TWI679765B - Display device and manufacturing method thereof - Google Patents

Abstract

A display device includes a plurality of sub pixels. A plurality of sub pixels are disposed 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 bank layer is disposed on the first electrode and has a first opening overlapping a part of the first electrode. The second bank layer is disposed on the first bank layer and has a second opening overlapping the first opening. 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 a first direction, and the material region has a second width in a second direction that intersects with the first direction. The first width of the material region of the first subpixel of the plurality of subpixels is not equal to the second width. In addition, a method for manufacturing the above display device is also proposed.

Description

Display device and manufacturing method thereof

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

With the advancement of science and technology, in the manufacturing process of organic light emitting diode (OLED) display devices, an inkjet printing process (IJP) can be used to form a light emitting layer. The inkjet printing process is to spray or inject a liquefied organic light-emitting material into an opening defined by a bank to form a light-emitting layer. However, the thickness of the light-emitting layer formed by the organic light-emitting material in the opening is uneven, 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 greatly different from the film thickness at the center of the opening.

The invention provides a display device with excellent performance.

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

A display device of the present invention includes a plurality of sub-pixels. A plurality of sub pixels are disposed 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 a part of the first electrode. The second bank layer is disposed on the first bank layer and has a second opening overlapping the first opening. The light emitting layer is disposed on a part of the first electrode, and is located on 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 region, and a vertical projection of the material region on the substrate is located between a vertical projection of the first opening on the substrate and a 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 with the first direction. The sub-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.

A method for manufacturing a display device according to 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, respectively, and the first electrodes are arranged in a plurality of directions in the first direction. A first electrode row, and a plurality of first electrode columns are arranged in a second direction, the first direction and the second direction are staggered; a mask structure is provided, and a plurality of strip-shaped solid parts and a plurality of strips are separated from each other Each of the strip-shaped openings separates adjacent strip-shaped solid portions; in the case where the strip-shaped solid portions of the masking structure respectively shield the first electrode row, the source material is passed through the stripe-shaped masking structure An opening portion 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, and the bank strips are spaced apart from each other in the first direction, and each of the first strips Shaped openings separate adjacent bank strips, and two adjacent bank strips are respectively disposed on opposite sides of each first electrode of the same first electrode row of a plurality of first electrode rows; a first bank layer is formed on the first bank layer; Second bank layer, second bank layer A plurality of openings respectively overlapping the first electrode; a plurality of droplets are injected into the first stripe openings of the first bank layer and the openings of the second bank layer, so that the first electrodes and the first stripe of the first bank layer The opening 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 a display device and a 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 region that does not overlap with the vertical projection of the second bank layer 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, and the first width is not equal to the second width. Thereby, the problem of uneven film thickness of the light emitting layer of the display device can be improved.

In order to make the above features and advantages of the present invention more comprehensible, embodiments are hereinafter described in detail with reference to the accompanying drawings.

The invention will be described more fully hereinafter with reference to the accompanying drawings, in which exemplary embodiments of the 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 thicknesses of layers, films, panels, regions, etc. are exaggerated for clarity. Throughout the description, the same reference numerals denote the same elements. It will 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 a physical and / or electrical connection. Furthermore, "electrically connected" or "coupled" 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 of one element to another element, as shown. It should be understood that relative terms are intended to include different orientations of the device in addition to the orientation shown in the figures. For example, if the device in one of the figures is turned over, elements described as being on the "lower" side of other elements would then be oriented on "upper" sides of the other elements. Thus, the exemplary term "down" may include orientations of "down" and "up", depending on the particular orientation of the drawings. Similarly, if the device in one of the figures 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" may include orientations above and below.

As used herein, "about," "approximately," or "substantially" includes the stated value and an average value within an acceptable deviation range of a particular value determined by one of ordinary skill in the art, taking into account the measurements and A specific number of measurement-related errors (ie, limitations of the measurement system). For example, "about" can mean within one or more standard deviations of the stated value, or within ± 30%, ± 20%, ± 10%, ± 5%. Furthermore, the terms "about", "approximately" or "substantially" used herein may select a more acceptable range of deviations or standard deviations based on optical properties, etching properties, or other properties, and all properties can be applied without one standard deviation. .

Exemplary embodiments are described herein with reference to cross-sectional views that are schematic views of idealized embodiments. Accordingly, variations in the shapes of the illustrations as a result of, for example, manufacturing techniques and / or tolerances can be expected. Therefore, the embodiments described herein should not be construed as limited to the particular shape of the area as shown herein, but include shape deviations caused by, for example, manufacturing. For example, a region shown or described as flat may generally have rough and / or non-linear characteristics. Furthermore, the acute angles shown may be round. Thus, the regions illustrated in the figures are schematic in nature and their shapes are not intended to illustrate the precise shape of a region 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 one 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 to have meanings consistent with their meanings in the context of the related art 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 elements of a display device according to an embodiment of the invention. FIG. 1B is a schematic cross-sectional view of a sub-pixel of the display device shown according to the section line A-A 'of FIG. 1A. FIG. 1A omits the drawing of the substrate 100, the active device 110, the flat layer 120, the hole injection layer 160, the hole transmission layer 170, the light emitting layer 180, the electron transmission layer 190, the electron injection layer 200, and the second electrode 210 of FIG. .

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 disposed on the substrate 100. In this embodiment, the substrate 100 is, for example, a rigid substrate. However, the present invention is not limited thereto. In other embodiments, the substrate 100 may be a flexible substrate. For example, the material of the aforementioned rigid substrate may be glass, quartz, or other appropriate materials; the material of the aforementioned flexible substrate may be plastic or other appropriate materials.

Each sub-pixel 10A of this embodiment includes an active device 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 transmission layer 170, an electron transmission 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 having a gate electrode, a semiconductor pattern, a drain electrode, and a source electrode. The drain electrode is electrically connected to the first electrode 130 (or pixel electrode). 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 is not limited thereto. The material of the flat layer 120 includes an inorganic material (for example, silicon oxide, silicon nitride, silicon oxynitride, other suitable materials, or a stacked layer of at least two of the foregoing materials), an organic material (for example, polyester (PET), polymer Olefins, polypropylenes, polycarbonates, polyalkylene oxides, polystyrenes, polyethers, polyketones, polyalcohols, polyaldehydes, other suitable materials or combinations thereof), others 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 140 a that overlaps 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, Ink affinity, and the second bank layer 150 is, for example, ink repellent, but the present invention is not limited thereto. In this embodiment, the material of the second bank layer 150 is, for example, a photoresist, but the present 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 140a on the substrate 100 and the vertical projection of the second opening 150a 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 is 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 is intersected with the first direction y and the second direction x.

The plurality of sub-pixels 10A of the display device 10 include a 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 may be selectively larger than the second width W2 of the first sub-pixel 10a.

The light emitting layer 180 is disposed on a part of the first electrode 130 and is located on 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 transmission layer 170, and the light emitting layer 180 are sequentially disposed on the first electrode 130 in the portion. The hole injection layer 160, the hole transmission 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, a method of sequentially injecting the hole injection layer 160, the hole transmission layer 170, and the light emitting layer 180 on a part of the first electrode 130 is, for example, using an inkjet printing process (Ink Jet Printing; IJP), but the present 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 of the vertical 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 a first distance T1. The distance from the top edge 182 of the light emitting layer 180 to the top surface 140t of the first bank layer 140 to the second bank layer 150 is a 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 thereto.

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 formation method of the electron transport layer 190 and the electron injection layer 200 is, for example, a vapor deposition process, but the present 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 the present embodiment, the second electrode 210 may have substantially the same film thickness in the third direction z of the vertical substrate 100. That is, in the third direction z of the vertical substrate 100, the top surface 182 of the light emitting layer 180 has a point 182a that overlaps the center of the second opening 150a, and the top surface 212 of the second electrode 210 has a distance from the second opening 150a. The center overlaps a point 212a. 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 directly on the point 182a Above, the distance in the third direction z from the point 182a to the point 212a 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 a 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 present invention is not limited thereto.

Based on the above, in the display device 10 according to an embodiment of the present 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 larger than the second width W2. Thereby, the problem of uneven thickness of the light emitting layer 180 can be improved, and the display quality of the display device 10 can be improved.

FIG. 2 is a schematic top view of some elements of a display device according to another embodiment of the present invention. It must be noted here that the embodiment of FIG. 2 follows the component numbers and parts of the embodiment of FIG. 1A, in which the same or similar reference numerals are used to indicate the same or similar components, 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 are not repeated.

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

Please refer to FIG. 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 subpixel 20a of the subpixel 20A in the first direction y is greater than the first opening. 140a has a width 140x in the second direction x, and the first width W1 is smaller than the second width W2.

Similarly, in the display device 20 according to an embodiment of the present 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, and the display quality of the display device 20 can be improved.

FIG. 3 is a schematic top view of some elements of a display device according to another embodiment of the present invention. It must be noted here that the embodiment of FIG. 3 inherits the component numbers and parts of the embodiment of FIG. 1A, in which the same or similar reference numerals are used to represent the same or similar components, 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 are not 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 subpixel 30a of the subpixel 30A has a plurality of curved sections 140b. In the present embodiment, the plurality of curved sections 140b are aligned in the first direction y. The plurality of curved sections 140b are connected into a wavy line section 140b '. Thereby, the aperture ratio of the display device 30 can be increased.

In this embodiment, the first bank layer 140 has a material region 145 having a first width W1 in the first direction y, and a minimum width of the material region 145 in the second direction x is the second width W2. The maximum width of the region 145 in the second direction x is a 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 larger than the width 140x, and the first width W1 is larger 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 thereto. For example, in this embodiment, the magnitude 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.

FIG. 4 is a schematic top view of some elements of a display device according to another embodiment of the present invention. It must be noted here that the embodiment of FIG. 4 follows the component numbers and parts of the embodiment of FIG. 3, wherein the same or similar reference numerals are used to indicate the same or similar components, 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 are not repeated.

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

Referring to FIG. 4, in the display device 40 of this embodiment, a plurality of curved segments 140 b of the first opening 140 a of the first bank layer 140 of the first sub-pixel 40 a of the sub-pixel 40A are arranged in the second direction x. . The plurality of curved sections 140b are connected as wavy line sections 140b '. Thereby, 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 a first width W1, and the material region 145 has a 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 thereto. For example, in this embodiment, the magnitude 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 elements of a display device according to another embodiment of the present invention. Fig. 5B is a schematic cross-sectional view of a sub-pixel of the display device shown according to the section line B-B 'of Fig. 5A. 6A to 6D are schematic cross-sectional views illustrating a manufacturing process of some components of the display device of FIG. 5A. FIG. 5A omits the drawing of the substrate 100, the active device 110, the planarization layer 120, the hole injection layer 160, the hole transmission layer 170, the light emitting layer 180, the electron transmission layer 190, the electron injection layer 200, and the second electrode 210 of FIG. 5B. . It must be explained here that the embodiments of FIGS. 5A to 5B follow the component numbers and parts of the embodiments of FIGS. 1A to 1B. The same or similar symbols are used to indicate the same or similar components, 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 are not repeated.

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

Please refer to FIG. 5A and FIG. 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 subpixel 50a of the subpixel 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. Thereby, 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. The manufacturing process of the display device 50 according to another embodiment of the present invention will be described below with reference to FIGS. 6A to 6D and FIGS. 7A to 7B. 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.

Referring to FIG. 6A, first, a 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 devices 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, and the flat layer 120 covers the active device 110 and the substrate 110, but the present 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 the plurality of first electrodes 130 are arranged in the second direction x (as shown in FIG. 7A). Show). The first direction y intersects the second direction x.

Please refer to FIG. 6B and FIG. 7A. Next, 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 opening portions 320 spaced apart from each other. Each strip-shaped opening portion 320 separates an adjacent strip-shaped solid portion 310. The plurality of strip-shaped solid portions 310 respectively shield a plurality of first electrode rows 130x. For example, each strip-shaped solid portion 310 covers a middle portion of each first electrode 130 of a corresponding one of the first electrode rows 130x, and adjacent strips The openings 320 expose opposite sides of each first electrode 130 corresponding to the first electrode row 130x in the first direction y.

Please refer to FIG. 6C. Then, in a case where the strip-shaped solid portions 310 of the masking structure 300 respectively shield the first electrode row 130x, the source material 410 is passed through the strip-shaped openings 320 of the masking 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 source material 410 is provided by using the component 400, and the source material 410 passes through the strip-shaped openings 320 of the mask structure 300 and is deposited in the strip-shaped openings 320 to be on the first electrode 130. A first bank layer 140 is formed. However, the present invention is not limited to this. In other embodiments, the first bank layer 140 may be formed by a physical vapor deposition process such as evaporation.

It is worth mentioning that, since one of the first width W1 and the second width W2 is zero, a physical vapor deposition process can be performed using the mask structure 300 to form the first bank layer 140. Compared with the use of processes such as lithography and etching, forming the first bank layer 140 by using the foregoing physical vapor deposition process is simpler and saves time, which helps to reduce the manufacturing cost of the display device 50.

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

Referring to FIG. 5B, a second bank layer 150 is formed on the first bank layer 140. The second bank layer 150 has a plurality of second openings 150 a that respectively overlap the first electrode 130.

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

After that, a 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.

FIG. 8 is a schematic top view of some elements of a display device according to another embodiment of the present invention. It must be noted here that the embodiment of FIG. 8 inherits the component numbers and parts of the embodiment of FIG. 5A, in which the same or similar reference numerals are used to indicate the same or similar components, 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 are not repeated.

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

Referring to FIG. 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 subpixel 60a of the subpixel 60A in the first direction y is greater than the first opening. 140a has a width 140x in the second direction x, the first width W1 is zero, and the second width W2 is not zero. Thereby, 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, which will not be repeated hereafter.

9A is a schematic top view of some elements of a display device according to another embodiment of the present invention. FIG. 9B is a schematic cross-sectional view of a sub-pixel of the display device shown according to a section line E-E 'of FIG. 9A. FIG. 9C is a schematic cross-sectional view of a sub-pixel of the display device shown according to the section line F-F 'of FIG. 9A. FIG. 9A omits the illustration of the substrate 100, the active device 110, and the flat layer 120 of FIG. 9B. It must be explained here that the embodiment of FIGS. 9A to 9C follows the component numbers and parts of the embodiments of FIGS. 1A to 1B, in which the same or similar reference numerals are used to indicate the same or similar components, and the same components are omitted. Description of technical content. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments are not repeated.

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

Please refer to FIG. 9A to FIG. 9C. In the display device 70 of this embodiment, the sub-pixel 70A includes adjacent fourth and fifth sub-pixels 72a and 74a. 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 and the fifth sub-pixel The second opening 1504 of 74a communicates. Since the second opening 1502 of the fourth sub-pixel 72a is in communication with the second opening 1504 of the fifth sub-pixel 74a, the light-emitting layer 180 of the fourth sub-pixel 72a and the fifth sub-pixel 74a can be distributed in the fourth The first droplet 1402 of the sub-pixel 72a is formed with the same droplet as the first opening 1404 of the fifth sub-pixel 74a.

The first bank layer 140 has a material region 145. In this embodiment, the material region 145 has a material region 1451 in a portion 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, a 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 openings 1402 and 1404 in the first direction y is larger than the width 140x of the first openings 1402 and 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 on the first opening 1402 of the fourth sub-pixel 72a and the fifth 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 is in communication 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 transmission layer 170, and the light emitting layer 180 can form droplets of electricity using the 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. 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 transmission layer 170, and the light emitting layer 180 are located at 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 transmission layer 170, and the light emitting layer 180 may be further formed on the first bank layer 142 located in the partial material region 1451. In the third direction z of the vertical 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 a first distance T1. A point 182b on the top surface 182 of the light emitting layer 180 to the top surface 142t of the first bank layer 142 has a distance T1 '. 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 present invention, the first width W1 is smaller than the second width W2. Accordingly, the problem of uneven film thickness of the light emitting layer 180 can be improved, and the display quality of the display device 70 can be improved.

FIG. 10A is a schematic top view of some elements of a display device according to another embodiment of the present invention. FIG. 10B is a schematic cross-sectional view of a sub-pixel of the display device shown according to the section line G-G 'of FIG. 10A. FIG. 10C is a schematic cross-sectional view of a sub-pixel of the display device according to the section line H-H 'of FIG. 10A. FIG. 10A omits the illustration of the substrate 100, the active device 110, and the flat layer 120 of FIG. 10B. It must be explained here that the embodiment of FIGS. 10A to 10C inherits the component numbers and parts of the embodiments of FIGS. 9A to 9C. The same or similar reference numerals are used to indicate the same or similar components, and the same components are omitted. Description of technical content. For the description of the omitted parts, reference may be made to the foregoing embodiments, and the following embodiments are not repeated.

The main difference between the embodiment of FIGS. 10A to 10C and the embodiment of FIGS. 9A to 9C is that the magnitude 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 a fourth sub-pixel 82a and a fifth sub-pixel 84a adjacent to each other. 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 and the fifth sub-pixel The second opening 1504 of 84a communicates.

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, a 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 openings 1402, 1404 in the first direction y is larger than the width 140x of the first openings 1402, 1404 in the second direction x, and the first width W1 is larger than the second width W2.

Similarly, in the display device 80 according to an embodiment of the present invention, the first width W1 is larger than the second width W2. Thereby, the problem of uneven film thickness of the light emitting layer 180 can be improved, and the display quality of the display device 80 can be improved.

11 is a schematic top view of some elements of a display device according to another embodiment of the present invention. It must be noted here that the embodiment of FIG. 11 inherits the component numbers and parts of the embodiment of FIG. 1A, in which the same or similar reference numerals are used to represent the same or similar components, 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 are not repeated.

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

Please refer 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 present 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 is The first width W1 of the region 1452 is larger 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, the magnitude relationship between the first width W1 and the second width W2 of the material region 1452 of the first sub-pixel 92a and the first width W1 and the second width of the material region 1454 of the second sub-pixel 94a in this embodiment. The size W2 has a different relationship.

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, 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 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 is different. However, the present invention is not limited to this. In other embodiments, the two sub-pixels may also be selectively set to have the same size relationship between 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 display red, green, and blue, respectively, but the present invention is not limited thereto.

In summary, a display device according to an embodiment of the present invention includes a plurality of sub pixels. A plurality of sub pixels are disposed 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 a part of the first electrode. The second bank layer is disposed on the first bank layer and has a second opening overlapping the first opening. The light emitting layer is disposed on a part of the first electrode, and is located on 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 a first direction, and the material region has a second width in a second direction. The plurality of sub pixels include a first sub pixel. In particular, 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. Thereby, the problem of uneven film thickness of the light emitting layer of the display device according to an embodiment of the present invention can be improved.

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

10, 20, 30, 40, 50, 60, 70, 80, 90‧‧‧ display devices

10A, 20A, 30A, 40A, 50A, 60A, 70A, 80A, 90A ‧‧‧ sub pixels

10a, 20a, 30a, 40a, 50a, 60a, 92a

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

130x‧‧‧first electrode row

130y‧‧‧First electrode row

140, 142‧‧‧ first bank layer

140’‧‧‧ Embankment

140t, 142t‧‧‧Top

140x, 140y‧‧‧Width

140a, 1402, 1404, 1406‧‧‧ First opening

140a’‧‧‧ first strip opening

140b‧‧‧curved section

140b’‧‧‧ wave segment

145, 1451, 1452, 1454, 1456‧‧‧ materials area

150‧‧‧ second bank layer

150a, 1502, 1504‧‧‧Second opening

150s‧‧‧ sidewall

150t‧‧‧Top

160‧‧‧ Hole injection layer

170‧‧‧ Hole Transmission Layer

180‧‧‧Light-emitting layer

180a‧‧‧junction

182‧‧‧Top

182a, 182b‧‧‧ points

190‧‧‧ electron transmission layer

200‧‧‧ electron injection layer

210‧‧‧Second electrode

212‧‧‧Top

212a‧‧‧points

300‧‧‧Mask structure

310‧‧‧Entity

320‧‧‧ opening

400‧‧‧ parts

410‧‧‧source material

A-A ’, B-B’, C-C ’, D-D’, E-E ’, F-F’, G-G ’, H-H’‧‧‧ hatched

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 elements of a display device according to an embodiment of the invention. FIG. 1B is a schematic cross-sectional view of a sub-pixel of the display device shown according to the section line A-A 'of FIG. 1A. FIG. 2 is a schematic top view of some elements of a display device according to another embodiment of the present invention. FIG. 3 is a schematic top view of some elements of a display device according to another embodiment of the present invention. FIG. 4 is a schematic top view of some elements of a display device according to another embodiment of the present invention. 5A is a schematic top view of some elements of a display device according to another embodiment of the present invention. Fig. 5B is a schematic cross-sectional view of a sub-pixel of the display device shown according to the section line B-B 'of Fig. 5A. 6A to 6D are schematic cross-sectional views illustrating a manufacturing process 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. FIG. 8 is a schematic top view of some elements of a display device according to another embodiment of the present invention. 9A is a schematic top view of some elements of a display device according to another embodiment of the present invention. FIG. 9B is a schematic cross-sectional view of a sub-pixel of the display device shown according to a section line E-E 'of FIG. 9A. FIG. 9C is a schematic cross-sectional view of a sub-pixel of the display device shown according to the section line F-F 'of FIG. 9A. FIG. 10A is a schematic top view of some elements of a display device according to another embodiment of the present invention. FIG. 10B is a schematic cross-sectional view of a sub-pixel of the display device shown according to the section line G-G 'of FIG. 10A. FIG. 10C is a schematic cross-sectional view of a sub-pixel of the display device according to the section line H-H 'of FIG. 10A. 11 is a schematic top view of some elements of a display device according to another embodiment of the present invention.

Claims (14)

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 is disposed on the first electrode and has a first opening overlapping a portion of the first electrode; a second bank layer is disposed on the first bank layer and has a first opening A second opening overlapping; a light-emitting layer disposed on the first electrode in the portion and located on the first opening of the first bank layer and the second opening of the second bank layer; and a second An electrode is disposed on the light-emitting layer, wherein the first bank layer has a material region, a vertical projection of the material region on the substrate is located on a vertical projection of the first opening on the substrate, and the second opening is on Between a vertical projection 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 that intersects with the first direction; Pixels include 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, wherein a third side perpendicular to the substrate faces upward and a top of the light-emitting layer The surface has a point overlapping the center of the second opening, the distance from the point to the top surface of the first electrode is a first distance, and an interface edge of the top surface of the light emitting layer and the second bank layer reaches the A distance from a top surface of the first bank layer is a second distance, the first distance is 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 according to item 1 of the scope of patent application, 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 width Two widths. 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 width Two widths. The display device according to item 1 of the scope of patent application, 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 scope of patent application, 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 not zero. And the second width is zero. The display device according to item 1 of the scope of patent application, wherein the outline of the first opening has a plurality of curved segments, and the curved segments are connected into a wavy line segment. The display device according to item 6 of the patent application, wherein the curved segments are arranged in the first direction or the second direction. The display device according to item 1 of the patent application scope, wherein the sub-pixels further include a second sub-pixel, and the size of the first width and the second width of the material region of the first sub-pixel The relationship is not the same as the size relationship between the first width and the second width of the material region of the second sub-pixel. The display device according to item 8 of the scope of patent application, wherein the first sub-pixel and the second sub-pixel display different colors from each other, and the first width of the material region of the second sub-pixel And this second width is substantially the same. The display device according to item 9 of the scope of patent application, wherein the sub-pixels further include a third sub-pixel, and the first sub-pixel, the second sub-pixel, and the third sub-pixel are displayed separately. With different colors, the first width of the material region of the first sub-pixel is larger than the second width of the material region of the first sub-pixel, and the material width of the material region of the third sub-pixel is The first width is smaller than the second width of the material region of the first sub-pixel. The display device according to item 1 of the scope of patent application, wherein the sub-pixels include an adjacent fourth sub-pixel and a fifth sub-pixel, and 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 communicates. A method for manufacturing a display device includes: providing a substrate; forming a plurality of active elements on the substrate; forming a plurality of first electrodes respectively electrically connected to the active elements, and the first electrodes are on a first side; A plurality of first electrode rows are arranged upward, and a plurality of first electrode rows are arranged in a second direction, the first direction is interleaved with the second direction; a mask structure is provided, and a plurality of spaced apart electrodes are provided. A strip-shaped solid portion and a plurality of strip-shaped openings, wherein each of the strip-shaped openings separates the adjacent strip-shaped solid portions; and the strip-shaped solid portions of the mask structure respectively shield the first and second strip-shaped solid portions; 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 banks. And a plurality of first strip-shaped openings, the bank strips are separated 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 Each of the first electrode rows of each of the first electrode rows Opposite sides of the electrode; forming a second bank layer on the first bank layer, the second bank layer having a plurality of openings respectively overlapping the first electrodes; injecting a plurality of droplets into the first bank layer The first strip-shaped openings and the openings of the second bank layer, so that the first electrodes, the first strip-shaped openings of the first bank layer, and the openings of the second bank layer Forming a plurality of light emitting layers; and forming a second electrode to cover the light emitting layers. 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 is disposed on the first electrode and has a first opening overlapping a portion of the first electrode; a second bank layer is disposed on the first bank layer and has a first opening A second opening overlapping; a light-emitting layer disposed on the first electrode in the portion and located on the first opening of the first bank layer and the second opening of the second bank layer; and a second An electrode is disposed on the light-emitting layer, wherein the first bank layer has a material region, a vertical projection of the material region on the substrate is located on a vertical projection of the first opening on the substrate, and the second opening is on Between a vertical projection 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 that intersects with the first direction; Pixels include 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; wherein a width of the first opening in the first direction is greater than the first width A width of an opening in the second direction, and the first width is smaller than the second width. 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 is disposed on the first electrode and has a first opening overlapping a portion of the first electrode; a second bank layer is disposed on the first bank layer and has a first opening A second opening overlapping; a light-emitting layer disposed on the first electrode in the portion and located on the first opening of the first bank layer and the second opening of the second bank layer; and a second An electrode is disposed on the light-emitting layer, wherein the first bank layer has a material region, a vertical projection of the material region on the substrate is located on a vertical projection of the first opening on the substrate, and the second opening is on Between a vertical projection 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 that intersects with the first direction; Pixels include 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; wherein a width of the first opening in the first direction is greater than the first width A width of an opening in the second direction, the first width is zero, and the second width is not zero.