WO2022153118A1 - 表示装置の作製方法 - Google Patents
表示装置の作製方法 Download PDFInfo
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- WO2022153118A1 WO2022153118A1 PCT/IB2021/062320 IB2021062320W WO2022153118A1 WO 2022153118 A1 WO2022153118 A1 WO 2022153118A1 IB 2021062320 W IB2021062320 W IB 2021062320W WO 2022153118 A1 WO2022153118 A1 WO 2022153118A1
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- layer
- film
- sacrificial
- pixel electrode
- display device
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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
- H10K59/80—Constructional details
- H10K59/87—Passivation; Containers; Encapsulations
- H10K59/873—Encapsulations
- H10K59/8731—Encapsulations multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers
Definitions
- One aspect of the present invention relates to a display device.
- One aspect of the present invention relates to a method for manufacturing a display 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 disclosed in the present specification and the like include semiconductor devices, display devices, light emitting devices, power storage devices, storage devices, electronic devices, lighting devices, input devices, input / output devices, and driving methods thereof. Alternatively, a method for producing them can be given as an example.
- Semiconductor devices refer to all devices that can function by utilizing semiconductor characteristics.
- Devices that require high-definition display panels include, for example, smartphones, tablet terminals, and notebook computers.
- stationary display devices such as television devices and monitor devices are also required to have higher definition as the resolution is increased.
- a device that requires the highest definition for example, there is a device for virtual reality (VR: Virtual Reality) or augmented reality (AR: Augmented Reality).
- VR Virtual Reality
- AR Augmented Reality
- a display device applicable to a display panel a liquid crystal display device, a light emitting device equipped with a light emitting device such as an organic EL (Electro Luminescence) device or a light emitting diode (LED: Light Emitting Diode), a light emitting device equipped with a light emitting device, an electrophoresis method, or the like is typically used for display.
- a light emitting device equipped with a light emitting device such as an organic EL (Electro Luminescence) device or a light emitting diode (LED: Light Emitting Diode)
- LED Light Emitting Diode
- Examples include electronic papers that perform the above.
- an organic EL device also referred to as an organic EL element
- a layer containing a luminescent organic compound is sandwiched between a pair of electrodes.
- luminescence can be obtained from a luminescent organic compound.
- the display device to which such an organic EL device is applied does not require a backlight, which is required for a liquid crystal display device or the like, a thin, lightweight, high-contrast, and low-power consumption display device can be realized.
- Patent Document 1 an example of a display device using an organic EL device is described in Patent Document 1.
- One aspect of the present invention is to provide a method for manufacturing a high-definition display device.
- One aspect of the present invention is to provide a display device having both high display quality and high definition.
- One aspect of the present invention is to provide a display device having high contrast.
- One aspect of the present invention is to provide a highly reliable display device.
- One aspect of the present invention is to provide a display device having a novel configuration or a method for manufacturing the display device.
- One aspect of the present invention is to provide a method for manufacturing the above-mentioned display device with a high yield.
- One aspect of the present invention is to alleviate at least one of the problems of the prior art.
- One aspect of the present invention is a first step of forming a first pixel electrode and a second pixel electrode, and a first EL film is formed on the first pixel electrode and the second pixel electrode. It has a second step of forming a film, a third step of forming a first sacrificial film covering the first EL film, and a region where the first sacrificial film is etched to overlap with the first pixel electrode.
- the fourth step of forming the first sacrificial layer the first EL film is etched to form the first EL layer having a region overlapping with the first sacrificial layer, and the second pixel electrode is formed.
- One aspect of the present invention is a first step of forming a first pixel electrode and a second pixel electrode, and a first EL film is formed on the first pixel electrode and the second pixel electrode. It has a second step of forming a film, a third step of forming a first sacrificial film covering the first EL film, and a region where the first sacrificial film is etched to overlap with the first pixel electrode.
- the fourth step of forming the first sacrificial layer the first EL film is etched to form the first EL layer having a region overlapping with the first sacrificial layer, and the second pixel electrode is formed.
- the first sacrificial film preferably has one or more of a metal film, an alloy film, a metal oxide film, a semiconductor film, or an inorganic insulating film. Further, in the fifth step, it is preferable to use dry etching with an etching gas containing no oxygen gas for the etching of the first EL film.
- the etching gas containing no oxygen gas is selected from CF 4 , C 4 F 8 , SF 6 , CHF 3 , Cl 2 , H 2 O, BCl 3 , H 2 , or noble gas. It is preferable that the number is one or more.
- the display device it is preferable to have a step of forming a first protective layer having a region overlapping with the first pixel electrode between the third step and the fourth step. Further, in the fourth step, it is preferable to form the first sacrificial layer by etching the first sacrificial film with the first protective layer as a mask.
- a common electrode covering the upper surface of the first EL layer, the upper surface of the second EL layer, the upper surface and the side surface of the first insulating layer is formed. It is preferable to have the above steps.
- the upper surface of the first EL layer, the upper surface of the second EL layer, the upper surface and the side surface of the first insulating layer are covered between the twelfth step and the thirteenth step. It is preferable to have a step of forming a layer. Further, the layer is preferably a layer containing a substance having high electron injectability.
- the upper surface of the first EL layer, the upper surface of the second EL layer, the upper surface and the side surface of the first insulating layer are covered between the twelfth step and the thirteenth step. It is preferable to have a step of forming a layer. Further, the layer preferably has a laminated structure of a first layer containing a substance having a high electron transport property and a second layer containing a substance having a high electron injection property on the first layer.
- the upper surface of the first EL layer, the upper surface of the second EL layer, the upper surface and the side surface of the first insulating layer are covered between the twelfth step and the thirteenth step. It is preferable to have a step of forming a layer. Further, the layer is preferably a layer containing a substance having a high hole injection property.
- the upper surface of the first EL layer, the upper surface of the second EL layer, the upper surface and the side surface of the first insulating layer are covered between the twelfth step and the thirteenth step. It is preferable to have a step of forming a layer. Further, the layer preferably has a laminated structure of a first layer containing a substance having a high hole transport property and a second layer containing a substance having a high hole injection property on the first layer.
- One aspect of the present invention is a first step of forming a first pixel electrode and a second pixel electrode, and forming an EL film on the first pixel electrode and the second pixel electrode.
- the second step the third step of forming the sacrificial film covering the EL film, the first sacrificial layer having a region overlapping with the first pixel electrode by etching the sacrificial film, and the second pixel electrode.
- the EL film has a light emitting layer that exhibits white light.
- One aspect of the present invention is a first step of forming a first pixel electrode and a second pixel electrode, and forming an EL film on the first pixel electrode and the second pixel electrode.
- the second step the third step of forming the sacrificial film covering the EL film, the first sacrificial layer having a region overlapping with the first pixel electrode by etching the sacrificial film, and the second pixel electrode.
- the EL film has a light emitting layer that exhibits white light.
- a method for manufacturing a high-definition display device it is possible to provide a method for manufacturing a high-definition display device.
- a display device having both high display quality and high definition it is possible to provide a display device having both high display quality and high definition.
- a display device having high contrast can be provided.
- a highly reliable display device can be provided.
- a display device having a novel configuration or a method for manufacturing the display device.
- a method for manufacturing the above-mentioned display device with a high yield.
- at least one of the problems of the prior art can be alleviated.
- 1A to 1D are diagrams showing a configuration example of a display device.
- 2A and 2B are diagrams showing a configuration example of the display device.
- 3A and 3B are diagrams showing a configuration example of the display device.
- 4A and 4B are diagrams showing a configuration example of a display device.
- 5A and 5B are diagrams showing a configuration example of a display device.
- 6A to 6C are diagrams showing a configuration example of a display device.
- 7A to 7C are diagrams showing a configuration example of a display device.
- 8A to 8C are diagrams showing a configuration example of a display device.
- 9A to 9C are diagrams showing a configuration example of the display device.
- 10A and 10B are diagrams showing a configuration example of a display device.
- FIG. 11 is a diagram showing a configuration example of the display device.
- 12A to 12C are diagrams showing a configuration example of the display device.
- 13A to 13E are diagrams showing an example of a method for manufacturing a display device.
- 14A to 14E are diagrams showing an example of a method for manufacturing a display device.
- 15A to 15D are diagrams showing an example of a method for manufacturing a display device.
- 16A to 16D are diagrams showing an example of a method for manufacturing a display device.
- 17A to 17D are views showing an example of a method for manufacturing a display device.
- FIG. 18 is a diagram showing an example of a method for manufacturing a display device.
- 19A to 19C are diagrams showing a configuration example of a display device.
- 20A to 20D are diagrams showing an example of a method for manufacturing a display device.
- 21A to 21E are diagrams showing an example of a method for manufacturing a display device.
- FIG. 22 is a diagram showing an example of a method for manufacturing a display device.
- FIG. 23 is a perspective view showing an example of the display device.
- 24A and 24B are cross-sectional views showing an example of a display device.
- FIG. 25A is a cross-sectional view showing an example of the display device.
- FIG. 25B is a cross-sectional view showing an example of a transistor.
- 26A and 26B are perspective views showing an example of a display module.
- FIG. 27 is a cross-sectional view showing an example of the display device.
- FIG. 28 is a cross-sectional view showing an example of the display device.
- FIG. 29 is a cross-sectional view showing an example of the display device.
- 30A and 30B are diagrams showing an example of an electronic device.
- 31A to 31D are diagrams showing an example of an electronic device.
- 32A to 32F are diagrams showing an example of an electronic device.
- 33A to 33F are diagrams showing an example of an electronic device.
- membrane and the term “layer” can be interchanged with each other.
- conductive layer or “insulating layer” may be interchangeable with the terms “conductive film” or “insulating film”.
- an EL layer means a layer (also referred to as a light emitting layer) which is provided between a pair of electrodes of a light emitting device and contains at least a light emitting substance, or a laminated body containing a light emitting layer.
- the display panel which is one aspect of the display device, has a function of displaying (outputting) an image or the like on the display surface. Therefore, the display panel is an aspect of the output device.
- an IC is mounted on a display panel board with a connector such as FPC (Flexible Printed Circuit) or TCP (Tape Carrier Package) attached, or on the board by a COG (Chip On Glass) method or the like. It may be referred to as a display panel module, a display module, or simply a display panel.
- a connector such as FPC (Flexible Printed Circuit) or TCP (Tape Carrier Package) attached, or on the board by a COG (Chip On Glass) method or the like.
- COG Chip On Glass
- One aspect of the present invention is a display device having a light emitting device (also referred to as a light emitting element).
- the display device has at least two light emitting devices that emit light of different colors.
- Each light emitting device has a pair of electrodes and an EL layer between them.
- the light emitting device is preferably an organic EL device (organic electroluminescent device).
- Two or more light emitting devices that emit different colors each have an EL layer containing different materials.
- a full-color display device can be realized by having three types of light emitting devices that emit red (R), green (G), or blue (B) light, respectively.
- the EL layer is formed separately between light emitting devices of different colors, it is formed by a vapor deposition method using a shadow mask such as a metal mask (MM: Metal Mask) or a fine metal mask (FMM: Fine Metal Mask).
- a shadow mask such as a metal mask (MM: Metal Mask) or a fine metal mask (FMM: Fine Metal Mask).
- MM Metal Mask
- FMM Fine Metal Mask
- a shadow mask such as a metal mask (MM) and a fine metal mask (FMM) may be referred to as a metal mask (MM).
- MM metal mask
- a device manufactured by using a metal mask (MM) may be referred to as a metal mask (MM) structure.
- MML Metal Mask Less
- SBS Side
- a light emitting device capable of emitting white light may be referred to as a white light emitting device.
- the white light emitting device can be a full color display light emitting device by combining with a colored layer (for example, a color filter).
- One aspect of the present invention is to process the EL layer into a fine pattern without using a metal mask. As a result, it is possible to realize a display device having a high definition and a high aperture ratio, which has been difficult to realize so far. Further, since the EL layer can be made separately, it is possible to realize a display device that is extremely vivid, has high contrast, and has high display quality.
- the first EL film and the first sacrificial film are laminated and formed by covering the two pixel electrodes. Subsequently, the first sacrificial film is etched to form a first sacrificial layer having a region overlapping with one pixel electrode (first pixel electrode). Subsequently, the first EL film is etched to form the first EL layer having a region overlapping with the first sacrificial layer, and the other pixel electrode (second pixel electrode) is exposed. Thereby, the first EL layer and the first sacrificial layer on the first EL layer can be formed on the first pixel electrode.
- the second EL film and the second sacrificial film are laminated and formed.
- the second sacrificial film is etched to form a second sacrificial layer having a region overlapping the second pixel electrode.
- the second EL film is etched to form a second EL layer having a region overlapping with the second sacrificial layer.
- a second EL layer and a second sacrificial layer on the second EL layer can be formed on the second pixel electrode. In this way, the first EL layer and the second EL layer can be made separately.
- an insulating film covering the upper surface and side surface of the first sacrificial layer, the side surface of the first EL layer, the upper surface and side surface of the second sacrificial layer, and the side surface of the second EL layer is formed.
- the insulating film is etched to form a protective insulating layer having a region in contact with the side surface of the first EL layer and a region in contact with the side surface of the second EL layer, the first sacrificial layer, and the first sacrificial layer. Exposing the sacrificial layer of 2.
- a two-color light emitting device can be made separately.
- the protective insulating layer on the side surface of the first EL layer and the side surface of the second EL layer, it is possible to suppress the invasion of oxygen, moisture, or these constituent elements from the side surface of the EL layer into the inside, and the reliability is high. It can be a highly effective display device.
- the EL layer of the light emitting device of three or more colors can be made separately, and a display device having a light emitting device of three colors or four or more colors can be realized.
- the interval can be narrowed to 500 nm or less, 200 nm or less, 100 nm or less, and even 50 nm or less.
- the aperture ratio is 50% or more, 60% or more, 70% or more, 80% or more, and even 90% or more, and less than 100% can be realized.
- the pattern of the EL layer itself can be made extremely small as compared with the case where a metal mask is used. Further, for example, when a metal mask is used to separate the EL layers, the thickness varies between the center and the edges of the pattern, so that the effective area that can be used as the light emitting region becomes smaller than the area of the entire pattern. ..
- the thickness can be made uniform within the pattern, and even a fine pattern emits light in almost the entire area. It can be used as an area. Therefore, according to the above-mentioned manufacturing method, it is possible to have both high definition and high aperture ratio.
- FIG. 1A A schematic top view of the display device 100 according to one aspect of the present invention is shown in FIG. 1A.
- the display device 100 has a plurality of light emitting devices 110R exhibiting red color, a light emitting device 110G exhibiting green color, and a plurality of light emitting device 110B exhibiting blue color.
- R, G, and B are designated in the light emitting region of each light emitting device in order to simplify the distinction between the light emitting devices.
- the light emitting device 110R, the light emitting device 110G, and the light emitting device 110B are arranged in a matrix.
- FIG. 1A shows a so-called striped array in which light emitting devices of the same color are arranged in one direction.
- the arrangement method of the light emitting device is not limited to this, and an arrangement method such as a delta arrangement or a zigzag arrangement may be applied, or a pentile arrangement may be used.
- an EL device such as an OLED (Organic Light Emitting Diode) or a QLED (Quantum-dot Light Emitting Diode).
- OLED Organic Light Emitting Diode
- QLED Quadrescent Light Emitting Diode
- luminescent substances possessed by EL devices substances that emit fluorescence (fluorescent materials), substances that emit phosphorescence (phosphorescent materials), inorganic compounds (quantum dot materials, etc.), and substances that exhibit thermally activated delayed fluorescence (thermally activated delayed fluorescence (thermally activated delayed fluorescence))
- TADF Thermally activated delayed fluorescence
- FIG. 1B A schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A is shown in FIG. 1B.
- FIG. 1B shows a cross section of a light emitting device 110R, a light emitting device 110G, and a light emitting device 110B provided on the substrate 101.
- the light emitting device 110R has a pixel electrode 111R, an EL layer 112R, a layer 116, and a common electrode 113.
- the light emitting device 110G has a pixel electrode 111G, an EL layer 112G, a layer 116, and a common electrode 113.
- the light emitting device 110B has a pixel electrode 111B, an EL layer 112B, a layer 116, and a common electrode 113.
- the light emitting device 110R, the light emitting device 110G, and the light emitting device 110B may not be distinguished, or these may be collectively referred to as the light emitting device 110.
- the pixel electrode 111R, the pixel electrode 111G, and the pixel electrode 111B may not be distinguished, or they may be collectively referred to as the pixel electrode 111.
- the EL layer 112R, the EL layer 112G, and the EL layer 112B may not be distinguished, or they may be collectively referred to as the EL layer 112.
- the same description may be made for other elements.
- the light emitting device 110R has an EL layer 112R between the pixel electrode 111R and the common electrode 113.
- the EL layer 112R has a luminescent organic compound that emits light having intensity in at least the red wavelength region.
- the light emitting device 110G has an EL layer 112G between the pixel electrode 111G and the common electrode 113.
- the EL layer 112G has a luminescent organic compound that emits light having intensity in at least the green wavelength region.
- the light emitting device 110B has an EL layer 112B between the pixel electrode 111B and the common electrode 113.
- the EL layer 112B has a luminescent organic compound that emits light having intensity in at least the blue wavelength region.
- the EL layer 112R, the EL layer 112G, and the EL layer 112B emit light of different colors.
- the EL layer 112R, the EL layer 112G, and the EL layer 112B are composed of an electron injection layer, an electron transport layer, a hole injection layer, and a hole transport layer, in addition to a layer containing a luminescent organic compound (light emitting layer), respectively. Of these, one or more may be possessed.
- the light emitting device 110R has a layer 116 between the EL layer 112R and the common electrode 113.
- the light emitting device 110G has a layer 116 between the EL layer 112G and the common electrode 113.
- the light emitting device 110B has a layer 116 between the EL layer 112B and the common electrode 113.
- Layer 116 can be a layer containing a substance having high carrier injection properties.
- the layer 116 can function as an electron injecting layer.
- the layer 116 is not limited to the function as an electron injection layer.
- a substance having a high hole injection property may be used for the layer 116, and the layer 116 may be provided with a function as a hole injection layer. The layer 116 may not be provided.
- the layer 116 is provided as a continuous layer common to each light emitting device. By making the layer 116 common to each light emitting device, the manufacturing process can be simplified and the manufacturing cost can be reduced.
- the pixel electrode 111R, the pixel electrode 111G, and the pixel electrode 111B are provided for each light emitting device.
- the common electrode 113 is provided as a continuous layer common to each light emitting device.
- a conductive film having translucency with respect to visible light is used for either one of the pixel electrodes and the common electrode 113, and a conductive film having reflectivity is used for the other.
- the width of the pixel electrode 111 is smaller than the width of the EL layer 112, that is, the end portion of the pixel electrode 111 is located inside the end portion of the EL layer 112.
- the width of the pixel electrode 111 may be larger than the width of the EL layer 112, that is, the end portion of the pixel electrode 111 may be located outside the end portion of the EL layer 112.
- the width of the pixel electrode 111 may be equal to the width of the EL layer 112, that is, the end of the pixel electrode 111 may coincide with the end of the EL layer 112.
- the display device 100 has an insulating layer 131.
- the insulating layer 131 is provided so as to cover the end portions of the pixel electrode 111R, the pixel electrode 111G, and the pixel electrode 111B.
- the end portion of the insulating layer 131 preferably has a tapered shape.
- the tapered shape refers to a shape in which at least a part of the side surface of the structure is provided so as to be inclined with respect to the substrate surface.
- the EL layer 112R, the EL layer 112G, and the EL layer 112B each have a region in contact with the upper surface of the pixel electrode and a region in contact with the surface of the insulating layer 131.
- the ends of the EL layer 112R, the EL layer 112G, and the EL layer 112B are located on the insulating layer 131.
- a gap is provided between the two EL layers between light emitting devices of different colors.
- the EL layer 112R, the EL layer 112G, and the EL layer 112B are provided so as not to be in contact with each other. As a result, it is possible to preferably prevent an unintended light emission due to a current flowing through the two adjacent EL layers. Therefore, the contrast can be enhanced, and a display device having high display quality can be realized.
- an insulating layer 133 is provided between the two EL layers on the insulating layer 131.
- the insulating layer 133 has a region in contact with the side surface of the EL layer 112 and a region in contact with the upper surface of the insulating layer 131.
- the insulating layer 133 has a region in contact with the side surface of the EL layer 112R and a region in contact with the side surface of the EL layer 112G.
- the insulating layer 133 has a region in contact with the side surface of the EL layer 112G and a region in contact with the side surface of the EL layer 112B. Further, although not shown in FIG. 1B, between the EL layer 112R and the EL layer 112B, the insulating layer 133 has a region in contact with the side surface of the EL layer 112R and a region in contact with the side surface of the EL layer 112B.
- the insulating layer 133 has a region in contact with the side surface of the EL layer 112, and functions as a protective insulating layer of the EL layer 112.
- the insulating layer 133 it is possible to suppress the invasion of oxygen, moisture, or these constituent elements from the side surface of the EL layer 112 into the inside, and it is possible to obtain a highly reliable display device. Further, by providing the insulating layer 133, it is possible to suppress the components of the layer 116 from adhering to the side surface of the EL layer 112 and suppress the generation of the leakage current of the light emitting device 110.
- FIG. 2A An enlarged view of the region P surrounded by the alternate long and short dash line in FIG. 1B is shown in FIG. 2A.
- the width 133w of the insulating layer 133 in the region in contact with the side surface of the EL layer 112 is large, the distance between the EL layers 112 may be large and the aperture ratio may be low. Further, if the width 133w of the insulating layer 133 is small, the effect of suppressing the invasion of oxygen, moisture, or these constituent elements from the side surface of the EL layer 112 to the inside may be reduced.
- the width 133w of the insulating layer 133 in the region in contact with the side surface of the EL layer 112 is preferably 3 nm or more and 200 nm or less, more preferably 3 nm or more and 150 nm or less, further preferably 5 nm or more and 150 nm or less, and further preferably 5 nm or more and 100 nm or less. Further, it is preferably 10 nm or more and 100 nm or less, and further preferably 10 nm or more and 50 nm or less.
- the width 133w of the insulating layer 133 the width of the insulating layer 133 in a region that is in contact with the side surface of the EL layer 112 and is sandwiched between the EL layer 112G and the layer 116 can be used.
- the insulating layer 133 for example, aluminum oxide, magnesium oxide, hafnium oxide, gallium oxide, indium gallium zinc oxide, silicon oxide, silicon nitride nitride, silicon nitride, silicon nitride or the like can be used.
- the insulating layer 133 may be used by laminating them.
- the oxidative nitride refers to a material having a higher oxygen content than nitrogen as its composition
- the nitride oxide refers to a material having a higher nitrogen content than oxygen as its composition.
- the description of silicon oxide refers to a material having a higher oxygen content than nitrogen as its composition
- the description of silicon nitride refers to a material having a higher nitrogen content than oxygen as its composition. Is shown.
- the insulating layer 133 is formed by a sputtering method, a chemical vapor deposition (CVD) method, a molecular beam epitaxy (MBE) method, a pulsed laser deposition (PLD) method, and a pulsed laser deposition (PLD) method.
- CVD chemical vapor deposition
- MBE molecular beam epitaxy
- PLD pulsed laser deposition
- PLD pulsed laser deposition
- PLD pulsed laser deposition
- PLD pulsed laser deposition
- the display device 100 shown in FIG. 1B and the like shows an example in which the height of the end surface of the insulating layer 133 in contact with the EL layer 112G is the same as the height of the upper surface of the EL layer 112G. Not limited to. The height of the end surface of the insulating layer 133 in contact with the EL layer 112G may be different from the height of the upper surface of the EL layer 112G.
- the end surface of the layer refers to a side surface when the surface in contact with the surface to be formed of the layer is the lower surface.
- the end surface of the insulating layer 133 refers to a side surface when the surface in contact with the EL layer 112, which is the surface to be formed of the insulating layer 133, is the lower surface.
- the height of the end face of the layer refers to the height from the substrate to the highest portion of the end face of the layer.
- the height of the upper surface of the layer refers to the height from the substrate to the highest portion of the upper surface of the layer.
- the layer 116 is provided so as to cover the insulating layer 133 and the EL layer 112.
- the layer 116 has an upper surface and an end surface of the insulating layer 133, and a region in contact with the upper surface of the EL layer 112.
- the height of the upper surface of the insulating layer 131 in the region overlapping the insulating layer 133 may be lower than the height of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112G.
- the height of the upper surface of the insulating layer 131 in the region overlapping the insulating layer 133 may be equal to or substantially equal to the height of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112G.
- the term “heights approximately equal” means that one of the two heights to be compared has a height of 0.8 or more and 1.2 or less.
- a configuration example of a light emitting device will be described.
- the light emitting device 110G will be described as an example.
- the light emitting device 110G has an EL layer 112G and a layer 116 between a pair of electrodes (pixel electrode 111G and common electrode 113).
- the EL layer 112G can have a configuration having a plurality of layers such as a layer 530, a light emitting layer 511, and a layer 520.
- the light emitting layer 511 has, for example, a luminescent compound.
- Layer 530 can have one or more of a carrier injection layer and a carrier transport layer.
- the carrier transport layer may have, for example, a laminated structure of a carrier injection layer and a carrier transport layer on the carrier injection layer.
- the carrier transport layer is a layer containing a substance having a high carrier transport property.
- the layer 520 is a layer containing a substance having a high carrier transport property.
- the layer 530 is a layer containing a substance having a high hole transport property (hereinafter referred to as a hole transport layer), and the layer 520 is a layer 520.
- a layer containing a substance having a high electron transport property (hereinafter referred to as an electron transport layer) can be used, and a layer 116 can be a layer containing a substance having a high electron injection property (hereinafter referred to as an electron injection layer).
- the layer 530 may have a laminated structure of a layer containing a substance having a high hole injection property (hereinafter referred to as a hole injection layer) and a hole transport layer on the hole injection layer.
- the layer 530 can be an electron transport layer
- the layer 520 can be a hole transport layer
- the layer 116 can be a hole injection layer.
- the layer 530 may have a laminated structure of an electron injection layer and an electron transport layer on the electron injection layer.
- the light emitting device has at least a light emitting layer. Further, as a layer other than the light emitting layer, the light emitting device includes a substance having a high hole injecting property, a substance having a high hole transporting property, a hole blocking material, a substance having a high electron transporting property, an electron blocking material, and a substance having a high electron injecting property. It may further have a layer containing a substance, a bipolar substance (a substance having high electron transport property and hole transport property), and the like.
- Either a low molecular weight compound or a high molecular weight compound can be used as the light emitting device, and an inorganic compound may be contained.
- the layers constituting the light emitting device 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.
- the light emitting device can be configured to 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 hole injection layer is a layer that injects holes from the anode into the hole transport layer, and is a layer that contains a material having high hole injection properties.
- the material having high hole injectability include an aromatic amine compound and a composite material containing a hole transporting material and an acceptor material (electron accepting material).
- the hole transport layer is a layer that transports holes injected from the anode to the light emitting layer by the hole injection layer.
- the hole transport layer is a layer containing a hole transport material.
- the hole transporting material is preferably a substance having a hole mobility of 10-6 cm 2 / Vs or more. In addition, any substance other than these can be used as long as it is a substance having a higher hole transport property than electrons.
- the hole-transporting material includes a material having high hole-transporting property such as a ⁇ -electron-rich heteroaromatic compound (for example, a carbazole derivative, a thiophene derivative, a furan derivative, etc.) and an aromatic amine (a compound having an aromatic amine skeleton). preferable.
- the electron transport layer is a layer that transports electrons injected from the cathode to the light emitting layer by the electron injection layer.
- the electron transport layer is a layer containing an electron transport material.
- the electron transporting material is preferably a substance having an electron mobility of 1 ⁇ 10-6 cm 2 / Vs or more. In addition, any substance other than these can be used as long as it is a substance having a higher electron transport property than holes.
- the electron-transporting material includes a metal complex having a quinoline skeleton, a metal complex having a benzoquinolin skeleton, a metal complex having an oxazole skeleton, a metal complex having a thiazole skeleton, and the like, as well as an oxadiazole derivative, a triazole derivative, an imidazole derivative, and an oxazole.
- a material having high electron transport property such as a heteroarocyclic compound can be used.
- the electron injection layer is a layer for injecting electrons from the cathode into the electron transport layer, and is a layer containing a material having high electron injectability.
- a material having high electron injection property an alkali metal, an alkaline earth metal, or a compound thereof can be used.
- a material having high electron injectability a composite material containing an electron transporting material and a donor material (electron donating material) can also be used.
- the electron injection layer is, for example, lithium, cesium, lithium fluoride (LiF), cesium fluoride (CsF), calcium fluoride (CaF 2 ), 8- (quinolinolato) lithium (abbreviation: Liq), 2- (2- (2-). Pyridyl) phenolatrithium (abbreviation: LiPP), 2- (2-pyridyl) -3-pyridinolatolithium (abbreviation: LiPPy), 4-phenyl-2- (2-pyridyl) phenoratrithium (abbreviation: LiPPP), Alkali metals such as lithium oxide (LiO x ), cesium carbonate and the like, alkaline earth metals, or compounds thereof can be used.
- a material having electron transportability may be used as the above-mentioned electron injection layer.
- a compound having an unshared electron pair and an electron-deficient heteroaromatic ring can be used as a material having electron transportability.
- a compound having at least one of a pyridine ring, a diazine ring (pyrimidine ring, pyrazine ring, pyridazine ring), and a triazine ring can be used.
- the minimum empty orbital (LUMO: Lowest Unellad Molecular Orbital) of the organic compound having an unshared electron pair is -3.6 eV or more and -2.3 eV or less.
- the highest occupied orbital (HOMO: highest occupied molecular orbital) level and LUMO level of an organic compound are determined by CV (cyclic voltammetry), photoelectron spectroscopy, photoabsorption spectroscopy, backlit electron spectroscopy, etc. Can be estimated.
- BPhen 4,7-diphenyl-1,10-phenanthroline
- NBPhen 2,9-bis (naphthalene-2-yl) -4,7-diphenyl-1,10-phenanthroline
- diquinoxalino [2,3-a: 2', 3'-c] Phenazine (abbreviation: HATNA), 2,4,6-tris [3'-(pyridin-3-yl) biphenyl-3-yl] -1,3 , 5-Triazine (abbreviation: TmPPPyTZ) and the like can be used for organic compounds having unshared electron pairs.
- NBPhen has a higher glass transition temperature (Tg) and is excellent in heat resistance as compared with BPhen.
- the light emitting layer is a layer containing a light emitting substance.
- the light emitting layer can have one or more kinds of light emitting substances.
- a substance exhibiting a luminescent color such as blue, purple, bluish purple, green, yellowish green, yellow, orange, and red is appropriately used. Further, as the luminescent substance, a substance that emits near-infrared light can also be used.
- luminescent substances include fluorescent materials, phosphorescent materials, TADF materials, quantum dot materials, and the like.
- fluorescent material examples include pyrene derivatives, anthracene derivatives, triphenylene derivatives, fluorene derivatives, carbazole derivatives, dibenzothiophene derivatives, dibenzofuran derivatives, dibenzoquinoxaline derivatives, quinoxalin derivatives, pyridine derivatives, pyrimidine derivatives, phenanthrene derivatives, naphthalene derivatives and the like. ..
- an organic metal complex having a 4H-triazole skeleton, a 1H-triazole skeleton, an imidazole skeleton, a pyrimidine skeleton, a pyrazine skeleton, or a pyridine skeleton (particularly an iridium complex), or a phenylpyridine derivative having an electron-withdrawing group is coordinated.
- organic metal complexes particularly iridium complexes
- platinum complexes platinum complexes
- rare earth metal complexes as children.
- the light emitting layer may have one or more kinds of organic compounds (host material, assist material, etc.) in addition to the light emitting substance (guest material).
- organic compounds host material, assist material, etc.
- guest material As one or more kinds of organic compounds, one or both of a hole transporting material and an electron transporting material can be used. Further, a bipolar material or a TADF material may be used as one or more kinds of organic compounds.
- the light emitting layer preferably has, for example, a phosphorescent material and a hole transporting material and an electron transporting material which are combinations that easily form an excitation complex.
- ExTET Exciplex-Triplet Energy Transfer
- a combination that forms an excitation complex that emits light that overlaps the wavelength of the absorption band on the lowest energy side of the luminescent substance energy transfer becomes smooth and light emission can be obtained efficiently.
- high efficiency, low voltage drive, and long life of the light emitting device can be realized at the same time.
- a configuration having a layer 530, a light emitting layer 511, a layer 520, and a layer 116 between a pair of electrodes (pixel electrode 111G and common electrode 113) shown in FIG. 2B can function as a single light emitting unit.
- This configuration is referred to as a single structure in the present specification and the like.
- the insulating layer 133 By providing the insulating layer 133 in contact with the side surface of the EL layer 112, it is possible to suppress the invasion of oxygen, moisture, or these constituent elements from the side surfaces of the layer 530, the light emitting layer 511, and the layer 520 into the inside, and the reliability is high. It can be a display device.
- the insulating layer 133 is preferably in contact with at least the side surface of the light emitting layer 511.
- the layer 116 may have a laminated structure.
- FIG. 3A shows an example in which the layer 116 has a laminated structure of the layer 116a and the layer 116b on the layer 116a.
- the layer 116a can be an electron transport layer and the layer 116b can be an electron injection layer.
- a layer 520 that functions as an electron transport layer, a layer 116a that functions as an electron transport layer, and a layer 116b that functions as an electron injection layer are laminated in this order. It can be configured. In this case, it can be said that the two electron transport layers are laminated.
- the step of the EL layer 112G is reduced, and the EL layer is formed.
- the step covering property of the layer (for example, the common electrode 113) formed on the 112G is improved, and it is possible to suppress the occurrence of defects such as step breakage and voids in the layer.
- the layer 116a can be a hole transport layer and the layer 116b can be a hole injection layer. Further, between the light emitting layer 511 and the common electrode 113, a layer 520 that functions as a hole transport layer, a layer 116a that functions as a hole transport layer, and a layer 116b that functions as a hole injection layer are arranged in this order. It can be a laminated structure. In this case, it can be said that the two hole transport layers are laminated.
- the step of the EL layer 112G becomes smaller.
- the step covering property of the layer (for example, the common electrode 113) formed on the EL layer 112G is improved, and it is possible to suppress the occurrence of defects such as step breakage and holes in the layer.
- the layer 116a may have a laminated structure of two or more layers. Further, the layer 116b may have a laminated structure of two or more layers.
- the configuration may not include the layer 116.
- the common electrode 113 is provided in contact with the insulating layer 133 and the EL layer 112G.
- the common electrode 113 has a region in contact with the upper surface and the end surface of the insulating layer 133 and the upper surface of the EL layer 112G.
- FIG. 2B shows a configuration in which the light emitting device 110G has one light emitting layer 511, but one aspect of the present invention is not limited to this.
- the light emitting device 110G may have a plurality of light emitting layers.
- FIG. 4A shows a configuration having a plurality of light emitting layers (light emitting layer 511, light emitting layer 512, light emitting layer 513) between the layer 530 and the layer 520.
- a configuration in which a plurality of light emitting layers are provided between the layer 530 and the layer 520 as shown in FIG. 4A can also be referred to as a single structure.
- the light emitting materials contained in the light emitting layer 511, the light emitting layer 512, and the light emitting layer 513 may be the same material or different materials.
- FIG. 4A shows an example in which the light emitting device 110G has three light emitting layers, but one aspect of the present invention is not limited to this.
- the number of light emitting layers included in the light emitting device 110G is not particularly limited.
- the light emitting device 110G may have two light emitting layers or may have four or more light emitting layers.
- FIG. 4B shows a configuration example different from the configurations shown in FIGS. 2B and 4A.
- the light emitting device shown in FIG. 4B has a configuration in which a plurality of light emitting units (EL layer 112G, EL layer 112Ga) are connected in series via an intermediate layer 540, and the configuration is referred to as a tandem structure in the present specification. ..
- the intermediate layer 540 functions as a charge generation layer.
- the tandem structure may be called a stack structure.
- the layer 522 can have, for example, an electron injection layer and an electron transport layer.
- Layer 532 can have, for example, a hole injection layer and a hole transport layer.
- the layer 532 can be a hole transport layer and the layer 522 can be an electron transport layer.
- the layer 532 may have a laminated structure of a hole injection layer and a hole transport layer on the hole injection layer.
- the layer 522 may have a laminated structure of an electron injection layer and an electron transport layer on the electron injection layer.
- the layer 530 can be a hole transport layer, the layer 520 can be an electron transport layer, and the layer 116 can be an electron injection layer.
- the layer 530 may have a laminated structure of a hole injection layer and a hole transport layer on the hole injection layer.
- the layer 532 can be an electron transport layer and the layer 522 can be a hole transport layer.
- the layer 532 may have a laminated structure of an electron injection layer and an electron transport layer on the electron injection layer.
- the layer 522 may have a laminated structure of a hole injection layer and a hole transport layer on the hole injection layer.
- the layer 530 can be an electron transport layer, the layer 520 can be a hole transport layer, and the layer 116 can be a hole injection layer.
- the layer 530 may have a laminated structure of an electron injection layer and an electron transport layer on the electron injection layer.
- the light emitting device can be roughly divided into a single structure and a tandem structure.
- a device having a single structure preferably has one light emitting unit between a pair of electrodes, and the light emitting unit preferably includes one or more light emitting layers.
- a light emitting layer may be selected so that the light emission of each of the two or more light emitting layers has a complementary color relationship. For example, by making the emission color of the first light emitting layer and the emission color of the second light emitting layer have a complementary color relationship, it is possible to obtain a configuration in which the entire light emitting device emits white light. The same applies to a light emitting device having three or more light emitting layers.
- the device having a tandem structure has two or more light emitting units between a pair of electrodes, and each light emitting unit includes one or more light emitting layers.
- each light emitting unit includes one or more light emitting layers.
- the light from the light emitting layers of the plurality of light emitting units may be combined to obtain white light emission.
- the configuration for obtaining white light emission is the same as the configuration for a single structure.
- the SBS structure light emitting device can have lower power consumption than the white light emitting device.
- the white light emitting device is suitable because the manufacturing process is simpler than that of the light emitting device having an SBS structure, so that the manufacturing cost can be lowered or the manufacturing yield can be increased.
- FIGS. 2A to 4B have been described by taking the light emitting device 110G as an example, the same configuration can be applied to the light emitting device 110R and the light emitting device 110B.
- the emission color of the light emitting device can be red, green, blue, cyan, magenta, yellow, white, or the like, depending on the material constituting the EL layer 112. Further, the color purity can be further improved by imparting a microcavity structure to the light emitting device.
- the light emitting device that emits white light has a structure in which the light emitting layer contains two or more kinds of light emitting substances.
- a light emitting substance may be selected so that the light emission of each of the two or more light emitting substances has a complementary color relationship. For example, by making the emission color of the first light emitting layer and the emission color of the second light emitting layer have a complementary color relationship, it is possible to obtain a light emitting device that emits white light as the entire light emitting device. The same applies to a light emitting device having three or more light emitting layers.
- the light emitting layer preferably contains two or more light emitting substances such as R (red), G (green), B (blue), Y (yellow), and O (orange).
- the luminescent substance has two or more, and the luminescence of each luminescent substance contains spectral components of two or more colors among R, G, and B.
- FIG. 1C shows a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A.
- FIG. 1C shows an example in which the EL layer 112G is processed into an island shape.
- the EL layer 112G may be processed into a strip shape so that the EL layer 112G is continuous in the column direction.
- the space required for dividing the EL layer 112G or the like is not required, and the area of the non-light emitting region between the light emitting devices can be reduced, so that the aperture ratio can be increased.
- the insulating layer 133 may not be provided between the EL layer 112G and the adjacent EL layer 112G.
- FIGS. 1C and 1D show a cross section of the light emitting device 110G as an example, the light emitting device 110R and the light emitting device 110B can also have the same shape.
- a protective layer 121 is provided on the common electrode 113 so as to cover the light emitting device 110R, the light emitting device 110G, and the light emitting device 110B.
- the protective layer 121 has a function of preventing impurities such as water from diffusing into each light emitting device from above.
- the protective layer 121 preferably includes a layer having a function of capturing or fixing at least one of water and oxygen (also referred to as gettering). More preferably, a layer having a function of capturing or fixing hydrogen, a substance to which hydrogen is bound (for example, water ( H2O ), etc.), oxygen, hydrogen, etc. may be contained in each light emitting device. It is suitable because it can adsorb oxygen, hydrogen, and the like.
- the protective layer 121 can have, for example, a single-layer structure or a laminated structure including at least an inorganic insulating film.
- the inorganic insulating film include an oxide film such as a silicon oxide film, a silicon nitride film, a silicon nitride film, a silicon nitride film, an aluminum oxide film, an aluminum nitride film, and a hafnium oxide film, or a nitride film.
- a semiconductor material such as indium gallium oxide or indium gallium zinc oxide may be used as the protective layer 121.
- a laminated film of an inorganic insulating film and an organic insulating film can also be used.
- the organic insulating film functions as a flattening film. As a result, the upper surface of the organic insulating film can be made flat, so that the covering property of the inorganic insulating film on the organic insulating film can be improved and the barrier property can be enhanced.
- the upper surface of the protective layer 121 is flat, when a structure (for example, a color filter, a touch sensor electrode, a lens array, etc.) is provided above the protective layer 121, an uneven shape due to the lower structure is formed. It is preferable because the influence can be reduced.
- a structure for example, a color filter, a touch sensor electrode, a lens array, etc.
- FIG. 2A and the like show an example in which the end face of the insulating layer 133 is flat, one aspect of the present invention is not limited to this.
- the end face of the insulating layer 133 may be a curved surface.
- the end face of the insulating layer 133 may have a convex shape.
- the insulating layer 133 when the width of the insulating layer 133 is not constant, the insulating layer has the widest width in the region that is in contact with the side surface of the EL layer 112 and is sandwiched between the EL layer 112G and the layer 116.
- the width of 133 may be 133w.
- the width 133w of the insulating layer 133 is preferably in the above range.
- FIGS. 6A and 6B A schematic cross-sectional view of the display device 100A according to one aspect of the present invention is shown in FIGS. 6A and 6B.
- a schematic top view of the display device 100A can be referred to FIG. 1A.
- FIG. 6A is a schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A.
- FIG. 6B is a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A.
- FIG. 6C An enlarged view of the region Q surrounded by the alternate long and short dash line in FIG. 6A is shown in FIG. 6C.
- the display device 100A has a portion in which the film thickness of the insulating layer 131 in the region overlapping the insulating layer 133 is equal to or substantially equal to the film thickness of the insulating layer 131 in the region overlapping the EL layer 112G. Mainly different from.
- the display device 100A has a configuration in which the film thickness of the insulating layer 131 in the region overlapping the insulating layer 133 is equal to or substantially equal to the film thickness of the insulating layer 131 in the region overlapping the EL layer 112G.
- the step between the upper surface of 112G and the upper surface of the insulating layer 131 becomes smaller. Therefore, the step covering property of the layer (for example, the insulating layer 133) formed on the insulating layer 131 is improved, and it is possible to suppress the occurrence of defects such as step breakage and voids in the layer.
- the EL layer 112G may be processed into a strip shape so that the EL layer 112G is continuous in the column direction as shown in FIG. 1D.
- FIGS. 7A and 7B A schematic cross-sectional view of the display device 100B according to one aspect of the present invention is shown in FIGS. 7A and 7B.
- a schematic view of the top surface of the display device 100B can be referred to with reference to FIG. 1A.
- FIG. 7A is a schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A.
- FIG. 7B is a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A.
- FIG. 7C An enlarged view of the region R surrounded by the alternate long and short dash line in FIG. 7A is shown in FIG. 7C.
- the display device 100B is mainly different from the above-mentioned display device 100 in that the height of the end surface of the insulating layer 133 in contact with the EL layer 112G is different from the height of the upper surface of the EL layer 112G.
- the height of the end surface of the insulating layer 133 in contact with the EL layer 112G is lower than the height of the upper surface of the EL layer 112G. It can be said that the end portion of the insulating layer 133 is in contact with the side surface of the EL layer 112G.
- the insulating layer 133 is in contact with at least the side surface of the light emitting layer 511.
- the insulating layer 133 By covering the side surface of the light emitting layer 511 with the insulating layer 133, it is possible to suppress the invasion of oxygen, moisture, or these constituent elements from the side surface of the light emitting layer 511 into the inside, and it is possible to obtain a highly reliable display device. ..
- the EL layer 112G may be processed into a strip shape so that the EL layer 112G is continuous in the column direction as shown in FIG. 1D.
- FIGS. 8A and 8B A schematic cross-sectional view of the display device 100C according to one aspect of the present invention is shown in FIGS. 8A and 8B.
- a schematic view of the top surface of the display device 100C can be referred to with reference to FIG. 1A.
- FIG. 8A is a schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A.
- FIG. 8B is a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A.
- FIG. 8C An enlarged view of the region S surrounded by the alternate long and short dash line in FIG. 8A is shown in FIG. 8C.
- the display device 100C is mainly different from the above-mentioned display device 100 in that the height of the end surface of the insulating layer 133 in contact with the EL layer 112G is higher than the height of the upper surface of the EL layer 112G.
- the insulating layer 133 covers the side surfaces of the layer 520, the light emitting layer 511, and the layer 530, so that oxygen, moisture, or a configuration thereof is formed from the side surfaces of the layer 520, the light emitting layer 511, and the layer 530 to the inside. It is possible to suppress the invasion of elements, and it is possible to obtain a highly reliable display device.
- the EL layer 112G may be processed into a strip shape so that the EL layer 112G is continuous in the column direction as shown in FIG. 1D.
- FIGS. 9A and 9B A schematic cross-sectional view of the display device 100D according to one aspect of the present invention is shown in FIGS. 9A and 9B.
- a schematic view of the top surface of the display device 100D can be referred to with reference to FIG. 1A.
- FIG. 9A is a schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A.
- FIG. 9B is a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A.
- FIG. 9C An enlarged view of the region T surrounded by the alternate long and short dash line in FIG. 9A is shown in FIG. 9C.
- the display device 100D is mainly different from the above-mentioned display device 100 in that the layer 116 has a region in contact with the upper surface of the insulating layer 131.
- the insulating layer 133 is preferably in contact with at least the side surface of the light emitting layer 511. By covering the side surface of the light emitting layer 511 with the insulating layer 133, it is possible to suppress the invasion of oxygen, moisture, or these constituent elements from the side surface of the light emitting layer 511 into the inside, and it is possible to obtain a highly reliable display device. ..
- the EL layer 112G may be processed into a strip shape so that the EL layer 112G is continuous in the column direction as shown in FIG. 1D.
- FIGS. 10A and 10B A schematic cross-sectional view of the display device 100E according to one aspect of the present invention is shown in FIGS. 10A and 10B.
- a schematic view of the top surface of the display device 100E can be referred to with reference to FIG. 1A.
- FIG. 10A is a schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A.
- FIG. 10B is a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A.
- An enlarged view of FIG. 10A is shown in FIG.
- the display device 100E is mainly different from the above-mentioned display device 100 in that the film thickness of the insulating layer 131 differs depending on the light emitting device.
- the height 131bG of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112G is lower than the height 131bR of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112R.
- the height 131bC of the upper surface of the insulating layer 131 in the region overlapping the insulating layer 133 is lower than the height 131bG.
- the height 131cB of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112B is lower than the height 131cG of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112G.
- the height 131cC of the upper surface of the insulating layer 131 in the region overlapping the insulating layer 133 is lower than the height 131cB.
- the height 131cG is equal to or substantially equal to the above-mentioned height 131bG.
- the height 131aB of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112B is the height of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112R. It is lower than 131aR.
- the height 131aC of the upper surface of the insulating layer 131 in the region overlapping the insulating layer 133 is lower than the height 131aB.
- the height 131aB is equal to or substantially equal to the above-mentioned height 131cB.
- the height 131aR is equal to or approximately equal to the height 131bR described above.
- the height of the upper surface of the insulating layer 131 refers to the distance from the substrate 101 to the highest portion of the upper surface of the insulating layer 131.
- the height 131bG and the height 131cB of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112G are higher than the height 131aR and the height 131bR of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112R.
- An example in which the height 131cB and the height 131aB of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112B are lower than the height 131bG and the height 131cG of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112G.
- one aspect of the present invention is not limited to this.
- the height of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112G is higher than the height of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112R, and the height of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112B.
- the height may be higher than the height of the upper surface of the insulating layer 131 in the region overlapping the EL layer 112G.
- the height of the upper surface of the insulating layer 131 in the region overlapping the EL layer can be made different in the order of formation of the light emitting device 110R, the light emitting device 110G, and the light emitting device 110B, for example.
- the height 131aC, height 131bC, and height 131cC of the upper surface of the insulating layer 131 in the region overlapping the insulating layer 133 may be equal or substantially equal, or may be different from each other.
- the height of the end face of the insulating layer 133 may differ depending on the light emitting device 110.
- the height of the end surface of the insulating layer 133 in contact with the EL layer 112R is lower than the height of the upper surface of the EL layer 112R
- the height of the end surface of the insulating layer 133 in contact with the EL layer 112G is the height of the upper surface of the EL layer 112G.
- An example is shown in which the height of the end surface of the insulating layer 133 in contact with the EL layer 112B is equal to the height of the upper surface of the EL layer 112B, but one aspect of the present invention is not limited to this.
- the height of the end face of any of the insulating layers 133 may be lower than the height of the EL layer 112.
- the EL layer 112G may be processed into a strip shape so that the EL layer 112G is continuous in the column direction.
- FIGS. 12A and 12B A schematic cross-sectional view of the display device 100F according to one aspect of the present invention is shown in FIGS. 12A and 12B.
- a schematic view of the upper surface of the display device 100F can be referred to with reference to FIG. 1A.
- FIG. 12A is a schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A.
- FIG. 12B is a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A.
- the display device 100F is mainly different from the above-mentioned display device 100 in that the configuration of the light emitting device is different.
- the light emitting device 110R has an optical adjustment layer 115R between the pixel electrode 111R and the EL layer 112R.
- the light emitting device 110G has an optical adjustment layer 115G between the pixel electrode 111G and the EL layer 112G.
- the light emitting device 110B has an optical adjustment layer 115B between the pixel electrode 111B and the EL layer 112B.
- the optical adjustment layer 115R, the optical adjustment layer 115G, and the optical adjustment layer 115B each have translucency with respect to visible light. Further, the optical adjustment layer 115R, the optical adjustment layer 115G, and the optical adjustment layer 115B have different thicknesses. As a result, the optical path length can be made different for each light emitting device.
- a conductive film having a reflective property with respect to visible light is used for the pixel electrode 111R, the pixel electrode 111G, and the pixel electrode 111B, and a conductive film having a reflective property and a transmissive property with respect to visible light is used for the common electrode 113. Is used.
- each light emitting device realizes a so-called microcavity structure (microresonator structure), and the light of a specific wavelength is strengthened. As a result, it is possible to realize a display device having improved color purity.
- a conductive material having translucency with respect to visible light can be used.
- conductive oxides such as indium oxide, indium tin oxide, indium zinc oxide, zinc oxide, zinc oxide containing gallium, indium tin oxide containing silicon, and indium zinc oxide containing silicon can be used. ..
- Each optical adjustment layer may use a conductive film having a different thickness, or may have a single-layer structure, a two-layer structure, a three-layer structure, or the like in order from the thinnest one.
- the EL layer 112G may be processed into a strip shape so that the EL layer 112G is continuous in the column direction.
- FIG. 12C A schematic cross-sectional view of the display device 100G according to one aspect of the present invention is shown in FIG. 12C.
- FIG. 1A can be referred to for a schematic top view of the display device 100G.
- FIG. 12C is a schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A.
- a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A can be referred to FIG. 1C or FIG. 1D.
- the display device 100G shown in FIG. 12C is mainly different from the above-mentioned display device 100F in that it does not have an optical adjustment layer.
- the display device 100G is an example in which a microcavity structure is realized by the thickness of the EL layer 112R, the EL layer 112G, and the EL layer 112B. With such a configuration, it is not necessary to separately provide an optical adjustment layer, so that the process can be simplified.
- the EL layer 112R of the light emitting device 110R that emits the light having the longest wavelength is the thickest
- the EL layer 112B of the light emitting device 110B that emits the light having the shortest wavelength is the thinnest.
- the thickness of each EL layer can be adjusted in consideration of the wavelength of light emitted by each light emitting device, the optical characteristics of the layers constituting the light emitting device, the electrical characteristics of the light emitting device, and the like. ..
- the height of the end surface of the insulating layer 133 in contact with the EL layer 112R is lower than the height of the upper surface of the EL layer 112R
- the height of the end surface of the insulating layer 133 in contact with the EL layer 112G is the height of the upper surface of the EL layer 112G.
- An example is shown in which the height is substantially the same as the height, and the height of the end surface of the insulating layer 133 in contact with the EL layer 112B is higher than the height of the upper surface of the EL layer 112B, but one aspect of the present invention is not limited to this.
- the EL layer 112G may be processed into a strip shape so that the EL layer 112G is continuous in the column direction.
- 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). ) Method, atomic layer deposition (ALD) method, etc. can be used for formation.
- CVD method 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: Metal Organic CVD) method.
- the thin films (insulating film, semiconductor film, conductive film, etc.) that make up the display device include spin coating, dip, spray coating, inkjet, dispense, screen printing, offset printing, doctor knife method, slit coating, roll coating, curtain coating, etc. It can be formed by a method such as knife coating.
- the thin film When processing the thin film that constitutes the display device, a photolithography method or the like can be used.
- the thin film may be processed by a nanoimprint method, a sandblast method, a lift-off method, or the like.
- the island-shaped thin film may be directly formed by a film forming method using a shielding mask such as a metal mask.
- the photolithography method is 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 of these 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, etc. can be used for etching the thin film.
- a substrate having at least enough heat resistance to withstand the subsequent heat treatment can be used.
- a glass substrate, a quartz substrate, a sapphire substrate, a ceramic substrate, an organic resin substrate, or the like can be used.
- a single crystal semiconductor substrate made of silicon, silicon carbide or the like, a polycrystalline semiconductor substrate, a compound semiconductor substrate such as silicon germanium, or a semiconductor substrate such as an SOI substrate can be used.
- the substrate 101 it is preferable to use a substrate in which a semiconductor circuit including a semiconductor element such as a transistor is formed on the semiconductor substrate or an insulating substrate.
- the semiconductor circuit preferably comprises, for example, a pixel circuit, a gate line drive circuit (gate driver), a source line drive circuit (source driver), and the like.
- gate driver gate line drive circuit
- source driver source driver
- an arithmetic circuit, a storage circuit, and the like may be configured.
- Pixel Electrode 111R Pixel Electrode 111G, and Pixel Electrode 111B
- a plurality of pixel electrodes 111 are formed on the substrate 101.
- a conductive film to be a pixel electrode is formed, a resist mask is formed by a photolithography method, and an unnecessary portion of the conductive film is removed by etching. After that, by removing the resist mask, the pixel electrode 111R, the pixel electrode 111G, and the pixel electrode 111B can be formed.
- each pixel electrode When a conductive film having reflectivity to visible light is used as each pixel electrode, it is preferable to apply a material having as high a reflectance as possible in the entire wavelength range of visible light (for example, silver or aluminum). As a result, not only the light extraction efficiency of the light emitting device can be improved, but also the color reproducibility can be improved.
- the optical adjustment layer 115R, the optical adjustment layer 115G, and the optical adjustment layer 115B are provided, after forming the pixel electrode 111R, the pixel electrode 111G, and the pixel electrode 111B, the optics are used.
- the adjustment layer 115R, the optical adjustment layer 115G, and the optical adjustment layer 115B are formed.
- the end portions of the pixel electrode 111R, the pixel electrode 111G, and the pixel electrode 111B are covered to form the insulating layer 131 (FIG. 13A).
- the insulating layer 131 an organic insulating film or an inorganic insulating film can be used. It is preferable that the end of the insulating layer 131 has a tapered shape in order to improve the step covering property of the later EL film. In particular, when an organic insulating film is used, it is preferable to use a photosensitive material because the shape of the end portion can be easily controlled depending on the exposure and development conditions.
- an EL film 112Rf which will later become an EL layer 112R, is formed on the pixel electrode 111R, the pixel electrode 111G, the pixel electrode 111B, and the insulating layer 131 (FIG. 13B).
- the EL film 112Rf has a film containing at least a luminescent compound.
- one or more of the membranes functioning as an electron injection layer, an electron transport layer, a charge generation layer, a hole transport layer, or a hole injection layer may be laminated.
- a thin-film deposition method, a sputtering method, an inkjet method, or the like can be used. Not limited to this, the above-mentioned film forming method can be appropriately used.
- a sputtering method for the formation of the sacrificial film 144a, a sputtering method, an ALD method (thermal ALD method, PEALD method), or a vacuum deposition method can be used.
- a method that does not damage the EL film 112Rf for the formation of the sacrificial film 144a, the ALD method or the vacuum deposition method can be preferably used.
- the sacrificial film 144a is particularly suitable when aluminum oxide is used because the manufacturing cost can be reduced.
- the ALD method can form less film formation damage to the surface to be formed (for example, EL film 112Rf) as compared with the sputtering method.
- the sacrificial film 144a it is preferable to use a film that can be removed by a wet etching method.
- a wet etching method By using the wet etching method, it is possible to reduce the damage applied to the EL film 112Rf when the sacrificial film 144a is processed, as compared with the case where the dry etching method is used.
- the wet etching method for example, a developing solution, an aqueous solution of tetramethylammonium hydroxide (TMAH), dilute phosphoric acid, oxalic acid, phosphoric acid, acetic acid, nitric acid, or a chemical solution using a mixed solution thereof may be used. preferable.
- TMAH tetramethylammonium hydroxide
- the sacrificial film 144a a film having high resistance to etching treatment of each EL film such as EL film 112Rf, that is, a film having a large etching selection ratio can be used. Further, as the sacrificial film 144a, a film having a large etching selection ratio with a protective film such as a protective film 146a described later can be used. Further, as the sacrificial film 144a, a film that can be removed by a wet etching method with less damage to each EL film can be used.
- the conductivity of the sacrificial film 144a is not particularly limited. As the sacrificial film 144a, at least one of an insulating film, a semiconductor film, and a conductive film can be used.
- the sacrificial film 144a for example, an inorganic film such as a metal film, an alloy film, a metal oxide film, a semiconductor film, or an inorganic insulating film can be used.
- an organic film such as polyvinyl alcohol can be used as the sacrificial film 144a.
- the sacrificial film 144a is a metal material such as gold, silver, platinum, magnesium, nickel, tungsten, chromium, molybdenum, iron, cobalt, copper, palladium, titanium, aluminum, yttrium, zirconium, and tantalum, or the metal material.
- An alloy material containing can be used.
- the sacrificial film 144a As the sacrificial film 144a, a metal oxide such as indium gallium zinc oxide (also referred to as In-Ga-Zn oxide or IGZO) can be used. Further, the sacrificial film 144a includes indium oxide, indium zinc oxide (In-Zn oxide), indium tin oxide (In-Sn oxide), indium titanium oxide (In-Ti oxide), and indium zinc oxide. A substance (In-Sn-Zn oxide), indium titanium zinc oxide (In-Ti-Zn oxide), indium gallium tin zinc oxide (In-Ga-Sn-Zn oxide) and the like can be used. Alternatively, indium tin oxide containing silicon or the like can be used for the sacrificial film 144a.
- indium tin oxide containing silicon or the like can be used for the sacrificial film 144a.
- M is aluminum, silicon, boron, yttrium, copper, vanadium, beryllium, titanium, iron, nickel, germanium, zirconium, molybdenum, lanthanum, cerium, neodymium, hafnium, tantalum, tungsten). , Or one or more selected from magnesium).
- M is preferably one or more selected from gallium, aluminum, and yttrium.
- the above-mentioned In-Ga-Zn oxide is used as the sacrificial film 144a, it can be removed by using, for example, oxalic acid, phosphoric acid, acetic acid, nitric acid, or a mixed liquid thereof.
- the sacrificial film 144a may use an inorganic insulating material such as aluminum oxide, hafnium oxide, or silicon oxide.
- the sacrificial film 144a is suitable because damage to the substrate (particularly the EL layer) can be reduced by forming an aluminum oxide film by using the ALD method.
- the sacrificial film 144a may have a single-layer structure or a laminated structure of two or more layers.
- the laminated structure is typically a two-layer structure consisting of an In-Ga-Zn oxide formed by a sputtering method and a silicon nitride film formed by a sputtering method, and In-Ga formed by a sputtering method.
- the structure etc. can be mentioned.
- heat film formation may be used when forming the sacrificial film 144a by the ALD method or the sputtering method. Further, for the formation of the sacrificial film 144a, it is preferable to use a temperature at which the substrate (here, the EL film 112Rf) does not deteriorate.
- the substrate temperature at the time of film formation of the sacrificial film 144a is preferably room temperature or higher and 200 ° C. or lower, more preferably 50 ° C. or higher and 150 ° C. or lower, further preferably 70 ° C. or higher and 100 ° C. or lower, and typically in the vicinity of 80 ° C. It may be the temperature.
- the substrate temperature at the time of film formation of the sacrificial film 144a is low, the sacrificial film 144a becomes a sparse film, and the etching rate with respect to the etchant becomes high in a later process, so that the sacrificial film 144a disappears or a problem such as peeling occurs. It may end up.
- the temperature as described above it is possible to suppress the disappearance or the occurrence of peeling and the deterioration of the substrate.
- the protective film 146a is a film used later as a hard mask when etching the sacrificial film 144a. Further, when the protective film 146a is processed later, the sacrificial film 144a is exposed. Therefore, the sacrificial film 144a and the protective film 146a select a combination of films having a large etching selection ratio with each other. Therefore, a film that can be used for the protective film 146a can be selected according to the etching conditions of the sacrificial film 144a and the etching conditions of the protective film 146a.
- etching using a gas containing fluorine also referred to as a fluorine-based gas
- silicon, silicon oxide, silicon oxide nitride, silicon nitride oxide, silicon nitride, tungsten, and titanium when dry etching using a gas containing fluorine (also referred to as a fluorine-based gas) is used for etching the protective film 146a, silicon, silicon oxide, silicon oxide nitride, silicon nitride oxide, silicon nitride, tungsten, and titanium.
- Molybdenum, tantalum, tantalum nitride, an alloy containing molybdenum and niobium, an alloy containing molybdenum and tungsten, and the like can be used for the protective film 146a.
- a film capable of increasing the etching selection ratio that is, the etching rate can be slowed down
- a metal oxide film such as IGZO or ITO, which is used. It can be used for the sacrificial film 144a.
- the protective film 146a can be selected from various materials according to the etching conditions of the sacrificial film 144a and the etching conditions of the protective film 146a.
- it can be selected from the membranes that can be used for the sacrificial membrane 144a.
- a nitride film can be used as the protective film 146a.
- silicon nitride, aluminum nitride, hafnium nitride, titanium nitride, tantalum nitride, tungsten nitride, gallium nitride, germanium nitride and the like can be used.
- an oxide film can be used as the protective film 146a.
- silicon oxide, aluminum oxide, hafnium oxide, titanium oxide, tantalum oxide, tungsten oxide, gallium oxide, germanium oxide and the like can be used.
- an organic film that can be used for the EL film 112Rf or the like may be used.
- the same film as the organic film used for the EL film 112Rf, the EL film 112Gf, or the EL film 112Bf can be used for the protective film 146a.
- By using such an organic film it is possible to use the EL film 112Rf or the like in common with the film forming apparatus, which is preferable.
- resist mask 143a is formed on the protective film 146a at a position overlapping the pixel electrode 111R (FIG. 13D).
- the EL film 112Rf is dissolved by the solvent of the resist material. There is a risk that it will end up.
- the protective film 146a it is possible to prevent such a problem from occurring.
- a resist material containing a photosensitive resin such as a positive type resist material or a negative type resist material can be used.
- etching the protective film 146a it is preferable to use etching conditions with a high selection ratio so that the sacrificial film 144a is not removed by the etching.
- a wet etching method or a dry etching method can be used for etching the protective film 146a.
- a dry etching method can be preferably used, and by using the dry etching, it is possible to suppress the reduction of the pattern of the protective film 146a.
- a wet etching method or a dry etching method can be used to remove the resist mask 143a.
- the resist mask 143a is removed in a state where the EL film 112Rf is covered with the sacrificial film 144a, the influence on the EL film 112Rf is suppressed.
- the EL film 112Rf comes into contact with oxygen, it may adversely affect the electrical characteristics. Therefore, it is suitable for etching using oxygen gas such as plasma ashing to remove the resist mask 143a.
- a wet etching method or a dry etching method can be used for etching the sacrificial film 144a.
- a dry etching method can be preferably used for etching the sacrificial film 144a, and shrinkage of the pattern can be suppressed by using the dry etching method.
- etching gas containing no oxygen gas one or more selected from CF 4 , C 4 F 8 , SF 6 , CHF 3 , Cl 2 , H 2 O, B Cl 3 , H 2 , or noble gas can be used. ..
- the noble gas for example, He can be used.
- etching of the EL film 112Rf for example, dry etching using a mixed gas of H2 and Ar can be preferably used. Further, a mixed gas of the above gas and a gas containing no oxygen can be used as the etching gas.
- the film thickness of the insulating layer 131 in the region that does not overlap with the protective layer 147a and the sacrificial layer 145a may be reduced.
- the display device 100A shown in FIG. 6A or the like can be manufactured by etching the EL film 112Rf so that the film thickness of the insulating layer 131 in the region that does not overlap with the protective layer 147a and the sacrificial layer 145a is not thinned.
- a wet etching method or a dry etching method can be used to remove the protective layer 147a. At this time, it is preferable to use a method that does not damage the EL layer 112R as much as possible.
- a dry etching method can be preferably used for removing the protective layer 147a.
- an etching gas that does not contain oxygen gas As the etching gas containing no oxygen gas, one or more selected from CF 4 , C 4 F 8 , SF 6 , CHF 3 , Cl 2 , H 2 O, B Cl 3 , H 2 , or noble gas can be used. .. As the noble gas, for example, He can be used. Further, a mixed gas of the above gas and a gas containing no oxygen can be used as the etching gas.
- the etching of the EL film 112Rf and the removal of the protective layer 147a may be performed by the same treatment. By performing the same processing, the process can be simplified and the manufacturing cost of the display device can be reduced.
- the EL film 112Rf is formed, and the sacrificial film 144a, the protective film 146a, and the resist mask 143a are formed on the EL film 112Rf in this order.
- the protective film 146a is etched to form the protective layer 147a, and then the resist mask 143a is removed.
- the sacrificial film 144a is etched to form the sacrificial layer 145a.
- the EL film 112Rf is etched to form an island-shaped or band-shaped EL layer 112R. After that, by removing the protective layer 147a, the island-shaped EL layer 112R and the sacrificial layer 145a can be formed.
- an EL film 112Gf which will later become an EL layer 112G, is formed on the sacrificial layer 145a, the insulating layer 131, the pixel electrode 111G, and the pixel electrode 111B (FIG. 14E).
- the description of the EL film 112Rf can be referred to, so detailed description thereof will be omitted.
- a sacrificial film 144b is formed on the EL film 112Gf.
- the sacrificial membrane 144b can be formed in the same manner as the sacrificial membrane 144a. In particular, it is preferable to use the same material as the sacrificial film 144a for the sacrificial film 144b.
- the sacrificial membrane 144b since the description of the sacrificial membrane 144a can be referred to, detailed description thereof will be omitted.
- a protective film 146b is formed on the sacrificial film 144b.
- the protective film 146b since the description of the protective film 146a can be referred to, detailed description thereof will be omitted.
- resist mask 143b is formed on the protective film 146b at a position overlapping the pixel electrode 111G (FIG. 15A).
- the description of the resist mask 143a can be referred to, so detailed description thereof will be omitted.
- the film thickness of the insulating layer 131 in the region that does not overlap with the sacrificial layer 145a and the film thickness of the insulating layer 131 in the region that does not overlap with the protective layer 147b and the sacrificial layer 145b may be reduced.
- the film thickness of the insulating layer 131 in the region that does not overlap with the protective layer 147a and the sacrificial layer 145a becomes thin, and further, when the EL film 112Gf is etched, the film thickness does not overlap with the sacrificial layer 145a.
- the film thickness of the insulating layer 131 in the region and the insulating layer 131 in the region that does not overlap with the protective layer 147b and the sacrificial layer 145b may be reduced. In this case, as shown in FIG. 11, the film thickness of the insulating layer 131 in the region overlapping the EL film 112Gf may be thinner than the film thickness of the insulating layer 131 in the region overlapping the EL film 112Rf.
- the description of the protective layer 147a can be referred to, so detailed description thereof will be omitted.
- an EL film 112Bf which will later become an EL layer 112B, is formed on the sacrificial layer 145a, the sacrificial layer 145b, the insulating layer 131, and the pixel electrode 111B.
- the description of the EL film 112Rf can be referred to, and detailed description thereof will be omitted.
- a sacrificial film 144c is formed on the EL film 112Bf.
- the sacrificial membrane 144c can be formed in the same manner as the sacrificial membrane 144a. In particular, it is preferable to use the same material as the sacrificial film 144a for the sacrificial film 144c.
- the sacrificial membrane 144c since the description of the sacrificial membrane 144a can be referred to, detailed description thereof will be omitted.
- protective film 146c is formed on the sacrificial film 144c.
- the protective film 146c since the description of the protective film 146a can be referred to, detailed description thereof will be omitted.
- resist mask 143c is formed on the protective film 146c at a position overlapping the pixel electrode 111B (FIG. 16A).
- the description of the protective film 146a can be referred to, so detailed description thereof will be omitted.
- the description of the resist mask 143a can be referred to, so detailed description thereof will be omitted.
- the film thickness may be reduced.
- the thickness of the insulating layer 131 in the region that does not overlap with the protective layer 147a and the sacrificial layer 145a becomes thin
- the thickness of the region that does not overlap with the sacrificial layer 145a becomes thin.
- the thickness of the insulating layer 131 and the insulating layer 131 in the region not overlapping with the protective layer 147b and the sacrificial layer 145b is reduced, and further, the insulating layer 131 in the region not overlapping with the sacrificial layer 145a during etching of the EL film 112Bf.
- the thickness of the insulating layer 131 in the region not overlapping with the sacrificial layer 145b and the insulating layer 131 in the region not overlapping with the protective layer 147c and the sacrificial layer 145c may be reduced.
- the film thickness of the insulating layer 131 in the region overlapping the EL film 112Gf is thinner than the film thickness of the insulating layer 131 in the region overlapping the EL film 112Rf, and the insulating layer in the region overlapping the EL film 112Gf.
- the film thickness of the insulating layer 131 in the region overlapping the EL film 112Bf may be thinner than the film thickness of 131.
- the description of the protective layer 147a can be referred to, so detailed description thereof will be omitted.
- insulating film 133f is formed on the insulating layer 131, the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c (FIG. 17A).
- the insulating film 133f is a film that will later become the insulating layer 133.
- As the insulating film 133f for example, aluminum oxide, magnesium oxide, hafnium oxide, gallium oxide, indium gallium zinc oxide, silicon oxide, silicon nitride nitride, silicon nitride, silicon nitride or the like can be used.
- the insulating film 133f may be formed by laminating these.
- a sputtering method for the formation of the insulating film 133f, a sputtering method, a chemical vapor deposition (CVD) method, a molecular beam epitaxy (MBE) method, a pulsed laser deposition (PLD) method, an atomic layer deposition (ALD) method, or the like can be used.
- the ALD method having good coverage can be preferably used.
- a part of the insulating film 133f is removed to expose a part of the sacrificial layer 145a, a part of the sacrificial layer 145b, and a part of the sacrificial layer 145c.
- the insulating layer 133 covering the side surfaces of the EL layer 112R, the EL layer 112G, and the EL layer 112B is formed, and the insulating layer 133a is formed on the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c.
- a wet etching method or a dry etching method can be used to form the insulating layer 133 and the insulating layer 133a. In particular, anisotropic etching using a dry etching method can be preferably used.
- the insulating layer 133 when forming the insulating layer 133, all the insulating films 133f on the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c are removed, that is, on the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c. If the insulating layer 133a is not formed in any of the above, the width 133w of the insulating layer 133 may become small.
- a part of the sacrificial layer 145a, a part of the sacrificial layer 145b, and a part of the sacrificial layer 145c are exposed, and an insulating layer 133a is formed on the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c.
- FIG. 17A shows an example in which the insulating layer 133a is formed on the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c, but one aspect of the present invention is not limited to this. ..
- the insulating layer 133a may be formed on any one or more of the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c. Further, the insulating layer 133a may not be formed on any of the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c.
- the height of the end face of the insulating layer 133 can be adjusted by the amount of etching. It is preferable to adjust the etching amount so that the insulating layer 133 covers the side surface of the EL layer 112. In particular, it is preferable to adjust the etching amount so that the insulating layer 133 covers the side surface of the light emitting layer of the EL layer 112. Further, it is preferable to adjust the etching amount so that the width 133w of the insulating layer 133 in the region in contact with the side surface of the EL layer 112 is within the above range. Further, the film thickness of the insulating film 133f may be adjusted so as to have the desired height and width of the end face of the insulating layer 133 together with the etching amount.
- the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c are removed to expose the upper surfaces of the EL layer 112R, the EL layer 112G, and the EL layer 112B (FIG. 17C).
- the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c are removed, and the insulating layer 133a on the sacrificial layer 145a, the insulating layer 133a on the sacrificial layer 145b, and the insulating layer 133a on the sacrificial layer 145c are also removed. Will be done.
- a wet etching method or a dry etching method can be used to remove the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c. At this time, it is preferable to use a method that does not damage the EL layer 112R, the EL layer 112G, and the EL layer 112B as much as possible. In particular, it is preferable to use the wet etching method.
- TMAH tetramethylammonium hydroxide
- dilute hydrofluoric acid oxalic acid
- phosphoric acid oxalic acid
- acetic acid nitric acid
- a mixed liquid thereof aqueous solution of tetramethylammonium hydroxide (TMAH)
- TMAH tetramethylammonium hydroxide
- the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c are removed, and the insulating layer 133a and the sacrificial layer on the sacrificial layer 145a are removed.
- the insulating layer 133a on the 145b and the insulating layer 133a on the sacrificial layer 145c can also be removed (hereinafter, also referred to as lift-off).
- a part of the insulating layer 133 may be removed when the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c are removed.
- the height of the end face of the insulating layer 133 may be lowered when the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c are removed.
- a drying treatment is performed to remove the water contained inside the EL layer 112R, the EL layer 112G, and the EL layer 112B, and the water adsorbed on the surface. It is preferable to do so.
- the heat treatment can be carried out at a substrate temperature of 50 ° C. or higher and 200 ° C. or lower, preferably 60 ° C. or higher and 150 ° C. or lower, and more preferably 70 ° C. or higher and 120 ° C. or lower. It is preferable to use a reduced pressure atmosphere because it can be dried at a lower temperature.
- the insulating layer 133, the EL layer 112R, the EL layer 112G, and the EL layer 112B are covered to form the layer 116 (FIG. 17D).
- a thin-film deposition method, a sputtering method, an inkjet method, or the like can be used for the formation of the layer 116.
- the above-mentioned film forming method can be appropriately used.
- each layer constituting the layer 116 is formed.
- the layer 116a is an electron transport layer and the layer 116b is an electron injection layer
- an electron transport layer and an electron injection layer on the electron transport layer are formed.
- common electrode 113 [Formation of common electrode 113] Subsequently, the layer 116 is covered to form the common electrode 113.
- a sputtering method or a vapor deposition method can be used (FIG. 17D).
- the light emitting device 110R, the light emitting device 110G, and the light emitting device 110B can be manufactured.
- the protective layer 121 is formed on the common electrode 113 (FIG. 10A). It is preferable to use a sputtering method, a PECVD method, or an ALD method for forming the inorganic insulating film used for the protective layer 121.
- the ALD method is preferable because it has excellent step coverage and is less likely to cause defects such as pinholes. Further, it is preferable to use an inkjet method for forming the organic insulating film because a uniform film can be formed in a desired area.
- the display device 100E illustrated in the configuration example 8 can be manufactured.
- the EL layer 112R, the EL layer 112G, and the EL layer 112B can be separately manufactured. Further, since the process damage to the EL layer 112R, the EL layer 112G, and the EL layer 112B can be reduced, an extremely reliable display device can be realized.
- the formation order of the EL layer 112R, the EL layer 112G, and the EL layer 112B can be arbitrarily determined.
- the EL layer that is less susceptible to process damage may be formed first, and the EL layer that is susceptible to process damage may be formed later.
- the reliability of the display device can be further improved by setting the formation order in consideration of process damage.
- the insulating layer 131, the sacrificial layer 145a, the sacrificial layer 145b, and the insulating film 133f on the sacrificial layer 145c are formed (FIG. 17A). Since the description of the manufacturing method example 1 can be referred to until the insulating film 133f is formed, detailed description thereof will be omitted.
- a part of the insulating film 133f is removed by anisotropic etching to expose the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c.
- the EL layer 112R, the EL layer 112G, and the insulating layer 133 covering the side surfaces of the EL layer 112B are formed (FIG. 18).
- anisotropic etching for example, a dry etching method can be preferably used.
- the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c are removed to expose the upper surfaces of the EL layer 112R, the EL layer 112G, and the EL layer 112B (FIG. 17C).
- the sacrificial layer 145a, the sacrificial layer 145b, and the sacrificial layer 145c since the description of the production method example 1 can be referred to, detailed description thereof will be omitted.
- a drying treatment is performed to remove the water contained inside the EL layer 112R, the EL layer 112G, and the EL layer 112B, and the water adsorbed on the surface. It is preferable to do so.
- the drying treatment since the description of Production Method Example 1 can be referred to, detailed description thereof will be omitted.
- layer 116 is formed (FIG. 17D). Since the description of the above-mentioned production method example 1 can be referred to after the formation of the layer 116, detailed description thereof will be omitted.
- the display device 100E can be manufactured by the above steps.
- FIGS. 19A and 19B A schematic cross-sectional view of the display device 150 according to one aspect of the present invention is shown in FIGS. 19A and 19B.
- a schematic view of the top surface of the display device 150 can be referred to with reference to FIG. 1A.
- FIG. 19A is a schematic cross-sectional view corresponding to the alternate long and short dash line A1-A2 in FIG. 1A.
- FIG. 19B is a schematic cross-sectional view corresponding to the alternate long and short dash line B1-B2 in FIG. 1A.
- the display device 150 includes a light emitting unit 120R, a light emitting unit 120G, and a light emitting unit 120B.
- the light emitting unit 120R, the light emitting unit 120G, and the light emitting unit 120B each have a light emitting device 110W.
- the light emitting device 110W has a pixel electrode 111, an EL layer 112W, and a common electrode 113.
- the EL layer 112W and the common electrode 113 are commonly provided over a plurality of pixels.
- the EL layer 112W has a light emitting layer that exhibits white light.
- the light emitting device 110W is a light emitting device that emits white light.
- the light emitting unit 120R, the light emitting unit 120G, and the light emitting unit 120B each have a colored layer 122R, a colored layer 122G, or a colored layer 122B on the protective layer 121.
- the colored layer 122R transmits red light
- the colored layer 122G transmits green light
- the colored layer 122B transmits blue light. This makes it possible to realize a full-color display device.
- each light emitting device and each colored layer are compared with the case where the two substrates are bonded after forming the colored layer on a substrate different from the substrate 101. It becomes easy to align the display device, and an extremely high-definition display device can be realized.
- the EL layer 112W is divided between different light emitting units. As a result, it is possible to preferably prevent an unintended light emission (also referred to as crosstalk) due to a current flowing through the EL layer 112W between adjacent light emitting units. Therefore, the contrast can be enhanced, and a display device having high display quality can be realized.
- an unintended light emission also referred to as crosstalk
- the EL layer 112W may not be separated between the light emitting units of the same color.
- a plurality of pixel electrodes 111 and an insulating layer 131 are formed on the substrate 101. Further, these are covered to form an EL film 112Wf, a sacrificial film 144, and a protective film 146. Further, a resist mask 143 is formed on the protective film 146 at a position overlapping the pixel electrodes 111.
- the sacrificial film 144 not covered by the protective layer 147 is removed by etching to form the sacrificial layer 145 (FIG. 20D).
- the protective layer 147 as a mask, the EL film 112Wf not covered by the protective layer 147 is removed by etching, and the EL film 112Wf is separated. As a result, a plurality of strip-shaped EL layers 112W are formed (FIG. 21A).
- the protective layer 147 is removed by etching.
- an insulating film 133f is formed on the insulating layer 131 and the sacrificial layer 145 (FIG. 21B).
- a part of the insulating film 133f is removed by using anisotropic etching to expose the sacrificial layer 145.
- the insulating layer 133 that covers the side surface of the EL layer 112W is formed (FIG. 21C).
- anisotropic etching for example, a dry etching method can be preferably used.
- the sacrificial layer 145 on the EL layer 112 is removed to expose the upper surface of the EL layer 112W (FIG. 21D).
- a plurality of light emitting devices 110W can be manufactured by covering the EL layer 112W and the insulating layer 131 to form the layer 116 and the common electrode 113.
- the protective layer 121 is formed by covering the common electrode 113 (FIG. 21E).
- the colored layer 122R, the colored layer 122G, and the colored layer 122B are formed on the protective layer 121, respectively.
- a photolithography method using a photosensitive resin can be used for the formation of the colored layer 122R, the colored layer 122G, and the colored layer 122B.
- the display device 150 illustrated in the configuration example 9 can be manufactured.
- the insulating layer 131 and the insulating film 133f on the sacrificial layer 145 are formed (FIG. 21B). Since the description of the manufacturing method example 3 can be referred to until the insulating film 133f is formed, detailed description thereof will be omitted.
- a part of the insulating film 133f is removed by using anisotropic etching to expose the sacrificial layer 145.
- anisotropic etching for example, a dry etching method can be preferably used.
- the sacrificial layer 145 on the EL layer 112 is removed to expose the upper surface of the EL layer 112W (FIG. 21D).
- the description of the above-mentioned production method example 3 can be referred to, so detailed description thereof will be omitted.
- the display device 150 can be manufactured by the above steps.
- This embodiment can be implemented by appropriately combining at least a part thereof with other embodiments described in the present specification.
- 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, a large game machine such as a pachinko machine, or the like. In addition to electronic devices, it can be used as a display unit of a digital camera, a digital video camera, a digital photo frame, a mobile phone, a portable game machine, a smartphone, a wristwatch type terminal, a tablet terminal, a mobile information terminal, and a sound reproduction device.
- FIG. 23 shows a perspective view of the display device 400A
- FIG. 24A shows a cross-sectional view of the display device 400A.
- the display device 400A has a configuration in which a substrate 452 and a substrate 451 are bonded together.
- the substrate 452 is clearly indicated by a broken line.
- the display device 400A has a display unit 462, a circuit 464, a wiring 465, and the like.
- FIG. 23 shows an example in which IC473 and FPC472 are mounted on the display device 400A. Therefore, the configuration shown in FIG. 23 can be said to be a display module having a display device 400A, an IC (integrated circuit), and an FPC.
- a scanning line drive circuit can be used.
- the wiring 465 has a function of supplying signals and power to the display unit 462 and the circuit 464.
- the signal and power are input to the wiring 465 from the outside via the FPC 472 or from the IC 473.
- FIG. 23 shows an example in which the IC 473 is provided on the substrate 451 by the COG (Chip On Glass) method, the COF (Chip on Film) method, or the like.
- the IC 473 an IC having, for example, a scanning line drive circuit or a signal line drive circuit can be applied.
- the display device 400A and the display module may be configured not to be provided with an IC. Further, the IC may be mounted on the FPC by the COF method or the like.
- FIG. 24A shows an example of a cross section of the display device 400A when a part of the region including the FPC 472, a part of the circuit 464, a part of the display unit 462, and a part of the region including the end are cut. show.
- the display device 400A shown in FIG. 24A has a transistor 201, a transistor 205, a light emitting device 430a that emits red light, a light emitting device 430b that emits green light, and a light emitting device that emits blue light between the substrates 451 and the substrate 452. It has a device 430c and the like.
- the light emitting device exemplified in the first embodiment can be applied to the light emitting device 430a, the light emitting device 430b, and the light emitting device 430c.
- the three sub-pixels include three sub-pixels of R, G, and B, yellow (Y), and yellow (Y). Examples thereof include sub-pixels of three colors of cyan (C) and magenta (M).
- examples of the four sub-pixels include sub-pixels of four colors of R, G, B, and white (W), and sub-pixels of four colors of R, G, B, and Y. ..
- the protective layer 416 and the substrate 452 are adhered to each other via the adhesive layer 442.
- a solid sealing structure, a hollow sealing structure, or the like can be applied to seal the light emitting device.
- the substrate 452, the adhesive layer 442, and the space 443 surrounded by the substrate 451 are filled with an inert gas (such as nitrogen or argon), and a hollow sealing structure is applied.
- the adhesive layer 442 may be provided so as to overlap with the light emitting device. Further, the space 443 surrounded by the substrate 452, the adhesive layer 442, and the substrate 451 may be filled with a resin different from that of the adhesive layer 442.
- the light emitting devices 430a, 430b, and 430c have an optical adjustment layer between the pixel electrode and the EL layer.
- the light emitting device 430a has an optical adjustment layer 426a
- the light emitting device 430b has an optical adjustment layer 426b
- the light emitting device 430c has an optical adjustment layer 426c.
- the first embodiment can be referred to for the details of the light emitting device.
- the pixel electrode 411a, the pixel electrode 411b, and the pixel electrode 411c 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 electrode and the optical adjustment layer are covered with the insulating layer 421.
- 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 452 side. It is preferable to use a material having high transparency to visible light for the substrate 452.
- Both the transistor 201 and the transistor 205 are formed on the substrate 451. 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 451 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 for each of the insulating layer 211, the insulating layer 213, and the insulating layer 215.
- the 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 400A. As a result, it is possible to prevent impurities from entering from the end of the display device 400A 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 400A so that the organic insulating film is not exposed at the end portion of the display device 400A.
- 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 462 from the outside via the insulating layer 214. Therefore, the reliability of the display device 400A can be improved.
- the transistors 201 and 205 include 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 sources and drains, 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. Here, 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.
- the transistor may be driven by connecting two gates and supplying the same signal to them.
- 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 either an amorphous semiconductor or a semiconductor having crystallinity (microcrystal semiconductor, polycrystalline semiconductor, single crystal semiconductor, or semiconductor having a partially crystalline region). May be used. It is preferable to use 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 layer includes, for example, indium and the element M (M is gallium, aluminum, silicon, boron, ittrium, tin, copper, vanadium, beryllium, titanium, iron, nickel, germanium, zirconium, molybdenum, lanthanum, cerium, neodymium). , Hafnium, tantalum, tungsten, and one or more selected from 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 atomic number ratio of In is 4
- the atomic number ratio of Ga is 1 or more and 3 or less.
- the atomic number ratio of Ga is larger than 0.1 when the atomic number ratio of In is 5. This includes the case where the number of atoms is 2 or less and the atomic number ratio of Zn is 5 or more and 7 or less.
- the atomic number ratio of Ga is larger than 0.1 when the atomic number ratio of In is 1. This includes the case where the number of atoms of Zn is 2 or less and the atomic number ratio of Zn is larger than 0.1 and 2 or less.
- the transistor included in the circuit 464 and the transistor included in the display unit 462 may have the same structure or different structures.
- the structures of the plurality of transistors included in the circuit 464 may all be the same, or there may be two or more types.
- the structures of the plurality of transistors included in the display unit 462 may all be the same, or there may be two or more types.
- a connecting portion 204 is provided in a region of the substrate 451 where the substrates 452 do not overlap.
- the wiring 465 is electrically connected to the FPC 472 via the conductive layer 466 and the connection layer 242.
- the conductive layer 466 shows an example in which the conductive film obtained by processing the same conductive film as the pixel electrode and the conductive film obtained by processing the same conductive film as the optical adjustment layer have a laminated structure. ..
- the conductive layer 466 is exposed on the upper surface of the connecting portion 204. As a result, the connection portion 204 and the FPC 472 can be electrically connected via the connection layer 242.
- a light-shielding layer 417 on the surface of the substrate 452 on the substrate 451 side.
- various optical members can be arranged on the outside of the substrate 452. Examples of the optical member include a polarizing plate, a retardation plate, a light diffusing layer (diffusing film, etc.), an antireflection layer, a condensing 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 and the like are arranged. You may.
- the protective layer 416 that covers the light emitting device By providing the protective layer 416 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 416 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 416 are in contact with each other.
- FIG. 24B shows an example in which the protective layer 416 has a three-layer structure.
- the protective layer 416 has an inorganic insulating layer 416a on the light emitting device 430c, an organic insulating layer 416b on the inorganic insulating layer 416a, and an inorganic insulating layer 416c on the organic insulating layer 416b.
- the end of the inorganic insulating layer 416a and the end of the inorganic insulating layer 416c extend outward from the end of the organic insulating layer 416b and are in contact with each other. Then, the inorganic insulating layer 416a comes into 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 416, so that the reliability of the light emitting device can be improved.
- the protective layer 416 may have a laminated structure of an organic insulating film and an inorganic insulating film. At this time, it is preferable that the end portion of the inorganic insulating film extends outward rather than the end portion of the organic insulating film.
- Glass, quartz, ceramic, sapphire, resin, metal, alloy, semiconductor, etc. can be used for the substrate 451 and the substrate 452, 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 451 and the substrate 452, the flexibility of the display device can be increased.
- a polarizing plate may be used as the substrate 451 or the substrate 452.
- the substrate 451 and the substrate 452 are polyester resins such as polyethylene terephthalate (PET) and polyethylene naphthalate (PEN), polyacrylonitrile resin, acrylic resin, polyimide resin, polymethylmethacrylate resin, polycarbonate (PC) resin, and polyether sulfone, respectively.
- PET polyethylene terephthalate
- PEN polyethylene naphthalate
- polyacrylonitrile resin acrylic resin
- acrylic resin polyimide resin
- PC polymethylmethacrylate
- PC polycarbonate
- polyether sulfone polyether sulfone
- 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 (PES) PTFE) resin, ABS resin, cellulose nanofibers and the like can be used.
- PES polytetrafluoroethylene
- ABS resin cellulose nanofibers and the like
- glass having a thickness sufficient to have flexibility may be used.
- a substrate having high optical isotropic properties has a small amount of 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 properties 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
- the film When a film is used as the substrate, the film absorbs water, which may cause shape changes such as wrinkles on the display panel. Therefore, it is preferable to use a film having a low water absorption rate as the substrate. For example, it is preferable to use 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 type adhesive, a thermosetting type adhesive, and an anaerobic type 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 epoxy resin is preferable.
- a two-component mixed type resin may be used.
- connection layer 242 an anisotropic conductive film (ACF: Anisotropic Conductive Film), an anisotropic conductive paste (ACP: Anisotropic Connective Paste), or the like can be used.
- ACF Anisotropic Conductive Film
- ACP Anisotropic Connective Paste
- Materials that can be used for conductive layers such as transistor gates, sources and drains, as well as various wirings and electrodes that make up display devices include aluminum, titanium, chromium, nickel, copper, yttrium, zirconium, molybdenum, silver, and tantalum. , And metals such as 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 conductive layers such as various wirings and electrodes constituting the display device, and conductive layers (conductive layers that function as pixel electrodes or common electrodes) of the 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, silicon nitride, and aluminum oxide.
- FIG. 25A shows a cross-sectional view of the display device 400B.
- the perspective view of the display device 400B is the same as that of the display device 400A (FIG. 23).
- FIG. 25A shows an example of a cross section of the display device 400B when a part of the region including the FPC 472, a part of the circuit 464, and a part of the display unit 462 are cut.
- FIG. 25A shows an example of a cross section of the display unit 462 when a region including a light emitting device 430b that emits green light and a light emitting device 430c that emits blue light is cut.
- the description of the same part as that of the display device 400A may be omitted.
- the display device 400B shown in FIG. 25A has a transistor 202, a transistor 210, a light emitting device 430b, a light emitting device 430c, and the like between the substrates 453 and the substrate 454.
- the substrate 454 and the protective layer 416 are adhered to each other via the adhesive layer 442.
- the adhesive layer 442 is provided so as to overlap the light emitting device 430b and the light emitting device 430c, respectively, and a solid-state sealing structure is applied to the display device 400B.
- the substrate 453 and the insulating layer 212 are bonded to each other by an adhesive layer 455.
- the manufacturing substrate provided with the insulating layer 212, each transistor, each light emitting device, etc. and the substrate 454 provided with the light shielding layer 417 are bonded together by the adhesive layer 442. Then, by peeling off the production substrate and attaching the substrate 453 to the exposed surface, each component formed on the production substrate is transposed to the substrate 453. It is preferable that the substrate 453 and the substrate 454 have flexibility, respectively. Thereby, the flexibility of the display device 400B 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 pixel electrode is connected to the conductive layer 222b of the transistor 210 via 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 421. Further, the side surface of the EL layer is covered with an insulating layer 433.
- the light emitted by the light emitting devices 430b and 430c is emitted to the substrate 454 side. It is preferable to use a material having high transparency to visible light for the substrate 454.
- a connecting portion 204 is provided in a region of the substrate 453 where the substrates 454 do not overlap.
- the wiring 465 is electrically connected to the FPC 472 via the conductive layer 466 and the connection layer 242.
- the conductive layer 466 can be obtained by processing the same conductive film as the pixel electrode. As a result, the connection portion 204 and the FPC 472 can be electrically connected via the connection layer 242.
- the transistor 202 and the transistor 210 include a conductive layer 221 that functions as a gate, an insulating layer 211 that functions as a gate insulating layer, a semiconductor layer having a channel forming region 231i and a pair of low resistance regions 231n, and one of 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. 25A 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. 25B 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 openings of the insulating layer 215.
- an insulating layer 218 may be provided to cover the transistor.
- the display device of this embodiment can be a high-definition display device. Therefore, the display device of the present embodiment is attached to the head of, 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, and a device for AR of a glasses type. 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 of a glasses type a device for AR of a glasses type.
- FIG. 26A shows a perspective view of the display module 280.
- the display module 280 includes a display device 400C and an FPC 290.
- the display device included in the display module 280 is not limited to the display device 400C, and may be the display device 400D or the display device 400E 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 in which light from each pixel provided in the pixel unit 284, which will be described later, can be visually recognized.
- FIG. 26B 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 arranged periodically. An enlarged view of one pixel 284a is shown on the right side of FIG. 26B.
- the pixel 284a has light emitting devices 430a, 430b, and 430c having different emission colors.
- the plurality of light emitting devices may be arranged in a striped arrangement as shown in FIG. 26B.
- various arrangement methods such as a delta 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 the light emission of the three light emitting debuses possessed by one pixel 284a.
- the one pixel circuit 283a may be configured to be provided with three circuits for controlling the light emission of one light emitting device.
- the pixel circuit 283a can have at least one selection transistor, one current control transistor (drive transistor), and a capacitive element for each 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 one of the source and 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 extremely high.
- 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 fineness of 2000 ppi or more, preferably 3000 ppi or more, more preferably 5000 ppi or more, still more preferably 6000 ppi or more, 20000 ppi or less, or 30000 ppi or less. preferable.
- 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 the 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.
- the display device 400C shown in FIG. 27 includes a substrate 301, light emitting devices 430a, 430b, 430c, a capacitance 240, and a transistor 310.
- the substrate 301 corresponds to the substrate 291 in FIGS. 26A and 26B.
- the laminated structure 401 from the substrate 301 to the insulating layer 255 corresponds to the substrate in the first embodiment.
- the transistor 310 is a transistor having a channel forming region on the substrate 301.
- the substrate 301 for example, 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 an insulating layer 243.
- An insulating layer 255 is provided so as to cover the capacity 240, and light emitting devices 430a, 430b, 430c and the like are provided on the insulating layer 255.
- a protective layer 416 is provided on the light emitting devices 430a, 430b, and 430c, and a substrate 420 is bonded to the upper surface of the protective layer 416 by a resin layer 419.
- the substrate 420 corresponds to the substrate 292 in FIG. 26A.
- 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 400D The display device 400D shown in FIG. 28 is mainly different from the display device 400C in that the transistor configuration is different. The description of the same part as that of the display device 400C 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. 26A and 26B.
- the laminated structure 401 from the substrate 331 to the insulating layer 255 corresponds to the layer 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 into the transistor 320 and oxygen from being desorbed from the semiconductor layer 321 to the insulating layer 332.
- 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 and 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 and hydrogen from diffusing from the insulating layer 264 and the like into the semiconductor layer 321 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 that reach 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 that prevents impurities such as water and hydrogen from diffusing from the insulating layer 265 and the like into 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 420 in the display device 400D is the same as that of the display device 400C.
- the display device 400E shown in FIG. 29 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 400C and 400D 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, an insulating layer 263 and an insulating layer 332 are provided so as to cover the conductive layer 252, and a 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 preferably contains 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 is subjected to a chemical vapor deposition (CVD) method such as a sputtering method, an organic metal chemical vapor deposition (MOCVD) method, or an atomic layer deposition (ALD) method. It can be formed by law or the like.
- CVD chemical vapor deposition
- MOCVD organic metal chemical vapor deposition
- ALD atomic layer deposition
- Crystal structure of the oxide semiconductor amorphous (including compactly atomous), CAAC (c-axis-aligned crystalline), nc (nanocrystalline), CAC (crowd-aligned crystal), single crystal (single crystal), single crystal (single crystal). Polycrystalline) 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 clearly indicates the presence of crystals in the film 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 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, 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.
- Non-single crystal oxide semiconductors include, for example, the above-mentioned CAAC-OS and nc-OS.
- the non-single crystal oxide semiconductor includes a polycrystalline oxide semiconductor, a pseudo-amorphous oxide semiconductor (a-like OS: amorphous-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, and the plurality of crystal regions are oriented in a specific direction on the c-axis.
- 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 is a layer having indium (In) and oxygen (element M).
- indium In
- oxygen element M
- a layered crystal structure also referred to as a layered structure
- an In layer and a layer having elements M, zinc (Zn), and oxygen
- (M, Zn) layer are laminated.
- the (M, Zn) layer may contain indium.
- 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.
- 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, or that the bond distance between atoms changes due to the substitution of metal atoms. It is thought that this is the reason.
- 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 that has 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 lowered due to the mixing of impurities or the generation of defects, 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, when 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 does not show 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 structural analysis is performed on an nc-OS film using an XRD apparatus, 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 a size close thereto.
- 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.
- CAC-OS has a structure in which the material is separated into a first region and a second region to form a mosaic shape, and the first region is distributed in the film (hereinafter, also referred to as a cloud shape). It says.). That is, 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 where ⁇ In> is larger than ⁇ In> in the composition of the CAC-OS film.
- the second region is a region where ⁇ Ga> is larger than ⁇ Ga> in the composition of the CAC-OS film.
- 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 in which indium oxide, indium zinc oxide, or the like is the main component.
- the second region is a region in which gallium oxide, gallium zinc oxide, or the like is the 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 region containing In as a main component in a material composition containing In, Ga, Zn, and O. Is a mosaic-like structure, and these regions are randomly present. Therefore, it is presumed that CAC-OS has a structure in which metal elements are non-uniformly distributed.
- CAC-OS can be formed by a sputtering method, for example, under the condition that the substrate is not intentionally 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.
- the lower 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 preferable.
- 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 preferably 0% or more and less than 30%. Is preferably 0% or more and 10% or less.
- a region containing In as a main component (No. 1) by EDX mapping acquired by using energy dispersive X-ray spectroscopy (EDX: Energy Dispersive X-ray spectroscopy). It can be confirmed that the region (1 region) and the region containing Ga as a main component (second region) have a structure in which they are unevenly distributed and mixed.
- EDX Energy Dispersive X-ray spectroscopy
- the first region is a region having higher conductivity than the second region. That is, when the carrier flows through the first region, 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 added 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 highly reliable. Therefore, 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 with high field effect mobility can be realized. Moreover, 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, more preferably 1 ⁇ 10 11 cm ⁇ . It is 3 or less, more preferably less than 1 ⁇ 10 10 cm -3 , and more than 1 ⁇ 10 -9 cm -3 .
- 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 formation 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 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 .
- This embodiment can be implemented by appropriately combining at least a part thereof with other embodiments described in the present specification.
- 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 of one aspect of the present invention can be manufactured at a low cost, the manufacturing cost of an 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 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.
- electronic devices include, for example, wristwatch-type and bracelet-type information terminals (wearable devices), VR devices such as head-mounted displays, and glasses-type AR devices, which are wearable devices that can be worn on the head. And so on.
- wearable devices include devices for SR and devices 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 wall or outer wall of a house or building, or 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 includes sensors (force, displacement, position, velocity, acceleration, angular velocity, rotation speed, distance, light, liquid, magnetism, temperature, chemical substance, voice, time, hardness, electric field, current, voltage). , Including the ability to measure power, radiation, flow rate, 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 function to display a calendar, 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. 30A is a portable information terminal that can be used as a smartphone.
- the electronic device 6500 has 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. 30B is a schematic cross-sectional view including the 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 the display panel 6511, the optical member 6512, the touch sensor panel 6513, and the printed circuit board are provided in the 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).
- a part of the display panel 6511 is folded back in the area outside the display unit 6502, and the FPC 6515 is connected to the folded back part.
- IC6516 is mounted on FPC6515.
- the FPC6515 is connected to a terminal provided on the printed circuit board 6517.
- a flexible display (flexible display device) 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. 31A shows an example of a television device.
- the display unit 7000 is incorporated in the housing 7101.
- the 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. 31A can be performed by the operation switch provided 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 controller 7111 may have a display unit that displays information output from the remote controller 7111.
- the channel and volume can be operated by the operation keys or the touch panel provided on 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.
- the receiver can receive general television broadcasts.
- information communication is performed in one direction (from sender to receiver) or in two directions (between sender and receiver, or between recipients, etc.). It is also possible.
- FIG. 31B 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.
- FIGS. 31C and 31D An example of digital signage is shown in FIGS. 31C and 31D.
- the digital signage 7300 shown in FIG. 31C 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. 31D 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 that can be provided at one time can be increased. 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 it, which is preferable. Further, when it is used for 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 such as a smartphone or the information terminal 7411 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 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. 32A 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 removable 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 in addition to the finder 8100, a strobe device or the like can be connected.
- 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.
- 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 8000 with a built-in finder may be used.
- FIG. 32B 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 mounting portion 8201 has a built-in battery 8206.
- 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 unit 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 where it touches 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 has a function of displaying the biometric information of the user on the display unit 8204 and a 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 includes 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, it is possible to perform three-dimensional display or the like using parallax.
- 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 by using the lens 8305 as shown in FIG. 32E, 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. 32F is a diagram showing the appearance of the 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 eyesight of the user.
- the display unit 8404 is preferably a square or a horizontally long rectangle. As a result, the sense of presence can be enhanced.
- the mounting portion 8402 has plasticity and elasticity 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.
- the cushioning member 8403 is preferably made of a soft material so that when the user wears the head-mounted display 8400, it comes into close contact with the user's face. 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. 33A to 33F 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 (Including the function of), microphone 9008, and the like.
- the electronic devices shown in FIGS. 33A to 33F 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. 33A to 33F Details of the electronic devices shown in FIGS. 33A to 33F will be described below.
- FIG. 33A 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. 33A 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. Examples of information 9051 include notification of incoming calls such as e-mail, SNS, and telephone, titles such as e-mail and SNS, sender name, date and time, time, remaining battery level, and antenna reception strength. Alternatively, an icon 9050 or the like may be displayed at the position where the information 9051 is displayed.
- FIG. 33B 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. 33C is a perspective view showing a wristwatch-type mobile information terminal 9200.
- the mobile information terminal 9200 can be used as, for example, 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.
- 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.
- 33D to 33F are perspective views showing a foldable mobile information terminal 9201.
- 33D is a perspective view of the mobile information terminal 9201 in an unfolded state
- FIG. 33F is a folded state
- FIG. 33E is a perspective view of a state in which one of FIGS. 33D and 33F 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 display listability due to a wide seamless display area in the unfolded state.
- the display unit 9001 included in the mobile 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.
Abstract
Description
図2A及び図2Bは、表示装置の構成例を示す図である。
図3A及び図3Bは、表示装置の構成例を示す図である。
図4A及び図4Bは、表示装置の構成例を示す図である。
図5A及び図5Bは、表示装置の構成例を示す図である。
図6A乃至図6Cは、表示装置の構成例を示す図である。
図7A乃至図7Cは、表示装置の構成例を示す図である。
図8A乃至図8Cは、表示装置の構成例を示す図である。
図9A乃至図9Cは、表示装置の構成例を示す図である。
図10A及び図10Bは、表示装置の構成例を示す図である。
図11は、表示装置の構成例を示す図である。
図12A乃至図12Cは、表示装置の構成例を示す図である。
図13A乃至図13Eは、表示装置の作製方法例を示す図である。
図14A乃至図14Eは、表示装置の作製方法例を示す図である。
図15A乃至図15Dは、表示装置の作製方法例を示す図である。
図16A乃至図16Dは、表示装置の作製方法例を示す図である。
図17A乃至図17Dは、表示装置の作製方法例を示す図である。
図18は、表示装置の作製方法例を示す図である。
図19A乃至図19Cは、表示装置の構成例を示す図である。
図20A乃至図20Dは、表示装置の作製方法例を示す図である。
図21A乃至図21Eは、表示装置の作製方法例を示す図である。
図22は、表示装置の作製方法例を示す図である。
図23は、表示装置の一例を示す斜視図である。
図24A及び図24Bは、表示装置の一例を示す断面図である。
図25Aは、表示装置の一例を示す断面図である。図25Bは、トランジスタの一例を示す断面図である。
図26A及び図26Bは、表示モジュールの一例を示す斜視図である。
図27は、表示装置の一例を示す断面図である。
図28は、表示装置の一例を示す断面図である。
図29は、表示装置の一例を示す断面図である。
図30A及び図30Bは、電子機器の一例を示す図である。
図31A乃至図31Dは、電子機器の一例を示す図である。
図32A乃至図32Fは、電子機器の一例を示す図である。
図33A乃至図33F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の構成例、及び表示装置の作製方法例について説明する。
本発明の一態様の表示装置100の上面概略図を、図1Aに示す。表示装置100は、赤色を呈する発光デバイス110R、緑色を呈する発光デバイス110G、及び青色を呈する発光デバイス110Bをそれぞれ複数有する。図1Aでは、各発光デバイスの区別を簡単にするため、各発光デバイスの発光領域内にR、G、Bの符号を付している。
本発明の一態様の表示装置100Aの断面概要図を、図6A及び図6Bに示す。表示装置100Aの上面概略図は、図1Aを参照できる。図6Aは、図1A中の一点鎖線A1−A2に対応する断面概略図である。図6Bは、図1A中の一点鎖線B1−B2に対応する断面概略図である。また、図6Aの一点鎖線で囲った領域Qの拡大図を、図6Cに示す。
本発明の一態様の表示装置100Bの断面概要図を、図7A及び図7Bに示す。表示装置100Bの上面概略図は、図1Aを参照できる。図7Aは、図1A中の一点鎖線A1−A2に対応する断面概略図である。図7Bは、図1A中の一点鎖線B1−B2に対応する断面概略図である。また、図7Aの一点鎖線で囲った領域Rの拡大図を、図7Cに示す。
本発明の一態様の表示装置100Cの断面概要図を、図8A及び図8Bに示す。表示装置100Cの上面概略図は、図1Aを参照できる。図8Aは、図1A中の一点鎖線A1−A2に対応する断面概略図である。図8Bは、図1A中の一点鎖線B1−B2に対応する断面概略図である。また、図8Aの一点鎖線で囲った領域Sの拡大図を、図8Cに示す。
本発明の一態様の表示装置100Dの断面概要図を、図9A及び図9Bに示す。表示装置100Dの上面概略図は、図1Aを参照できる。図9Aは、図1A中の一点鎖線A1−A2に対応する断面概略図である。図9Bは、図1A中の一点鎖線B1−B2に対応する断面概略図である。また、図9Aの一点鎖線で囲った領域Tの拡大図を、図9Cに示す。
本発明の一態様の表示装置100Eの断面概要図を、図10A及び図10Bに示す。表示装置100Eの上面概略図は、図1Aを参照できる。図10Aは、図1A中の一点鎖線A1−A2に対応する断面概略図である。図10Bは、図1A中の一点鎖線B1−B2に対応する断面概略図である。また、図10Aの拡大図を、図11に示す。
本発明の一態様の表示装置100Fの断面概要図を、図12A及び図12Bに示す。表示装置100Fの上面概略図は、図1Aを参照できる。図12Aは、図1A中の一点鎖線A1−A2に対応する断面概略図である。図12Bは、図1A中の一点鎖線B1−B2に対応する断面概略図である。
本発明の一態様の表示装置100Gの断面概要図を、図12Cに示す。表示装置100Gの上面概略図は、図1Aを参照できる。図12Cは、図1A中の一点鎖線A1−A2に対応する断面概略図である。図1A中の一点鎖線B1−B2に対応する断面概略図は、図1Cまたは図1Dを参照できる。
以下では、本発明の一態様の表示装置の作製方法の一例について、図面を参照して説明する。ここでは、上記構成例で示した表示装置100Eを例に挙げて説明する。図13A乃至図17Dは、以下で例示する表示装置の作製方法の、各工程における断面概略図である。
基板101は、少なくとも後の熱処理に耐えうる程度の耐熱性を有する基板を用いることができる。基板101として、絶縁性基板を用いる場合には、ガラス基板、石英基板、サファイア基板、セラミック基板、有機樹脂基板などを用いることができる。また、シリコン、または炭化シリコンなどを材料とした単結晶半導体基板、多結晶半導体基板、シリコンゲルマニウム等の化合物半導体基板、SOI基板などの半導体基板を用いることができる。
続いて、基板101上に複数の画素電極111を形成する。まず画素電極となる導電膜を成膜し、フォトリソグラフィ法によりレジストマスクを形成し、導電膜の不要な部分をエッチングにより除去する。その後、レジストマスクを除去することで、画素電極111R、画素電極111G、及び画素電極111Bを形成することができる。
続いて、画素電極111R、画素電極111G、及び画素電極111Bの端部を覆って、絶縁層131を形成する(図13A)。絶縁層131は、有機絶縁膜または無機絶縁膜を用いることができる。絶縁層131は、後のEL膜の段差被覆性を向上させるために、端部をテーパー形状とすることが好ましい。特に、有機絶縁膜を用いる場合には、感光性の材料を用いると、露光及び現像の条件により端部の形状を制御しやすいため好ましい。
続いて、画素電極111R、画素電極111G、画素電極111B、及び絶縁層131上に、後にEL層112RとなるEL膜112Rfを成膜する(図13B)。
続いて、EL膜112Rfを覆って犠牲膜144aを形成する。
続いて、犠牲膜144a上に、保護膜146aを形成する(図13C)。
続いて、保護膜146a上であって、画素電極111Rと重なる位置に、レジストマスク143aを形成する(図13D)。
続いて、レジストマスク143aに覆われない保護膜146aの一部をエッチングにより除去し、島状または帯状の保護層147aを形成する(図13E)。
続いて、レジストマスク143aを除去する(図14A)。
続いて、保護層147aをマスクとして、保護層147aに覆われない犠牲膜144aの一部をエッチングにより除去し、島状または帯状の犠牲層145aを形成する(図14B)。
続いて、保護層147a及び犠牲層145aをマスクとして、保護層147a及び犠牲層145aに覆われないEL膜112Rfの一部をエッチングにより除去し、島状または帯状のEL層112Rを形成する(図14C)。当該処理により、絶縁層131の上面の一部、画素電極111Gの上面及び画素電極111Bの上面を露出させる。
続いて、エッチングにより保護層147aを除去する(図14D)。
続いて、犠牲層145a、絶縁層131、画素電極111G、及び画素電極111B上に、後にEL層112GとなるEL膜112Gfを成膜する(図14E)。
続いて、EL膜112Gf上に、犠牲膜144bを形成する。犠牲膜144bは、犠牲膜144aと同様の方法で形成することができる。特に、犠牲膜144bは、犠牲膜144aと同一材料を用いることが好ましい。犠牲膜144bについては、犠牲膜144aの記載を参照できるため、詳細な説明は省略する。
続いて、犠牲膜144b上に、保護膜146bを形成する。保護膜146bについては、保護膜146aの記載を参照できるため、詳細な説明は省略する。
続いて、保護膜146b上であって、画素電極111Gと重なる位置に、レジストマスク143bを形成する(図15A)。
続いて、レジストマスク143bに覆われない保護膜146bの一部をエッチングにより除去し、島状または帯状の保護層147bを形成する(図15B)。
続いて、レジストマスク143bを除去する。
続いて、保護層147bをマスクとして、保護層147bに覆われない犠牲膜144bの一部をエッチングにより除去し、島状または帯状の犠牲層145bを形成する。
続いて、保護層147b及び犠牲層145bをマスクとして、保護層147b及び犠牲層145bに覆われないEL膜112Gfの一部をエッチングにより除去し、島状または帯状のEL層112Gを形成する(図15C)。当該処理により、絶縁層131の上面の一部、画素電極111Bの上面を露出させる。
続いて、エッチングにより保護層147bを除去する(図15D)。
続いて、犠牲層145a、犠牲層145b、絶縁層131、及び画素電極111B上に、後にEL層112BとなるEL膜112Bfを成膜する。
続いて、EL膜112Bf上に、犠牲膜144cを形成する。犠牲膜144cは、犠牲膜144aと同様の方法で形成することができる。特に、犠牲膜144cは、犠牲膜144aと同一材料を用いることが好ましい。犠牲膜144cについては、犠牲膜144aの記載を参照できるため、詳細な説明は省略する。
続いて、犠牲膜144c上に、保護膜146cを形成する。保護膜146cについては、保護膜146aの記載を参照できるため、詳細な説明は省略する。
続いて、保護膜146c上であって、画素電極111Bと重なる位置に、レジストマスク143cを形成する(図16A)。
続いて、レジストマスク143cに覆われない保護膜146cの一部をエッチングにより除去し、島状または帯状の保護層147cを形成する。
続いて、レジストマスク143cを除去する(図16B)。
続いて、保護層147cをマスクとして、保護層147cに覆われない犠牲膜144cの一部をエッチングにより除去し、島状または帯状の犠牲層145cを形成する。
続いて、保護層147c及び犠牲層145cをマスクとして、保護層147c及び犠牲層145cに覆われないEL膜112Bfの一部をエッチングにより除去し、島状または帯状のEL層112Bを形成する(図16C)。当該処理により、絶縁層131の上面の一部、犠牲層145aの上面及び犠牲層145bの上面を露出させる。
続いて、エッチングにより保護層147cを除去する(図16D)。
続いて、絶縁層131、犠牲層145a、犠牲層145b及び犠牲層145c上に、絶縁膜133fを形成する(図17A)。
続いて、絶縁膜133fの一部を除去し、犠牲層145aの一部、犠牲層145bの一部、及び犠牲層145cの一部を露出させる。これにより、EL層112R、EL層112G、及びEL層112Bの側面を覆う絶縁層133が形成されるとともに、犠牲層145a上、犠牲層145b上、及び犠牲層145c上に絶縁層133aが形成される(図17B)。絶縁層133、及び絶縁層133aの形成は、ウェットエッチング法またはドライエッチング法を用いることができる。特に、ドライエッチング法を用いた異方性エッチングを好適に用いることができる。
続いて、犠牲層145a、犠牲層145b、及び犠牲層145cを除去し、EL層112R、EL層112G、及びEL層112Bの上面を露出させる(図17C)。このとき、犠牲層145a、犠牲層145b、及び犠牲層145cが除去されるとともに、犠牲層145a上の絶縁層133a、犠牲層145b上の絶縁層133a、及び犠牲層145c上の絶縁層133aも除去される。
続いて、絶縁層133、EL層112R、EL層112G、及びEL層112Bを覆って、層116を形成する(図17D)。層116の形成は、例えば、蒸着法、スパッタリング法、またはインクジェット法等を用いることができる。なお、これに限られず、上述した成膜方法を適宜用いることができる。
続いて、層116を覆って、共通電極113を形成する。共通電極113の形成は、例えば、スパッタリング法または蒸着法などを用いることができる(図17D)。
続いて、共通電極113上に、保護層121を形成する(図10A)。保護層121に用いる無機絶縁膜の成膜には、スパッタリング法、PECVD法、またはALD法を用いることが好ましい。特にALD法は、段差被覆性に優れ、ピンホールなどの欠陥が生じにくいため、好ましい。また、有機絶縁膜の成膜には、インクジェット法を用いると、所望のエリアに均一な膜を形成できるため好ましい。
以下では、前述の作製方法例1と一部が異なる作製方法例について、説明する。なお、前述の作製方法例1と重複する部分については説明を省略し、相違する部分について説明する。
続いて、異方性エッチングを用いて絶縁膜133fの一部を除去し、犠牲層145a、犠牲層145b、及び犠牲層145cを露出させる。これにより、EL層112R、EL層112G、及びEL層112Bの側面を覆う絶縁層133が形成される(図18)。異方性エッチングには、例えば、ドライエッチング法を好適に用いることができる。
続いて、犠牲層145a、犠牲層145b、及び犠牲層145cを除去し、EL層112R、EL層112G、及びEL層112Bの上面を露出させる(図17C)。犠牲層145a、犠牲層145b、及び犠牲層145cの除去については、作製方法例1の記載を参照できるため、詳細な説明は省略する。
続いて、層116を形成する(図17D)。層116の形成以降は、前述の作製方法例1の記載を参照できるため、詳細な説明は省略する。
以下では、白色発光を呈する発光デバイスを用いた場合の例について説明する。
以下では、上記構成例9で例示した表示装置150の作製方法の一例について、説明する。なお、前述の作製方法1と重複する部分については説明を省略する場合がある。
以下では、前述の作製方法例3と一部が異なる作製方法例について、説明する。なお、前述の作製方法例3と重複する部分については説明を省略し、相違する部分について説明する。
本実施の形態では、本発明の一態様の表示装置の構成例について説明する。
図23に、表示装置400Aの斜視図を示し、図24Aに、表示装置400Aの断面図を示す。
図25Aに、表示装置400Bの断面図を示す。表示装置400Bの斜視図は表示装置400A(図23)と同様である。図25Aには、表示装置400Bの、FPC472を含む領域の一部、回路464の一部、及び、表示部462の一部をそれぞれ切断したときの断面の一例を示す。図25Aでは、表示部462のうち、特に、緑色の光を発する発光デバイス430bと青色の光を発する発光デバイス430c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400A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、上記とは異なる表示装置の構成例について説明する。
図26A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400C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400Cに限られず、後述する表示装置400Dまたは表示装置400Eであってもよい。
図27に示す表示装置400Cは、基板301、発光デバイス430a、430b、430c、容量240、及び、トランジスタ310を有する。
図28に示す表示装置400Dは、トランジスタの構成が異なる点で、表示装置400Cと主に相違する。なお、表示装置400Cと同様の部分については説明を省略することがある。
図29に示す表示装置400E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400C、400D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、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(poly crystal)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、本発明の一態様の電子機器について図30乃至図33を用いて説明する。
Claims (13)
- 第1の画素電極と、第2の画素電極と、を形成する第1の工程と、
前記第1の画素電極及び前記第2の画素電極上に、第1のEL膜を成膜する第2の工程と、
前記第1のEL膜を覆う第1の犠牲膜を形成する第3の工程と、
前記第1の犠牲膜をエッチングして、前記第1の画素電極と重なる領域を有する第1の犠牲層を形成する第4の工程と、
前記第1のEL膜をエッチングして、前記第1の犠牲層と重なる領域を有する第1のEL層を形成するとともに、前記第2の画素電極を露出させる第5の工程と、
前記第1の犠牲層、及び前記第2の画素電極上に、第2のEL膜を成膜する第6の工程と、
前記第2のEL膜を覆う第2の犠牲膜を形成する第7の工程と、
前記第2の犠牲膜をエッチングして、前記第2の画素電極と重なる領域を有する第2の犠牲層を形成する第8の工程と、
前記第2のEL膜をエッチングして、前記第2の犠牲層と重なる領域を有する第2のEL層を形成する第9の工程と、
前記第1の犠牲層の上面及び側面、前記第1のEL層の側面、前記第2の犠牲層の上面及び側面、並びに前記第2のEL層の側面を覆う絶縁膜を形成する第10の工程と、
前記絶縁膜をエッチングして、前記第1のEL層の側面と接する領域、及び前記第2のEL層の側面と接する領域を有する第1の絶縁層を形成するとともに、前記第1の犠牲層、及び前記第2の犠牲層を露出させる第11の工程と、
前記第1の犠牲層、及び前記第2の犠牲層を除去する第12の工程と、を有する表示装置の作製方法。 - 第1の画素電極と、第2の画素電極と、を形成する第1の工程と、
前記第1の画素電極及び前記第2の画素電極上に、第1のEL膜を成膜する第2の工程と、
前記第1のEL膜を覆う第1の犠牲膜を形成する第3の工程と、
前記第1の犠牲膜をエッチングして、前記第1の画素電極と重なる領域を有する第1の犠牲層を形成する第4の工程と、
前記第1のEL膜をエッチングして、前記第1の犠牲層と重なる領域を有する第1のEL層を形成するとともに、前記第2の画素電極を露出させる第5の工程と、
前記第1の犠牲層、及び前記第2の画素電極上に、第2のEL膜を成膜する第6の工程と、
前記第2のEL膜を覆う第2の犠牲膜を形成する第7の工程と、
前記第2の犠牲膜をエッチングして、前記第2の画素電極と重なる領域を有する第2の犠牲層を形成する第8の工程と、
前記第2のEL膜をエッチングして、前記第2の犠牲層と重なる領域を有する第2のEL層を形成する第9の工程と、
前記第1の犠牲層の上面及び側面、前記第1のEL層の側面、前記第2の犠牲層の上面及び側面、並びに前記第2のEL層の側面を覆う絶縁膜を形成する第10の工程と、
前記絶縁膜をエッチングして、前記第1のEL層の側面と接する領域、及び前記第2のEL層の側面と接する領域を有する第1の絶縁層を形成するとともに、前記第1の犠牲層上の第2の絶縁層、及び前記第2の犠牲層上の第3の絶縁層を形成する第11の工程と、
前記第1の犠牲層、及び前記第2の犠牲層を除去するとともに、前記第2の絶縁層、及び前記第3の絶縁層を除去する第12の工程と、を有する表示装置の作製方法。 - 請求項1または請求項2において、
前記第1の犠牲膜は、金属膜、合金膜、金属酸化物膜、半導体膜、または無機絶縁膜の一または複数を有し、
前記第5の工程において、前記第1のEL膜のエッチングは、酸素ガスを含まないエッチングガスによるドライエッチングを用いる表示装置の作製方法。 - 請求項3において、
前記酸素ガスを含まないエッチングガスは、CF4、C4F8、SF6、CHF3、Cl2、H2O、BCl3、H2、または貴ガスから選ばれる一または複数である表示装置の作製方法。 - 請求項1乃至請求項4のいずれか一において、
前記第3の工程と前記第4の工程の間に、前記第1の画素電極と重なる領域を有する第1の保護層を形成する工程を有し、
前記第4の工程において、前記第1の保護層をマスクに、前記第1の犠牲膜をエッチングして、前記第1の犠牲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5の工程と前記第6の工程の間に、前記第1の保護層を除去する工程を有する表示装置の作製方法。 - 請求項1乃至請求項6のいずれか一において、
前記第12の工程の後に、前記第1のEL層の上面、前記第2のEL層の上面、前記第1の絶縁層の上面及び側面を覆う共通電極を形成する第13の工程を有する表示装置の作製方法。 - 請求項7において、
前記第12の工程と前記第13の工程との間に、前記第1のEL層の上面、前記第2のEL層の上面、前記第1の絶縁層の上面及び側面を覆う層を形成する工程を有し、
前記層は、電子注入性の高い物質を含む層である表示装置の作製方法。 - 請求項7において、
前記第12の工程と前記第13の工程との間に、前記第1のEL層の上面、前記第2のEL層の上面、前記第1の絶縁層の上面及び側面を覆う層を形成する工程を有し、
前記層は、電子輸送性の高い物質を含む第1の層と、前記第1の層上の電子注入性の高い物質を含む第2の層と、の積層構造である表示装置の作製方法。 - 請求項7において、
前記第12の工程と前記第13の工程との間に、前記第1のEL層の上面、前記第2のEL層の上面、前記第1の絶縁層の上面及び側面を覆う層を形成する工程を有し、
前記層は、正孔注入性の高い物質を含む層である表示装置の作製方法。 - 請求項7において、
前記第12の工程と前記第13の工程との間に、前記第1のEL層の上面、前記第2のEL層の上面、前記第1の絶縁層の上面及び側面を覆う層を形成する工程を有し、
前記層は、正孔輸送性の高い物質を含む第1の層と、前記第1の層上の正孔注入性の高い物質を含む第2の層と、の積層構造である表示装置の作製方法。 - 第1の画素電極と、第2の画素電極と、を形成する第1の工程と、
前記第1の画素電極及び前記第2の画素電極上に、EL膜を成膜する第2の工程と、
前記EL膜を覆う犠牲膜を形成する第3の工程と、
前記犠牲膜をエッチングして、前記第1の画素電極と重なる領域を有する第1の犠牲層と、前記第2の画素電極と重なる領域を有する第2の犠牲層と、を形成する第4の工程と、
前記EL膜をエッチングして、前記第1の犠牲層と重なる領域を有する第1のEL層と、前記第2の犠牲層と重なる領域を有する第2のEL層と、を形成する第5の工程と、
前記第1の犠牲層の上面及び側面、前記第1のEL層の側面、前記第2の犠牲層の上面及び側面、並びに前記第2のEL層の側面を覆う絶縁膜を形成する第6の工程と、
前記絶縁膜をエッチングして、前記第1のEL層の側面と接する領域、及び前記第2のEL層の側面と接する領域を有する第1の絶縁層を形成するとともに、前記第1の犠牲層、及び前記第2の犠牲層を露出させる第7の工程と、
前記第1の犠牲層、及び前記第2の犠牲層を除去する第8の工程と、を有し、
前記EL膜は、白色光を呈する発光層を有する、表示装置の作製方法。 - 第1の画素電極と、第2の画素電極と、を形成する第1の工程と、
前記第1の画素電極及び前記第2の画素電極上に、EL膜を成膜する第2の工程と、
前記EL膜を覆う犠牲膜を形成する第3の工程と、
前記犠牲膜をエッチングして、前記第1の画素電極と重なる領域を有する第1の犠牲層と、前記第2の画素電極と重なる領域を有する第2の犠牲層と、を形成する第4の工程と、
前記EL膜をエッチングして、前記第1の犠牲層と重なる領域を有する第1のEL層と、前記第2の犠牲層と重なる領域を有する第2のEL層と、を形成する第5の工程と、
前記第1の犠牲層の上面及び側面、前記第1のEL層の側面、前記第2の犠牲層の上面及び側面、並びに前記第2のEL層の側面を覆う絶縁膜を形成する第6の工程と、
前記絶縁膜をエッチングして、前記第1のEL層の側面と接する領域、及び前記第2のEL層の側面と接する領域を有する第1の絶縁層を形成するとともに、前記第1の犠牲層上の第2の絶縁層、及び前記第2の犠牲層上の第3の絶縁層を形成する第7の工程と、
前記第1の犠牲層、及び前記第2の犠牲層を除去するとともに、前記第2の絶縁層、及び前記第3の絶縁層を除去する第8の工程と、を有し、
前記EL膜は、白色光を呈する発光層を有する、表示装置の作製方法。
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