Self-luminous display panel manufacturing method and self-luminous display panel

• US 10,644,085 B2
• Filed: 08/28/2018
• Issued: 05/05/2020
• Est. Priority Date: 08/28/2017
• Status: Active Grant

• Current Assignee: JDI Design and Development GK
• Original Assignee: JOLED Inc.
• Inventors: Kondo, Tetsuro
• Primary Examiner(s): Landis, Lisa S
• Application Number:
  US16/114,228
• Publication Number:
  US 20190067395A1
• Time in Patent Office: 616 Days
• CPC Class Codes: G09G 3/3225 using an active matrix
• CPC Class Codes: H10K 50/11 characterised by the electroluminescent [EL] layers
• CPC Class Codes: H10K 50/16 Electron transporting layers
• CPC Class Codes: H10K 50/171 Electron injection layers
• CPC Class Codes: H10K 50/818 Reflective anodes, e.g. ITO combined with thick metallic layers
• CPC Class Codes: H10K 50/828 Transparent cathodes, e.g. comprising thin metal layers
• CPC Class Codes: H10K 50/8426 Peripheral sealing arrangements, e.g. adhesives, sealants
• CPC Class Codes: H10K 59/122 Pixel-defining structures or layers, e.g. banks
• CPC Class Codes: H10K 59/173 comprising banks or shadow masks
• CPC Class Codes: H10K 59/35 comprising red-green-blue [RGB] subpixels
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 71/135 using ink-jet printing
• CPC Class Codes: H10K 71/861 Repairing

Abstract

A method of manufacturing a self-luminous display panel, includes: preparing a substrate; forming banks above the substrate; detecting a bank having a defect portion; determining, with respect to the detected bank, only one of two adjacent spaces as a repair target space; forming a dam structure in the repair target space; and forming light-emitting layers. The banks are elongated and extend in a column direction, and are arranged in a row direction with spaces therebetween. The two adjacent spaces are each located between the detected bank and an adjacent bank. The dam structure is located within a predetermined distance from the defect portion, and at least partially surrounds the defect portion or is composed of a pair of dam elements disposed with the defect portion therebetween in the column direction. The light-emitting layers are formed by applying inks to the spaces between the banks. The inks contain self-luminous materials.

Claims

1. A method of manufacturing a self-luminous display panel, the method comprising:

preparing a substrate;

forming, above the substrate, banks that are each elongated and each extend in a column direction, the banks being arranged in a row direction with spaces therebetween;

detecting a bank having a defect portion among the banks;

determining, with respect to the detected bank having the defect portion, only one of two adjacent spaces as a repair target space, the two adjacent spaces each being located between the detected bank and a bank adjacent to the detected bank in the row direction;

forming, in the repair target space, a dam structure within a predetermined distance from the defect portion, the dam structure at least partially surrounding the defect portion or being composed of a pair of dam elements disposed with the defect portion therebetween in the column direction; and

forming light-emitting layers by applying inks to the spaces between the banks, the inks containing self-luminous materials.

2. The method of claim 1, wherein

the determining determines, as the repair target space, the one space in which a light-emitting layer emitting light at a shorter wavelength is to be formed than in the other space.

3. The method of claim 1, wherein

in the forming of the light-emitting layers, an ink that is applied to a region defined by the dam structure in the repair target space flows into the other space via the defect portion.

4. The method of claim 1, wherein

in the forming of the light-emitting layers, an ink that is applied to the other space flows into a region defined by the dam structure in the repair target space via the defect portion.

5. A self-luminous display panel comprising:

a substrate;

banks disposed above the substrate, the banks each being elongated and extending in a column direction and being arranged in a row direction with spaces therebetween; and

light-emitting layers containing self-luminous materials, the light-emitting layers being formed by applying inks to the spaces between the banks, wherein

at least one of the banks has a defect portion, and

with respect to the bank having the defect portion, a dam structure is provided in only one of two adjacent spaces that are each located between the bank and a bank adjacent to the bank in the row direction, the dam structure being within a predetermined distance from the defect portion, and at least partially surrounding the defect portion or being composed of a pair of dam elements disposed with the defect portion therebetween in the column direction.

6. The self-luminous display panel of claim 5, wherein

the dam structure is provided in the one space in which a light-emitting layer emitting light at a shorter wavelength is formed than in the other space.

7. The self-luminous display panel of claim 5, wherein

the other space includes a self-luminous material that is contained in an ink applied to the one space.

8. The self-luminous display panel of claim 5, wherein

the one space includes a self-luminous material that is contained in an ink applied to the other space.