ORGANIC EL DISPLAY MANUFACTURING METHOD

• US 20110287682A1
• Filed: 02/01/2010
• Published: 11/24/2011
• Est. Priority Date: 02/10/2009
• Status: Active Grant

• Current Assignee: JDI Design and Development GK
• Original Assignee: Panasonic Corporation (Panasonic Holdings Corporation)
• Inventors: Kuriya, Yutaka, Miyazawa, Kazutoshi
• Granted Patent: US 9,111,886 B2
• Time in Patent Office: Days
• US Class Current: 445/2
• 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 71/135 using ink-jet printing
• CPC Class Codes: H10K 71/861 Repairing

Abstract

The disclosed method is for manufacturing organic EL displays that comprise a substrate and multiple organic EL elements that are disposed in a matrix form on said substrate, and wherein said organic EL elements comprise pixel electrodes that are disposed on said substrate, an organic layer that is disposed on said pixel electrodes and a counter-electrode that is disposed on said organic layer. The organic EL display manufacturing method comprises a step for forming banks that delineate the organic layer on the substrate, a step for coating the region delineated by said banks with a solution comprising an organic material and forming the organic layer, a step for detecting defectively formed portions of said organic layer, a step for removing said defectively formed portions, a step for forming a recessed part or a protruding part around the region from which said poorly formed portion has been removed, and a step for re-coating the region from which said defectively formed portion was removed with the solution comprising the organic material.

Claims

1. A method of manufacturing an organic EL display, the organic EL display including a substrate and a plurality of organic EL devices disposed on the substrate in a matrix pattern, the method comprising:

forming on the substrate banks for defining an organic layer;

applying a solution of organic material in a region defined by the banks, to form the organic layer;

detecting a defect of the organic layer;

removing the defect;

forming a depression or a protrusion around a region from which the defect has been removed; and

reapplying the solution of organic material in the region from which the defect has been removed.

2. The manufacturing method according to claim 1, wherein the defect is removed by laser irradiation.

3. The manufacturing method according to claim 1, wherein an inkjet printer, a dispenser or a coating needle is used to reapply the solution of organic material in the region from which the defect has been removed.

4. The manufacturing method according to claim 1, wherein a fine droplet transfer device is used to reapply the solution of organic material in the region from which the defect has been removed.

5. The manufacturing method according to claim 4, wherein the fine droplet transfer device includes a solution container tube for containing therein the solution of organic material, and a transfer pin configured to be capable of passing through the solution container tube,

the solution of organic material is applied in the region from which the defect has been removed, by lowering the transfer pin through the solution container tube to the region from which the defect has been removed, and

when the solution of organic material is applied in the region from which the defect has been removed, the transfer pin does not come in direct contact with the organic layer.

6. The manufacturing method according to claim 5, wherein a tip of the transfer pin is planar.

7. The manufacturing method according to claim 1, wherein the depression is a groove.

8. The manufacturing method according to claim 1, wherein the depression is a hole.

9. The manufacturing method according to claim 1, wherein the protrusion is a partition wall formed around the region from which the defect has been removed.