Display device and manufacturing method thereof

• US 7,535,018 B2
• Filed: 11/17/2005
• Issued: 05/19/2009
• Est. Priority Date: 04/27/2001
• Status: Expired due to Fees

• Current Assignee: Semiconductor Energy Laboratory Co., Ltd.
• Original Assignee: Semiconductor Energy Laboratory Co., Ltd.
• Inventors: Takahashi, Masahiro, Maruyama, Junya
• Primary Examiner(s): Pham; Long
• Application Number:
  US11/281,108
• Publication Number:
  US 20060065960A1
• Time in Patent Office: 1,279 Days
• Field of Search: 257/40, 257/79, 257/103
• US Class Current: 257/40
• CPC Class Codes: H10K 50/841 Self-supporting sealing arrangements
• CPC Class Codes: H10K 50/8426 Peripheral sealing arrangements, e.g. adhesives, sealants
• CPC Class Codes: H10K 50/846 comprising getter material or desiccants
• CPC Class Codes: H10K 59/12 Active-matrix OLED [AMOLED] displays
• 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 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass

Abstract

A technique for obtaining light emitting devices manufactured with high yield is provided. The width of a seal pattern (605b) can be kept thin by manufacturing a light emitting device using a second substrate (600a) which has a concave portion (607a) and a concave portion (608a). It therefore becomes possible to make the light emitting device have a narrow frame. In addition, the light emitting device with the narrow frame can be realized by a manufacturing method thereof in which a portion of the second substrate from the concave portion to an edge surface is cut.

Claims

1. A display device comprising:

a first substrate;

a second substrate in which at least a first concave portion and a second concave portion are formed; and

a light emitting element in which an anode, an organic layer, and a cathode are laminated over the first substrate,

wherein the second substrate and the first substrate are bonded through a sealing material,

wherein the sealing material fills the first concave portion of the second substrate,

wherein a drying agent is provided in the second concave portion,

wherein a width of the first concave portion is 0.8 to 1.0 mm, and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the sealing material is 1.1 to 1.3 mm.

2. The display device according to claim 1, the light emitting element comprising:

an anode over the first substrate, an organic layer over the anode, and a cathode over the organic layer.

3. The display device according to claim 1, wherein an inert gas fills a region surrounded by the first substrate, the second substrate and the sealing material.

4. The display device according to claim 3, wherein said inert gas includes at least one of molecular nitrogen and a noble gas.

5. The display device according to claim 1, wherein a resin fills a region surrounded by the first substrate, the second substrate and the sealing material.

6. The display device according to claim 5, wherein said resin is organic resin.

7. The display device according to claim 1, wherein the display device is one of the group consisting of a personal computer, a video camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

26. The display device according to claim 1, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

55. The display device according to claim 1, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

64. The display device according to claim 1, wherein the sealing material fills at least a portion of the first concave portion.

72. The display device according to claim 1 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.

8. A display device comprising:

a first substrate;

a second substrate in which at least a first concave portion and a second concave portion are formed, and

a light emitting element in which an anode, an organic layer, and a cathode are laminated over the first substrate,

wherein the second substrate and the first substrate are bonded through a seal pattern,

wherein a portion of the seal pattern is formed in a portion of the first concave portion,

wherein a drying agent is provided in the second concave portion,

wherein a width of the first concave portion is 0.8 to 1.0 mm, and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the seal pattern is 1.1 to 1.3 mm.

9. The display device according to claim 8, the light emitting element comprising:

an anode over the first substrate, an organic layer over the anode, and a cathode over the organic layer.

10. The display device according to claim 8, wherein an inert gas fills a region surrounded by the first substrate, the second substrate and the sealing material.

11. The display device according to claim 10, wherein said inert gas includes at least one of molecular nitrogen and a noble gas.

12. The display device according to claim 8, wherein a resin fills a region surrounded by the first substrate, the second substrate and the sealing material.

13. The display device according to claim 12, wherein said resin is organic resin.

14. The display device according to claim 8, wherein the display device is one of the group consisting of a personal computer, a video camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

27. The display device according to claim 8, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

56. The display device according to claim 8, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

73. The display device according to claim 8 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.

15. A display device comprising:

a first substrate;

a second substrate in which at least a first concave portion and a second concave portion are formed; and

a thin film transistor over the first substrate,

wherein the second substrate and the first substrate are bonded through a sealing material,

wherein the sealing material fills the first concave portion of the second substrate,

wherein a drying agent is provided in the second concave portion,

wherein a width of the first concave portion is 0.8 to 1.0 mm. and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the sealing material is 1.1 to 1.3 mm.

16. The display device according to claim 15 further comprising a light emitting element in which an anode, an organic layer, and a cathode are laminated on the first substrate.

17. The display device according to claim 15, wherein the display device is one of the group consisting of a personal computer, a video camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

28. The display device according to claim 15, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

57. The display device according to claim 16, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

65. The display device according to claim 15, wherein the sealing material fills at least a portion of the first concave portion.

74. The display device according to claim 15 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.

18. A display device comprising:

a first substrate;

a second substrate in which at least a first concave portion and a second concave portion are formed; and

a thin film transistor over the first substrate,

wherein the second substrate and the first substrate are bonded through a sealing material,

wherein the sealing material fills the first concave portion of the second substrate,

wherein a drying agent is provided in the second concave portion,

wherein an inert gas fills a region surrounded by the first substrate, the second substrate and the sealing material,

wherein a width of the first concave portion is 0.8 to 1.0 mm, and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the sealing material is 1.1 to 1.3 mm.

19. The display device according to claim 18 further comprising a light emitting element in which an anode, an organic layer, and a cathode are laminated on the first substrate.

20. The display device according to claim 18, wherein said inert gas includes at least one of molecular nitrogen and a noble gas.

21. The display device according to claim 18, wherein the display device is one of the group consisting of a personal computer, a video camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

29. The display device according to claim 18, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

58. The display device according to claim 19, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

66. The display device according to claim 18, wherein the sealing material fills at least a portion of the first concave portion.

75. The display device according to claim 18 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.

22. A display device comprising:

a first substrate;

a second substrate in which at least a first concave portion and a second concave portion are formed; and

a thin film transistor over the first substrate,

wherein the second substrate and the first substrate are bonded through a sealing material,

wherein the sealing material fills the first concave portion of the second substrate,

wherein a drying agent is provided in the second concave portion,

wherein a resin fills a region surrounded by the first substrate, the second substrate and the sealing material,

wherein a width of the first concave portion is 0.8 to 1.0 mm, and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the sealing material is 1.1 to 1.3 mm.

23. The display device according to claim 22 further comprising a light emitting element in which an anode, an organic layer, and a cathode are laminated on the first substrate.

24. The display device according to claim 22, wherein said resin is organic resin.

25. The display device according to claim 22, wherein the display device is one of the group consisting of a personal computer, a video camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

30. The display device according to claim 22, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

59. The display device according to claim 23, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

67. The display device according to claim 22, wherein the sealing material fills at least a portion of the first concave portion.

76. The display device according to claim 22 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.

31. A display device comprising:

a first substrate having a pixel region and a driver circuit region;

a second substrate in which at least a first concave portion and a second concave portion are formed;

a light emitting element in which an anode, an organic layer, and a cathode are laminated in the pixel region over the first substrate; and

a driver circuit in the driver circuit region over the first substrate,

wherein the second substrate and the first substrate are bonded through a sealing material,

wherein the pixel region and the driver circuit region are surrounded by the sealing material,

wherein the sealing material fills the first concave portion of the second substrate,

wherein a width of the first concave portion is 0.8 to 1.0 mm, and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the sealing material is 1.1 to 1.3 mm.

32. The display device according to claim 31, the light emitting element comprising:

an anode over the first substrate, an organic layer over the anode, and a cathode over the organic layer.

33. The display device according to claim 31, wherein an inert gas fills a region surrounded by the first substrate, the second substrate and the sealing material.

34. The display device according to claim 33, wherein said inert gas includes at least one of molecular nitrogen and a noble gas.

35. The display device according to claim 31, wherein a resin fills a region surrounded by the first substrate, the second substrate and the sealing material.

36. The display device according to claim 35, wherein said resin is organic resin.

37. The display device according to claim 31, wherein the display device is one of the group consisting of a personal computer, a video, camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

38. The display device according to claim 31, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

60. The display device according to claim 31, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

68. The display device according to claim 31, wherein the sealing material fills at least a portion of the first concave portion.

77. The display device according to claim 31 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.

39. A display device comprising:

a first substrate having a pixel region and a driver circuit region;

a second substrate in which at least a first concave portion and a second concave portion are formed;

a light emitting element in which an anode, an organic layer, and a cathode are laminated in the pixel region over the first substrate; and

a driver circuit in the driver circuit region over the first substrate,

wherein the second substrate and the first substrate are bonded through a sealing material,

wherein the pixel region and the driver circuit region are surrounded by the sealing material,

wherein the sealing material fills the first concave portion of the second substrate,

wherein a drying agent is provided in the second concave portion,

wherein a width of the first concave portion is 0.8 to 1.0 mm, and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the sealing material is 1.1 to 1.3 mm.

40. The display device according to claim 39, the light emitting element comprising:

an anode over the first substrate, an organic layer over the anode, and a cathode over the organic layer.

41. The display device according to claim 39, wherein an inert gas fills a region surrounded by the first substrate, the second substrate and the sealing material.

42. The display device according to claim 41, wherein said inert gas includes at least one of molecular nitrogen and a noble gas.

43. The display device according to claim 39, wherein a resin fills a region surrounded by the first substrate, the second substrate and the sealing material.

44. The display device according to claim 43, wherein said resin is orgamc resin.

45. The display device according to claim 39, wherein the display device is one of the group consisting of a personal computer, a video camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

46. The display device according to claim 39, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

61. The display device according to claim 39, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

69. The display device according to claim 39, wherein the sealing material fills at least a portion of the first concave portion.

78. The display device according to claim 39 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.

47. A display device comprising:

a first substrate having a pixel region and a driver circuit region;

a second substrate in which at least a first concave portion and a second concave portion are formed;

a thin film transistor in the pixel region over the first substrate; and

a driver circuit in the driver circuit region over the first substrate,

wherein the second substrate and the first substrate are bonded through a sealing material,

wherein the pixel region and the driver circuit region are surrounded by the sealing material,

wherein the sealing material fills the first concave portion of the second substrate,

wherein a width of the first concave portion is 0.8 to 1.0 mm, and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the sealing material is 1.1 to 1.3 mm.

48. The display device according to claim 47 further comprising a light emitting element in which an anode, an organic layer, and a cathode are laminated on the first substrate.

49. The display device according to claim 47, wherein the display device is one of the group consisting of a personal computer, a video camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

50. The display device according to claim 47, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

62. The display device according to claim 48, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

70. The display device according to claim 47, wherein the sealing material fills at least a portion of the first concave portion.

79. The display device according to claim 47 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.

51. A display device comprising:

a first substrate having a pixel region and a driver circuit region;

a second substrate in which at least a first concave portion and a second concave portion are formed;

a thin film transistor in the pixel region over the first substrate; and

a driver circuit in the driver circuit region over the first substrate,

wherein the second substrate and the first substrate are bonded through a sealing material,

wherein the pixel region and the driver circuit region are surrounded by the sealing material,

wherein the sealing material fills the first concave portion of the second substrate,

wherein a drying agent is provided in the second concave portion,

wherein a width of the first concave portion is 0.8 to 1.0 mm, and a depth of the first concave portion is 0.08 to 0.12 mm, and

wherein a width of the sealing material is 1.1 to 1.3 mm.

52. The display device according to claim 51 further comprising a light emitting element in which an anode, an organic layer, and a cathode are laminated on the first substrate.

53. The display device according to claim 51, wherein the display device is one of the group consisting of a personal computer, a video camera, a portable information terminal, a digital camera, a DVD player, an onboard reverse direction confirmation monitor for a vehicle, a TV telephone, a head-mounted display, a car navigation system, a car audio system, and an electronic amusement device.

54. The display device according to claim 51, wherein a third concave portion is formed in the second substrate, and

wherein the second concave portion is formed in said third concave portion.

63. The display device according to claim 52, wherein the organic layer comprises a high molecular weight organic material, and wherein the organic layer is formed by ink jet printing.

71. The display device according to claim 51, wherein the sealing material fills at least a portion of the first concave portion.

80. The display device according to claim 51 further comprising a fourth concave portion adjacent to the first concave portion,

wherein the sealing material fills at least a portion of the first concave portion and a portion of the fourth concave portion.