BANK REPAIR METHOD, ORGANIC EL DISPLAY DEVICE AND MANUFACTURING METHOD THEREOF

• US 20170170244A1
• Filed: 02/06/2015
• Published: 06/15/2017
• Est. Priority Date: 02/10/2014
• Status: Active Grant

• Current Assignee: JDI Design and Development GK
• Original Assignee: JOLED Inc.
• Inventors: ONIMARU, Toshiaki, SHIMAMURA, Takayuki, KOBAYASHI, Kazuhiro, HAYASHIDA, Yoshiki
• Granted Patent: US 9,818,809 B2
• Time in Patent Office: Days
• CPC Class Codes: H10K 50/11 characterised by the electroluminescent [EL] layers
• CPC Class Codes: H10K 59/1201 Manufacture or treatment
• 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 71/13 using printing techniques, e.g. ink-jet printing or screen printing
• CPC Class Codes: H10K 71/861 Repairing

Abstract

An examination is performed of whether or not a bank having a defect portion is present. When a bank having a defect portion is present, the bank having the defect portion is repaired by forming a dam in each of adjacent concave spaces between which the bank having the defect portion is located. A dam formed in a concave space partitions the concave space into a first space in a vicinity of the defect portion and a second space outside the vicinity of the defect portion. The dam, at a portion thereof with lowest height, satisfies (h/H)+0.1W≧1.5, 0.5≦(h/H)≦2.0, and 5≦W≦50, where a ratio of the height h of the dam to a height H of the banks is denoted as h/H, and a width of the dam is denoted as W μm.

Claims

1. A bank repair method for repairing a defect portion of a bank in a process of manufacturing an organic electroluminescence (EL) display device including a substrate, banks formed over the substrate, and light-emitting layers formed in concave spaces defined by the banks, the bank repair method comprising:

examining whether or not a bank having a defect portion is present; and

when a bank having a defect portion is present, repairing the bank having the defect portion by forming a dam in each of adjacent concave spaces between which the bank having the defect portion is located, a dam formed in a concave space partitioning the concave space into a first space in a vicinity of the defect portion and a second space outside the vicinity of the defect portion, wherein

the dam, at a portion thereof with lowest height, satisfies (h/H)+0.1 W≧

1.5, 0.5≦

(h/H)≦

2.0, and 5≦

W≦

50, where

a ratio of the height h of the dam to a height H of the banks is denoted as h/H, and a width of the dam is denoted as W μ

m.

2. The bank repair method according to claim 1, wherein

the banks all extend in one direction along a surface of the substrate and each have a rectangular shape in plan view, and appear as a plurality of parallel lines in plan view, and

the dam in each of the adjacent concave spaces is a pair of dams, the dams each extending from a different one of two points of the bank having the defect portion to an adjacent bank, the defect portion being located between the two points in the one direction.

3. The bank repair method according to claim 2 further comprising

forming protruding portions protruding from upper portions of bank portions in contact with the dams, the bank portions comprising portions of the bank having the defect portion that are in contact with end portions of the dams and portions of the adjacent bank that are in contact with end portions of the dams.

4. The bank repair method according to claim 1, wherein

the banks all extend in one direction along a surface of the substrate and each have a rectangular shape in plan view, and appear as a plurality of parallel lines in plan view, and

the dam in each of the adjacent concave spaces is a single dam extending between two points of the bank having the defect portion while detouring around the defect portion, the defect portion being located between the two points in the one direction.

5. The bank repair method according to claim 4, wherein

the single dam is in contact with a bank adjacent to the bank having the defect portion at some point along a path between the two points.

6. The bank repair method according to claim 4, wherein

the single dam is not in contact with a bank adjacent to the bank having the defect portion.

7. The bank repair method according to claim 1, wherein

the defect portion is a portion of a bank where a foreign particle is present or a portion of a bank having collapsed.

8. The bank repair method according to claim 1, wherein

the ratio h/H and the width W satisfy

(h/H)+0.1W≧

2.0.

9. An organic electroluminescence (EL) display device comprising:

a substrate;

banks formed over the substrate; and

light-emitting layers disposed in concave spaces defined by the banks, wherein

a dam is disposed in each of adjacent concave spaces between which a bank having a defect portion is located, a dam disposed in a concave space partitioning a light-emitting layer disposed in the concave space into a first light-emitting layer in a vicinity of the defect portion and a second light-emitting layer outside the vicinity of the defect portion, and

the dam, at a portion thereof with lowest height, satisfies (h/H)+0.1 W≧

1.5, 0.5≦

(h/H)≦

2.0, and 5≦

W≦

50, where

a ratio of the height h of the dam to a height H of the banks is denoted as h/H, and a width of the dam is denoted as W μ

m.

10. The organic EL display device according to claim 9, wherein

the banks all extend in one direction along a surface of the substrate and each have a rectangular shape in plan view, and appear as a plurality of parallel lines in plan view, and

the dam in each of the adjacent concave spaces is a pair of dams, the dams each extending from a different one of two points of the bank having the defect portion to an adjacent bank, the defect portion being located between the two points in the one direction.

11. The organic EL display device according to claim 10 further comprising

protruding portions protruding from upper portions of bank portions in contact with the dams, the bank portions comprising portions of the bank having the defect portion that are in contact with end portions of the dams and portions of the adjacent bank that are in contact with end portions of the dams.

12. The organic EL display device according to claim 9, wherein

the banks all extend in one direction along a surface of the substrate and each have a rectangular shape in plan view, and appear as a plurality of parallel lines in plan view, and

the dam in each of the adjacent concave spaces is a single dam extending between two points of the bank having the defect portion while detouring around the defect portion, the defect portion being located between the two points in the one direction.

13. The organic EL display device according to claim 12, wherein

the single dam is in contact with a bank adjacent to the bank having the defect portion at some point along a path between the two points.

14. The organic EL display device according to claim 12, wherein

the single dam is not in contact with a bank adjacent to the bank having the defect portion.

15. The organic EL display device according to claim 9, wherein

the defect portion is a portion of a bank where a foreign particle is present or a portion of a bank having collapsed.

16. The organic EL display device according to claim 9, wherein

the first light-emitting layer contains materials of adjacent second light-emitting layers between which the bank having the defect portion is located.

17. The organic EL display device according to claim 9, wherein

the ratio h/H and the width W satisfy

(h/H)+0.1W≧

2.0.

18. A manufacturing method for an organic EL display device, comprising:

forming banks over a substrate;

examining whether or not a bank having a defect portion is present;

when a bank having a defect portion is present, repairing the bank having the defect portion by forming a dam in each of adjacent concave spaces between which the defect portion is located, a dam formed in a concave space partitioning the concave space into a first space in a vicinity of the defect portion, and a second space outside the vicinity of the defect portion; and

forming light-emitting layers in concave spaces defined by the banks after forming the dam, wherein

the dam, at a portion thereof with lowest height, satisfies (h/H)+0.1W≧

1.5, 0.5≦

(h/H)≦

2.0, and W≦

50, where

a ratio of the height h of the dam to a height H of the banks is denoted as h/H, and a width of the dam is denoted as W μ

m.

19. The manufacturing method according to claim 18, wherein

the dam is formed to be spaced away from the defect portion, and

in the forming of the light-emitting layers, a portion of a light-emitting layer is formed in the space between the dam and the defect portion.

20. The manufacturing method according to claim 18, wherein

the ratio h/H and the width W satisfy

(h/H)+0.1W≧

2.0.