiment, the bank strips 140' are spaced apart from each other in the first direction y. Each first strip-shaped opening 140a' separates the adjacent bank strip 140'. Adjacent two bank strips 140' are respectively disposed on opposite sides of each first electrode 130 in the same first electrode row 130x.

Please refer to FIG. 5B. Next, a second bank layer 150 is formed on the first bank layer 140. The second bank layer 150 has a plurality of second openings 150a overlapping the first electrodes 130, respectively.

Then, a plurality of droplets are injected into the first stripe openings 140a' of the first bank layer 140 and the plurality of second openings 150a of the second bank layer 150, so that the plurality of first electrodes 130 and the first bank layer 140 A plurality of light emitting layers 180 are formed in the plurality of first strip-shaped openings 140a' and the plurality of second openings 150a of the second bank layer 150. For example, in this embodiment, a hole injection layer 160, a hole transport layer 170, and a light emitting layer 180 may be formed in the first stripe opening 140a' and the plurality of second openings 150a (as shown in FIG. 5B) .

After that, the second electrode 210 is formed to cover the light emitting layer 180. For example, in this embodiment, the electron transport layer 190, the electron injection layer 200, and the second electrode 210 are sequentially disposed on the light emitting layer 180 and the second bank layer 150. At this point, the display device 50 is completed.

8 is a schematic top view of some components of a display device according to another embodiment of the invention. It must be noted here that the embodiment of FIG. 8 uses the element numbers and partial contents of the embodiment of FIG. 5A, wherein the same or similar reference numerals are used to indicate the same or similar elements, and the description of the same technical content is omitted. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments will not be repeated.

The main difference between the embodiment of FIG. 8 and the embodiment of FIG. 5A is that the size relationship between the first width W1 and the second width W2 is different.

8, in the display device 60 of this embodiment, the width 140y of the first opening 140a of the first bank layer 140 of the first sub-pixel 60a of the first sub-pixel 60a of the sub-pixel 60A in the first direction y is greater than the first opening The width of 140a in the second direction x is 140x, the first width W1 is zero, and the second width W2 is not zero. With this, the aperture ratio of the display device 60 can be increased.

In this embodiment, since the first width W1 is zero, the manufacturing method of the display device 60 may be the same as the manufacturing method of the foregoing embodiment of the display device 50, and will not be repeated below.

9A is a schematic top view of some components of a display device according to another embodiment of the invention. 9B is a schematic cross-sectional view of the sub-pixels of the display device according to the cross-sectional line E-E' of FIG. 9A. 9C is a schematic cross-sectional view of the sub-pixels of the display device according to the section line F-F' of FIG. 9A. FIG. 9A omits the drawing of the substrate 100, the active device 110, and the flat layer 120 of FIG. 9B. It must be noted here that the embodiments of FIGS. 9A-9C continue to use the element numbers and partial contents of the embodiments of FIGS. 1A-1B, wherein the same or similar reference numbers are used to denote the same or similar elements, and the same is omitted Description of technical content. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments will not be repeated.

The main difference between the embodiment of FIGS. 9A-9C and the embodiment of FIGS. 1A-1B is that: in the embodiment of FIGS. 9A-9C, the second openings 1502, 1504 of the adjacent two sub-pixels 72a, 74a Connected.

Please refer to FIGS. 9A to 9C. In the display device 70 of this embodiment, the sub-pixel 70A includes an adjacent fourth sub-pixel 72 a and a fifth sub-pixel 74 a. The fourth sub-pixel 72a and the fifth sub-pixel 74a are used to display the same color. In this embodiment, the first opening 1402 of the fourth sub-pixel 72a is separated from the first opening 1404 of the fifth sub-pixel 74a, and the second opening 1502 of the fourth sub-pixel 72a is separated from the fifth sub-pixel The second opening 1504 of 74a is in communication. Since the second opening 1502 of the fourth sub-pixel 72a communicates with the second opening 1504 of the fifth sub-pixel 74a, the light-emitting layers 180 of the fourth sub-pixel 72a and the fifth sub-pixel 74a can be utilized to distribute in the fourth The same opening of the first opening 1402 of the sub-pixel 72a and the first opening 1404 of the fifth sub-pixel 74a are formed.

The first bank layer 140 has a material region 145. In this embodiment, the material region 145 has a material region 1451 located between the first opening 1402 of the fourth sub-pixel 72a and the first opening 1404 of the fifth sub-pixel 74a. In this embodiment, the material region 145 has a first width W1 in the first direction y, the portion of the material region 145 adjacent to the second bank layer 150 has a second width W2 in the second direction x, and a portion of the material region 1451 It has a width W3 in the second direction x. In this embodiment, the width 140y of the first opening 1402, 1404 in the first direction y is greater than the width 140x of the first opening 1402, 1404 in the second direction x, and the first width W1 is smaller than the second width W2.

The light emitting layer 180 is disposed on a portion of the first electrode 130 of the fourth sub-pixel 72a and a portion of the first electrode 130 of the fifth sub-pixel 74a, and is located in the first opening 1402 and the fifth sub-pixel of the fourth sub-pixel 72a The first opening 1404 of the pixel 74a, the second opening 1502 of the fourth sub-pixel 72a, and the second opening 1504 of the fifth sub-pixel 74a. For example, in this embodiment, since the second opening 1502 of the fourth sub-pixel 72a communicates with the second opening 1504 of the fifth sub-pixel 74a, the fourth sub-pixel 72a and the fifth sub-pixel 74a The hole injection layer 160, the hole transport layer 170, and the light-emitting layer 180 can use droplets distributed in the first opening 1402 of the fourth sub-pixel 72a and the first opening 1404 of the fifth sub-pixel 74a, respectively, to form electricity. The hole injection layer 160, the hole transport layer 170 and the light emitting layer 180 are formed on the plurality of first electrodes 130 of the fourth sub-pixel 72a and the fifth sub-pixel 74a. The hole injection layer 160, the hole transport layer 170 and the light emitting layer 180 are located in the first opening 1402 of the fourth sub-pixel 72a, the first opening 1404 of the fifth sub-pixel 74a, and the second opening of the fourth sub-pixel 72a 1502 and the second opening 1504 of the fifth sub-pixel 74a.

In this embodiment, the hole injection layer 160, the hole transport layer 170, and the light-emitting layer 180 can also be formed on the first bank layer 142 located in a part of the material region 1451. In the third direction z perpendicular to the substrate 100, the top surface 182 of the light emitting layer 180 has a point 182a overlapping the center of the second opening and a point 182b overlapping the center of the first bank layer 142. The distance from a point 182a on the top surface 182 of the light emitting layer 180 to the top surface 130t of the first electrode 130 is the first distance T1. A point 182b on the top surface 182 of the light emitting layer 180 has a distance T1' from the top surface 142t of the first bank layer 142. In this embodiment, the first distance T1 is approximately equal to the distance T1'.

The electron transport layer 190, the electron injection layer 200, and the second electrode 210 are sequentially disposed on the light emitting layer 180 and the second bank layer 150. For example, in this embodiment, each of the electron transport layer 190, the electron injection layer 200, and the second electrode 210 may have substantially the same film thickness, but the present invention is not limited thereto.

Similarly, in the display device 70 according to an embodiment of the invention, the first width W1 is smaller than the second width W2. Thereby, the problem of uneven film thickness of the light-emitting layer 180 can be improved, thereby further improving the display quality of the display device 70.

10A is a schematic top view of some components of a display device according to another embodiment of the invention. 10B is a schematic cross-sectional view of the sub-pixels of the display device according to the cross-sectional line G-G' of FIG. 10A. FIG. 10C is a schematic cross-sectional view of the sub-pixels of the display device according to line H-H' of FIG. 10A. FIG. 10A omits the drawing of the substrate 100, the active device 110, and the flat layer 120 of FIG. 10B. It must be noted here that the embodiments of FIGS. 10A to 10C continue to use the element numbers and partial contents of the embodiments of FIGS. 9A to 9C, wherein the same or similar reference numbers are used to indicate the same or similar elements, and the same is omitted. Description of technical content. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments will not be repeated.

The main difference between the embodiments of FIGS. 10A to 10C and the embodiments of FIGS. 9A to 9C is that the size relationship between the first width W1 and the second width W2 is different.

Please refer to FIGS. 10A to 10C. In the display device 80 of this embodiment, the sub-pixel 80A includes an adjacent fourth sub-pixel 82 a and a fifth sub-pixel 84 a. The fourth sub-pixel 82a and the fifth sub-pixel 84a are used to display the same color. In this embodiment, the first opening 1402 of the fourth sub-pixel 82a is separated from the first opening 1404 of the fifth sub-pixel 84a, and the second opening 1502 of the fourth sub-pixel 82a is separated from the fifth sub-pixel The second opening 1504 of 84a is in communication.

The first bank layer 140 has a material region 145. In this embodiment, the material region 145 has a partial material region 1451 located between the first opening 1402 of the fourth sub-pixel 82a and the first opening 1404 of the fifth sub-pixel 84a. In this embodiment, the material region 145 has a first width W1 in the first direction y, the portion of the material region 145 adjacent to the second bank layer 150 has a second width W2 in the second direction x, and a portion of the material region 1451 It has a width W3 in the second direction x. In this embodiment, the width 140y of the first opening 1402, 1404 in the first direction y is greater than the width 140x of the first opening 1402, 1404 in the second direction x, and the first width W1 is greater than the second width W2.

Similarly, in the display device 80 according to an embodiment of the invention, the first width W1 is greater than the second width W2. As a result, the problem of uneven film thickness of the light-emitting layer 180 can be improved, thereby further improving the display quality of the display device 80.

11 is a schematic top view of some components of a display device according to another embodiment of the invention. It must be noted here that the embodiment of FIG. 11 follows the element numbers and part of the contents of the embodiment of FIG. 1A, wherein the same or similar reference numerals are used to indicate the same or similar elements, and the description of the same technical content is omitted. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments will not be repeated.

The main difference between the embodiment of FIG. 11 and the embodiment of FIG. 1A is that the plurality of sub-pixels 92a, 94b, and 96a of the display device 90 may be different.

Referring to FIG. 11, in the display device 90 of this embodiment, the sub-pixel 90A includes a first sub-pixel 92a and a second sub-pixel 94a. In this embodiment, the sub-pixel 90A may further include a third sub-pixel 96a, but the invention is not limited thereto. In this embodiment, the width 140y of the first opening 1402 of the first sub-pixel 92a in the first direction y is greater than the width 140x of the first opening 1402 in the second direction x, and the material of the first sub-pixel 92a The first width W1 of the region 1452 is greater than the second width W2. The width 140y of the first opening 1404 of the second sub-pixel 94a in the first direction y is greater than the width 140x of the first opening 1404 in the second direction x, and the first width of the material region 1454 of the second sub-pixel 94a W1 is smaller than the second width W2. That is to say, the size relationship between the first width W1 and the second width W2 of the material region 1452 of the first sub-pixel 92a in this embodiment is related to the first width W1 and the second width of the material region 1454 of the second sub-pixel 94a The size relationship of the width W2 is different.

In this embodiment, the third sub-pixel 96a is adjacent to the second sub-pixel 94a, and the second sub-pixel 94a is disposed between the first sub-pixel 92a and the third sub-pixel 96a. The width 140y of the first opening 1406 of the third sub-pixel 96a in the first direction y is greater than the width 140x of the first opening 1406 in the second direction x, and the first width of the material region 1456 of the third sub-pixel 96a W1 is equal to the second width W2. That is to say, the material region 1452 of the first sub-pixel 92a, the material region 1454 of the second sub-pixel 94a and the material region 1456 of the third sub-pixel 96a in this embodiment each have a first width W1 and a second width W2, and the size relationship between the first width W1 and the second width W2 in different sub-pixels are different. However, the present invention is not limited to this. In other embodiments, the two sub-pixels may be selectively set to have the same size relationship of the first width W1 and the second width W2.

In this embodiment, the first sub-pixel 92a, the second sub-pixel 94a, and the third sub-pixel 96a may display different colors from each other, but the present invention is not limited thereto. In this embodiment, the first sub-pixel 92a, the second sub-pixel 94a, and the third sub-pixel 96a can respectively display red, green, and blue, but the present invention is not limited thereto.

In summary, the display device according to an embodiment of the present invention includes multiple sub-pixels. A plurality of sub-pixels are arranged on the substrate. Each sub-pixel includes an active element, a first electrode, a first bank layer, a second bank layer, a light-emitting layer, and a second electrode. The first electrode is electrically connected to the active element. The first bank layer is disposed on the first electrode and has a first opening overlapping with a part of the first electrode. The second bank layer is disposed on the first bank layer and has a second opening overlapping with the first opening. The light emitting layer is disposed on part of the first electrode, and is located in the first opening of the first bank layer and the second opening of the second bank layer. The second electrode is disposed on the light emitting layer. The first bank layer has a material area. The vertical projection of the material region on the substrate is between the vertical projection of the first opening on the substrate and the vertical projection of the second opening on the substrate. The material region has a first width in the first direction, and the material region has a second width in the second direction. The plurality of sub-pixels includes the first sub-pixel. In particular, the first width of the material area of the first sub-pixel is not equal to the second width of the material area of the first sub-pixel. Thereby, the problem of uneven film thickness of the light-emitting layer of the display device according to an embodiment of the invention can be improved.

Although the present invention has been disclosed as above with examples, it is not intended to limit the present invention. Any person with ordinary knowledge in the technical field can make some changes and modifications without departing from the spirit and scope of the present invention. The scope of protection of the present invention shall be subject to the scope defined in the appended patent application.

10, 20, 30, 40, 50, 60, 70, 80, 90‧‧‧ Display device 10A, 20A, 30A, 40A, 50A, 60A, 70A, 80A, 90A , 40a, 50a, 60a, 92a ‧‧‧ first sub-pixel 94a‧‧‧ second sub-pixel 96a‧‧‧ third sub-pixel 72a, 82a‧‧‧ fourth sub-pixel 74a, 84a‧‧ ‧Fifth sub-pixel 100‧‧‧Substrate 110‧‧‧Active element 120‧‧‧Flat layer 130‧‧‧First electrode 130t‧‧‧Top surface 130x‧‧‧First electrode column 130y‧‧‧First Electrode row 140, 142‧‧‧ first bank layer 140′‧‧‧ bank strip 140t, 142t‧‧‧ top surface 140x, 140y‧‧‧ width 140a, 1402, 1404, 1406‧‧‧ first opening 140a'‧ ‧‧The first strip-shaped opening 140b‧‧‧Bent section 140b′‧‧‧Wave line section 145,1451,1452,1454,1456‧‧‧Material area 150‧‧‧Second bank layer 150a,1502,1504‧‧‧ Second opening 150s ‧‧‧ Side wall 150t ‧‧‧ Top surface 160 ‧ ‧ ‧ hole injection layer 170 ‧ ‧ ‧ hole transmission layer 180 ‧ ‧ ‧ light emitting layer 180a ‧ ‧ ‧ junction boundary 182 ‧ ‧ ‧ top surface 182a, 182b‧‧‧ point 190‧‧‧ electron transport layer 200‧‧‧ electron injection layer 210‧‧‧second electrode 212‧‧‧ top surface 212a‧‧‧ point 300‧‧‧ mask structure 310‧‧‧ physical part 320‧‧‧Opening 400‧‧‧Part 410‧‧‧ Source materials A-A', B-B', C-C', D-D', E-E', F-F', G-G ', H-H' ‧‧‧ section line H1, T1‧‧‧ first distance H2, T2‧‧‧ second distance T1'‧‧‧ distance W1‧‧‧ first width W2‧‧‧ second width W1 ', W2', W3‧‧‧ width x‧‧‧ second direction y‧‧‧ first direction z‧‧‧ third direction

FIG. 1A is a schematic top view of some components of a display device according to an embodiment of the invention. FIG. 1B is a schematic cross-sectional view of the sub-pixels of the display device according to section line A-A' of FIG. 1A. 2 is a schematic top view of some components of a display device according to another embodiment of the invention. 3 is a schematic top view of some components of a display device according to another embodiment of the invention. 4 is a schematic top view of some components of a display device according to another embodiment of the invention. 5A is a schematic top view of some components of a display device according to another embodiment of the invention. 5B is a schematic cross-sectional view of the sub-pixels of the display device according to the cross-sectional line B-B' of FIG. 5A. 6A to 6D are schematic cross-sectional views of manufacturing processes of some components of the display device of FIG. 5A. 7A and 7B are schematic top views of manufacturing steps of the display device of FIGS. 6B and 6D, respectively. 8 is a schematic top view of some components of a display device according to another embodiment of the invention. 9A is a schematic top view of some components of a display device according to another embodiment of the invention. 9B is a schematic cross-sectional view of the sub-pixels of the display device according to the cross-sectional line E-E' of FIG. 9A. 9C is a schematic cross-sectional view of the sub-pixels of the display device according to the section line F-F' of FIG. 9A. 10A is a schematic top view of some components of a display device according to another embodiment of the invention. 10B is a schematic cross-sectional view of the sub-pixels of the display device according to the cross-sectional line G-G' of FIG. 10A. FIG. 10C is a schematic cross-sectional view of the sub-pixels of the display device according to line H-H' of FIG. 10A. 11 is a schematic top view of some components of a display device according to another embodiment of the invention.

10‧‧‧Display device

10A‧‧‧subpixel

10a‧‧‧The first pixel

130‧‧‧First electrode

140‧‧‧The first embankment

140x、140y‧‧‧Width

140a‧‧‧First opening

145‧‧‧Material area

150‧‧‧Second embankment

150a‧‧‧Second opening

150s‧‧‧Side wall

A-A’‧‧‧Cut line

W1‧‧‧First width

W2‧‧‧second width

x‧‧‧Second direction

y‧‧‧first direction

Claims (13)

A display device includes: a plurality of sub-pixels disposed on a substrate, wherein each of the sub-pixels includes: an active element; a first electrode electrically connected to the active element; a first A bank layer disposed on the first electrode and having a first opening overlapping with part of the first electrode; a second bank layer disposed on the first bank layer and having the first opening A second opening that overlaps; a light-emitting layer disposed on the first electrode of the portion and located at the first opening of the first bank layer and the second opening of the second bank layer; and a second The electrode is arranged on the light-emitting layer, wherein the first bank layer has a material area, a vertical projection of the material area on the substrate is located in a vertical projection of the first opening on the substrate and the second opening is in Between a vertical projection on the substrate; the material area has a first width in a first direction, and the material area has a second width in a second direction interlaced with the first direction; The pixel includes a first sub-pixel, the first width of the material region of the first sub-pixel is not equal to the second width of the material region of the first sub-pixel. The display device according to item 1 of the patent application scope, wherein a width of the first opening in the first direction is greater than a width of the first opening in the second direction, and the first width is greater than the first Two width. The display device according to item 1 of the patent application scope, wherein a width of the first opening in the first direction is greater than a width of the first opening in the second direction, and the first width is smaller than the first Two width. The display device according to item 1 of the patent application scope, wherein a width of the first opening in the first direction is greater than a width of the first opening in the second direction, the first width is zero, and The second width is not zero. The display device according to item 1 of the patent application scope, wherein a width of the first opening in the first direction is greater than a width of the first opening in the second direction, the first width is not zero, And the second width is zero. The display device according to item 1 of the patent application scope, wherein the outline of the first opening has a plurality of curved sections, and the curved sections are connected to form a wavy line section. The display device of claim 6 of the patent application, wherein the curved sections are arranged in the first direction or the second direction. The display device as described in item 1 of the patent application scope, wherein the sub-pixels further include a second sub-pixel, the size of the first width and the second width of the material area of the first sub-pixel The relationship is different from the size relationship between the first width and the second width of the material region of the second sub-pixel. The display device as described in item 8 of the patent application scope, wherein the first sub-pixel and the second sub-pixel respectively display different colors, and the first width of the material area of the second sub-pixel It is substantially the same as the second width. The display device as described in item 9 of the patent application scope, wherein the sub-pixels further include a third sub-pixel, the first sub-pixel, the second sub-pixel and the third sub-pixel are respectively displayed Different colors, the first width of the material area of the first sub-pixel is greater than the second width of the material area of the first sub-pixel, and the material width of the material area of the third sub-pixel The first width is smaller than the second width of the material region of the first sub-pixel. The display device as claimed in item 1 of the patent application, wherein a top surface of the light-emitting layer has a point overlapping with the center of the second opening in a third direction perpendicular to the substrate, from the point to the first electrode The distance of the top surface of is a first distance, and the distance between a boundary of the top surface of the light-emitting layer and the second bank layer to a top surface of the first bank layer is a second distance, the first distance Less than or equal to the second distance, and the second distance is less than or equal to 20 times the first distance. The display device as described in item 1 of the patent application scope, wherein the sub-pixels include an adjacent fourth sub-pixel and a fifth sub-pixel, the fourth sub-pixel and the fifth sub-pixel To display the same color, a first opening of the fourth sub-pixel is separated from a first opening of the fifth sub-pixel, and a second opening of the fourth sub-pixel is separate from the fifth sub-pixel A second opening of the pixel is connected. A manufacturing method of a display device, comprising: providing a substrate; forming a plurality of active elements on the substrate; forming a plurality of first electrodes electrically connected to the active elements, respectively, the first electrodes being on a first side A plurality of first electrode rows are arranged upward, and a plurality of first electrode columns are arranged in a second direction, the first direction and the second direction are interleaved; a mask structure is provided, having a plurality of spaced apart from each other A strip-shaped solid portion and a plurality of strip-shaped opening portions, wherein each strip-shaped opening portion separates the adjacent strip-shaped solid portions; the strip-shaped solid portions of the mask structure respectively shield the first In the case of an electrode row, a source material is passed through the strip-shaped openings of the mask structure to form a first bank layer on the first electrodes, wherein the first bank layer has a plurality of bank strips And a plurality of first strip-shaped openings, the bank strips are spaced apart from each other in the first direction, each of the first strip-shaped openings separates the adjacent bank strips, and two adjacent bank strips are respectively disposed at Opposite sides of each first electrode of the same first electrode row of the first electrode rows; forming a second bank layer on the first bank layer, the second bank layer having the first electrodes respectively A plurality of overlapping openings; injecting a plurality of droplets into the first stripe openings of the first bank layer and the openings of the second bank layer, so that the first electrodes, the first bank layer The first strip-shaped openings and the openings of the second bank layer form a plurality of light-emitting layers; and a second electrode is formed to cover the light-emitting layers.

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