WO2022123382A1 - 表示装置の作製方法、表示装置、表示モジュール、及び、電子機器 - Google Patents
表示装置の作製方法、表示装置、表示モジュール、及び、電子機器 Download PDFInfo
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- WO2022123382A1 WO2022123382A1 PCT/IB2021/060952 IB2021060952W WO2022123382A1 WO 2022123382 A1 WO2022123382 A1 WO 2022123382A1 IB 2021060952 W IB2021060952 W IB 2021060952W WO 2022123382 A1 WO2022123382 A1 WO 2022123382A1
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- counter electrode
- pixel electrode
- display device
- insulating layer
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Classifications
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- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/10—OLED displays
- H10K59/12—Active-matrix OLED [AMOLED] displays
- H10K59/1201—Manufacture or treatment
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- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L33/00—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof
- H01L33/36—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the electrodes
- H01L33/38—Semiconductor devices having potential barriers specially adapted for light emission; Processes or apparatus specially adapted for the manufacture or treatment thereof or of parts thereof; Details thereof characterised by the electrodes with a particular shape
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L25/00—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof
- H01L25/03—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes
- H01L25/04—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers
- H01L25/075—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00
- H01L25/0753—Assemblies consisting of a plurality of individual semiconductor or other solid state devices ; Multistep manufacturing processes thereof all the devices being of a type provided for in the same subgroup of groups H01L27/00 - H01L33/00, or in a single subclass of H10K, H10N, e.g. assemblies of rectifier diodes the devices not having separate containers the devices being of a type provided for in group H01L33/00 the devices being arranged next to each other
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/10—Apparatus or processes specially adapted to the manufacture of electroluminescent light sources
-
- H—ELECTRICITY
- H05—ELECTRIC TECHNIQUES NOT OTHERWISE PROVIDED FOR
- H05B—ELECTRIC HEATING; ELECTRIC LIGHT SOURCES NOT OTHERWISE PROVIDED FOR; CIRCUIT ARRANGEMENTS FOR ELECTRIC LIGHT SOURCES, IN GENERAL
- H05B33/00—Electroluminescent light sources
- H05B33/12—Light sources with substantially two-dimensional radiating surfaces
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/30—Devices specially adapted for multicolour light emission
- H10K59/35—Devices specially adapted for multicolour light emission comprising red-green-blue [RGB] subpixels
-
- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K59/00—Integrated devices, or assemblies of multiple devices, comprising at least one organic light-emitting element covered by group H10K50/00
- H10K59/80—Constructional details
- H10K59/87—Passivation; Containers; Encapsulations
- H10K59/873—Encapsulations
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/10—Deposition of organic active material
- H10K71/16—Deposition of organic active material using physical vapour deposition [PVD], e.g. vacuum deposition or sputtering
- H10K71/166—Deposition of organic active material using physical vapour deposition [PVD], e.g. vacuum deposition or sputtering using selective deposition, e.g. using a mask
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- H—ELECTRICITY
- H10—SEMICONDUCTOR DEVICES; ELECTRIC SOLID-STATE DEVICES NOT OTHERWISE PROVIDED FOR
- H10K—ORGANIC ELECTRIC SOLID-STATE DEVICES
- H10K71/00—Manufacture or treatment specially adapted for the organic devices covered by this subclass
- H10K71/20—Changing the shape of the active layer in the devices, e.g. patterning
- H10K71/231—Changing the shape of the active layer in the devices, e.g. patterning by etching of existing layers
- H10K71/233—Changing the shape of the active layer in the devices, e.g. patterning by etching of existing layers by photolithographic etching
-
- H—ELECTRICITY
- H01—ELECTRIC ELEMENTS
- H01L—SEMICONDUCTOR DEVICES NOT COVERED BY CLASS H10
- H01L2933/00—Details relating to devices covered by the group H01L33/00 but not provided for in its subgroups
- H01L2933/0008—Processes
- H01L2933/0016—Processes relating to electrodes
Definitions
- One aspect of the present invention relates to a method for manufacturing a display device.
- One aspect of the present invention relates to a display device, a display module, and an electronic device.
- one aspect of the present invention is not limited to the above technical fields.
- the technical fields of one aspect of the present invention include semiconductor devices, display devices, light emitting devices, power storage devices, storage devices, electronic devices, lighting devices, input devices (for example, touch sensors), input / output devices (for example, touch panels), and the like.
- the driving method thereof or the manufacturing method thereof can be given as an example.
- display devices are expected to be applied to various applications.
- applications of a large display device include a television device for home use (also referred to as a television or television receiver), digital signage (electronic signage), and PID (Public Information Display).
- a television device for home use also referred to as a television or television receiver
- digital signage electronic signage
- PID Public Information Display
- Devices that require a high-definition display device include, for example, virtual reality (VR: Virtual Reality), augmented reality (AR: Augmented Reality), alternative reality (SR: Substitutional Reality), and mixed reality (MR: Mixed Reality). ) Is being actively developed.
- VR Virtual Reality
- AR Augmented Reality
- SR Substitutional Reality
- MR Mixed Reality
- a light emitting device having a light emitting device (also referred to as a light emitting element) has been developed.
- a light emitting device (also referred to as an EL device or EL element) that utilizes an electroluminescence (hereinafter referred to as EL) phenomenon is a DC constant voltage power supply that is easy to be thin and lightweight, can respond to an input signal at high speed, and is capable of responding to an input signal at high speed. It has features such as being driveable using electroluminescence, and is applied to display devices.
- Patent Document 1 discloses a display device for VR using an organic EL device (also referred to as an organic EL element).
- an island-shaped light emitting layer can be formed by a vacuum vapor deposition method using a metal mask (also referred to as a shadow mask).
- a metal mask also referred to as a shadow mask.
- the contours of the layers may be blurred and the thickness of the edges may be reduced. That is, the island-shaped light emitting layer may vary in thickness depending on the location.
- the manufacturing yield may be lowered due to the low dimensional accuracy of the metal mask and the deformation due to heat or the like.
- the light emitting layer can be processed into an island shape by using a photolithography method.
- a photolithography method it is possible to suppress the variation in the thickness of the light emitting layer, but the manufacturing cost of the photomask is high.
- three types of photomasks are manufactured. This will significantly increase the manufacturing cost of the display device.
- One of the problems of one aspect of the present invention is to provide a method for manufacturing a high-definition display device.
- One of the objects of the present invention is to provide a method for manufacturing a high-resolution display device.
- One aspect of the present invention is to provide a method for manufacturing a large-sized display device.
- One of the problems of one aspect of the present invention is to provide a method for manufacturing a highly reliable display device.
- One of the problems of one aspect of the present invention is to provide a method for manufacturing a display device having a low manufacturing cost.
- One aspect of the present invention is to provide a high-definition display device.
- One aspect of the present invention is to provide a high-resolution display device.
- One aspect of the present invention is to provide a large-sized display device.
- One aspect of the present invention is to provide a highly reliable display device.
- One of the problems of one aspect of the present invention is to provide a display device having a low manufacturing cost.
- One aspect of the present invention forms an insulating layer that forms a first pixel electrode and a second pixel electrode, and covers an end portion of the first pixel electrode and an end portion of the second pixel electrode. Then, a first layer is formed on the first pixel electrode, the second pixel electrode, and the insulating layer, and the first metal mask having the first opening is formed by the first opening. By arranging it on the first layer so as to overlap with the first pixel electrode and forming a film through the first metal mask, the first layer overlaps with the first pixel electrode through the first layer.
- a counter electrode is formed, and the first counter electrode is used as a hard mask to remove at least a part of the region overlapping the second pixel electrode in the first layer, and the second pixel on the first pixel electrode is removed.
- a second layer is formed on the electrode and on the insulating layer, and the second metal mask having the second opening is placed on the second layer so that the second opening overlaps with the second pixel electrode.
- At least a part of the region overlapping the first pixel electrode in the second layer is removed, and an opening is made on the first counter electrode and on the second counter electrode at a position overlapping the insulating layer. At least one of the regions overlapping the insulating layer in at least one of the first layer, the second layer, the first counter electrode, and the second counter electrode.
- the first protective layer is formed so as to cover the first counter electrode, the second counter electrode, and the insulating layer. It is a manufacturing method.
- a second protective layer that overlaps with the first pixel electrode is formed via the first layer by forming a film through the first metal mask before forming the first counter electrode. good. Even if a third protective layer that overlaps with the second pixel electrode is formed via the second layer by forming a film through the second metal mask before forming the second counter electrode. good.
- the thickness of the second protective layer and the thickness of the third protective layer may be different from each other.
- At least one of a metal oxide layer containing indium, gallium, and zinc and a metal oxide layer containing indium and tin may be formed, respectively.
- a fourth protective layer that overlaps with the first pixel electrode is formed via the first counter electrode by forming a film through the first metal mask after forming the first counter electrode. good.
- the fourth protective layer at least one of a metal oxide layer containing indium, gallium, and zinc and a metal oxide layer containing indium and tin may be formed.
- One aspect of the present invention forms an insulating layer that forms a first pixel electrode and a second pixel electrode, and covers an end portion of the first pixel electrode and an end portion of the second pixel electrode.
- the first layer is formed on the first pixel electrode, the second pixel electrode, and the insulating layer, and the first counter electrode is formed on the first layer.
- a first metal mask having an opening is placed on the first counter electrode so that the first opening overlaps the second pixel electrode, and the first metal mask is used to make the first layer and the first. At least a part of the region overlapping the second pixel electrode in the counter electrode 1 is removed, and a second layer is formed on the first pixel electrode, the second pixel electrode, and the insulating layer.
- a second counter electrode is formed on the second layer, and a second metal mask having a second opening is placed on the second counter electrode so that the second opening overlaps with the first pixel electrode. Placed on top and using a second metal mask, at least a portion of the area of the second layer and the second counter electrode that overlaps the first pixel electrode is removed, on the first counter electrode, and A resist mask having an opening at a position overlapping the insulating layer is formed on the second counter electrode, and the resist mask is used to form a first layer, a second layer, a first counter electrode, and a second counter electrode.
- a second protective layer may be formed on the first layer before the first counter electrode is formed.
- a third protective layer may be formed on the second layer before the second counter electrode is formed. The thickness of the second protective layer and the thickness of the third protective layer may be different from each other.
- At least one of a metal oxide layer containing indium, gallium, and zinc and a metal oxide layer containing indium and tin may be formed, respectively.
- a fourth protective layer may be formed on the first counter electrode before placing the first metal mask.
- As the fourth protective layer at least one of a metal oxide layer containing indium, gallium, and zinc and a metal oxide layer containing indium and tin may be formed.
- One aspect of the present invention includes a first light emitting device, a second light emitting device, an insulating layer, and a first protective layer
- the first light emitting device includes a first pixel electrode and a first light emitting device. It has a first layer on a pixel electrode and a first counter electrode on the first layer
- the second light emitting device has a second pixel electrode and a second on the second pixel electrode.
- the first light emitting device and the second light emitting device have a function of emitting light of different colors from each other
- the insulating layer has a layer of the above and a second counter electrode on the second layer.
- the end of the first pixel electrode and the end of the second pixel electrode are covered, and the first protective layer covers the first light emitting device, the second light emitting device, and the insulating layer, and is an insulating layer. Is a first region overlapping the first layer, a first counter electrode, a second layer, a second counter electrode, and a first protective layer, and a second region in contact with the first protective layer. It is a display device having and.
- the first light emitting device may have a second protective layer between the first layer and the first counter electrode.
- the second light emitting device may have a third protective layer between the second layer and the second counter electrode.
- the thickness of the second protective layer and the thickness of the third protective layer may be different from each other.
- the second protective layer and the third protective layer may have at least one of a metal oxide layer containing indium, gallium, and zinc, and a metal oxide layer containing indium and tin, respectively.
- the first light emitting device may have a fourth protective layer on the first counter electrode.
- the fourth protective layer may have at least one of a metal oxide layer containing indium, gallium, and zinc, and a metal oxide layer containing indium and tin.
- One aspect of the present invention is a display module having a display device having any of the above configurations and to which a connector such as a flexible printed circuit board (hereinafter referred to as FPC) or TCP (Tape Carrier Package) is attached.
- a display module such as a display module on which an integrated circuit (IC) is mounted by a COG (Chip On Glass) method, a COF (Chip On Film) method, or the like.
- One aspect of the present invention is an electronic device having the above display module and at least one of an antenna, a battery, a housing, a camera, a speaker, a microphone, and an operation button.
- a method for manufacturing a high-definition display device it is possible to provide a method for manufacturing a high-resolution display device.
- a method for manufacturing a large-sized display device can be provided.
- a high-definition display device can be provided.
- a high resolution display device can be provided.
- a large display device can be provided.
- a highly reliable display device can be provided.
- 1A and 1B are cross-sectional views showing an example of a display device.
- 2A to 2D are cross-sectional views showing an example of a method for manufacturing a display device.
- 3A to 3D are cross-sectional views showing an example of a method for manufacturing a display device.
- 4A to 4D are cross-sectional views showing an example of a method for manufacturing a display device.
- 5A to 5D are cross-sectional views showing an example of a method for manufacturing a display device.
- 6A to 6C are cross-sectional views showing an example of a method for manufacturing a display device.
- 7A to 7D are cross-sectional views showing an example of a method for manufacturing a display device.
- FIG. 8A to 8D are cross-sectional views showing an example of a method for manufacturing a display device.
- 9A to 9D are cross-sectional views showing an example of a method for manufacturing a display device.
- FIG. 10 is a perspective view showing an example of a display device.
- 11A and 11B are sectional views showing an example of a display device.
- FIG. 12A is a cross-sectional view showing an example of a display device.
- FIG. 12B is a cross-sectional view showing an example of a transistor.
- 13A and 13B are perspective views showing an example of a display module.
- FIG. 14 is a cross-sectional view showing an example of a display device.
- FIG. 15 is a cross-sectional view showing an example of a display device.
- FIG. 15 is a cross-sectional view showing an example of a display device.
- 16 is a cross-sectional view showing an example of a display device.
- 17A and 17B are diagrams showing an example of an electronic device.
- 18A and 18B are diagrams showing an example of an electronic device.
- 19A to 19D are views showing an example of an electronic device.
- 20A to 20F are views showing an example of an electronic device.
- 21A to 21F are views showing an example of an electronic device.
- membrane and the word “layer” can be interchanged with each other in some cases or depending on the situation.
- conductive layer can be changed to the term “conductive film”.
- insulating film can be changed to the term “insulating layer”.
- a device using a metal mask or an FMM may be referred to as an MM (metal mask) structure.
- MM metal mask
- MML metal maskless
- an island-shaped pixel electrode (which can also be said to be a lower electrode) is formed, an insulating layer covering the end of the pixel electrode is formed, and an EL layer including a light emitting layer is formed on one surface.
- a metal mask is placed on the EL layer, and a film is formed through the metal mask to form an island-shaped counter electrode (which can also be said to be an upper electrode).
- the EL layer is processed by using the counter electrode as a hard mask to form an island-shaped EL layer.
- the island-shaped EL layer can be formed with a uniform thickness.
- an island-shaped pixel electrode is formed, an insulating layer covering the end portion of the pixel electrode is formed, an EL layer including a light emitting layer, and a counter electrode.
- a metal mask is placed on the counter electrode, and the EL layer and the counter electrode are processed using the metal mask. Even with such a method, the EL layer is processed after being formed on one surface without using a film forming method using a metal mask, so that an island-shaped EL layer is formed with a uniform thickness. can do.
- the layers of the adjacent light emitting devices may overlap each other on the insulating layer. Therefore, in the production of the display device according to one aspect of the present invention, after producing a plurality of light emitting devices having different emission colors of the light emitting layers, a resist mask is formed on the plurality of light emitting devices. Then, a part of the insulating layer is exposed by removing the plurality of EL layers and the plurality of counter electrodes that overlap each other on the insulating layer using a resist mask. This makes it possible to electrically insulate adjacent light emitting devices on the insulating layer.
- the number of steps using the photolithography method can be reduced to one.
- Display device configuration example 1A and 1B show a display device according to an aspect of the present invention.
- the display device of one aspect of the present invention is a top emission type (top emission type) that emits light in the direction opposite to the substrate on which the light emitting device is formed, and emits light to the substrate side on which the light emitting device is formed. It may be either a bottom injection type (bottom emission type) or a double-sided injection type (dual emission type) that emits light on both sides.
- the display device shown in FIG. 1A is a bottom emission type, and the display device shown in FIG. 1B is a top emission type.
- transistors 122a, 122b, and 122c are provided on the substrate 110, respectively, an insulating layer 105 is provided so as to cover these transistors, and a light emitting device 130a, 130b and 130c are provided, and a protective layer 116 is provided so as to cover these light emitting devices.
- the substrate 120 is bonded to the protective layer 116 by the resin layer 119.
- the light-shielding layer 117 is provided on the substrate 120.
- the light emitting devices 130a, 130b, and 130c each emit light of different colors.
- the light emitting devices 130a, 130b, and 130c are preferably a combination that emits three colors of light, for example, red (R), green (G), and blue (B).
- the light emitting device 130a has a pixel electrode 111a on the insulating layer 105, an EL layer 113a on the pixel electrode 111a, and a counter electrode 114a on the EL layer 113a.
- the pixel electrode 111a is electrically connected to the transistor 122a.
- the light emitting device 130b has a pixel electrode 111b on the insulating layer 105, an EL layer 113b on the pixel electrode 111b, and a counter electrode 114b on the EL layer 113b.
- the pixel electrode 111b is electrically connected to the transistor 122b.
- the light emitting device 130c has a pixel electrode 111c on the insulating layer 105, an EL layer 113c on the pixel electrode 111c, and a counter electrode 114c on the EL layer 113c.
- the pixel electrode 111c is electrically connected to the transistor 122c.
- a conductive film that transmits visible light is used for the electrode on the side that extracts light. Further, it is preferable to use a conductive film that reflects visible light for the electrode on the side that does not take out light.
- a metal, an alloy, an electrically conductive compound, a mixture thereof, or the like can be appropriately used.
- In—Sn oxide also referred to as ITO
- In—Si—Sn oxide also referred to as ITSO
- In—Zn oxide In—W—Zn oxide
- aluminum, nickel, and lanthanum examples thereof include alloys containing aluminum such as alloys (Al-Ni-La) (aluminum alloys) and alloys of silver, palladium and copper (also referred to as Ag-Pd-Cu and APC).
- a micro-optical resonator (microcavity) structure is applied to the light emitting device. Therefore, one of the pair of electrodes of the light emitting device preferably has an electrode having transparency and reflection to visible light (semi-transmissive / semi-reflective electrode), and the other has an electrode having reflection to visible light (semi-transmissive / semi-reflective electrode). It is preferable to have a reflective electrode).
- the light emitting device has a microcavity structure, the light emitted from the light emitting layer can be resonated between both electrodes to enhance the light emitted from the light emitting device.
- the semi-transmissive / semi-reflective electrode can have a laminated structure of a reflective electrode and an electrode having transparency to visible light (also referred to as a transparent electrode).
- the light transmittance of the transparent electrode shall be 40% or more.
- an electrode having a transmittance of visible light (light having a wavelength of 400 nm or more and less than 750 nm) of 40% or more as the light emitting device.
- the reflectance of visible light of the semi-transmissive / semi-reflective electrode is 10% or more and 95% or less, preferably 30% or more and 80% or less.
- the reflectance of visible light of the reflecting electrode is 40% or more and 100% or less, preferably 70% or more and 100% or less.
- the resistivity of these electrodes is preferably 1 ⁇ 10 ⁇ 2 ⁇ cm or less.
- the EL layer has at least a light emitting layer.
- the EL layer includes a substance having a high hole injecting property, a substance having a high hole transporting property, a hole blocking material, an electron blocking material, a substance having a high electron transporting property, and a substance having a high electron injecting property.
- it may further have a layer containing a bipolar substance (a substance having high electron transport property and hole transport property) and the like.
- the EL layer may have one or more of a hole injection layer, a hole transport layer, a hole block layer, an electron block layer, an electron transport layer, and an electron injection layer.
- the light emitting layer is a layer containing a light emitting substance.
- a substance exhibiting a luminescent color such as blue, purple, bluish purple, green, yellowish green, yellow, orange, and red is appropriately used. Further, a substance that emits near-infrared light may be used.
- the luminescent substance that can be used for the light emitting layer is not particularly limited, and a luminescent substance that converts singlet excitation energy into light emission in the visible light region or a luminescent substance that converts triplet excitation energy into light emission in the visible light region is used. Can be done. Examples of the luminescent substance that converts the singlet excitation energy into luminescence include a substance that emits fluorescence (fluorescent material).
- the light emitting substance that converts triplet excitation energy into light emission examples include a substance that emits phosphorescence (phosphorescent material) and a thermally activated delayed fluorescent (TADF) material that exhibits thermal activated delayed fluorescence.
- the light emitting layer may have one or more kinds of compounds (host material, assist material) in addition to the light emitting substance (guest material).
- the host material and the assist material one or a plurality of substances having an energy gap larger than the energy gap of the light emitting substance (guest material) can be selected and used.
- the host material and the assist material it is preferable to use a combination of compounds forming an excitation complex. In order to efficiently form an excited complex, it is particularly preferable to combine a compound that easily receives holes (hole transporting material) and a compound that easily receives electrons (electron transporting material).
- Either a low molecular weight compound or a high molecular weight compound can be used as the light emitting device, and an inorganic compound (quantum dot material or the like) may be contained.
- the protective layer 115a on the light emitting device 130a.
- the protective layer 115b on the light emitting device 130b.
- the protective layer 115c on the light emitting device 130c.
- the conductivity of the protective layers 115a, 115b, 115c does not matter.
- As the protective layers 115a, 115b, 115c, at least one of an insulating film, a semiconductor film, and a conductive film can be used.
- the protective layers 115a, 115b, and 115c are layers that function as hard masks when the display device is manufactured, they are preferably inorganic films.
- the protective layer having an inorganic film protects the EL layer and the counter electrode by preventing oxidation of the counter electrode and suppressing impurities (moisture, oxygen, etc.) from entering the counter electrode and the EL layer. It is possible to increase the reliability of the light emitting device.
- the protective layers 115a, 115b, 115c for example, one or a plurality of an oxide insulating film, a nitride insulating film, a nitride nitride insulating film, and an oxide insulating film can be used.
- the oxide insulating film include a silicon oxide film, an aluminum oxide film, a gallium oxide film, a germanium oxide film, an yttrium oxide film, a zirconium oxide film, a lanthanum oxide film, a neodymium oxide film, a hafnium oxide film, and a tantalum oxide film. ..
- Examples of the nitride insulating film include a silicon nitride film and an aluminum nitride film.
- Examples of the oxidative nitride insulating film include a silicon oxynitride film.
- Examples of the nitride oxide insulating film include a silicon nitride oxide film.
- the oxidative nitride refers to a material having a higher oxygen content than nitrogen in its composition, and the nitride oxide has a higher nitrogen content than oxygen in its composition. Refers to the material.
- the silicon nitride film, the silicon oxide film, and the aluminum oxide film are suitable as the protective layers 115a, 115b, and 115c because they have high moisture resistance, respectively.
- the protective layers 115a, 115b, 115c are provided with In-Sn oxide (also referred to as ITO), In-Zn oxide, Ga-Zn oxide, Al-Zn oxide, or In-Ga-Zn oxide (also referred to as ITO).
- ITO In-Sn oxide
- In-Zn oxide Ga-Zn oxide
- Al-Zn oxide In-Ga-Zn oxide
- ITO In-Ga-Zn oxide
- An inorganic film containing (also referred to as IGZO) or the like can also be used.
- the inorganic film preferably has a high resistance, and specifically, it preferably has a higher resistance than the counter electrodes 114a, 114b, and 114c.
- the inorganic film may further contain nitrogen.
- the protective layers 115a, 115b, 115c have high transparency to visible light.
- ITO, IGZO, and aluminum oxide are preferable because they are inorganic materials having high transparency to visible light, respectively.
- the protective layers 115a, 115b, 115c include, for example, a laminated structure of an aluminum oxide film and a silicon nitride film on an aluminum oxide film, or a laminated structure of an aluminum oxide film and an IGZO film on an aluminum oxide film. Can be used. By using the laminated structure, impurities (water, oxygen, etc.) that enter the EL layer side can be suppressed.
- the film thicknesses of the protective layers 115a, 115b, and 115c, respectively it is possible to improve the light extraction efficiency of the light emitting device.
- the materials that can be used for the protective layer 116 are the same as the materials that can be used for the protective layers 115a, 115b, 115c.
- the protective layer 116 may have an organic film.
- the protective layer 116 may have both an organic film and an inorganic film.
- the insulating layer 121 includes a region 121a that overlaps the EL layer 113a, the counter electrode 114a, the EL layer 113b, and the counter electrode 114b, and a region 121b that overlaps the EL layer 113b, the counter electrode 114b, the EL layer 113c, and the counter electrode 114c. , A region 121c in contact with the protective layer 116.
- the region 121a may further have a protective layer 115a and a protective layer 115b.
- the region 121b may further have a protective layer 115b and a protective layer 115c.
- light emitting layers of each color are provided in an island shape for each light emitting device, and are manufactured by a so-called separate painting method. Therefore, it is possible to realize a light emitting device having high light extraction efficiency as compared with a configuration in which a light emitting device for white light emission and a color filter are combined. Further, since a single-structured light-emitting device can be applied, it is possible to realize a light-emitting device having a lower drive voltage than a configuration using a tandem-structured light-emitting device.
- Example 1 of manufacturing method of display device Next, an example of a method for manufacturing a display device will be described with reference to FIGS. 2 to 5.
- the thin films (insulating film, semiconductor film, conductive film, etc.) constituting the display device include a sputtering method, a chemical vapor deposition (CVD) method, a vacuum vapor deposition method, and a pulsed laser deposition (PLD).
- CVD chemical vapor deposition
- ALD Atomic Layer Deposition
- CVD method examples include a plasma chemical vapor deposition (PECVD: Plasma Enhanced CVD) method and a thermal CVD method.
- PECVD plasma chemical vapor deposition
- thermal CVD there is an organometallic chemical vapor deposition (MOCVD: Metalorganic CVD) method.
- the thin films (insulating film, semiconductor film, conductive film, etc.) constituting the semiconductor device include spin coating, dip, spray coating, inkjet, dispense, screen printing, offset printing, doctor knife, slit coating, roll coating, etc. It can be formed by a method such as a curtain coat or a knife coat.
- a vacuum process such as a thin-film deposition method and a solution process such as a spin coating method and an inkjet method can be used to fabricate the light emitting device.
- the vapor deposition method include a physical vapor deposition method (PVD method) such as a sputtering method, an ion plating method, an ion beam vapor deposition method, a molecular beam vapor deposition method, and a vacuum vapor deposition method, and a chemical vapor deposition method (CVD method).
- PVD method physical vapor deposition method
- CVD method chemical vapor deposition method
- a vapor deposition method vacuum vapor deposition method, etc.
- a coating method dip coat method, etc.
- printing method inkprint method, screen (lithographic printing) method, offset (lithographic printing) method, flexo (lithographic printing) method, gravure method, or micro It can be formed by a method such as the contact method).
- a thin film constituting a semiconductor device when processing a thin film constituting a semiconductor device, it can be processed by using a photolithography method or the like.
- the thin film may be processed by a nanoimprint method, a sandblast method, a lift-off method, or the like.
- an island-shaped thin film may be directly formed by a film forming method using a shielding mask such as a metal mask.
- a photolithography method there are typically the following two methods.
- One is a method of forming a resist mask on a thin film to be processed, processing the thin film by etching or the like, and removing the resist mask.
- the other is a method in which a photosensitive thin film is formed, and then exposed and developed to process the thin film into a desired shape.
- the light used for exposure for example, i-line (wavelength 365 nm), g-line (wavelength 436 nm), h-line (wavelength 405 nm), or a mixture thereof can be used.
- ultraviolet rays, KrF laser light, ArF laser light, or the like can also be used.
- the exposure may be performed by the immersion exposure technique.
- extreme ultraviolet (EUV: Extreme Ultra-violet) light or X-rays may be used.
- an electron beam can be used instead of the light used for exposure. It is preferable to use extreme ultraviolet light, X-rays or an electron beam because extremely fine processing is possible.
- extreme ultraviolet light, X-rays or an electron beam because extremely fine processing is possible.
- a dry etching method, a wet etching method, a sandblasting method, or the like can be used for etching the thin film.
- the pixel electrodes 111a, 111b, 111c are formed on the layer 101 including the transistor.
- the insulating layer 121 that covers the ends of the pixel electrodes 111a, 111b, and 111c is formed.
- the EL layer 113a is formed on the pixel electrodes 111a, 111b, 111c, and the insulating layer 121.
- the layer 101 including the transistor corresponds to, for example, a laminated structure of the substrate 110, the transistors 122a, 122b, 122c, and the insulating layer 105 shown in FIGS. 1A and 1B.
- the materials that can be used as the pixel electrodes are as described above.
- a sputtering method or a vacuum vapor deposition method can be used for forming the pixel electrodes.
- the insulating layer 121 may have a single-layer structure or a laminated structure using one or both of an inorganic insulating film and an organic insulating film.
- Examples of the organic insulating material that can be used for the insulating layer 121 include acrylic resin, epoxy resin, polyimide resin, polyamide resin, polyimideamide resin, polysiloxane resin, benzocyclobutene resin, and phenol resin. Further, as the inorganic insulating film that can be used for the insulating layer 121, the inorganic insulating film that can be used for the protective layers 115a, 115b, 115c can be used.
- an inorganic insulating film is used as the insulating layer 121 covering the end of the pixel electrode, impurities are less likely to enter the light emitting device as compared with the case where an organic insulating film is used, and the reliability of the light emitting device can be improved.
- the step covering property is higher than when the inorganic insulating film is used, and the shape of the pixel electrode is less affected. Therefore, it is possible to prevent a short circuit of the light emitting device.
- the configuration applicable to the EL layer 113a is as described above.
- the layers constituting the EL layer 113a can be formed by a vapor deposition method (including a vacuum vapor deposition method), a transfer method, a printing method, an inkjet method, a coating method, or the like, respectively. Further, the layer constituting the EL layer 113a may be formed by using a premix material.
- the metal mask 190a is arranged on the EL layer 113a.
- the metal mask 190a has an opening at a position overlapping the pixel electrode 111a.
- the metal mask 190a overlaps each of the pixel electrode 111b and the pixel electrode 111c.
- the counter electrode 114a is formed on the EL layer 113a through the opening of the metal mask 190a. Since the metal mask 190a has an opening at a position where it overlaps with the pixel electrode 111a, the counter electrode 114a is formed at a position where it overlaps with the pixel electrode 111a via the EL layer 113a. The counter electrode 114a may also be formed at a position where it overlaps with the pixel electrode 111b or the pixel electrode 111c via the insulating layer 121 and the EL layer 113a. On the other hand, it is not preferable that the counter electrode 114a is formed at a position where it overlaps with the pixel electrode 111b or the pixel electrode 111c without passing through the insulating layer 121.
- a protective layer 115a on the counter electrode 114a via the metal mask 190a.
- the materials that can be used as the counter electrode 114a are as described above.
- a sputtering method or a vacuum vapor deposition method can be used to form the counter electrode 114a.
- the materials that can be used for the protective layer 115a are as described above.
- As the protective layer 115a it is preferable to form at least one of a metal oxide layer containing indium, gallium, zinc, and oxygen, and a metal oxide layer containing indium, tin, and oxygen.
- Examples of the film forming method of the protective layer 115a include a vacuum vapor deposition method, a sputtering method, a CVD method, and an ALD method.
- As the protective layer 115a two or more films formed by using different film forming methods may be laminated.
- the counter electrode 114a and the protective layer 115a as a hard mask, at least a part of the region overlapping the pixel electrode 111b and at least a region overlapping the pixel electrode 111c in the EL layer 113a. Remove some.
- the region of the EL layer 113a that does not overlap with the counter electrode 114a and the protective layer 115a can be removed.
- the EL layer 113a can be formed in an island shape.
- the processing of the EL layer 113a is preferably performed by anisotropic etching.
- anisotropic dry etching is preferable.
- the etching gas it is preferable to use a gas containing nitrogen, a gas containing hydrogen, a gas containing nitrogen and hydrogen, and the like. By not using a gas containing oxygen as the etching gas, deterioration of the EL layer 113a can be suppressed.
- a gas containing oxygen may be used as the etching gas. Since the etching gas contains oxygen, the etching speed can be increased. Therefore, it is possible to perform etching under low power conditions while maintaining the etching speed at a sufficient speed. Therefore, the damage given to the EL layer 113a can be suppressed. Further, it is possible to suppress problems such as adhesion of reaction products that occur during etching.
- a noble gas also referred to as a rare gas
- a gas containing one or more such as H 2 , CF 4 , C 4 F 8 , SF 6 , CHF 3 , Cl 2 , H 2 O, BCl 3 , or He, Ar.
- a gas containing one or more such as H 2 , CF 4 , C 4 F 8 , SF 6 , CHF 3 , Cl 2 , H 2 O, BCl 3 , or He, Ar.
- oxygen gas may be used as the etching gas.
- a gas containing H 2 and Ar or a gas containing CF 4 and He can be used as the etching gas.
- a gas containing CF 4 , He, and oxygen can be used as the etching gas.
- a gas containing H 2 and Ar and a gas containing oxygen can be used as the etching gas.
- the protective layer 115a By providing the protective layer 115a, it is possible to prevent damage to the region overlapping the protective layer 115a of the EL layer 113a and the counter electrode 114a in the processing step of the EL layer 113a. This makes it possible to increase the reliability of the light emitting device.
- the material of the protective layer 115a and the processing method of the EL layer 113a it is preferable to select the material of the protective layer 115a and the processing method of the EL layer 113a so that the protective layer 115a is not processed.
- the EL layer 113b is formed on the protective layer 115a, the pixel electrodes 111b and 111c, and the insulating layer 121.
- the EL layer 113b emits light having a color different from that of the EL layer 113a.
- the configuration and materials applicable to the EL layer 113b are the same as those of the EL layer 113a.
- the EL layer 113b can be formed into a film by the same method as the EL layer 113a.
- the metal mask 190b is arranged on the EL layer 113b.
- the metal mask 190b has an opening at a position overlapping the pixel electrode 111b.
- the metal mask 190b overlaps each of the pixel electrode 111a and the pixel electrode 111c.
- the counter electrode 114b is formed on the EL layer 113b through the opening of the metal mask 190b. Since the metal mask 190b has an opening at a position where it overlaps with the pixel electrode 111b, the counter electrode 114b is formed at a position where it overlaps with the pixel electrode 111b via the EL layer 113b. The counter electrode 114b may also be formed at a position where it overlaps with the pixel electrode 111a or the pixel electrode 111c via the insulating layer 121 and the EL layer 113b. On the other hand, it is not preferable that the counter electrode 114b is formed at a position where it overlaps with the pixel electrode 111a or the pixel electrode 111c without passing through the insulating layer 121.
- a protective layer 115b on the counter electrode 114b via the metal mask 190b.
- the material that can be used for the counter electrode 114b is the same as that of the counter electrode 114a.
- the counter electrode 114b can be formed into a film by the same method as that of the counter electrode 114a.
- the materials that can be used for the protective layer 115b are the same as those for the protective layer 115a.
- the protective layer 115b can be formed into a film by the same method as that of the protective layer 115a.
- the counter electrode 114b and the protective layer 115b as a hard mask, at least a part of the region overlapping the pixel electrode 111a and at least a region overlapping the pixel electrode 111c in the EL layer 113b. Remove some.
- the region of the EL layer 113b that does not overlap with the counter electrode 114b and the protective layer 115b can be removed.
- the EL layer 113b can be formed in an island shape.
- the EL layer 113b can be processed by the same method as the EL layer 113a.
- the protective layer 115a on the EL layer 113a and the counter electrode 114a, it is possible to prevent the EL layer 113a and the counter electrode 114a from being damaged when the EL layer 113b is processed. can. This makes it possible to increase the reliability of the light emitting device.
- the EL layer 113c is formed on the protective layers 115a and 115b, the pixel electrodes 111c, and the insulating layer 121.
- the EL layer 113c emits light having a color different from that of the EL layer 113a and the EL layer 113b.
- the configuration and materials applicable to the EL layer 113c are the same as those of the EL layer 113a.
- the metal mask 190c is arranged on the EL layer 113c.
- the metal mask 190c has an opening at a position overlapping the pixel electrode 111c.
- the metal mask 190c overlaps each of the pixel electrode 111a and the pixel electrode 111b.
- the counter electrode 114c is formed on the EL layer 113c through the opening of the metal mask 190c. Since the metal mask 190c has an opening at a position where it overlaps with the pixel electrode 111c, the counter electrode 114c is formed at a position where it overlaps with the pixel electrode 111c via the EL layer 113c. The counter electrode 114c may also be formed at a position where it overlaps with the pixel electrode 111a or the pixel electrode 111b via the insulating layer 121 and the EL layer 113c. On the other hand, it is not preferable that the counter electrode 114c is formed at a position where it overlaps with the pixel electrode 111a or the pixel electrode 111b without passing through the insulating layer 121.
- a protective layer 115c on the counter electrode 114c via the metal mask 190c.
- the material that can be used for the EL layer 113c is the same as that of the EL layer 113a.
- the EL layer 113c can be formed into a film by the same method as the EL layer 113a.
- the material that can be used for the counter electrode 114c is the same as that of the counter electrode 114a.
- the counter electrode 114c can be formed into a film by the same method as that of the counter electrode 114a.
- the materials that can be used for the protective layer 115c are the same as those for the protective layer 115a.
- the protective layer 115c can be formed into a film by the same method as that of the protective layer 115a.
- the counter electrode 114c and the protective layer 115c as a hard mask, at least a part of the region overlapping the pixel electrode 111a and at least a region overlapping the pixel electrode 111b in the EL layer 113c. Remove some.
- the region of the EL layer 113c that does not overlap with the counter electrode 114c and the protective layer 115c can be removed.
- the EL layer 113c can be formed in an island shape.
- the EL layer 113c can be processed by the same method as the EL layer 113a.
- the protective layer 115a on the EL layer 113a and the counter electrode 114a, it is possible to prevent the EL layer 113a and the counter electrode 114a from being damaged when the EL layer 113c is processed. can.
- the protective layer 115b on the EL layer 113b and the counter electrode 114b, it is possible to prevent the EL layer 113b and the counter electrode 114b from being damaged when the EL layer 113c is processed. can.
- the material of the protective layers 115a, 115b, 115c and the processing method of the EL layer 113c so that the protective layers 115a, 115b, 115c are not processed when the EL layer 113c is processed.
- At least one of an EL layer 113c, a counter electrode 114c, and a protective layer 115c may be provided on the light emitting device 130a and the light emitting device 130b.
- the counter electrode 114c and the protective layer 115c may be formed without arranging the metal mask 190c.
- the protective layers 115a and 115b in contact with the EL layer 113c are insulating films, respectively.
- the counter electrode 114c may be formed over the metal mask 190c, and the protective layer 115c may be formed on one surface without using the metal mask 190c.
- the protective layer 115c can be used to suppress deterioration of each light emitting device and improve reliability.
- a photosensitive resin (photoresist) is applied onto the protective layers 115a, 115b, 115c to form a resist film 191.
- a protective layer may be further formed on the protective layers 115a, 115b, 115c.
- the materials that can be used for the protective layer are the same as those for the protective layers 115a, 115b, 115c.
- the resist mask 192 shown in FIG. 5B is formed.
- the resist mask 192 has an opening at a position overlapping the insulating layer 121.
- the resist mask 192 has a plurality of island-shaped regions that overlap with one or more of the pixel electrodes, and there is a region on the insulating layer 121 in which the resist mask 192 is not provided.
- FIG. 5C mainly a part of the portion on the insulating layer 121 on which the EL layers 113a and 113b, the counter electrodes 114a and 114b, and the protective layers 115a and 115b are laminated, and the EL layers 113b and 113c face each other.
- An example is shown in which the electrodes 114b and 114c and a part of the portion where the protective layers 115b and 115c are laminated are removed.
- the end of the EL layer 113a is in contact with the EL layer 113b, and the end of the EL layer 113b is in contact with the EL layer 113c. Therefore, when the EL layer contains a highly conductive layer or the like, a current may leak to the adjacent light emitting device, and other than the desired light emitting device may emit light. Therefore, as shown in FIG. 5C, it is preferable to electrically insulate adjacent light emitting devices on the insulating layer 121.
- the protective layer 116 is formed on the protective layers 115a, 115b, 115c, and the insulating layer 121.
- the protective layer 116 is provided so as to be in contact with the side surface of the laminated structure in which the EL layer 113a, the counter electrode 114a, the protective layer 115a, the EL layer 113b, the counter electrode 114b, and the protective layer 115b are laminated in this order.
- the protective layer 116 is provided so as to be in contact with the side surface of the laminated structure in which the EL layer 113b, the counter electrode 114b, the protective layer 115b, the EL layer 113c, the counter electrode 114c, and the protective layer 115c are laminated in this order.
- the materials that can be used as the protective layer 116 are as described above.
- Example 1 of the manufacturing method of the display device since the EL layer is processed after being formed on one surface without using the film forming method using a metal mask, the island-shaped EL layer is made uniform. It can be formed by thickness. In addition, the number of steps using the photolithography method can be reduced to one. Alternatively, it is not necessary to perform the process using the photolithography method. Therefore, the manufacturing cost of the display device can be reduced.
- each EL layer 113a, 113b, and 113c constituting the light emitting device of each color are formed in different steps. Therefore, each EL layer can be manufactured with a configuration (material, film thickness, etc.) suitable for a light emitting device of each color. This makes it possible to manufacture a light emitting device having good characteristics.
- the layer constituting the light emitting device 130a and the layer constituting the light emitting device 130b may not overlap each other.
- the layer constituting the light emitting device 130b and the layer constituting the light emitting device 130c do not overlap each other.
- the step using the photolithography method shown in FIGS. 5A to 5C can be omitted.
- the configuration shown in FIG. 6A may be obtained by performing a process using a photolithography method (that is, at the stage of FIG. 5C).
- the protective layer 116 is then formed on the protective layers 115a, 115b, 115c and the insulating layer 121, as shown in FIG. 6B.
- each light emitting device may have a protective layer between the EL layer and the counter electrode.
- the light emitting device 130a shown in FIG. 6C has a protective layer 125a between the EL layer 113a and the counter electrode 114a.
- the light emitting device 130b shown in FIG. 6C has a protective layer 125b between the EL layer 113b and the counter electrode 114b
- the light emitting device 130c has a protective layer between the EL layer 113c and the counter electrode 114c. It has 125c.
- the protective layers 125a, 125b, 125c preferably function as part of the EL layer or part of the electrodes. Therefore, it is preferably composed of a material that can be used for the EL layer or the electrode. Further, it is preferable that the protective layers 125a, 125b and 125c have high transparency to visible light.
- the protective layers 125a, 125b, and 125c may have a function as an optical adjustment layer.
- the protective layers 125a, 125b and 125c may have different thicknesses. By making the thicknesses of the protective layers 125a, 125b, and 125c different, it is possible to intensify and extract light of a specific color in each light emitting device. Specifically, it is preferable to adjust the film thickness of the protective layer 125a so that the optical distance between the pair of electrodes of the light emitting device 130a is an optical distance that enhances the color light emitted by the EL layer 113a.
- the film thickness of the protective layer 125b so that the optical distance between the pair of electrodes of the light emitting device 130b is an optical distance that enhances the color light emitted by the EL layer 113b. Further, it is preferable to adjust the film thickness of the protective layer 125c so that the optical distance between the pair of electrodes of the light emitting device 130c is an optical distance that enhances the color light emitted by the EL layer 113c.
- Example 2 of manufacturing method of display device Subsequently, an example of a method for manufacturing a display device different from the above will be described with reference to FIGS. 7 to 9. The description of the same part as that of the production method Example 1 may be omitted.
- the pixel electrodes 111a, 111b, 111c are formed on the layer 101 including the transistor.
- the insulating layer 121 that covers the ends of the pixel electrodes 111a, 111b, and 111c is formed.
- the EL layer 113a is formed on the pixel electrodes 111a, 111b, 111c, and the insulating layer 121.
- the counter electrode 114a is formed on the EL layer 113a. Further, it is preferable to form the protective layer 115a on the counter electrode 114a.
- the metal mask 190a is arranged on the protective layer 115a.
- the metal mask 190a has an opening at a position where it overlaps with the pixel electrode 111b and the pixel electrode 111c.
- the metal mask 190a overlaps with the pixel electrode 111a.
- the metal mask 190a using the metal mask 190a, at least a part of the region overlapping the pixel electrode 111b and the region overlapping the pixel electrode 111c in the EL layer 113a, the counter electrode 114a, and the protective layer 115a. Remove at least part of.
- the region of the EL layer 113a, the counter electrode 114a, and the protective layer 115a that does not overlap with the metal mask 190a can be removed.
- the EL layer 113a, the counter electrode 114a, and the protective layer 115a can be formed in an island shape so as to overlap the pixel electrode 111a (FIG. 7D).
- the EL layer 113a, the counter electrode 114a, and the protective layer 115a at least a region that overlaps with the pixel electrode 111b without the insulating layer 121 and a region that overlaps with the pixel electrode 111c without the insulating layer 121 are removed.
- the region of the EL layer 113a, the counter electrode 114a, and the protective layer 115a that overlaps with the pixel electrode 111b or the pixel electrode 111c via the insulating layer 121 may remain without being removed.
- the EL layer 113a can be processed by the same method as in Production Method Example 1.
- the counter electrode 114a is preferably processed by anisotropic etching.
- anisotropic dry etching is preferable.
- Wet etching may be used.
- the protective layer 115a is preferably processed by anisotropic etching.
- anisotropic dry etching is preferable. Wet etching may be used.
- the processing steps of these three layers are continuously processed without being exposed to the atmosphere in order to suppress deterioration of the light emitting device. Therefore, it is preferable to select a method that can be continuously performed using one device without opening to the atmosphere.
- the EL layer 113b is formed on the protective layer 115a, the pixel electrodes 111b and 111c, and the insulating layer 121.
- the counter electrode 114b is formed on the EL layer 113b. Further, it is preferable to form the protective layer 115b on the counter electrode 114b.
- the EL layer 113b can be formed into a film by the same method as the EL layer 113a.
- the counter electrode 114b can be formed into a film by the same method as that of the counter electrode 114a.
- the protective layer 115b can be formed into a film by the same method as that of the protective layer 115a.
- the metal mask 190b is arranged on the protective layer 115b.
- the metal mask 190b has an opening at a position where it overlaps with the pixel electrode 111a and the pixel electrode 111c.
- the metal mask 190b overlaps with the pixel electrode 111b.
- the metal mask 190b using the metal mask 190b, at least a part of the region overlapping the pixel electrode 111a and the region overlapping the pixel electrode 111c in the EL layer 113b, the counter electrode 114b, and the protective layer 115b. Remove at least part of.
- the region of the EL layer 113b, the counter electrode 114b, and the protective layer 115b that does not overlap with the metal mask 190b can be removed.
- the EL layer 113b, the counter electrode 114b, and the protective layer 115b can be formed in an island shape so as to overlap the pixel electrode 111b (FIG. 8D).
- the EL layer 113b, the counter electrode 114b, and the protective layer 115b can be processed by the same method as the EL layer 113a, the counter electrode 114a, and the protective layer 115a, respectively.
- the EL layer 113b, the counter electrode 114b, and the protective layer 115b at least a region that overlaps with the pixel electrode 111a without the insulating layer 121 and a region that overlaps with the pixel electrode 111c without the insulating layer 121 are removed.
- the region of the EL layer 113b, the counter electrode 114b, and the protective layer 115b that overlaps with the pixel electrode 111a or the pixel electrode 111c via the insulating layer 121 may remain without being removed.
- the protective layer 115a on the EL layer 113a and the counter electrode 114a, it is possible to prevent the EL layer 113a and the counter electrode 114a from being damaged when the EL layer 113b or the like is processed. Can be done. This makes it possible to increase the reliability of the light emitting device.
- the EL layer 113c is formed on the protective layers 115a and 115b, the pixel electrodes 111c, and the insulating layer 121.
- the counter electrode 114c is formed on the EL layer 113c. Further, it is preferable to form the protective layer 115c on the counter electrode 114c.
- the EL layer 113c can be formed into a film by the same method as the EL layer 113a.
- the counter electrode 114c can be formed into a film by the same method as that of the counter electrode 114a.
- the protective layer 115c can be formed into a film by the same method as that of the protective layer 115a.
- the metal mask 190c is placed on the protective layer 115c.
- the metal mask 190c has an opening at a position where it overlaps with the pixel electrode 111a and the pixel electrode 111b.
- the metal mask 190c overlaps with the pixel electrode 111c.
- the metal mask 190c using the metal mask 190c, at least a part of the region overlapping the pixel electrode 111a and the region overlapping the pixel electrode 111b in the EL layer 113c, the counter electrode 114c, and the protective layer 115c. Remove at least part of.
- the region of the EL layer 113c, the counter electrode 114c, and the protective layer 115c that does not overlap with the metal mask 190c can be removed.
- the EL layer 113c, the counter electrode 114c, and the protective layer 115c can be formed in an island shape so as to overlap the pixel electrode 111c (FIG. 9D).
- the EL layer 113c, the counter electrode 114c, and the protective layer 115c can be processed by the same method as the EL layer 113a, the counter electrode 114a, and the protective layer 115a, respectively.
- the EL layer 113c, the counter electrode 114c, and the protective layer 115c at least a region that overlaps with the pixel electrode 111a without the insulating layer 121 and a region that overlaps with the pixel electrode 111b without the insulating layer 121 are removed.
- the region of the EL layer 113c, the counter electrode 114c, and the protective layer 115c that overlaps with the pixel electrode 111a or the pixel electrode 111b via the insulating layer 121 may remain without being removed.
- the protective layer 115a on the EL layer 113a and the counter electrode 114a it is possible to prevent the EL layer 113a and the counter electrode 114a from being damaged when the EL layer 113c or the like is processed. Can be done.
- the protective layer 115b on the EL layer 113b and the counter electrode 114b it is possible to prevent the EL layer 113b and the counter electrode 114b from being damaged when the EL layer 113c or the like is processed. Can be done.
- the laminated structure shown in FIG. 9D is the same as the laminated structure shown in FIG. 4D. Therefore, after that, the steps shown in FIGS. 5A to 5D described above can be sequentially performed. A description of these steps can be found in the description above.
- the layer constituting the light emitting device 130a and the layer constituting the light emitting device 130b may not overlap each other.
- the layer constituting the light emitting device 130b and the layer constituting the light emitting device 130c do not overlap each other.
- the step using the photolithography method shown in FIGS. 5A to 5C can be omitted.
- the configuration shown in FIG. 6A may be obtained by performing a process using a photolithography method (that is, at the stage of FIG. 5C).
- the protective layer 116 is then formed on the protective layers 115a, 115b, 115c and the insulating layer 121, as shown in FIG. 6B.
- At least one of an EL layer 113c, a counter electrode 114c, and a protective layer 115c may be provided on the light emitting device 130a and the light emitting device 130b. be. Therefore, as shown in FIG. 9A, after forming the protective layer 115c, a step using the photolithography method shown in FIG. 5A may be performed.
- Example 2 of the manufacturing method of the display device the EL layer is processed after being formed on one surface without using the film forming method using a metal mask, so that the island-shaped EL layer is uniform. It can be formed by thickness.
- the number of steps using the photolithography method can be reduced to one. Alternatively, it is not necessary to perform the process using the photolithography method. Therefore, the manufacturing cost of the display device can be reduced.
- each EL layer 113a, 113b, and 113c constituting the light emitting device of each color are formed in different steps. Therefore, each EL layer can be manufactured with a configuration (material, film thickness, etc.) suitable for a light emitting device of each color. This makes it possible to manufacture a light emitting device having good characteristics.
- the display device of the present embodiment can be manufactured by a method that reduces the number of steps using the photolithography method without forming an EL layer using a metal mask, the size of the display device can be increased, the resolution can be increased, or the display device can be manufactured. , High definition can be realized.
- the display device of the present embodiment can be a high-resolution display device or a large-scale display device. Therefore, the display device of the present embodiment includes a relatively large screen such as a television device, a desktop or notebook personal computer, a monitor for a computer, a digital signage, and a large game machine such as a pachinko machine. In addition to electronic devices, it can be used as a display unit for digital cameras, digital video cameras, digital photo frames, mobile phones, portable game machines, mobile information terminals, and sound reproduction devices.
- Display device 100A 10A shows a perspective view of the display device 100A, and FIG. 11A shows a cross-sectional view of the display device 100A.
- the display device 100A has a configuration in which the substrate 152 and the substrate 151 are bonded together.
- the substrate 152 is clearly indicated by a broken line.
- the display device 100A includes a display unit 162, a circuit 164, wiring 165, and the like.
- FIG. 10 shows an example in which IC173 and FPC172 are mounted on the display device 100A. Therefore, the configuration shown in FIG. 10 can be said to be a display module having a display device 100A, an IC (integrated circuit), and an FPC.
- a scanning line drive circuit can be used.
- the wiring 165 has a function of supplying signals and electric power to the display unit 162 and the circuit 164.
- the signal and power are input to the wiring 165 from the outside via the FPC 172, or are input to the wiring 165 from the IC 173.
- FIG. 10 shows an example in which the IC 173 is provided on the substrate 151 by a COG (Chip On Glass) method, a COF (Chip on Film) method, or the like.
- a COG Chip On Glass
- COF Chip on Film
- an IC having, for example, a scanning line drive circuit or a signal line drive circuit can be applied.
- the display device 100A and the display module may be configured without an IC. Further, the IC may be mounted on the FPC by the COF method or the like.
- FIG. 11A shows an example of a cross section of the display device 100A when a part of the region including the FPC 172, a part of the circuit 164, a part of the display unit 162, and a part of the region including the end are cut. show.
- the display device 100A shown in FIG. 11A has a transistor 201, a transistor 205, a light emitting device 130a that emits red light, a light emitting device 130b that emits green light, and a light emitting device that emits blue light between the substrate 151 and the substrate 152. It has a device 130c and the like.
- the three sub-pixels include three sub-pixels of R, G, and B, and yellow (Y). , Cyan (C), and magenta (M) three-color sub-pixels and the like.
- the four sub-pixels include four-color sub-pixels of R, G, B, and white (W), and four-color sub-pixels of R, G, B, and Y. Be done.
- the protective layer 116 and the substrate 152 are adhered to each other via the adhesive layer 142.
- a solid sealing structure, a hollow sealing structure, or the like can be applied to the sealing of the light emitting device.
- the space 143 surrounded by the substrate 152, the adhesive layer 142, and the substrate 151 is filled with an inert gas (such as nitrogen or argon), and a hollow sealing structure is applied.
- the adhesive layer 142 may be provided so as to overlap with the light emitting device.
- the space 143 surrounded by the substrate 152, the adhesive layer 142, and the substrate 151 may be filled with a resin different from that of the adhesive layer 142.
- the light emitting devices 130a, 130b, and 130c each have the same structure as the laminated structure shown in FIG. 6A, except that the optical adjustment layer is provided between the pixel electrode and the EL layer.
- the light emitting device 130a has an optical adjustment layer 126a
- the light emitting device 130b has an optical adjustment layer 126b
- the light emitting device 130c has an optical adjustment layer 126c.
- the details of the light emitting device can be referred to the first embodiment.
- protective layers 115a, 115b, 115c are provided on the light emitting devices 130a, 130b, and 130c, respectively.
- the pixel electrodes 111a, 111b, and 111c are each connected to the conductive layer 222b of the transistor 205 via an opening provided in the insulating layer 214.
- the edges of the pixel electrodes and the optical adjustment layer are covered with an insulating layer 121.
- the pixel electrode contains a material that reflects visible light
- the counter electrode contains a material that transmits visible light.
- the light emitted by the light emitting device is emitted to the substrate 152 side. It is preferable to use a material having high transparency to visible light for the substrate 152.
- Both the transistor 201 and the transistor 205 are formed on the substrate 151. These transistors can be manufactured by the same material and the same process.
- An insulating layer 211, an insulating layer 213, an insulating layer 215, and an insulating layer 214 are provided on the substrate 151 in this order.
- a part of the insulating layer 211 functions as a gate insulating layer of each transistor.
- a part of the insulating layer 213 functions as a gate insulating layer of each transistor.
- the insulating layer 215 is provided so as to cover the transistor.
- the insulating layer 214 is provided so as to cover the transistor and has a function as a flattening layer.
- the number of gate insulating layers and the number of insulating layers covering the transistors are not limited, and may be a single layer or two or more layers, respectively.
- the insulating layer can function as a barrier layer.
- an inorganic insulating film as the insulating layer 211, the insulating layer 213, and the insulating layer 215, respectively.
- an inorganic insulating film for example, a silicon nitride film, a silicon nitride film, a silicon oxide film, a silicon nitride film, an aluminum oxide film, an aluminum nitride film, or the like can be used.
- a hafnium oxide film, an yttrium oxide film, a zirconium oxide film, a gallium oxide film, a tantalum oxide film, a magnesium oxide film, a lanthanum oxide film, a cerium oxide film, a neodymium oxide film and the like may be used. Further, two or more of the above-mentioned insulating films may be laminated and used.
- the organic insulating film often has a lower barrier property than the inorganic insulating film. Therefore, the organic insulating film preferably has an opening near the end of the display device 100A. As a result, it is possible to prevent impurities from entering from the end of the display device 100A via the organic insulating film.
- the organic insulating film may be formed so that the end portion of the organic insulating film is inside the end portion of the display device 100A so that the organic insulating film is not exposed at the end portion of the display device 100A.
- An organic insulating film is suitable for the insulating layer 214 that functions as a flattening layer.
- the material that can be used for the organic insulating film include acrylic resin, polyimide resin, epoxy resin, polyamide resin, polyimideamide resin, siloxane resin, benzocyclobutene resin, phenol resin, and precursors of these resins. ..
- an opening is formed in the insulating layer 214.
- an organic insulating film is used for the insulating layer 214, it is possible to prevent impurities from entering the display unit 162 from the outside via the insulating layer 214. Therefore, the reliability of the display device 100A can be improved.
- the transistor 201 and the transistor 205 are a conductive layer 221 that functions as a gate, an insulating layer 211 that functions as a gate insulating layer, a conductive layer 222a and a conductive layer 222b that function as a source and a drain, a semiconductor layer 231 and an insulation that functions as a gate insulating layer. It has a layer 213 and a conductive layer 223 that functions as a gate.
- the same hatching pattern is attached to a plurality of layers obtained by processing the same conductive film.
- the insulating layer 211 is located between the conductive layer 221 and the semiconductor layer 231.
- the insulating layer 213 is located between the conductive layer 223 and the semiconductor layer 231.
- the structure of the transistor included in the display device of this embodiment is not particularly limited.
- a planar type transistor, a stagger type transistor, an inverted stagger type transistor and the like can be used.
- a top gate type or a bottom gate type transistor structure may be used.
- gates may be provided above and below the semiconductor layer on which the channel is formed.
- a configuration in which a semiconductor layer on which a channel is formed is sandwiched between two gates is applied to the transistor 201 and the transistor 205.
- Transistors may be driven by connecting two gates and supplying them with the same signal.
- the threshold voltage of the transistor may be controlled by giving a potential for controlling the threshold voltage to one of the two gates and giving a potential for driving to the other.
- the crystallinity of the semiconductor material used for the transistor is also not particularly limited, and is an amorphous semiconductor, a single crystal semiconductor, or a semiconductor having a crystalline property other than a single crystal (microcrystalline semiconductor, polycrystalline semiconductor, or a partially crystalline region. Any of the semiconductors) may be used. It is preferable to use a single crystal semiconductor or a semiconductor having crystallinity because deterioration of transistor characteristics can be suppressed.
- the semiconductor layer of the transistor preferably has a metal oxide (also referred to as an oxide semiconductor). That is, it is preferable that the display device of the present embodiment uses a transistor (hereinafter, OS transistor) in which a metal oxide is used in the channel forming region.
- OS transistor a transistor
- the semiconductor layer of the transistor may have silicon. Examples of silicon include amorphous silicon and crystalline silicon (low temperature polysilicon, single crystal silicon, etc.).
- the semiconductor layers include, for example, indium and M (M is gallium, aluminum, silicon, boron, ittrium, tin, copper, vanadium, berylium, titanium, iron, nickel, germanium, zirconium, molybdenum, lantern, cerium, neodymium, etc. It is preferred to have one or more selected from hafnium, tantalum, tungsten, and magnesium) and zinc.
- M is preferably one or more selected from aluminum, gallium, yttrium, and tin.
- an oxide containing indium (In), gallium (Ga), and zinc (Zn) also referred to as IGZO
- IGZO oxide containing indium (In), gallium (Ga), and zinc (Zn)
- the atomic number ratio of In in the In—M—Zn oxide is preferably equal to or higher than the atomic number ratio of M.
- the transistor included in the circuit 164 and the transistor included in the display unit 162 may have the same structure or different structures.
- the structures of the plurality of transistors included in the circuit 164 may all be the same, or may have two or more types.
- the structures of the plurality of transistors included in the display unit 162 may all be the same, or may have two or more types.
- connection portion 204 is provided in a region of the substrate 151 where the substrates 152 do not overlap.
- the wiring 165 is electrically connected to the FPC 172 via the conductive layer 166 and the connection layer 242.
- the conductive layer 166 shows an example of a laminated structure of a conductive film obtained by processing the same conductive film as the pixel electrode and a conductive film obtained by processing the same conductive film as the optical adjustment layer. ..
- the conductive layer 166 is exposed on the upper surface of the connecting portion 204. As a result, the connection portion 204 and the FPC 172 can be electrically connected via the connection layer 242.
- a light-shielding layer 117 on the surface of the substrate 152 on the substrate 151 side.
- various optical members can be arranged on the outside of the substrate 152.
- the optical member include a polarizing plate, a retardation plate, a light diffusing layer (diffusing film, etc.), an antireflection layer, a light collecting film, and the like.
- an antistatic film for suppressing the adhesion of dust, a water-repellent film for preventing the adhesion of dirt, a hard coat film for suppressing the occurrence of scratches due to use, a shock absorbing layer, etc. are arranged on the outside of the substrate 152. You may.
- the protective layer 116 that covers the light emitting device, it is possible to suppress the entry of impurities such as water into the light emitting device and improve the reliability of the light emitting device.
- the insulating layer 215 and the protective layer 116 are in contact with each other through the opening of the insulating layer 214.
- the inorganic insulating film of the insulating layer 215 and the inorganic insulating film of the protective layer 116 are in contact with each other.
- FIG. 11B shows an example in which the protective layer 116 has a three-layer structure.
- the protective layer 116 has an inorganic insulating layer 116a on the light emitting device 130c, an organic insulating layer 116b on the inorganic insulating layer 116a, and an inorganic insulating layer 116c on the organic insulating layer 116b.
- the end portion of the inorganic insulating layer 116a and the end portion of the inorganic insulating layer 116c extend outward from the end portion of the organic insulating layer 116b and are in contact with each other. Then, the inorganic insulating layer 116a is in contact with the insulating layer 215 (inorganic insulating layer) through the opening of the insulating layer 214 (organic insulating layer). As a result, the light emitting device can be surrounded by the insulating layer 215 and the protective layer 116, so that the reliability of the light emitting device can be improved.
- the protective layer 116 may have a laminated structure of an organic insulating film and an inorganic insulating film. At this time, it is preferable to extend the end portion of the inorganic insulating film to the outside rather than the end portion of the organic insulating film.
- Glass, quartz, ceramic, sapphire, resin, metal, alloy, semiconductor and the like can be used for the substrate 151 and the substrate 152, respectively.
- a material that transmits the light is used for the substrate on the side that extracts the light from the light emitting device.
- a flexible material is used for the substrate 151 and the substrate 152, the flexibility of the display device can be increased.
- a polarizing plate may be used as the substrate 151 or the substrate 152.
- the substrate 151 and the substrate 152 include polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), polyacrylonitrile resin, acrylic resin, polyimide resin, polymethylmethacrylate resin, polycarbonate (PC) resin, and polyether, respectively.
- Sulphonic (PES) resin, polyamide resin (nylon, aramid, etc.), polysiloxane resin, cycloolefin resin, polystyrene resin, polyamideimide resin, polyurethane resin, polyvinyl chloride resin, polyvinylidene chloride resin, polypropylene resin, polytetrafluoroethylene (PTFE) resin, ABS resin, cellulose nanofibers and the like can be used. Glass having a thickness sufficient to have flexibility may be used for one or both of the substrate 151 and the substrate 152.
- a substrate having high optical isotropic properties has a small birefringence (it can be said that the amount of birefringence is small).
- the absolute value of the retardation (phase difference) value of the substrate having high optical isotropic property is preferably 30 nm or less, more preferably 20 nm or less, still more preferably 10 nm or less.
- the film having high optical isotropic properties examples include a triacetyl cellulose (TAC, also referred to as cellulose triacetate) film, a cycloolefin polymer (COP) film, a cycloolefin copolymer (COC) film, and an acrylic film.
- TAC triacetyl cellulose
- COP cycloolefin polymer
- COC cycloolefin copolymer
- a film having a low water absorption rate as the substrate.
- a film having a water absorption rate of 1% or less more preferably a film having a water absorption rate of 0.1% or less, and further preferably using a film having a water absorption rate of 0.01% or less.
- various curable adhesives such as a photocurable adhesive such as an ultraviolet curable type, a reaction curable adhesive, a thermosetting adhesive, and an anaerobic adhesive can be used.
- these adhesives include epoxy resin, acrylic resin, silicone resin, phenol resin, polyimide resin, imide resin, PVC (polyvinyl chloride) resin, PVB (polyvinyl butyral) resin, EVA (ethylene vinyl acetate) resin and the like.
- a material having low moisture permeability such as an epoxy resin is preferable.
- a two-component mixed type resin may be used.
- an adhesive sheet or the like may be used.
- connection layer 242 an anisotropic conductive film (ACF: Anisotropic Conducive Film), an anisotropic conductive paste (ACP: Anisotropic Connective Paste), or the like can be used.
- ACF Anisotropic Conducive Film
- ACP Anisotropic Connective Paste
- Materials that can be used for conductive layers such as gates, sources and drains of transistors, as well as various wiring and electrodes that make up display devices include aluminum, titanium, chromium, nickel, copper, ittrium, zirconium, molybdenum, and silver. Examples thereof include metals such as tantalum and tungsten, and alloys containing the metal as a main component. A film containing these materials can be used as a single layer or as a laminated structure.
- a conductive oxide such as indium oxide, indium tin oxide, indium zinc oxide, zinc oxide, zinc oxide containing gallium, or graphene can be used.
- a metal material such as gold, silver, platinum, magnesium, nickel, tungsten, chromium, molybdenum, iron, cobalt, copper, palladium, and titanium, or an alloy material containing the metal material can be used.
- a nitride of the metal material for example, titanium nitride
- the laminated film of the above material can be used as the conductive layer.
- a laminated film of an alloy of silver and magnesium and an indium tin oxide because the conductivity can be enhanced.
- These can also be used for a conductive layer such as various wirings and electrodes constituting a display device, and a conductive layer (a conductive layer that functions as a pixel electrode or a common electrode) of a light emitting device.
- Examples of the insulating material that can be used for each insulating layer include resins such as acrylic resin and epoxy resin, and inorganic insulating materials such as silicon oxide, silicon oxide, silicon nitride oxide, silicon nitride, and aluminum oxide.
- FIG. 12A shows a cross-sectional view of the display device 100B.
- the perspective view of the display device 100B is the same as that of the display device 100A (FIG. 10).
- FIG. 12A shows an example of a cross section of the display device 100B when a part of the region including the FPC 172, a part of the circuit 164, and a part of the display unit 162 are cut.
- FIG. 12A shows an example of a cross section of the display unit 162 when a region including a light emitting device 130b that emits green light and a light emitting device 130c that emits blue light is cut.
- the description of the same part as that of the display device 100A may be omitted.
- the display device 100B shown in FIG. 12A has a transistor 202, a transistor 210, a light emitting device 130b, a light emitting device 130c, and the like between the substrate 153 and the substrate 154.
- the substrate 154 and the protective layer 116 are adhered to each other via the adhesive layer 142.
- the adhesive layer 142 is provided on top of each of the light emitting device 130b and the light emitting device 130c, and a solid-state sealing structure is applied to the display device 100B.
- the substrate 153 and the insulating layer 212 are bonded to each other by an adhesive layer 155.
- a manufacturing substrate provided with an insulating layer 212, each transistor, each light emitting device, and the like and a substrate 154 provided with a light-shielding layer 117 are bonded together by an adhesive layer 142. Then, by peeling off the production substrate and attaching the substrate 153 to the exposed surface, each component formed on the production substrate is transposed to the substrate 153. It is preferable that the substrate 153 and the substrate 154 each have flexibility. Thereby, the flexibility of the display device 100B can be increased.
- an inorganic insulating film that can be used for the insulating layer 211, the insulating layer 213, and the insulating layer 215 can be used, respectively.
- the light emitting devices 130b and 130c each have the same structure as the laminated structure shown in FIG. 6A.
- the pixel electrode is connected to the conductive layer 222b of the transistor 210 through an opening provided in the insulating layer 214.
- the conductive layer 222b is connected to the low resistance region 231n via the openings provided in the insulating layer 215 and the insulating layer 225.
- the transistor 210 has a function of controlling the drive of the light emitting device.
- the end of the pixel electrode is covered with an insulating layer 121.
- the light emitted by the light emitting devices 130b and 130c is emitted to the substrate 154 side. It is preferable to use a material having high transparency to visible light for the substrate 154.
- connection portion 204 is provided in a region of the substrate 153 where the substrates 154 do not overlap.
- the wiring 165 is electrically connected to the FPC 172 via the conductive layer 166 and the connection layer 242.
- the conductive layer 166 can be obtained by processing the same conductive film as the pixel electrode. As a result, the connection portion 204 and the FPC 172 can be electrically connected via the connection layer 242.
- the transistor 202 and the transistor 210 include one of a conductive layer 221 functioning as a gate, an insulating layer 211 functioning as a gate insulating layer, a semiconductor layer having a channel forming region 231i and a pair of low resistance regions 231n, and a pair of low resistance regions 231n.
- the insulating layer 211 is located between the conductive layer 221 and the channel forming region 231i.
- the insulating layer 225 is located between the conductive layer 223 and the channel forming region 231i.
- the conductive layer 222a and the conductive layer 222b are each connected to the low resistance region 231n via an opening provided in the insulating layer 215.
- the conductive layer 222a and the conductive layer 222b one functions as a source and the other functions as a drain.
- FIG. 12A shows an example in which the insulating layer 225 covers the upper surface and the side surface of the semiconductor layer.
- the conductive layer 222a and the conductive layer 222b are connected to the low resistance region 231n via openings provided in the insulating layer 225 and the insulating layer 215, respectively.
- the insulating layer 225 overlaps with the channel forming region 231i of the semiconductor layer 231 and does not overlap with the low resistance region 231n.
- the structure shown in FIG. 12B can be produced by processing the insulating layer 225 using the conductive layer 223 as a mask.
- the insulating layer 215 is provided so as to cover the insulating layer 225 and the conductive layer 223, and the conductive layer 222a and the conductive layer 222b are connected to the low resistance region 231n, respectively, through the opening of the insulating layer 215.
- an insulating layer 218 may be provided to cover the transistor.
- the display device of the present embodiment can be a high-definition display device. Therefore, the display device of the present embodiment is attached to the head, for example, an information terminal (wearable device) such as a wristwatch type or a bracelet type, a device for VR such as a head-mounted display, a device for glasses type AR, and the like. It can be used as a display unit of a wearable device that can be worn.
- an information terminal wearable device
- VR such as a head-mounted display
- AR head-mounted display
- the display device of the present embodiment is attached to the head, for example, an information terminal (wearable device) such as a wristwatch type or a bracelet type, a device for VR such as a head-mounted display, a device for glasses type AR, and the like. It can be used as a display unit of a wearable device that can be worn.
- FIG. 13A shows a perspective view of the display module 280.
- the display module 280 includes a display device 100C and an FPC 290.
- the display device included in the display module 280 is not limited to the display device 100C, and may be the display device 100D or the display device 100E described later.
- the display module 280 has a substrate 291 and a substrate 292.
- the display module 280 has a display unit 281.
- the display unit 281 is an area for displaying an image in the display module 280, and is an area where light from each pixel provided in the pixel unit 284, which will be described later, can be visually recognized.
- FIG. 13B shows a perspective view schematically showing the configuration on the substrate 291 side.
- a circuit unit 282, a pixel circuit unit 283 on the circuit unit 282, and a pixel unit 284 on the pixel circuit unit 283 are laminated on the substrate 291.
- a terminal portion 285 for connecting to the FPC 290 is provided in a portion of the substrate 291 that does not overlap with the pixel portion 284.
- the terminal portion 285 and the circuit portion 282 are electrically connected by a wiring portion 286 composed of a plurality of wirings.
- the pixel unit 284 has a plurality of pixels 284a that are periodically arranged. An enlarged view of one pixel 284a is shown on the right side of FIG. 13B. Pixels 284a have light emitting devices 130a, 130b, 130c having different emission colors. The plurality of light emitting devices may be arranged in a delta arrangement as shown in FIG. 13B. Since the delta array can arrange the pixel circuits at high density, it is possible to provide a high-definition display device. Further, various arrangement methods such as a stripe arrangement and a pentile arrangement can be applied.
- the pixel circuit unit 283 has a plurality of pixel circuits 283a arranged periodically.
- One pixel circuit 283a is a circuit that controls light emission of three light emitting devices included in one pixel 284a.
- One pixel circuit 283a may be configured to be provided with three circuits for controlling light emission of one light emitting device.
- the pixel circuit 283a may have at least one selection transistor, one current control transistor (driving transistor), and a capacitive element for one light emitting device. At this time, a gate signal is input to the gate of the selection transistor, and a source signal is input to either the source or the drain. As a result, an active matrix type display device is realized.
- the circuit unit 282 has a circuit for driving each pixel circuit 283a of the pixel circuit unit 283.
- a gate line drive circuit and a source line drive circuit.
- it may have at least one of an arithmetic circuit, a memory circuit, a power supply circuit, and the like.
- the FPC 290 functions as wiring for supplying a video signal, a power supply potential, or the like to the circuit unit 282 from the outside. Further, the IC may be mounted on the FPC 290.
- the aperture ratio (effective display area ratio) of the display unit 281 is provided.
- the aperture ratio of the display unit 281 can be 40% or more and less than 100%, preferably 50% or more and 95% or less, and more preferably 60% or more and 95% or less.
- the pixels 284a can be arranged at an extremely high density, and the definition of the display unit 281 can be extremely high.
- pixels 284a may be arranged with a definition of 2000 ppi or more, preferably 3000 ppi or more, more preferably 5000 ppi or more, further preferably 6000 ppi or more, and 20000 ppi or less, or 30,000 ppi or less. preferable.
- a display module 280 Since such a display module 280 has extremely high definition, it can be suitably used for a device for VR such as a head-mounted display or a device for glasses-type AR. For example, even in the case of a configuration in which the display unit of the display module 280 is visually recognized through a lens, since the display module 280 has an extremely high-definition display unit 281, the pixels are not visually recognized even if the display unit is enlarged by the lens. , A highly immersive display can be performed. Further, the display module 280 is not limited to this, and can be suitably used for an electronic device having a relatively small display unit. For example, it can be suitably used for a display unit of a wearable electronic device such as a wristwatch.
- Display device 100C The display device 100C shown in FIG. 14 includes a substrate 301, light emitting devices 130a, 130b, 130c, a capacitance 240, and a transistor 310.
- the substrate 301 corresponds to the substrate 291 in FIGS. 13A and 13B.
- the laminated structure from the substrate 301 to the insulating layer 255 corresponds to the layer 101 including the transistor in the first embodiment.
- the transistor 310 is a transistor having a channel forming region on the substrate 301.
- a semiconductor substrate such as a single crystal silicon substrate can be used.
- the transistor 310 has a part of the substrate 301, a conductive layer 311, a low resistance region 312, an insulating layer 313, and an insulating layer 314.
- the conductive layer 311 functions as a gate electrode.
- the insulating layer 313 is located between the substrate 301 and the conductive layer 311 and functions as a gate insulating layer.
- the low resistance region 312 is a region where the substrate 301 is doped with impurities and functions as either a source or a drain.
- the insulating layer 314 is provided so as to cover the side surface of the conductive layer 311 and functions as an insulating layer.
- an element separation layer 315 is provided between two adjacent transistors 310 so as to be embedded in the substrate 301.
- an insulating layer 261 is provided so as to cover the transistor 310, and a capacity 240 is provided on the insulating layer 261.
- the capacity 240 has a conductive layer 241 and a conductive layer 245, and an insulating layer 243 located between them.
- the conductive layer 241 functions as one electrode of the capacity 240
- the conductive layer 245 functions as the other electrode of the capacity 240
- the insulating layer 243 functions as a dielectric of the capacity 240.
- the conductive layer 241 is provided on the insulating layer 261 and is embedded in the insulating layer 254.
- the conductive layer 241 is electrically connected to either the source or the drain of the transistor 310 by a plug 271 embedded in the insulating layer 261.
- the insulating layer 243 is provided so as to cover the conductive layer 241.
- the conductive layer 245 is provided in a region overlapping the conductive layer 241 via the insulating layer 243.
- An insulating layer 255 is provided so as to cover the capacity 240, and light emitting devices 130a, 130b, 130c and the like are provided on the insulating layer 255.
- the light emitting devices 130a, 130b, 130c have the same structure as the laminated structure shown in FIG. 6A.
- protective layers 115a, 115b, 115c are provided on the light emitting devices 130a, 130b, and 130c, respectively.
- a protective layer 116 is provided on the protective layers 115a, 115b, and 115c, and a substrate 120 is bonded to the protective layer 116 by a resin layer 119.
- the substrate 120 corresponds to the substrate 292 in FIG. 13A.
- the pixel electrodes of the light emitting device are electrically connected to one of the source or drain of the transistor 310 by the plug 256 embedded in the insulating layer 255, the conductive layer 241 embedded in the insulating layer 254, and the plug 271 embedded in the insulating layer 261. Is connected.
- Display device 100D The display device 100D shown in FIG. 15 is mainly different from the display device 100C in that the transistor configuration is different. The description of the same part as that of the display device 100C may be omitted.
- the transistor 320 is a transistor in which a metal oxide (also referred to as an oxide semiconductor) is applied to a semiconductor layer on which a channel is formed.
- a metal oxide also referred to as an oxide semiconductor
- the transistor 320 has a semiconductor layer 321, an insulating layer 323, a conductive layer 324, a pair of conductive layers 325, an insulating layer 326, and a conductive layer 327.
- the substrate 331 corresponds to the substrate 291 in FIGS. 13A and 13B.
- the laminated structure from the substrate 331 to the insulating layer 255 corresponds to the layer 101 including the transistor in the first embodiment.
- An insulating layer 332 is provided on the substrate 331.
- the insulating layer 332 functions as a barrier layer that prevents impurities such as water or hydrogen from diffusing from the substrate 331 to the transistor 320 and oxygen from being desorbed from the semiconductor layer 321 to the insulating layer 332 side.
- a film such as an aluminum oxide film, a hafnium oxide film, or a silicon nitride film, in which hydrogen or oxygen is less likely to diffuse than the silicon oxide film, can be used.
- a conductive layer 327 is provided on the insulating layer 332, and an insulating layer 326 is provided so as to cover the conductive layer 327.
- the conductive layer 327 functions as a first gate electrode of the transistor 320, and a part of the insulating layer 326 functions as a first gate insulating layer. It is preferable to use an oxide insulating film such as a silicon oxide film for at least a portion of the insulating layer 326 in contact with the semiconductor layer 321.
- the upper surface of the insulating layer 326 is preferably flattened.
- the semiconductor layer 321 is provided on the insulating layer 326.
- the semiconductor layer 321 preferably has a metal oxide (also referred to as an oxide semiconductor) film having semiconductor characteristics. Details of the materials that can be suitably used for the semiconductor layer 321 will be described later.
- the pair of conductive layers 325 are provided in contact with the semiconductor layer 321 and function as a source electrode and a drain electrode.
- an insulating layer 328 is provided so as to cover the upper surface and side surfaces of the pair of conductive layers 325, the side surfaces of the semiconductor layer 321 and the like, and the insulating layer 264 is provided on the insulating layer 328.
- the insulating layer 328 functions as a barrier layer that prevents impurities such as water or hydrogen from diffusing into the semiconductor layer 321 from the insulating layer 264 and the like, and oxygen from being desorbed from the semiconductor layer 321.
- the same insulating film as the insulating layer 332 can be used as the insulating layer 332.
- the insulating layer 328 and the insulating layer 264 are provided with openings reaching the semiconductor layer 321. Inside the opening, the insulating layer 264, the insulating layer 328, the side surfaces of the conductive layer 325, the insulating layer 323 in contact with the upper surface of the semiconductor layer 321 and the conductive layer 324 are embedded.
- the conductive layer 324 functions as a second gate electrode, and the insulating layer 323 functions as a second gate insulating layer.
- the upper surface of the conductive layer 324, the upper surface of the insulating layer 323, and the upper surface of the insulating layer 264 are flattened so that their heights are substantially the same, and the insulating layer 329 and the insulating layer 265 are provided to cover them. ..
- the insulating layer 264 and the insulating layer 265 function as an interlayer insulating layer.
- the insulating layer 329 functions as a barrier layer for preventing impurities such as water and hydrogen from diffusing from the insulating layer 265 and the like to the transistor 320.
- the same insulating film as the insulating layer 328 and the insulating layer 332 can be used.
- the plug 274 that is electrically connected to one of the pair of conductive layers 325 is provided so as to be embedded in the insulating layer 265, the insulating layer 329, and the insulating layer 264.
- the plug 274 is a conductive layer 274a that covers a part of the side surface of each opening of the insulating layer 265, the insulating layer 329, the insulating layer 264, and the insulating layer 328, and a part of the upper surface of the conductive layer 325, and the conductive layer 274a. It is preferable to have a conductive layer 274b in contact with the upper surface. At this time, it is preferable to use a conductive material as the conductive layer 274a, which is difficult for hydrogen and oxygen to diffuse.
- the configuration of the insulating layer 254 to the substrate 120 in the display device 100D is the same as that of the display device 100C.
- Display device 100E The display device 100E shown in FIG. 16 has a configuration in which a transistor 310 having a channel formed on the substrate 301 and a transistor 320 containing a metal oxide are laminated on a semiconductor layer on which the channel is formed. The description of the same parts as those of the display devices 100C and 100D may be omitted.
- An insulating layer 261 is provided so as to cover the transistor 310, and a conductive layer 251 is provided on the insulating layer 261. Further, an insulating layer 262 is provided so as to cover the conductive layer 251, and a conductive layer 252 is provided on the insulating layer 262. The conductive layer 251 and the conductive layer 252 each function as wiring. Further, the insulating layer 263 and the insulating layer 332 are provided so as to cover the conductive layer 252, and the transistor 320 is provided on the insulating layer 332. Further, an insulating layer 265 is provided so as to cover the transistor 320, and a capacity 240 is provided on the insulating layer 265. The capacitance 240 and the transistor 320 are electrically connected by a plug 274.
- the transistor 320 can be used as a transistor constituting a pixel circuit. Further, the transistor 310 can be used as a transistor constituting a pixel circuit or a transistor constituting a drive circuit (gate line drive circuit, source line drive circuit) for driving the pixel circuit. Further, the transistor 310 and the transistor 320 can be used as transistors constituting various circuits such as an arithmetic circuit or a storage circuit.
- the metal oxide preferably contains at least indium or zinc. In particular, it is preferable to contain indium and zinc. In addition to them, it is preferable that aluminum, gallium, yttrium, tin and the like are contained. It may also contain one or more selected from boron, silicon, titanium, iron, nickel, germanium, zirconium, molybdenum, lanthanum, cerium, neodymium, hafnium, tantalum, tungsten, magnesium, cobalt and the like. ..
- the metal oxide can be deposited by a chemical vapor deposition (CVD) method such as a sputtering method, a metalorganic chemical vapor deposition (MOCVD) method, or an atomic layer deposition (ALD). It can be formed by the Layer Deposition) method or the like.
- CVD chemical vapor deposition
- MOCVD metalorganic chemical vapor deposition
- ALD atomic layer deposition
- the crystal structure of the oxide semiconductor includes amorphous (including compactly atomous), CAAC (c-axis-aligned crystalline), nc (nanocrystalline), CAC (crowd-aligned crystal), single crystal (single crystal), and single crystal. (Polycrystal) and the like.
- the crystal structure of the film or substrate can be evaluated using an X-ray diffraction (XRD: X-Ray Diffraction) spectrum.
- XRD X-Ray Diffraction
- it can be evaluated using the XRD spectrum obtained by GIXD (Grazing-Incidence XRD) measurement.
- GIXD Gram-Incidence XRD
- the GIXD method is also referred to as a thin film method or a Seemann-Bohlin method.
- the shape of the peak of the XRD spectrum is almost symmetrical.
- the shape of the peak of the XRD spectrum is asymmetrical.
- the asymmetrical shape of the peaks in the XRD spectrum indicates the presence of crystals in the membrane or substrate. In other words, the film or substrate cannot be said to be in an amorphous state unless the shape of the peak of the XRD spectrum is symmetrical.
- the crystal structure of the film or the substrate can be evaluated by a diffraction pattern (also referred to as a microelectron diffraction pattern) observed by a micro electron diffraction method (NBED: Nano Beam Electron Diffraction).
- a diffraction pattern also referred to as a microelectron diffraction pattern
- NBED Nano Beam Electron Diffraction
- halos are observed, and it can be confirmed that the quartz glass is in an amorphous state.
- a spot-like pattern is observed instead of a halo. Therefore, it is presumed that the IGZO film formed at room temperature is neither in a crystalline state nor in an amorphous state, is in an intermediate state, and cannot be concluded to be in an amorphous state.
- oxide semiconductors may be classified differently from the above.
- oxide semiconductors are divided into single crystal oxide semiconductors and other non-single crystal oxide semiconductors.
- the non-single crystal oxide semiconductor include the above-mentioned CAAC-OS and nc-OS.
- the non-single crystal oxide semiconductor includes a polycrystal oxide semiconductor, a pseudo-amorphous oxide semiconductor (a-like OS: atomous-like oxide semiconductor), an amorphous oxide semiconductor, and the like.
- CAAC-OS CAAC-OS
- nc-OS nc-OS
- a-like OS the details of the above-mentioned CAAC-OS, nc-OS, and a-like OS will be described.
- CAAC-OS is an oxide semiconductor having a plurality of crystal regions, the plurality of crystal regions having the c-axis oriented in a specific direction.
- the specific direction is the thickness direction of the CAAC-OS film, the normal direction of the surface to be formed of the CAAC-OS film, or the normal direction of the surface of the CAAC-OS film.
- the crystal region is a region having periodicity in the atomic arrangement. When the atomic arrangement is regarded as a lattice arrangement, the crystal region is also a region in which the lattice arrangement is aligned. Further, the CAAC-OS has a region in which a plurality of crystal regions are connected in the ab plane direction, and the region may have distortion.
- the strain refers to a region in which a plurality of crystal regions are connected in which the orientation of the lattice arrangement changes between a region in which the lattice arrangement is aligned and a region in which another grid arrangement is aligned. That is, CAAC-OS is an oxide semiconductor that is c-axis oriented and not clearly oriented in the ab plane direction.
- Each of the plurality of crystal regions is composed of one or a plurality of minute crystals (crystals having a maximum diameter of less than 10 nm).
- the maximum diameter of the crystal region is less than 10 nm.
- the size of the crystal region may be about several tens of nm.
- CAAC-OS has indium (In) and oxygen. It tends to have a layered crystal structure (also referred to as a layered structure) in which a layer (hereinafter, In layer) and a layer having elements M, zinc (Zn), and oxygen (hereinafter, (M, Zn) layer) are laminated. There is. Indium and element M can be replaced with each other. Therefore, the (M, Zn) layer may contain indium. In addition, the In layer may contain the element M. The In layer may contain Zn.
- the layered structure is observed as a lattice image in, for example, a high-resolution TEM (Transmission Electron Microscope) image.
- the position of the peak indicating the c-axis orientation may vary depending on the type and composition of the metal elements constituting CAAC-OS.
- a plurality of bright spots are observed in the electron diffraction pattern of the CAAC-OS film. Note that a certain spot and another spot are observed at point-symmetrical positions with the spot of the incident electron beam passing through the sample (also referred to as a direct spot) as the center of symmetry.
- the lattice arrangement in the crystal region is based on a hexagonal lattice, but the unit lattice is not limited to a regular hexagon and may be a non-regular hexagon. Further, in the above strain, it may have a lattice arrangement such as a pentagon or a heptagon.
- a clear grain boundary cannot be confirmed even in the vicinity of strain. That is, it can be seen that the formation of grain boundaries is suppressed by the distortion of the lattice arrangement. This is because CAAC-OS can tolerate distortion due to the fact that the arrangement of oxygen atoms is not dense in the ab plane direction and that the bond distance between atoms changes due to the substitution of metal atoms. it is conceivable that.
- CAAC-OS for which no clear crystal grain boundary is confirmed, is one of the crystalline oxides having a crystal structure suitable for the semiconductor layer of the transistor.
- a configuration having Zn is preferable.
- In-Zn oxide and In-Ga-Zn oxide are more suitable than In oxide because they can suppress the generation of grain boundaries.
- CAAC-OS is an oxide semiconductor having high crystallinity and no clear grain boundary is confirmed. Therefore, it can be said that CAAC-OS is unlikely to cause a decrease in electron mobility due to grain boundaries. Further, since the crystallinity of the oxide semiconductor may be deteriorated due to the mixing of impurities, the generation of defects, etc., CAAC-OS can be said to be an oxide semiconductor having few impurities and defects (oxygen deficiency, etc.). Therefore, the oxide semiconductor having CAAC-OS has stable physical properties. Therefore, the oxide semiconductor having CAAC-OS is resistant to heat and has high reliability. CAAC-OS is also stable against high temperatures (so-called thermal budgets) in the manufacturing process. Therefore, if CAAC-OS is used for the OS transistor, the degree of freedom in the manufacturing process can be expanded.
- nc-OS has periodicity in the atomic arrangement in a minute region (for example, a region of 1 nm or more and 10 nm or less, particularly a region of 1 nm or more and 3 nm or less).
- nc-OS has tiny crystals. Since the size of the minute crystal is, for example, 1 nm or more and 10 nm or less, particularly 1 nm or more and 3 nm or less, the minute crystal is also referred to as a nanocrystal.
- nc-OS has no regularity in crystal orientation between different nanocrystals. Therefore, no orientation is observed in the entire film.
- nc-OS may be indistinguishable from a-like OS or amorphous oxide semiconductor depending on the analysis method.
- a peak indicating crystallinity is not detected in the Out-of-plane XRD measurement using a ⁇ / 2 ⁇ scan.
- electron beam diffraction also referred to as limited field electron diffraction
- a diffraction pattern such as a halo pattern is performed. Is observed.
- electron diffraction also referred to as nanobeam electron diffraction
- an electron beam having a probe diameter for example, 1 nm or more and 30 nm or less
- An electron diffraction pattern in which a plurality of spots are observed in a ring-shaped region centered on a direct spot may be acquired.
- the a-like OS is an oxide semiconductor having a structure between nc-OS and an amorphous oxide semiconductor.
- the a-like OS has a void or low density region. That is, the a-like OS has lower crystallinity than the nc-OS and CAAC-OS.
- a-like OS has a higher hydrogen concentration in the membrane than nc-OS and CAAC-OS.
- CAC-OS relates to the material composition.
- CAC-OS is, for example, a composition of a material in which the elements constituting the metal oxide are unevenly distributed in a size of 0.5 nm or more and 10 nm or less, preferably 1 nm or more and 3 nm or less, or in the vicinity thereof.
- the metal oxide one or more metal elements are unevenly distributed, and the region having the metal element has a size of 0.5 nm or more and 10 nm or less, preferably 1 nm or more and 3 nm or less, or a size close thereto.
- the mixed state is also called a mosaic shape or a patch shape.
- the CAC-OS has a structure in which the material is separated into a first region and a second region to form a mosaic, and the first region is distributed in the film (hereinafter, also referred to as a cloud shape). It is said.). That is, the CAC-OS is a composite metal oxide having a structure in which the first region and the second region are mixed.
- the atomic number ratios of In, Ga, and Zn with respect to the metal elements constituting CAC-OS in the In-Ga-Zn oxide are expressed as [In], [Ga], and [Zn], respectively.
- the first region is a region in which [In] is larger than [In] in the composition of CAC-OS.
- the second region is a region in which [Ga] is larger than [Ga] in the composition of CAC-OS.
- the first region is a region in which [In] is larger than [In] in the second region and [Ga] is smaller than [Ga] in the second region.
- the second region is a region in which [Ga] is larger than [Ga] in the first region and [In] is smaller than [In] in the first region.
- the first region is a region containing indium oxide, indium zinc oxide, or the like as a main component.
- the second region is a region containing gallium oxide, gallium zinc oxide, or the like as a main component. That is, the first region can be rephrased as a region containing In as a main component. Further, the second region can be rephrased as a region containing Ga as a main component.
- CAC-OS in In-Ga-Zn oxide is a region containing Ga as a main component and a part of In as a main component in a material composition containing In, Ga, Zn, and O. Each of the regions is a mosaic, and these regions are randomly present. Therefore, it is presumed that CAC-OS has a structure in which metal elements are non-uniformly distributed.
- the CAC-OS can be formed by a sputtering method, for example, under the condition that the substrate is not heated.
- a sputtering method one or more selected from an inert gas (typically argon), an oxygen gas, and a nitrogen gas may be used as the film forming gas. good.
- an inert gas typically argon
- oxygen gas typically argon
- a nitrogen gas may be used as the film forming gas. good.
- the flow rate ratio of the oxygen gas to the total flow rate of the film-forming gas at the time of film formation is low. Is preferably 0% or more and 10% or less.
- EDX Energy Dispersive X-ray spectroscopy
- the first region is a region having higher conductivity as compared with the second region. That is, the carrier flows through the first region, so that the conductivity as a metal oxide is exhibited. Therefore, high field effect mobility ( ⁇ ) can be realized by distributing the first region in the metal oxide in a cloud shape.
- the second region is a region having higher insulating properties than the first region. That is, the leakage current can be suppressed by distributing the second region in the metal oxide.
- CAC-OS when used for a transistor, the conductivity caused by the first region and the insulating property caused by the second region act in a complementary manner to switch the function (On / Off). Function) can be given to CAC-OS. That is, the CAC-OS has a conductive function in a part of the material and an insulating function in a part of the material, and has a function as a semiconductor in the whole material. By separating the conductive function and the insulating function, both functions can be maximized. Therefore, by using CAC-OS for the transistor, high on -current (Ion), high field effect mobility ( ⁇ ), and good switching operation can be realized.
- Ion on -current
- ⁇ high field effect mobility
- CAC-OS is most suitable for various semiconductor devices including display devices.
- Oxide semiconductors have various structures, and each has different characteristics.
- the oxide semiconductor of one aspect of the present invention has two or more of amorphous oxide semiconductor, polycrystalline oxide semiconductor, a-like OS, CAC-OS, nc-OS, and CAAC-OS. You may.
- the oxide semiconductor as a transistor, a transistor having high field effect mobility can be realized. In addition, a highly reliable transistor can be realized.
- the carrier concentration of the oxide semiconductor is 1 ⁇ 10 17 cm -3 or less, preferably 1 ⁇ 10 15 cm -3 or less, more preferably 1 ⁇ 10 13 cm -3 or less, and more preferably 1 ⁇ 10 11 cm ⁇ . It is 3 or less, more preferably less than 1 ⁇ 10 10 cm -3 , and more preferably 1 ⁇ 10 -9 cm -3 or more.
- the impurity concentration in the oxide semiconductor film may be lowered to lower the defect level density.
- a low impurity concentration and a low defect level density is referred to as high-purity intrinsic or substantially high-purity intrinsic.
- An oxide semiconductor having a low carrier concentration may be referred to as a high-purity intrinsic or substantially high-purity intrinsic oxide semiconductor.
- the trap level density may also be low.
- the charge captured at the trap level of the oxide semiconductor takes a long time to disappear, and may behave as if it were a fixed charge. Therefore, a transistor in which a channel forming region is formed in an oxide semiconductor having a high trap level density may have unstable electrical characteristics.
- impurities include hydrogen, nitrogen, alkali metals, alkaline earth metals, iron, nickel, silicon and the like.
- the concentration of silicon or carbon in the oxide semiconductor and the concentration of silicon or carbon near the interface with the oxide semiconductor are 2 ⁇ 10 18 atoms / cm 3 or less, preferably 2 ⁇ 10 17 atoms / cm 3 or less.
- the oxide semiconductor contains an alkali metal or an alkaline earth metal
- defect levels may be formed and carriers may be generated. Therefore, a transistor using an oxide semiconductor containing an alkali metal or an alkaline earth metal tends to have a normally-on characteristic. Therefore, the concentration of the alkali metal or alkaline earth metal in the oxide semiconductor obtained by SIMS is set to 1 ⁇ 10 18 atoms / cm 3 or less, preferably 2 ⁇ 10 16 atoms / cm 3 or less.
- the nitrogen concentration in the oxide semiconductor obtained by SIMS is less than 5 ⁇ 10 19 atoms / cm 3 , preferably 5 ⁇ 10 18 atoms / cm 3 or less, and more preferably 1 ⁇ 10 18 atoms / cm 3 or less. , More preferably 5 ⁇ 10 17 atoms / cm 3 or less.
- hydrogen contained in an oxide semiconductor reacts with oxygen bonded to a metal atom to become water, which may form an oxygen deficiency.
- oxygen deficiency When hydrogen enters the oxygen deficiency, electrons that are carriers may be generated.
- a part of hydrogen may be combined with oxygen that is bonded to a metal atom to generate an electron as a carrier. Therefore, a transistor using an oxide semiconductor containing hydrogen tends to have a normally-on characteristic. Therefore, it is preferable that hydrogen in the oxide semiconductor is reduced as much as possible.
- the hydrogen concentration obtained by SIMS is less than 1 ⁇ 10 20 atoms / cm 3 , preferably less than 1 ⁇ 10 19 atoms / cm 3 , and more preferably 5 ⁇ 10 18 atoms / cm. Less than 3 , more preferably less than 1 ⁇ 10 18 atoms / cm 3 .
- the display module 6000 shown in FIG. 17A has a display device 6006, a frame 6009, a printed circuit board 6010, and a battery 6011 to which an FPC 6005 is connected between the upper cover 6001 and the lower cover 6002.
- the display device of one aspect of the present invention can be used for the display device 6006. With the display device 6006, a highly reliable display module can be realized.
- the shape and dimensions of the upper cover 6001 and the lower cover 6002 can be appropriately changed according to the size of the display device 6006.
- the display device 6006 may have a function as a touch panel.
- the display module 6000 may have a touch panel separately from the display device 6006.
- the frame 6009 may have a protective function of the display device 6006, a function of blocking electromagnetic waves generated by the operation of the printed circuit board 6010, a function of a heat sink, and the like.
- the printed circuit board 6010 includes a power supply circuit, a signal processing circuit for outputting a video signal and a clock signal, a battery control circuit, and the like.
- the power source for supplying electric power to the power supply circuit may be an external commercial power source or a power source provided by a separately provided battery 6011.
- FIG. 17B is a schematic cross-sectional view of the display module 6000 including an optical touch sensor.
- the display module 6000 has a light emitting unit 6015 and a light receiving unit 6016 provided on the printed circuit board 6010. Further, the area surrounded by the upper cover 6001 and the lower cover 6002 has a pair of light guides (light guide 6017a, light guide 6017b).
- the display device 6006 is provided so as to overlap the printed circuit board 6010 and the battery 6011 with the frame 6009 interposed therebetween.
- the display device 6006 and the frame 6009 are fixed to the light guide unit 6017a and the light guide unit 6017b.
- the light 6018 emitted from the light emitting unit 6015 passes through the upper part of the display device 6006 by the light guide unit 6017a, passes through the light guide unit 6017b, and reaches the light receiving unit 6016.
- the touch operation can be detected by blocking the light 6018 by a detected object such as a finger or a stylus.
- a plurality of light emitting units 6015 are provided, for example, along two adjacent sides of the display device 6006.
- a plurality of light receiving units 6016 are provided at positions facing the light emitting unit 6015. As a result, it is possible to acquire information on the position where the touch operation is performed.
- a light source such as an LED element can be used for the light emitting unit 6015, and it is particularly preferable to use a light source that emits infrared rays.
- a light source that emits infrared rays As the light receiving unit 6016, a photoelectric element that receives light emitted by the light emitting unit 6015 and converts it into an electric signal can be used.
- a photodiode capable of receiving infrared rays can be used.
- the light emitting unit 6015 and the light receiving unit 6016 can be arranged under the display device 6006 by the light guide unit 6017a and the light receiving unit 6017b that transmit the light 6018, and the external light reaches the light receiving unit 6016 and the touch sensor. Can be suppressed from malfunctioning. In particular, if a resin that absorbs visible light and transmits infrared rays is used for the light guide unit 6017a and the light guide unit 6017b, the malfunction of the touch sensor can be suppressed more effectively.
- the electronic device of the present embodiment has a display device of one aspect of the present invention.
- the display device according to one aspect of the present invention can be easily increased in definition, resolution, and size. Therefore, the display device of one aspect of the present invention can be used for the display unit of various electronic devices.
- the display device according to one aspect of the present invention can be manufactured at a low cost, the manufacturing cost of the electronic device can be reduced.
- Electronic devices include, for example, television devices, desktop or notebook personal computers, monitors for computers, digital signage, electronic devices with relatively large screens such as pachinko machines, and digital devices. Examples include cameras, digital video cameras, digital photo frames, mobile phones, portable game machines, mobile information terminals, sound reproduction devices, and the like.
- the display device of one aspect of the present invention can increase the definition, it can be suitably used for an electronic device having a relatively small display unit.
- Such electronic devices can be attached to the head, for example, information terminals (wearable devices) such as wristwatch type and bracelet type, VR devices such as head-mounted displays, and glasses-type AR devices. Wearable devices and the like. Further, examples of the wearable device include a device for SR and a device for MR.
- the display device of one aspect of the present invention includes HD (number of pixels 1280 ⁇ 720), FHD (number of pixels 1920 ⁇ 1080), WQHD (number of pixels 2560 ⁇ 1440), WQXGA (number of pixels 2560 ⁇ 1600), 4K2K (number of pixels). It is preferable to have an extremely high resolution such as 3840 ⁇ 2160) and 8K4K (number of pixels 7680 ⁇ 4320). In particular, it is preferable to set the resolution to 4K2K, 8K4K, or higher.
- the pixel density (definition) in the display device of one aspect of the present invention is preferably 300 ppi or more, more preferably 500 ppi or more, more preferably 1000 ppi or more, more preferably 2000 ppi or more, more preferably 3000 ppi or more, and more preferably 5000 ppi or more. Is more preferable, and 7,000 ppi or more is further preferable.
- a display device having such a high resolution or high definition it is possible to further enhance the sense of presence and depth in an electronic device for personal use such as a portable type or a home use.
- the electronic device of the present embodiment can be incorporated along the inner or outer wall of a house or building, or along the curved surface of the interior or exterior of an automobile.
- the electronic device of this embodiment may have an antenna.
- the display unit can display images, information, and the like.
- the antenna may be used for non-contact power transmission.
- the electronic device of the present embodiment is a sensor (force, displacement, position, speed, acceleration, angular speed, rotation speed, distance, light, liquid, magnetism, temperature, chemical substance, voice, time, hardness, electric field, current, voltage. , Including the ability to measure power, radiation, current flow, humidity, gradient, vibration, odor or infrared rays).
- the electronic device of this embodiment can have various functions. For example, a function to display various information (still images, moving images, text images, etc.) on the display unit, a touch panel function, a calendar, a function to display a date or time, a function to execute various software (programs), wireless communication. It can have a function, a function of reading a program or data recorded on a recording medium, and the like.
- the electronic device 6500 shown in FIG. 18A is a portable information terminal that can be used as a smartphone.
- the electronic device 6500 includes a housing 6501, a display unit 6502, a power button 6503, a button 6504, a speaker 6505, a microphone 6506, a camera 6507, a light source 6508, and the like.
- the display unit 6502 has a touch panel function.
- a display device can be applied to the display unit 6502.
- FIG. 18B is a schematic cross-sectional view including an end portion of the housing 6501 on the microphone 6506 side.
- a translucent protective member 6510 is provided on the display surface side of the housing 6501, and a display panel 6511, an optical member 6512, a touch sensor panel 6513, and a print are provided in a space surrounded by the housing 6501 and the protective member 6510.
- a substrate 6517, a battery 6518, and the like are arranged.
- a display panel 6511, an optical member 6512, and a touch sensor panel 6513 are fixed to the protective member 6510 by an adhesive layer (not shown).
- the FPC 6515 is connected to the folded back portion.
- the IC6516 is mounted on the FPC6515.
- the FPC6515 is connected to a terminal provided on the printed circuit board 6517.
- a flexible display (a flexible display device) according to an aspect of the present invention can be applied to the display panel 6511. Therefore, an extremely lightweight electronic device can be realized. Further, since the display panel 6511 is extremely thin, it is possible to mount a large-capacity battery 6518 while suppressing the thickness of the electronic device. Further, by folding back a part of the display panel 6511 and arranging the connection portion with the FPC 6515 on the back side of the pixel portion, an electronic device having a narrow frame can be realized.
- FIG. 19A shows an example of a television device.
- the display unit 7000 is incorporated in the housing 7101.
- a configuration in which the housing 7101 is supported by the stand 7103 is shown.
- a display device can be applied to the display unit 7000.
- the operation of the television device 7100 shown in FIG. 19A can be performed by the operation switch included in the housing 7101 and the separate remote control operation machine 7111.
- the display unit 7000 may be provided with a touch sensor, and the television device 7100 may be operated by touching the display unit 7000 with a finger or the like.
- the remote control operation machine 7111 may have a display unit for displaying information output from the remote control operation machine 7111.
- the channel and volume can be operated by the operation keys or the touch panel included in the remote controller 7111, and the image displayed on the display unit 7000 can be operated.
- the television device 7100 is configured to include a receiver, a modem, and the like.
- a general television broadcast can be received by the receiver.
- information communication is performed in one direction (sender to receiver) or two-way (sender and receiver, or between receivers, etc.). It is also possible.
- FIG. 19B shows an example of a notebook personal computer.
- the notebook personal computer 7200 has a housing 7211, a keyboard 7212, a pointing device 7213, an external connection port 7214, and the like.
- a display unit 7000 is incorporated in the housing 7211.
- a display device can be applied to the display unit 7000.
- 19C and 19D show an example of digital signage.
- the digital signage 7300 shown in FIG. 19C has a housing 7301, a display unit 7000, a speaker 7303, and the like. Further, it may have an LED lamp, an operation key (including a power switch or an operation switch), a connection terminal, various sensors, a microphone, and the like.
- FIG. 19D is a digital signage 7400 attached to a columnar pillar 7401.
- the digital signage 7400 has a display unit 7000 provided along the curved surface of the pillar 7401.
- the display device of one aspect of the present invention can be applied to the display unit 7000.
- the wider the display unit 7000 the more information can be provided at one time. Further, the wider the display unit 7000 is, the easier it is for people to see it, and for example, the advertising effect of the advertisement can be enhanced.
- the touch panel By applying the touch panel to the display unit 7000, not only the image or moving image can be displayed on the display unit 7000, but also the user can intuitively operate the display unit 7000, which is preferable. In addition, when used for the purpose of providing information such as route information or traffic information, usability can be improved by intuitive operation.
- the digital signage 7300 or the digital signage 7400 can be linked with the information terminal 7311 or the information terminal 7411 such as a smartphone owned by the user by wireless communication.
- the information of the advertisement displayed on the display unit 7000 can be displayed on the screen of the information terminal 7311 or the information terminal 7411. Further, by operating the information terminal 7311 or the information terminal 7411, the display of the display unit 7000 can be switched.
- the digital signage 7300 or the digital signage 7400 can be made to execute a game using the screen of the information terminal 7311 or the information terminal 7411 as an operation means (controller). As a result, an unspecified number of users can participate in and enjoy the game at the same time.
- FIG. 20A is a diagram showing the appearance of the camera 8000 with the finder 8100 attached.
- the camera 8000 has a housing 8001, a display unit 8002, an operation button 8003, a shutter button 8004, and the like.
- a detachable lens 8006 is attached to the camera 8000.
- the lens 8006 and the housing may be integrated.
- the camera 8000 can take an image by pressing the shutter button 8004 or touching the display unit 8002 that functions as a touch panel.
- the housing 8001 has a mount having electrodes, and can be connected to a finder 8100, a strobe device, or the like.
- the finder 8100 has a housing 8101, a display unit 8102, a button 8103, and the like.
- the housing 8101 is attached to the camera 8000 by a mount that engages with the mount of the camera 8000.
- the finder 8100 can display an image or the like received from the camera 8000 on the display unit 8102.
- the button 8103 has a function as a power button or the like.
- the display device of one aspect of the present invention can be applied to the display unit 8002 of the camera 8000 and the display unit 8102 of the finder 8100.
- the camera may be a camera 8000 with a built-in finder.
- FIG. 20B is a diagram showing the appearance of the head-mounted display 8200.
- the head-mounted display 8200 has a mounting unit 8201, a lens 8202, a main body 8203, a display unit 8204, a cable 8205, and the like. Further, the battery 8206 is built in the mounting portion 8201.
- the cable 8205 supplies electric power from the battery 8206 to the main body 8203.
- the main body 8203 is provided with a wireless receiver or the like, and the received video information can be displayed on the display unit 8204. Further, the main body 8203 is provided with a camera, and information on the movement of the user's eyeball or eyelid can be used as an input means.
- the mounting portion 8201 may be provided with a plurality of electrodes capable of detecting the current flowing with the movement of the user's eyeball at a position touching the user, and may have a function of recognizing the line of sight. Further, it may have a function of monitoring the pulse of the user by the current flowing through the electrode. Further, the mounting unit 8201 may have various sensors such as a temperature sensor, a pressure sensor, and an acceleration sensor, and may have a function of displaying the biometric information of the user on the display unit 8204 and the movement of the user's head. At the same time, it may have a function of changing the image displayed on the display unit 8204.
- a display device can be applied to the display unit 8204.
- the head-mounted display 8300 has a housing 8301, a display unit 8302, a band-shaped fixture 8304, and a pair of lenses 8305.
- the user can visually recognize the display of the display unit 8302 through the lens 8305. It is preferable to arrange the display unit 8302 in a curved manner because the user can feel a high sense of presence. Further, by visually recognizing another image displayed in a different area of the display unit 8302 through the lens 8305, three-dimensional display using parallax or the like can be performed.
- the configuration is not limited to the configuration in which one display unit 8302 is provided, and two display units 8302 may be provided and one display unit may be arranged for one eye of the user.
- a display device can be applied to the display unit 8302.
- the display device of one aspect of the present invention can also realize extremely high definition. For example, even when the display is magnified and visually recognized using the lens 8305 as shown in FIG. 20E, it is difficult for the user to visually recognize the pixels. That is, the display unit 8302 can be used to make the user visually recognize a highly realistic image.
- FIG. 20F is a diagram showing the appearance of a goggle-type head-mounted display 8400.
- the head-mounted display 8400 has a pair of housings 8401, a mounting portion 8402, and a cushioning member 8403.
- a display unit 8404 and a lens 8405 are provided in the pair of housings 8401, respectively. By displaying different images on the pair of display units 8404, it is possible to perform three-dimensional display using parallax.
- the user can visually recognize the display unit 8404 through the lens 8405.
- the lens 8405 has a focus adjustment mechanism, and the position can be adjusted according to the visual acuity of the user.
- the display unit 8404 is preferably a square or a horizontally long rectangle. This makes it possible to enhance the sense of presence.
- the mounting portion 8402 is preferably plastic and elastic so that it can be adjusted according to the size of the user's face and does not slip off. Further, it is preferable that a part of the mounting portion 8402 has a vibration mechanism that functions as a bone conduction earphone. As a result, you can enjoy video and audio just by wearing it without the need for separate audio equipment such as earphones and speakers.
- the housing 8401 may have a function of outputting voice data by wireless communication.
- the mounting portion 8402 and the cushioning member 8403 are portions that come into contact with the user's face (forehead, cheeks, etc.). When the cushioning member 8403 is in close contact with the user's face, light leakage can be prevented and the immersive feeling can be further enhanced. It is preferable to use a soft material for the cushioning member 8403 so that the cushioning member 8403 is in close contact with the user's face when the user wears the head-mounted display 8400. For example, materials such as rubber, silicone rubber, urethane, and sponge can be used.
- a gap is unlikely to occur between the user's face and the cushioning member 8403, and light leakage is suitably prevented. Can be done. Further, it is preferable to use such a material because it is soft to the touch and does not make the user feel cold when worn in a cold season or the like.
- the electronic devices shown in FIGS. 21A to 21F include a housing 9000, a display unit 9001, a speaker 9003, an operation key 9005 (including a power switch or an operation switch), a connection terminal 9006, and a sensor 9007 (force, displacement, position, speed). , Acceleration, angular velocity, rotation speed, distance, light, liquid, magnetism, temperature, chemical substance, voice, time, hardness, electric field, current, voltage, power, radiation, flow rate, humidity, gradient, vibration, smell or infrared ), Microphone 9008, etc.
- the electronic devices shown in FIGS. 21A to 21F have various functions. For example, a function to display various information (still images, moving images, text images, etc.) on the display unit, a touch panel function, a function to display a calendar, date or time, etc., a function to control processing by various software (programs), It can have a wireless communication function, a function of reading and processing a program or data recorded on a recording medium, and the like.
- the functions of electronic devices are not limited to these, and can have various functions.
- the electronic device may have a plurality of display units.
- the electronic device even if the electronic device is provided with a camera or the like, it has a function of shooting a still image or a moving image and saving it on a recording medium (external or built in the camera), a function of displaying the shot image on a display unit, and the like. good.
- a display device can be applied to the display unit 9001.
- FIGS. 21A to 21F The details of the electronic devices shown in FIGS. 21A to 21F will be described below.
- FIG. 21A is a perspective view showing a mobile information terminal 9101.
- the mobile information terminal 9101 can be used as, for example, a smartphone.
- the mobile information terminal 9101 may be provided with a speaker 9003, a connection terminal 9006, a sensor 9007, and the like. Further, the mobile information terminal 9101 can display character and image information on a plurality of surfaces thereof.
- FIG. 21A shows an example in which three icons 9050 are displayed. Further, the information 9051 indicated by the broken line rectangle can be displayed on the other surface of the display unit 9001.
- notification of incoming call such as e-mail, SNS (social networking service) message, notification of incoming call, e-mail, title such as SNS message and sender name, date and time, time, remaining battery level, There are radio wave strength and so on.
- an icon 9050 or the like may be displayed at the position where the information 9051 is displayed.
- FIG. 21B is a perspective view showing a mobile information terminal 9102.
- the mobile information terminal 9102 has a function of displaying information on three or more surfaces of the display unit 9001.
- information 9052, information 9053, and information 9054 are displayed on different surfaces.
- the user can check the information 9053 displayed at a position that can be observed from above the mobile information terminal 9102 with the mobile information terminal 9102 stored in the chest pocket of the clothes.
- the user can check the display without taking out the mobile information terminal 9102 from the pocket, and can determine, for example, whether or not to receive a call.
- FIG. 21C is a perspective view showing a wristwatch-type mobile information terminal 9200.
- the mobile information terminal 9200 can be used, for example, as a smart watch (registered trademark).
- the display unit 9001 is provided with a curved display surface, and can display along the curved display surface. It is also possible to make a hands-free call by communicating the mobile information terminal 9200 with, for example, a headset capable of wireless communication. Further, the mobile information terminal 9200 can also perform data transmission and charge with other information terminals by means of the connection terminal 9006. The charging operation may be performed by wireless power supply.
- 21D to 21F are perspective views showing a foldable mobile information terminal 9201.
- 21D is a perspective view of the mobile information terminal 9201 in an unfolded state
- FIG. 21F is a folded state
- FIG. 21E is a perspective view of a state in which one of FIGS. 21D and 21F is in the process of changing to the other.
- the mobile information terminal 9201 is excellent in portability in the folded state, and is excellent in the listability of the display due to the wide seamless display area in the unfolded state.
- the display unit 9001 included in the portable information terminal 9201 is supported by three housings 9000 connected by a hinge 9055.
- the display unit 9001 can be bent with a radius of curvature of 0.1 mm or more and 150 mm or less.
- 116a Inorganic insulating layer
- 116b Organic insulating layer
- 116c Inorganic insulating layer
- 117 Light-shielding layer
- 119 Resin layer
- 126a Optical adjustment layer
- 126b Optical adjustment layer
- 126c Optical adjustment layer
- 130a light emitting device
- 130b light emitting device
- 130c light emitting device
- 142 adhesive layer
- 143 space
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Abstract
Description
図2A乃至図2Dは、表示装置の作製方法の一例を示す断面図である。
図3A乃至図3Dは、表示装置の作製方法の一例を示す断面図である。
図4A乃至図4Dは、表示装置の作製方法の一例を示す断面図である。
図5A乃至図5Dは、表示装置の作製方法の一例を示す断面図である。
図6A乃至図6Cは、表示装置の作製方法の一例を示す断面図である。
図7A乃至図7Dは、表示装置の作製方法の一例を示す断面図である。
図8A乃至図8Dは、表示装置の作製方法の一例を示す断面図である。
図9A乃至図9Dは、表示装置の作製方法の一例を示す断面図である。
図10は、表示装置の一例を示す斜視図である。
図11A及び図11Bは、表示装置の一例を示す断面図である。
図12Aは、表示装置の一例を示す断面図である。図12Bは、トランジスタの一例を示す断面図である。
図13A及び図13Bは、表示モジュールの一例を示す斜視図である。
図14は、表示装置の一例を示す断面図である。
図15は、表示装置の一例を示す断面図である。
図16は、表示装置の一例を示す断面図である。
図17A及び図17Bは、電子機器の一例を示す図である。
図18A及び図18Bは、電子機器の一例を示す図である。
図19A乃至図19Dは、電子機器の一例を示す図である。
図20A乃至図20Fは、電子機器の一例を示す図である。
図21A乃至図21Fは、電子機器の一例を示す図である。
本実施の形態では、本発明の一態様の表示装置とその作製方法について図1乃至図9を用いて説明する。
図1A及び図1Bに、本発明の一態様の表示装置を示す。
次に、図2乃至図5を用いて表示装置の作製方法例を説明する。
続いて、図7乃至図9を用いて、上記とは異なる表示装置の作製方法の例を説明する。なお、作製方法例1と同様の部分については説明を省略することがある。
本実施の形態では、本発明の一態様の表示装置について図10乃至図12を用いて説明する。
図10に、表示装置100Aの斜視図を示し、図11Aに、表示装置100Aの断面図を示す。
図12Aに、表示装置100Bの断面図を示す。表示装置100Bの斜視図は表示装置100A(図10)と同様である。図12Aには、表示装置100Bの、FPC172を含む領域の一部、回路164の一部、及び、表示部162の一部をそれぞれ切断したときの断面の一例を示す。図12Aでは、表示部162のうち、特に、緑色の光を発する発光デバイス130bと青色の光を発する発光デバイス130cを含む領域を切断したときの断面の一例を示す。なお、表示装置100Aと同様の部分については説明を省略することがある。
本実施の形態では、本発明の一態様の表示装置について図13乃至図16を用いて説明する。
図13Aに、表示モジュール280の斜視図を示す。表示モジュール280は、表示装置100Cと、FPC290と、を有する。なお、表示モジュール280が有する表示装置は表示装置100Cに限られず、後述する表示装置100Dまたは表示装置100Eであってもよい。
図14に示す表示装置100Cは、基板301、発光デバイス130a、130b、130c、容量240、及び、トランジスタ310を有する。
図15に示す表示装置100Dは、トランジスタの構成が異なる点で、表示装置100Cと主に相違する。なお、表示装置100Cと同様の部分については説明を省略することがある。
図16に示す表示装置100Eは、基板301にチャネルが形成されるトランジスタ310と、チャネルが形成される半導体層に金属酸化物を含むトランジスタ320とが積層された構成を有する。なお、表示装置100C、100Dと同様の部分については説明を省略することがある。
本実施の形態では、上記の実施の形態で説明したOSトランジスタに用いることができる金属酸化物(酸化物半導体ともいう)について説明する。
酸化物半導体の結晶構造としては、アモルファス(completely amorphousを含む)、CAAC(c−axis−aligned crystalline)、nc(nanocrystalline)、CAC(cloud−aligned composite)、単結晶(single crystal)、及び多結晶(polycrystal)等が挙げられる。
なお、酸化物半導体は、構造に着目した場合、上記とは異なる分類となる場合がある。例えば、酸化物半導体は、単結晶酸化物半導体と、それ以外の非単結晶酸化物半導体と、に分けられる。非単結晶酸化物半導体としては、例えば、上述のCAAC−OS、及びnc−OSがある。また、非単結晶酸化物半導体には、多結晶酸化物半導体、擬似非晶質酸化物半導体(a−like OS:amorphous−like oxide semiconductor)、非晶質酸化物半導体、などが含まれる。
CAAC−OSは、複数の結晶領域を有し、当該複数の結晶領域はc軸が特定の方向に配向している酸化物半導体である。なお、特定の方向とは、CAAC−OS膜の厚さ方向、CAAC−OS膜の被形成面の法線方向、またはCAAC−OS膜の表面の法線方向である。また、結晶領域とは、原子配列に周期性を有する領域である。なお、原子配列を格子配列とみなすと、結晶領域とは、格子配列の揃った領域でもある。さらに、CAAC−OSは、a−b面方向において複数の結晶領域が連結する領域を有し、当該領域は歪みを有する場合がある。なお、歪みとは、複数の結晶領域が連結する領域において、格子配列の揃った領域と、別の格子配列の揃った領域と、の間で格子配列の向きが変化している箇所を指す。つまり、CAAC−OSは、c軸配向し、a−b面方向には明らかな配向をしていない酸化物半導体である。
nc−OSは、微小な領域(例えば、1nm以上10nm以下の領域、特に1nm以上3nm以下の領域)において原子配列に周期性を有する。別言すると、nc−OSは、微小な結晶を有する。なお、当該微小な結晶の大きさは、例えば、1nm以上10nm以下、特に1nm以上3nm以下であることから、当該微小な結晶をナノ結晶ともいう。また、nc−OSは、異なるナノ結晶間で結晶方位に規則性が見られない。そのため、膜全体で配向性が見られない。従って、nc−OSは、分析方法によっては、a−like OSまたは非晶質酸化物半導体と区別が付かない場合がある。例えば、nc−OS膜に対し、XRD装置を用いて構造解析を行うと、θ/2θスキャンを用いたOut−of−plane XRD測定では、結晶性を示すピークが検出されない。また、nc−OS膜に対し、ナノ結晶よりも大きいプローブ径(例えば50nm以上)の電子線を用いる電子線回折(制限視野電子線回折ともいう。)を行うと、ハローパターンのような回折パターンが観測される。一方、nc−OS膜に対し、ナノ結晶の大きさと近いかナノ結晶より小さいプローブ径(例えば1nm以上30nm以下)の電子線を用いる電子線回折(ナノビーム電子線回折ともいう。)を行うと、ダイレクトスポットを中心とするリング状の領域内に複数のスポットが観測される電子線回折パターンが取得される場合がある。
a−like OSは、nc−OSと非晶質酸化物半導体との間の構造を有する酸化物半導体である。a−like OSは、鬆または低密度領域を有する。即ち、a−like OSは、nc−OS及びCAAC−OSと比べて、結晶性が低い。また、a−like OSは、nc−OS及びCAAC−OSと比べて、膜中の水素濃度が高い。
次に、上述のCAC−OSの詳細について、説明を行う。なお、CAC−OSは材料構成に関する。
CAC−OSとは、例えば、金属酸化物を構成する元素が、0.5nm以上10nm以下、好ましくは、1nm以上3nm以下、またはその近傍のサイズで偏在した材料の一構成である。なお、以下では、金属酸化物において、一つまたは複数の金属元素が偏在し、該金属元素を有する領域が、0.5nm以上10nm以下、好ましくは、1nm以上3nm以下、またはその近傍のサイズで混合した状態をモザイク状、またはパッチ状ともいう。
続いて、上記酸化物半導体をトランジスタに用いる場合について説明する。
ここで、酸化物半導体中における各不純物の影響について説明する。
本実施の形態では、本発明の一態様の表示モジュールについて図17を用いて説明する。
本実施の形態では、本発明の一態様の電子機器について図18乃至図21を用いて説明する。
Claims (20)
- 第1の画素電極、及び、第2の画素電極を形成し、
前記第1の画素電極の端部、及び、前記第2の画素電極の端部を覆う、絶縁層を形成し、
前記第1の画素電極上、前記第2の画素電極上、及び、前記絶縁層上に、第1の層を形成し、
第1の開口を有する第1のメタルマスクを、前記第1の開口が前記第1の画素電極と重なるように、前記第1の層上に配置し、
前記第1のメタルマスクを介して成膜することで、前記第1の層を介して前記第1の画素電極と重なる、第1の対向電極を形成し、
前記第1の対向電極をハードマスクに用いて、前記第1の層における前記第2の画素電極と重なる領域の少なくとも一部を除去し、
前記第1の画素電極上、前記第2の画素電極上、及び、前記絶縁層上に、第2の層を形成し、
第2の開口を有する第2のメタルマスクを、前記第2の開口が前記第2の画素電極と重なるように、前記第2の層上に配置し、
前記第2のメタルマスクを介して成膜することで、前記第2の層を介して前記第2の画素電極と重なる、第2の対向電極を形成し、
前記第2の対向電極をハードマスクに用いて、前記第2の層における前記第1の画素電極と重なる領域の少なくとも一部を除去し、
前記第1の対向電極上、及び、前記第2の対向電極上に、前記絶縁層と重なる位置に開口を有するレジストマスクを形成し、
前記レジストマスクを用いて、前記第1の層、前記第2の層、前記第1の対向電極、及び、前記第2の対向電極の少なくとも一つにおける、前記絶縁層と重なる領域の少なくとも一部を除去することで、前記絶縁層の一部を露出させ、
前記第1の対向電極、前記第2の対向電極、及び、前記絶縁層を覆うように、第1の保護層を形成する、表示装置の作製方法。 - 請求項1において、
前記第1の対向電極を形成する前に、前記第1のメタルマスクを介して成膜することで、前記第1の層を介して前記第1の画素電極と重なる、第2の保護層を形成し、
前記第2の対向電極を形成する前に、前記第2のメタルマスクを介して成膜することで、前記第2の層を介して前記第2の画素電極と重なる、第3の保護層を形成する、表示装置の作製方法。 - 請求項2において、
前記第2の保護層の厚さと前記第3の保護層の厚さは互いに異なる、表示装置の作製方法。 - 請求項2または3において、
前記第2の保護層及び前記第3の保護層として、それぞれ、インジウム、ガリウム、及び亜鉛を含む金属酸化物層、及び、インジウム及びスズを含む金属酸化物層の少なくとも一方を形成する、表示装置の作製方法。 - 請求項1乃至4のいずれか一において、
前記第1の対向電極を形成した後に、前記第1のメタルマスクを介して成膜することで、前記第1の対向電極を介して前記第1の画素電極と重なる、第4の保護層を形成する、表示装置の作製方法。 - 請求項5において、
前記第4の保護層として、インジウム、ガリウム、及び亜鉛を含む金属酸化物層、及び、インジウム及びスズを含む金属酸化物層の少なくとも一方を形成する、表示装置の作製方法。 - 第1の画素電極、及び、第2の画素電極を形成し、
前記第1の画素電極の端部、及び、前記第2の画素電極の端部を覆う、絶縁層を形成し、
前記第1の画素電極上、前記第2の画素電極上、及び、前記絶縁層上に、第1の層を形成し、
前記第1の層上に、第1の対向電極を形成し、
第1の開口を有する第1のメタルマスクを、前記第1の開口が前記第2の画素電極と重なるように、前記第1の対向電極上に配置し、
前記第1のメタルマスクを用いて、前記第1の層及び前記第1の対向電極における、前記第2の画素電極と重なる領域の少なくとも一部を除去し、
前記第1の画素電極上、前記第2の画素電極上、及び、前記絶縁層上に、第2の層を形成し、
前記第2の層上に、第2の対向電極を形成し、
第2の開口を有する第2のメタルマスクを、前記第2の開口が前記第1の画素電極と重なるように、前記第2の対向電極上に配置し、
前記第2のメタルマスクを用いて、前記第2の層及び前記第2の対向電極における、前記第1の画素電極と重なる領域の少なくとも一部を除去し、
前記第1の対向電極上、及び、前記第2の対向電極上に、前記絶縁層と重なる位置に開口を有するレジストマスクを形成し、
前記レジストマスクを用いて、前記第1の層、前記第2の層、前記第1の対向電極、及び、前記第2の対向電極の少なくとも一つにおける、前記絶縁層と重なる領域の少なくとも一部を除去することで、前記絶縁層の一部を露出させ、
前記第1の対向電極、前記第2の対向電極、及び、前記絶縁層を覆うように、第1の保護層を形成する、表示装置の作製方法。 - 請求項7において、
前記第1の対向電極を形成する前に、前記第1の層上に第2の保護層を形成し、
前記第2の対向電極を形成する前に、前記第2の層上に第3の保護層を形成する、表示装置の作製方法。 - 請求項8において、
前記第2の保護層の厚さと前記第3の保護層の厚さは互いに異なる、表示装置の作製方法。 - 請求項8または9において、
前記第2の保護層及び前記第3の保護層として、それぞれ、インジウム、ガリウム、及び亜鉛を含む金属酸化物層、及び、インジウム及びスズを含む金属酸化物層の少なくとも一方を形成する、表示装置の作製方法。 - 請求項7乃至10のいずれか一において、
前記第1のメタルマスクを配置する前に、前記第1の対向電極上に第4の保護層を形成する、表示装置の作製方法。 - 請求項11において、
前記第4の保護層として、インジウム、ガリウム、及び亜鉛を含む金属酸化物層、及び、インジウム及びスズを含む金属酸化物層の少なくとも一方を形成する、表示装置の作製方法。 - 第1の発光デバイス、第2の発光デバイス、絶縁層、及び、第1の保護層を有し、
前記第1の発光デバイスは、第1の画素電極と、前記第1の画素電極上の第1の層と、前記第1の層上の第1の対向電極と、を有し、
前記第2の発光デバイスは、第2の画素電極と、前記第2の画素電極上の第2の層と、前記第2の層上の第2の対向電極と、を有し、
前記第1の発光デバイスと前記第2の発光デバイスとは、互いに異なる色の光を発する機能を有し、
前記絶縁層は、前記第1の画素電極の端部と、前記第2の画素電極の端部を覆い、
前記第1の保護層は、前記第1の発光デバイス、前記第2の発光デバイス、及び、前記絶縁層を覆い、
前記絶縁層は、前記第1の層、前記第1の対向電極、前記第2の層、前記第2の対向電極、及び、前記第1の保護層と重なる第1の領域と、前記第1の保護層と接する第2の領域と、を有する、表示装置。 - 請求項13において、
前記第1の発光デバイスは、前記第1の層と前記第1の対向電極との間に、第2の保護層を有し、
前記第2の発光デバイスは、前記第2の層と前記第2の対向電極との間に、第3の保護層を有する、表示装置。 - 請求項14において、
前記第2の保護層の厚さと前記第3の保護層の厚さは互いに異なる、表示装置。 - 請求項14または15において、
前記第2の保護層及び前記第3の保護層は、それぞれ、インジウム、ガリウム、及び亜鉛を含む金属酸化物層、及び、インジウム及びスズを含む金属酸化物層の少なくとも一方を有する、表示装置。 - 請求項13乃至16のいずれか一において、
前記第1の発光デバイスは、前記第1の対向電極上に第4の保護層を有する、表示装置。 - 請求項17において、
前記第4の保護層は、インジウム、ガリウム、及び亜鉛を含む金属酸化物層、及び、インジウム及びスズを含む金属酸化物層の少なくとも一方を有する、表示装置。 - 請求項13乃至18のいずれか一に記載の表示装置と、
コネクタ及び集積回路のうち少なくとも一方と、を有する、表示モジュール。 - 請求項19に記載の表示モジュールと、
アンテナ、バッテリ、筐体、カメラ、スピーカ、マイク、及び操作ボタンのうち少なくとも一つと、を有する、電子機器。
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