Patent Application
20100308332
1. Technical Field
This present invention relates to a display device that uses electroluminescent elements (hereinafter, referred to simply as EL).
2. Background Art
In recent years, among many kinds of flat panel display devices, those display devices that use electroluminescent elements have drawn public expectations. The display device using EL elements has advantages, such as a spontaneous light-emitting property, superior visibility, a wide viewing angle and a high response speed. Moreover, EL elements that have been currently developed include inorganic EL elements in which an inorganic material is used for its illuminant, and organic EL elements in which an organic material is used for its illuminant.
The inorganic EL element using an inorganic phosphor, such as zinc sulfide as an illuminant, has such a structure that electrons, accelerated by an electric field as high as 106V/cm, are made to collide with the luminescence centers of the phosphors so as to be exited and when they are alleviated, light is emitted. The inorganic EL elements include dispersion-type EL elements having a structure in which phosphor powder is dispersed in a polymer organic material or the like with electrodes being formed on the upper and lower sides thereof, and thin-film-type EL elements having a structure in which two dielectric layers are formed between a pair of electrodes with a thin-film phosphor layer being sandwiched between the dielectric layers. Although the dispersion-type EL elements can be easily produced, they have low luminance and short service life, with the result that the application thereof is limited. In contrast, with respect to the thin-film-type EL elements, those elements having a double insulating structure, which have been proposed by Inokuchi et al., in 1974, exhibit high luminance and long service life, and have been put into practical use as displays for use in vehicles, as shown in Japanese Patent Laid-open Publication No. 52-33491.
Referring to
Moreover, upon configuring a display device by arranging a plurality of EL elements two-dimensionally, a plurality of EL elements aligned over the same row may be made to use the common transparent electrode, and a plurality of EL elements aligned over the same column may be made to use the common back electrode. In this case, one transparent electrode serves as a data electrode that extends in a column direction, and one back electrode serves as a scanning electrode that extends in a row direction so that a plurality of data electrodes that are in parallel with each other and a plurality of scanning electrodes are patterned into stripes that are made orthogonal to each other. By applying a voltage to a specific pixel selected within the matrix of the data electrodes and the scanning electrodes, a display device of a passive matrix driving system, which carries out a desired pattern display, can be obtained.
In this case, however, when the display device using the inorganic EL elements is utilized as a high-quality display device, such as a television, luminance of about 300 cd/m2 or more is required, with the result that the device becomes insufficient from the viewpoint of light emission luminance. Moreover, with a display device of a passive matrix driving system, when the number of the scanning lines increases along with the developments of a high definition system, the luminance is further lowered. Furthermore, in order to drive the above-mentioned inorganic EL element, normally, an AC voltage of about 200V needs to be applied with a high frequency of several kHz, with the result that problems arise in which an active element such as a thin-film transistor is not applicable and in which a high-cost driving circuit is required; therefore, there are still some problems in order to put this system into practical use.
As a result of extensive studies made by the inventors of the present invention to achieve a low voltage and high luminance of the inorganic EL element, the inventors have found an inorganic EL element that can be driven by using a direct current, and emits light with high luminance by using a low voltage of several 10V that is sufficiently low in comparison with the voltage required for the conventional inorganic EL element (hereinafter, referred to as “direct-current driving type inorganic EL element”).
The direct-current driving type inorganic EL element uses a phosphor layer that has a resistance value in the semiconductor region that is lower by several digits in resistivity than that of a phosphor layer used for the conventional light emitting element. In a case where this EL element is applied to a display device of a simple matrix structure, even when a light emission threshold-value voltage is applied to a scanning electrode Xi and a data electrode Yj, in order to allow only the specific pixel (supposing that this is indicated by Ci, j) to emit light, a leakage current flows between a scanning electrode Xi+1 and a data electrode Yj that form a peripheral pixel (for example, Ci+1, j), which sometimes causes an erroneous light emission (hereinafter, this phenomenon is referred to as “crosstalk”). In this manner, in contrast to the effect of high luminance, new problems arise in the direct-current driving-type inorganic EL element to be solved upon being put into practical use.
The following display device of a simple matrix type that utilizes organic EL elements using an organic material as its illuminant is exemplified as a device having similar problems described above. In accordance with the technique described in Japanese Patent Laid-open Publication No. 9-320760, a method has been proposed in which, in an organic thin-film EL element, in order to prevent a leakage current in the organic thin-film layer upon emitting light, by applying an excimer laser to the respective layers that have been film-formed from the surface layer side, one or a plurality of electrode layers or organic thin-film layers are patterned so that crosstalk in the matrix-shaped organic thin-film EL element is prevented. In accordance with the technique described in Japanese Patent Laid-open Publication No. 7-50197, although its direct objective is different, a method similar to the method described above has been proposed in which, in a conventional inorganic EL element, by applying a laser beam having a desired wavelength focused from the surface layer side to the respective layers that have been film-formed, one portion of the lower dielectric layer is directly removed, while the phosphor layer, the upper dielectric layer and the transparent electrode, stacked on the upper side of the lower dielectric layer are indirectly removed. In this method, upon forming a stripe-shaped fine pattern of the transparent electrode, the phosphor layer is also simultaneously patterned.
An objective of the present invention is to provide a display device that uses a light-emitting element that can be driven at a low voltage, and has high luminance and high efficiency so that it becomes possible to prevent crosstalk and achieve high display quality.
A display device according to the present invention includes:
a pair of a first electrode and a second electrode, at least one electrode of the first second electrodes being transparent or translucent; and
a phosphor layer provided as being sandwiched between the first electrode and the second electrode,
wherein the phosphor layer has a polycrystal structure made of a first semiconductor substance in which a second semiconductor substance different from the first semiconductor substance is segregated on a grain boundary of the polycrystal structure, and the phosphor layer has a plurality of pixel regions that are selectively allowed to emit light in a predetermined range thereof and non-pixel regions that divide at least one portion of the pixel regions.
Moreover, the pixel regions and the non-pixel regions may be periodically distributed over the same plane of the phosphor layer with the pixel regions being divided by the non-pixel regions.
Further, the non-pixel regions may be provided to divide the pixel regions into a stripe shape.
Furthermore, the non-pixel regions may include discontinuous regions of the phosphor layer forming the pixel regions.
Moreover, the non-pixel regions may include one portion of the first electrode or the second electrode that divides at least one portion of the phosphor layer forming the pixel regions.
Further, the non-pixel regions may be made of regions having higher resistance than that of the pixel regions.
Furthermore, each of the non-pixel regions may be a void region that is in a vacuum state or filled with a nonvolatile gas. The non-pixel regions may be solid-state regions mainly including an insulating resin.
Moreover, the phosphor layer may contain one or more elements selected from the group consisting of Ag, Cu, Ga, Mn, Al and In, and the non-pixel regions may have a different content density of the element from that of the pixel regions.
Further, the phosphor layer may be made of a compound semiconductor.
Moreover, the non-pixel regions may be formed by amorphous phase.
Further, the pixel regions may be formed by crystalline phase of the material of the phosphor layer, and the non-pixel regions may be formed by amorphous phase of the material of the phosphor layer.
Furthermore, the first semiconductor substance and the second semiconductor substance may have semiconductor structures having respectively different conductive types.
Moreover, the first semiconductor substance may have an n-type semiconductor structure and the second semiconductor substance has a p-type semiconductor structure. The first semiconductor substance and the second semiconductor substance may be compound semiconductors respectively.
Further, the first semiconductor substance may be a compound semiconductor including elements belonging to Group 12 to Group 16.
Furthermore, the first semiconductor substance may have a cubic structure.
Moreover, the first semiconductor substance may contain at least one element selected from the group consisting of Cu, Ag, Au, Al, Ga, In, Mn, CI, Br, I, Li, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm and Yb.
Further, the polycrystalline structure made of the first semiconductor substance may have an average crystal grain size in a range from 5 to 50 nm.
Furthermore, the second semiconductor substance may contain at least one element selected from the group consisting of ZnS, ZnSe, ZnSSe, ZnSeTe, ZnTe, GaN and InGaN.
Moreover, the first semiconductor substance may a zinc-based material containing zinc. In this case, at least one of the electrodes may be made of a material containing zinc.
Further, the material containing zinc forming one of the electrodes may mainly include zinc oxide, and contain at least one element selected from group consisting of aluminum, gallium, titanium, niobium, tantalum, tungsten, copper, silver and boron.
Furthermore, the display device according to the present invention may include a supporting substrate that faces at least one of the electrodes, and supports the electrodes. The display device according to the present invention may further include a color conversion layer provided as being parallel to the electrode, and the color conversion layer being placed in front thereof in a light emission taking-out direction.
A method for manufacturing a display device includes:
preparing a substrate;
forming a first electrode on the substrate;
forming a phosphor layer on the first electrode;
by carrying out a laser annealing process on one portion of the phosphor layer, defining crystalline pixel regions and amorphous non-pixel regions in a divided manner; and
forming a second electrode that is transparent or translucent on the phosphor layer.
A display device according to the present invention includes:
a pair of a first electrode and a second electrode, at least one electrode of the first and second electrodes being transparent or translucent; and
a phosphor layer having a p-type semiconductor and an n-type semiconductor, the phosphor layer being sandwiched between the first electrode and the second electrode,
wherein the phosphor layer has a plurality of pixel regions that are selectively allowed to emit light in a predetermined range thereof and non-pixel regions that divide at least one portion of the pixel regions.
The phosphor layer may have a structure in which n-type semiconductor particles are dispersed in a medium made of a p-type semiconductor. Further, the phosphor layer may include an aggregated body of n-type semiconductor particles with a p-type semiconductor being segregated between the particles.
Moreover, the n-type semiconductor particles may be electrically joined to the first and second electrodes through the p-type semiconductor.
Further, the pixel regions and the non-pixel regions may be periodically distributed over the same plane of the phosphor layer with the pixel regions being divided by the non-pixel regions. Furthermore, the non-pixel regions may be provided to divide the pixel regions into a stripe shape.
Moreover, the non-pixel regions may include discontinuous regions of the phosphor layer having the pixel regions.
Further, the non-pixel regions may include one portion of the first electrode or the second electrode that divides at least one portion of the phosphor layer having the pixel regions.
Furthermore, the non-pixel regions may be made of regions having higher resistance than that of the pixel regions.
Moreover, each of the non-pixel regions may be a void region that is in a vacuum state or filled with a nonvolatile gas. The non-pixel regions may be solid-state regions mainly including an insulating resin.
Further, the non-pixel regions may be formed by amorphous phase. The pixel regions may be formed by crystalline phase of the material of the phosphor layer, and the non-pixel regions may be formed by amorphous phase of the material of the phosphor layer.
Furthermore, the n-type semiconductor particles and the p-type semiconductor may be compound semiconductors respectively. The n-type semiconductor particles may be made of a compound semiconductor including elements belonging to Group 12 to Group 16. The n-type semiconductor particles may be made of a compound semiconductor including elements belonging to Group 13 to Group 15.
The n-type semiconductor particles may be made of a chalco-pyrite-type compound semiconductor.
The n-type semiconductor particles may be made of at least one element selected from the group consisting of ZnS, ZnSe, ZnSSe, ZnSeTe, ZnTe, GaN and InGaN.
Further, the n-type semiconductor particles may be made of a zinc-based material containing zinc. In this case, at least one of the first and second electrodes may be made of a material containing zinc.
Moreover, the material containing zinc forming one of the electrodes may mainly include zinc oxide, and contain at least one element selected from group consisting of aluminum, gallium, titanium, niobium, tantalum, tungsten, copper, silver and boron.
Furthermore, the display device according to the present invention may include: a supporting substrate that faces at least one of the electrodes between the first and second electrodes, and supports the electrodes.
Moreover, the display device according to the present invention may include a color conversion layer provided as being parallel to the first electrode and the second electrode respectively, and the color conversion layer is placed in front thereof in a light emission taking-out direction from the phosphor layer.
In accordance with the present invention, it is possible to provide a display device that uses a light-emitting element that can be driven at a low voltage, and has high luminance and high efficiency, the display device making it possible to prevent crosstalk and consequently to achieve high display quality.
In accordance with the display device of the present invention, the phosphor layer has a polycrystal structure made of an n-type semiconductor substance with a p-type second semiconductor substance being segregated on the grain boundary of the polycrystal structure. Since the phosphor layer has such a structure, the injection characteristic of holes is improved by the p-type semiconductor substance segregated on the grain boundary so that it possible to achieve a display device that can emit light at a low voltage with high luminance, and also has a long service life.
The present invention will become readily understood from the following description of preferred embodiments thereof made with reference to the accompanying drawings, in which like parts are designated by like reference numeral and in which:
Referring to attached drawings, the following description will discuss a display device in accordance with embodiments of the present invention. In the drawings, those members that are virtually the same are indicated by the same reference numerals.
Moreover, as shown in
Additionally, not limited to the above-mentioned structure, for example, another structure may be used in which a plurality of phosphor layers 3 are formed, both of the first and second electrode are prepared as the transparent electrodes, the back electrode 4 is prepared as a black-colored electrode, a structure for sealing the entire portion or one portion of the display device 10 is further provided, or a color-converting structure that converts the color of light emission from the phosphor layer 3 is further prepared in front of the color filter 17.
The following description will discuss the respective components of this display device 10.
A material that can support respective layers formed thereon, and also has a high electric insulating property is used as the transparent substrate 1. Moreover, the material needs to have a light transmitting property to a light wavelength that is emitted from the phosphor layer 3. Examples of the material include glass, such as corning 1737, quartz, ceramics and the like. In order to prevent alkaline ion or the like, contained in normal glass, from giving adverse effects to the light-emitting device, non-alkaline glass, or soda lime glass, formed by coating alumina or the like as an ion barrier layer on the glass surface, may be used. However, these materials are exemplary only, and the material of the transparent substrate 1 is not particularly limited by these. Moreover, with a structure in which no light is taken out from the substrate side, the above-mentioned light transmitting property is not required, and a material having no light transmitting property may also be used. Examples of the material include a metal substrate, a ceramic substrate, a silicon wafer and the like with an insulating layer being formed on the surface thereof.
Any material may be used as the transparent electrode 2 on the side from which light is taken out as long as it has a light-transmitting property so as to take light emission generated in the phosphor layer 3 out of the layer, and in particular, those materials having a high transmittance within a visible light range are desirably used. Moreover, those materials that exert low resistance are preferably used, and in particular, those materials having a superior adhesive property to a protective layer 18 and the phosphor layer 3 are desirably used. In particular, preferable examples of materials for the transparent electrode 2 include those ITO materials (In2O3 doped with SnO2, referred to also as indium tin oxide), metal oxides mainly including InZnO, ZnO, SnO2 or the like, metal thin films such as Pt, Au, Pd, Ag, Ni, Cu, Al, Ru, Rh, and Ir, or conductive polymers, such as polyaniline, polypyrrole, PEDOT/PSS and polythiophene; however, the material is not particularly limited by these.
For example, the ITO material may be formed into a film by using a film-forming method, such as a sputtering method, an electron beam vapor deposition method and an ion plating method so as to improve the transparency thereof or to lower the resistivity thereof. Moreover, after the film-forming process, the film may be surface-treated by a plasma treatment or the like so as to control the resistivity thereof. The film thickness of the transparent electrode 2 is determined based upon the sheet resistance value and visible light transmittance to be required.
Moreover, any of generally well-known conductive materials may be applied as the back electrode 4 on the side from which no light is taken out. Preferable examples thereof include metal oxides, such as ITO, InZnO, ZnO and SnO2, metals, such as Pt, Au, Pd, Ag, Ni, Cu, Al, Ru, Rh and Ir, or conductive polymers, such as polyaniline, polypyrrole and PEDOT[poly(3,4-ethylenedioxythiophene)]/PSS(polystyrene sulfonate), or conductive carbon.
The transparent electrode 2 and the back electrode 4 may have a structure in which a plurality of electrodes are formed into a striped pattern within the layer. Moreover, both of the transparent electrodes 2 (first electrodes) and the back electrodes 4 (second electrodes) may be formed into a plurality of stripe-shaped electrodes with the respective striped-shaped electrodes of the first electrodes 2 and all the stripe-shaped electrodes of the second electrodes 4 being set to a twisted positional relationship, and with projected shapes onto the light-emitting face of the respective stripe-shaped electrodes of the first electrodes 2 and projected shapes onto the light emitting face of all the stripe-shaped electrodes of the second electrodes 4 being made to intersect with one another. In this case, it is possible to obtain a display in which, by applying a voltage to electrodes respectively selected from the stripe-shaped electrodes of the first electrodes and the stripe-shaped electrodes of the second electrodes, a predetermined position is allowed to emit light.
The following description will discuss the phosphor layer 3.
As the first semiconductor substance 21, those materials having a band gap size ranging from a near ultraviolet area to a visible light area (from 1.7 eV to 3.6 eV) are preferably used, and more preferably, those materials having a band gap size ranging from the near ultraviolet area to a blue color area (from 2.6 eV to 3.6 eV) are used. Specific examples thereof include: the aforementioned compounds between Group 12 to Group 16 elements, such as ZnS, ZnSe, ZnTe, CdS and CdSe, and mixed crystals of these (for example, ZnSSe or the like), compounds between Group II to Group 16 elements, such as CaS and SrS, and mixed crystals of these (for example, CaSSe or the like), compounds between Group 13 to Group 15 elements, such as AlP, AlAs, GaN and GaP, and mixed crystals of these (for example, InGaN or the like), and mixed crystals of the above-mentioned compounds, such as ZnMgS, CaSSe and CaSrS. Moreover, chalcopyrite-type compounds, such as CuAlS2, may be used. Furthermore, as the polycrystal material made of the first semiconductor substance 21, those having a cubic crystal structure in the main portion thereof are preferably used. Here, one or a plurality of kinds of atoms or ions, selected from the group consisting of the following elements, may be contained as additives: Cu, Ag, Au, Ir, Al, Ga, In, Mn, CI, Br, I, Li, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm and Yb. The light emission color from the phosphor layer 3 is also determined by the kinds of these elements.
As the second semiconductor substance 23, any one of Cu2S, ZnS, ZnSe, ZnSSe, ZnSeTe, ZnTe, GaN and InGaN may be used. These materials may contain one kind or a plurality of kinds of elements, selected from N, Cu and In, as additives used for imparting the p-type conductivity thereto.
The feature of the display device 10 relating to first embodiment lies in that the phosphor layer 3 has a polycrystal structure made of the n-type semiconductor substance 21 with the p-type semiconductor substance 23 being segregated on the grain boundary 22 of the polycrystal structure. In the conventional inorganic EL, by enhancing the crystallinity of the phosphor layer, electrons accelerated by a high electric field are prevented from being diffused; however, in general, since ZnS, ZnSe or the like exhibits the n-type conductivity, a supply of holes is not sufficient, with the result that light emission with high luminance derived from a recombination of an electron and a hole is not expected. In contrast, when the crystal grains of the phosphor layer are grown, the crystal grain boundary is uniquely expanded as well, as long as it is not a single crystal. With a conventional inorganic EL element to which a high voltage is applied, the grain boundary in the film thickness direction forms a conductive path, resulting in a problem of a reduction in voltage resistance. In contrast, after hard studies, the present inventors have found that, in a phosphor layer 3 having a polycrystal structure made of the n-type semiconductor substrate 21, by providing a structure in which the p-type semiconductor substance 23 is segregated on the grain boundary 22 of the polycrystal structure, the injecting property of holes is improved by the p-type semiconductor substance segregated on the grain boundary. Moreover, they have also found that by scattering the segregated portions in the phosphor layer 3 with a high concentration, the recombination-type light emission of electrons and holes can be efficiently generated. Thus, it becomes possible to achieve a light emitting device that emits light with high luminance at a low voltage, and consequently to complete the present invention. Moreover, by introducing a donor or an acceptor thereto, free electrons and holes captured by the acceptor can be recombined, free holes and electrons captured by donor can be recombined, and light emission of the paired donor and acceptor can also be carried out. Furthermore, since other kinds of ions are located closely, light emission derived from an energy transfer can also be carried out.
Moreover, in a case where a zinc-based material such as ZnS is used as the first semiconductor particles 21 of the phosphor layer 3, an electrode, made of a metal oxide containing zinc, such as ZnO, AZO (zinc oxide doped with, for example, aluminum) and GZO (zinc oxide doped with, for example, gallium), is preferably used as at least either one of the transparent electrode 2 and the back electrode 4. The present inventors have found that, by adopting a combination of specific n-type semiconductor particles 21 and a specific transparent electrode 2 (or back electrode 4), light emission can be produced with high efficiency.
That is, when attention is drawn to a work function in the transparent electrode 2 (or back electrode 4), the work function of ZnO is 5.8 eV, while the work function of ITO (indium-tin oxide) that has been conventionally used as the transparent electrode is 7.0 eV. In contrast, since the work function of a zinc-based material that is the n-type semiconductor particles 21 of the phosphor layer 3 is 5 to 6 eV, the work function of ZnO is closer to the work function of the zinc-based material in comparison with that of ITO; therefore, the resulting advantage is that the ion injecting property to the phosphor layer 3 is improved. The same is true in a case where AZO or GZO, which is a zinc-based material, is used as the transparent electrode 2 (or back electrode 4) in the same manner.
As shown in
In a comparative example, on the other hand, as shown in
As described above, in a case where a zinc-based material, such as ZnS and ZnSe, is used as the n-type semiconductor particles 21 of the phosphor layer 3, by combining the transparent electrode 2 (or back electrode 4) made of a zinc oxide-based material with the semiconductor particles, it becomes possible to provide a display device having superior light emitting efficiency.
Here, in the above-mentioned example, the explanation has been given by exemplifying AZO doped with aluminum and GZO doped with gallium as the transparent electrode 2 (or back electrode 4) containing zinc; however, the same effects can be obtained even by the use of zinc oxide doped with at least one kind selected from the group consisting of aluminum, gallium, titanium, niobium, tantalum, tungsten, copper, silver and boron.
The following description will discuss one example of a method for manufacturing the display device 10 in accordance with first embodiment.
(1) First, a glass substrate is prepared as a transparent substrate 1.
(2) On the glass substrate 1, a black matrix 19 is formed by using a resin material containing carbon black through a photolithography method. The black matrix 19 is disposed virtually in a lattice shape by using a plurality of linear patterns that extend in a first direction in parallel with the surface of the glass substrate 1 with predetermined intervals and a plurality of linear patterns that extend in a direction orthogonal to the first direction with predetermined intervals.
(3) Next, by using color resists, colored patterns are formed between adjacent matrix lines of the black matrix 19 by a photolithography method. These processes are repeatedly carried out for each of the colors of R, G and B so that a color filter 17 is formed.
(4) Next, a protective layer 18 is formed on each of the colored patterns of the color filter 17, and a transparent electrode 2 is formed on the protective layer 18 by a sputtering method. As the material for the transparent electrode 2, ITO is used, and the transparent electrode 2 is formed in a manner so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the first direction.
(5) Next, a phosphor layer 3 having a flat face is formed on the protective layer 18 and the transparent electrode 2 of the color filter 17. The phosphor layer 3 is formed in the following manner. First, powdered ZnS and Cu2S are respectively charged into a plurality of evaporating sources, and an electron beam is applied to each of the materials under vacuum (about 10−6 Torr) so as to be film-formed thereon. At this time, the substrate temperature is set to 200° C. so that ZnS and Cu2S are commonly vapor deposited.
(6) After forming the film, this is subjected to a firing process at 700° C. for about one hour in a sulfur atmosphere so that a phosphor layer 3 is obtained. By examining this film by using the X-ray diffraction and the SEM, the polycrystal structure with minute ZnS crystal grains and the segregated portion of CuxS on its grain boundary can be observed. Although the reason for this has not been clarified, it is considered that a phase separation occurs between ZnS and CuxS, with the result that the above-mentioned segregated structure is formed (
(7) Next, a YAG laser beam 24 having a virtually linear shape is intermittently applied to the black matrix 19 that extends in the first direction from above the phosphor layer 3 so that the phosphor layer 3 is patterned (
(8) Next, a back electrode 4 is formed on the phosphor layer 3 by a sputtering method. As the material for the back electrode 4, Pt is used, and the back electrode 4 is formed in a manner so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the second direction. As a result, the transparent electrode 2 and the back electrode 4 are made orthogonal to each other on the colored patterns of the color filter 17, and also made face to face with each other with the phosphor layer 3 interposed therebetween.
(9) Next, an insulating protective layer 11 is formed on the phosphor layer 3 and the back electrode 4.
By using the above-mentioned processes, a display device of the present embodiment is obtained.
Additionally, the spot shape of the laser 24 may be formed into a virtually dot shape. In this case, the patterning process of the phosphor layer 3 can be carried out by scanning the laser spot in the first direction as well as in the second direction (
Moreover, a mask pattern having an opening through which an area to be irradiated with the laser 24 is exposed is superposed on the phosphor layer 3 so that the area covering a plurality of pixels and a plurality of electrodes may be subjected to a laser irradiation at one time from above the mask pattern.
In the display device in accordance with first embodiment, by removing the phosphor layer 3 located in an interpixel region between adjacent pixels over the same plane of the phosphor layer 3, a non-pixel region 3b having a higher resistance than that of the phosphor layer 3 of the pixel region 3a is formed. With this arrangement, even with a display device using a low resistance phosphor layer 3 that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
The following description will discuss one example of a method for manufacturing the display device 10a in accordance with second embodiment.
(1) A phosphor layer 3 is formed on a glass substrate 1 in a solid state in the same manner as in the method for manufacturing the display device in accordance with the aforementioned first embodiment (
(2) Next, a virtually linear excimer laser 24 is applied to an area that is virtually in parallel with the stripe-shaped transparent electrode 2 and located between adjacent transparent electrodes 2 from above the phosphor layer 3 so that the phosphor layer 3 is patterned (
(3) Next, in the same manner as in the manufacturing method for the display device of the aforementioned first embodiment, a back electrode 4 and a protective layer 11 are formed on the phosphor layer 3. The back electrode 4 and the transparent electrode 2 are made orthogonal to each other on the colored patterns of the color filter 17, and also made face to face with each other with the phosphor layer 3 interposed therebetween.
By using the above-mentioned processes, the display device 10a of the present embodiment is obtained.
Additionally, the spot shape of the laser 24 may be formed into a virtually dot shape. In this case, the patterning process of the phosphor layer 3 can be carried out by scanning the laser spot 24 in the first direction as well as in the second direction (
Moreover, a mask pattern having an opening through which an area to be irradiated with the laser 24 is exposed is superposed on the phosphor layer 3 so that the area covering a plurality of pixels and a plurality of electrodes may be subjected to a laser irradiation at one time from above the mask pattern.
In the display device 10a of the present embodiment, by removing the phosphor layer 3 located in an interpixel region between adjacent pixels over the same plane of the phosphor layer 3, an area that makes the phosphor layer 3 disconnected is formed so that a non-pixel region 3b having a higher resistance than that of the phosphor layer 3 of the pixel region 3a is formed. With this arrangement, even with a display device using a low resistance phosphor layer that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
As the barrier plate 26, a material having higher resistance in comparison with the phosphor layer 3 can be used. The barrier plate 26 may be formed by using, for example, an organic material, an inorganic material and the like. Examples of the organic material include polyimide resin, acrylic resin, epoxy resin and urethane resin. Moreover, examples of the inorganic material include SiO2, SiNx, alumina and the like, or a composite structure, such as a laminated structure and a mixed structure (for example, a binder in which an inorganic filler is dispersed) of these materials, may be used. The shape of the barrier plate 26 is not particularly limited, but the height of the barrier plate 26 is preferably set to about 0.5 to 1.5 times the film thickness of the phosphor layer 3. Moreover, the width of the barrier plate 26 is preferably set to 0.5 to 1.5 times the interval between the adjacent transparent electrodes.
The following description will discuss one example of a method for manufacturing a display device 10b in accordance with third embodiment.
(1) In the same manner as in the method for manufacturing the display device of the aforementioned first embodiment, a color filter 17 is formed on a glass substrate 1, and a first protective layer 18 is formed thereon. Moreover, a transparent electrode 2 is formed on the first protective layer 18. The transparent electrode 2 is formed so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the first direction (
(2) Next, barrier plates 26 are formed on the first protective layer 18. The barrier plates 26 are formed in the following manner. First, a glass paste in which alumina powder is dispersed is formed into a stripe pattern by a screen printing process, with each stripe being located between the adjacent transparent electrodes 2 so as to extend in a first direction. Then, this is fired to obtain barrier plates 26 formed into a desired pattern (
(3) Next, in the same manner as in the method for manufacturing the display device relating to the aforementioned first embodiment, a phosphor layer 3 is formed on the transparent electrode 2. The barrier plates 26 are shield by using a metal mask (
(4) Next, in the same manner as in the method for manufacturing the display device relating to the aforementioned first embodiment, a back electrode 4 and a second protective layer 11 are formed on the phosphor layer 3. The back electrode 4 is made orthogonal to the transparent electrode 2 on the colored patterns of the color filter 17, and also made face to face therewith, with the phosphor layer 3 interposed therebetween.
By using the above-mentioned processes, a display device 10b of the present embodiment is obtained.
Additionally, the pattern shape of the barrier plates 26 may be formed into a virtually lattice shape. In this case, each of the barrier plates 26 located in a manner so as to extend in the second direction is positioned between the adjacent back electrodes 4 (
Moreover, the method for forming the barrier plates 26 is not intended to be limited by the screen printing method, and other methods, such as etching by the photolithography method, a sand-blasting method and an ink-jet method, may be used.
In the display device 10b of the present embodiment, each of the barrier plates 26, mainly made of an insulating resin, is formed in an interpixel region between adjacent pixels 3a over the same plane of the phosphor layer 3 so that a non-pixel region 3b having a higher resistance than that of the phosphor layer 3 of the pixel region 3a is formed. With this arrangement, even with a display device using a low resistance phosphor layer 3 that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
(1) In the same manner as in the method for manufacturing the display device of the aforementioned first embodiment, a transparent electrode 2 is formed on a glass substrate 1. The transparent electrode 2 is formed in a manner so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the first direction.
(2) Thereafter, in the same manner as in the method for manufacturing the display device relating to the aforementioned first embodiment, a phosphor layer 3 is formed thereon in a solid state, and this is then subjected to a photolithography method by using a photosensitive resist so that a mask pattern 28 is formed. This mask pattern 28 is designed so as to be located between adjacent transparent electrodes, and to extend in the first direction in parallel therewith, with openings formed therein with predetermined intervals from one another (
(3) Next, the exposed portions of the phosphor layer 3 are etched by using a dry etching method so as to have a desired thickness (
(4) Next, the mask pattern 28 made of the photosensitive resist is removed (
(5) Thereafter, in the same manner as in the method for manufacturing the display device relating to the aforementioned first embodiment, a back electrode 4 and a protective layer 11 are formed on the phosphor layer 3. The back electrode 4 and the transparent electrode 2 are made orthogonal to each other on the colored patterns of the color filter 17, and also made face to face with each other, with the phosphor layer 3 interposed therebetween.
The display device 10c of the present example is obtained by the above-mentioned processes.
Additionally, the pattern shape of the mask pattern 28 made of the photosensitive resist for use in the etching process is not limited by the above-mentioned stripe shape, but may be formed into a virtually lattice shape. In this case, the openings that are located to extend in the second direction, each being positioned between the adjacent back electrodes 4, are also placed in parallel with one another with predetermined intervals therebetween (
Moreover, the etching method is not intended to be limited by the dry etching and another method, such as a wet-etching method and a sand-blasting method, may be used.
Furthermore,
In the display device 10c of the present fourth embodiment, an area having a higher resistance than that of the pixel region 3a is formed in an interpixel region 3b between the adjacent pixels over the same plane of the phosphor layer 3. Thus, even with a display device using a low resistance phosphor layer 3 that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
On the other hand, not limited to the above-mentioned structure, for example, another structure may be used in which a plurality of phosphor layers 3 are formed, both of the first and second electrode are prepared as the transparent electrodes, the back electrode 4 is prepared as a black-colored electrode, a structure for sealing the entire portion or one portion of the display device 20 by the protective layer 11 is further provided, or a color-converting structure (color-conversion layer 16) that converts the color of light emission from the phosphor layer 3 is further prepared in front of the color filter 17.
The following description will discuss one example of a method for manufacturing a display device 20 in accordance with fifth embodiment.
(1) First, a glass substrate is prepared as a substrate 1.
(2) Next, a back electrode 4 is formed on the substrate 1 by using a sputtering method. In this case, Pt is used as the back electrode 4, and the back electrode 4 is formed as a plurality of linear patterns that extend in a first direction in parallel with the surface of the glass substrate 1, in parallel with one another, with predetermined intervals being formed therebetween.
(3) Next, a phosphor layer 3 is formed in a solid state from the glass substrate 1 to the back electrode 4, in the same manner as in first embodiment.
(4) Next, after a dopant material has been vapor deposited by using a mask on a region 3a corresponding to pixels on the phosphor layer 3, the dopant is heated and diffused by using an annealing process. Thus, the phosphor layer 3 forms a dopant density distribution including the pixel region 3a with a high density and the interpixel regions 3b with a low density, within the in-plane thereof.
(5) Next, a transparent electrode 2 is formed on the phosphor layer 3 by a sputtering method. As the material for the transparent electrode 2, ITO is used, and the transparent electrode 2 is formed as a linear pattern having a plurality of lines that are located in parallel with the surface of the glass substrate 1 and extend in a second direction virtually orthogonal to the aforementioned first direction, in parallel with one another with predetermined intervals between one another.
(6) Next, after film-forming SiN as a protective layer from the phosphor layer 3 to the transparent electrode 2, a black matrix 19 is formed by a photolithography method by using a resin material containing carbon black. The black matrix 19 is disposed virtually in a lattice shape by using a plurality of linear patterns that extend in the first direction in parallel with the surface of the glass substrate, between gaps of the back electrodes 4, and a plurality of linear patterns that extend in the second direction between gaps of the adjacent transparent electrodes 2.
(7) Next, by using color resists, colored patterns are formed between adjacent matrix lines of the black matrix 19 by a photolithography method. These processes are repeatedly carried out for the respective colors of R, G and B so that a color filter 17 is formed.
(8) Next, an insulating protective layer 11 is formed on the color filter 17 by using an epoxy resin.
By using the above-mentioned processes, a top-emission-type display device 20 of the present embodiment is obtained.
Additionally, as the annealing means, an entire heating process by using an electric furnace or the like may be carried out, or a local heating process by using laser irradiation may be carried out. Moreover, as shown in
In the display device 20 in accordance with fifth embodiment, over the same plane of the phosphor layer 3, the phosphor layer 3b in the interpixel region between the adjacent pixel regions 3a is made to have higher resistance than that of the phosphor layer 3a in the pixel region so that even with a display device using a low resistance phosphor layer that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
The following description will discuss one example of a method for manufacturing the display device 20b in accordance with sixth embodiment.
(1) First, a glass substrate is prepared as a transparent substrate 1.
(2) On the glass substrate 1, a black matrix 19 is formed by using a resin material containing carbon black through a photolithography method. The black matrix 19 is disposed virtually in a lattice shape by using a plurality of linear patterns that extend in a first direction in parallel with the surface of the glass substrate 1 with predetermined intervals and a plurality of linear patterns that extend in a direction orthogonal to the first direction with predetermined intervals.
(3) Next, by using color resists, colored patterns are formed between adjacent matrix lines of the black matrix 19 by a photolithography method. These processes are repeatedly carried out for each of the colors of R, G and B so that a color filter 17 is formed.
(4) Next, a protective layer 16 is formed on each of the colored patterns of the color filter 17, and a transparent electrode 2 is formed on the protective layer 16 by a sputtering method. As the material for the transparent electrode 2, ITO is used, and the transparent electrode 2 is formed in a manner so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the first direction.
(5) Next, a phosphor layer 3 is formed in a solid state from the color-conversion layer 16 to the transparent electrode 2 in the same manner as in first embodiment. Moreover, by ion-injecting a dopant material to the region 3a corresponding to pixels on the phosphor layer 3, it is possible to form a dopant density distribution including the pixel region 3a with a high density and the interpixel regions 3b with a low density, within the in-plane of the phosphor layer 3.
(6) Next, a back electrode 4 is formed on the phosphor layer 3 by a sputtering method. As the material for the back electrode 4, Pt is used, and the back electrode 4 is formed in a manner so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the second direction. As a result, the transparent electrode 2 and the back electrode 4 are made orthogonal to each other on the colored patterns of the color filter 17, and also made face to face with each other with the phosphor layer 3 interposed therebetween.
(7) Next, an insulating protective layer 11 is formed on the phosphor layer 3 and the back electrode 4 by using an epoxy resin.
By using the above-mentioned processes, a bottom-emission-type display device 20b of the present embodiment is obtained.
In this display device 20b, each pixel includes a light-emitting element, and a plurality of pixels are disposed two-dimensionally to form this structure. In accordance with this display device 20b, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality in the same manner as in first embodiment.
In the same manner as in the display device of the first embodiment, the display device 20c makes it possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
In the same manner as in the display device of the first embodiment, the display device 20d makes it possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
On the other hand, not limited to the above-mentioned structure, for example, another structure may be used in which a plurality of phosphor layers 3 are formed, both of the first and second electrode are prepared as the transparent electrodes, the back electrode 4 is prepared as a black-colored electrode, or a structure for sealing the entire portion or one portion of the display device 30 by the protective layer 11 is further provided. When the light emission from the phosphor layer 3 corresponds to a white-color light ray, a structure that eliminates the necessity of the color conversion layer 16 is also available.
The following description will discuss one example of a method for manufacturing a display device 30 in accordance with ninth embodiment.
(1) First, a glass substrate is prepared as a substrate 1.
(2) Next, a back electrode 4 is formed on the substrate 1 by using a sputtering method. In this case, Pt is used as the back electrode 4, and the back electrode 4 is formed as a plurality of linear patterns that extend in a first direction in parallel with the surface of the glass substrate 1, in parallel with one another, with predetermined intervals being formed therebetween.
(3) Next, a phosphor layer 3 is formed in a solid state from the glass substrate 1 to the back electrode 4, in the same manner as in first embodiment.
(4) Next, by applying a laser annealing process only to the pixel region 3a corresponding to the pixels on the phosphor layer 3, a crystalline distribution pattern in which the pixel region 3a forms a crystalline phase while the interpixel regions 3b form amorphous phase is formed is formed within the in-plane of the phosphor layer 3.
(5) Next, a transparent electrode 2 is formed on the phosphor layer 3 by a sputtering method. As the material for the transparent electrode 2, ITO is used, and the transparent electrode 2 is formed as a linear pattern having a plurality of lines that are located in parallel with the surface of the glass substrate and extend in a second direction virtually orthogonal to the aforementioned first direction, in parallel with one another with predetermined intervals between one another.
(6) Next, after film-forming SiN as a protective layer 18 on the phosphor layer 3 or the transparent electrode 2, a black matrix 19 is formed by a photolithography method by using a resin material containing carbon black. The black matrix 19 is disposed virtually in a lattice shape by using a plurality of linear patterns that extend in the first direction in parallel with the surface of the glass substrate 1, between gaps of the back electrodes 4, and a plurality of linear patterns that extend in the second direction between gaps of the adjacent transparent electrodes 2.
(7) Next, after forming the cover conversion layer 16 by using an inkjet method, colored patterns are formed between adjacent matrix lines of the black matrix 19 by using color resists through a photolithography method. These processes are repeatedly carried out for the respective colors of R, G and B so that a color filter 17 is formed.
(8) Next, an insulating protective layer 11 is formed on the color filter 17 by using an epoxy resin.
By using the above-mentioned processes, a top-emission-type display device 30 of the present embodiment is obtained.
Additionally, as shown in
In the display device 30 in accordance with ninth embodiment, over the same plane of the phosphor layer 3, the pixel region 3a is formed into a crystalline phase, while the interpixel region 3b between the adjacent pixel regions is formed into an amorphous phase so that even with a display device using a low resistance phosphor layer that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
In the same manner as in the display device of the first embodiment, the display device 30b makes it possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
The display device 10 is characterized in that, as shown in
Moreover, in the display device 10, a plurality of pixel regions 3a capable of selectively emitting light are disposed two-dimensionally in the phosphor layer 3. The respective pixel regions 3a are selected by a combination of the transparent electrode 2 and the back electrode 4, and allowed to emit light. Moreover, the respective pixel regions 3a are also divided by non-pixel regions 3b. The non-pixel regions 3b are formed by discontinuous portions of the phosphor layer 3. The back electrode 4 is formed on one portion of the discontinuous portions within the interpixel regions in a manner so as to surround each pixel region 3a. Moreover, the display device 10 is further provided with a color filter 17 between the transparent electrode 2 and the transparent substrate 1. This color filter 17 is provided with a black matrix 19 formed on an area between adjacent pixels. Thus, a region corresponding to a pixel surrounded by the black matrix 19 selectively transmits light emitted from the phosphor layer 3 to each of the colors of RGB.
Additionally, not limited to the above-mentioned structure, for example, another structure may be used in which a plurality of phosphor layers 3 are formed, both of the first and second electrode are prepared as the transparent electrodes, the back electrode 4 is prepared as a black-colored electrode, a structure for sealing the entire portion or one portion of the display device 10 is further provided, or a color-converting structure that converts the color of light emission from the phosphor layer 3 is further prepared in front of the color filter 17.
The following description will discuss the respective components of this display device 10.
A material that can support respective layers formed thereon, and also has a high electric insulating property is used as the transparent substrate 1. Moreover, the material needs to have a light transmitting property to a light wavelength that is emitted from the phosphor layer 3. Examples of the material include glass, such as corning 1737, quartz, ceramics and the like. In order to prevent alkaline ion or the like, contained in normal glass, from giving adverse effects to the light-emitting device, non-alkaline glass, or soda lime glass, formed by coating alumina or the like as an ion barrier layer on the glass surface, may be used. However, these materials are exemplary only, and the material of the transparent substrate 1 is not particularly limited by these. Moreover, with a structure in which no light is taken out from the substrate side, the above-mentioned light transmitting property is not required, and a material having no light transmitting property may also be used. Examples of the material include a metal substrate, a ceramic substrate, a silicon wafer and the like with an insulating layer being formed on the surface thereof.
Any material may be used as the transparent electrode 2 on the side from which light is taken out as long as it has a light-transmitting property so as to take light emission generated in the phosphor layer 3 out of the layer, and in particular, those materials having a high transmittance within a visible light range are desirably used. Moreover, those materials that exert low resistance are preferably used, and in particular, those materials having a superior adhesive property to a protective layer 18 and the phosphor layer 3 are desirably used. In particular, preferable examples of materials for the transparent electrode 2 include those ITO materials (In2O3 doped with SnO2, referred to also as indium tin oxide), metal oxides mainly including InZnO, ZnO, SnO2 or the like, metal thin films such as Pt, Au, Pd, Ag, Ni, Cu, Al, Ru, Rh, and Ir, or conductive polymers, such as polyaniline, polypyrrole, PEDOT/PSS and polythiophene; however, the material is not particularly limited by these.
For example, the ITO material may be formed into a film by using a film-forming method, such as a sputtering method, an electron beam vapor deposition method and an ion plating method so as to improve the transparency thereof or to lower the resistivity thereof. Moreover, after the film-forming process, the film may be surface-treated by a plasma treatment or the like so as to control the resistivity thereof. The film thickness of the transparent electrode 2 is determined based upon the sheet resistance value and visible light transmittance to be required.
Moreover, any of generally well-known conductive materials may be applied as the back electrode 4 on the side from which no light is taken out. Preferable examples thereof include metal oxides, such as ITO, InZnO, ZnO and SnO2, metals, such as Pt, Au, Pd, Ag, Ni, Cu, Al, Ru, Rh and Ir, or conductive polymers, such as polyaniline, polypyrrole and PEDOT[poly(3,4-ethylenedioxythiophene)]/PSS(polystyrene sulfonate), or conductive carbon.
The transparent electrode 2 and the back electrode 4 may have a structure in which a plurality of electrodes are formed into a striped pattern within the layer. Moreover, both of the transparent electrodes 2 (first electrodes) and the back electrodes 4 (second electrodes) may be formed into a plurality of stripe-shaped electrodes with the respective striped-shaped electrodes of the first electrodes 2 and all the stripe-shaped electrodes of the second electrodes 4 being set to a twisted positional relationship, and with projected shapes onto the light-emitting face of the respective stripe-shaped electrodes of the first electrodes 2 and projected shapes onto the light emitting face of all the stripe-shaped electrodes of the second electrodes 4 being made to intersect with one another. In this case, it is possible to obtain a display in which, by applying a voltage to electrodes respectively selected from the stripe-shaped electrodes of the first electrodes and the stripe-shaped electrodes of the second electrodes, a predetermined position is allowed to emit light.
The phosphor layer 3, which is sandwiched between the transparent electrode 2 and the back electrode 4, has either one of the following two structures.
(i) A structure (see
(ii) A structure (see
Moreover, the respective n-type semiconductor particles 21 forming the phosphor layer 3 are preferably electrically joined to the electrodes 2 and 4 through the p-type semiconductor 23.
The material for n-type semiconductor particles 21 is an n-type semiconductor material having a majority of carriers as electrons that exhibits an n-type conductive property. The material may be a compound semiconductor located between Group 12 to Group 16. Moreover, the material may be a compound semiconductor located between Group 13 to Group 15. More specifically, the material has an optical band gap size in a range of visible light rays, and examples thereof include: ZnS, ZnSe, GaN, InGaN, AlN, GaAlN, GaP, CdSe, CdTe, SrS and CaS, serving as host crystals, and these may be used as host crystals, or may include as additives, one or a plurality of kinds of atoms or ions, selected from the group consisting of Cu, Ag, Au, Ir, Al, Ga, In, Mn, CI, Br, I, Li, Ce, Pr, Nd, Pm, Sm, Eu, Gd, Tb, Dy, Ho, Er, Tm and Yb. The light emission color from the phosphor layer 20 is also determined by the kinds of these elements.
In contrast, the material for the p-type semiconductor 23 is a p-type semiconductor material having a majority of carriers as holes that exhibits a p-type conductive property. Examples of this p-type semiconductor material include compounds, such as Cu2S, ZnS, ZnSe, ZnSSe, ZnSeTe and ZnTe, and nitrides, such as GaN and InGaN. Among these p-type semiconductor materials, Cu2S and the like inherently exhibit a p-type conductive property; however, with respect to the other materials, one or more kinds of elements, selected from the group consisting of nitrogen, Ag, Cu and In, are added thereto as additives and used. Moreover, a chalcopyrite type compound, such as CuGaS2 and CuAlS2, that exerts a p-type conductive property may be used.
The display device 10 relating to the present embodiment is characterized in that the phosphor layer 3 is provided with: either one of (i) the structure in which the p-type semiconductor 23 is segregated between the particles of the n-type semiconductor particles 21 (
In a case where a zinc-based material, such as ZnS, is used as the n-type semiconductor particles 21 of the phosphor layer 3, an electrode made of a metal oxide containing zinc, such as ZnO, AZO (made by doping zinc oxide, for example, with aluminum) and GZO (made by doping zinc oxide, for example, with gallium), is preferably used as, at least, either one of the transparent electrode 2 and the back electrode 4. The present inventors have found that, by using a combination of specific n-type semiconductor particles 21 and a specific transparent electrode 2 (or a back electrode 4), light emission with high efficiency is obtained.
That is, consideration, given to the work function of the transparent electrode 2 (or the back electrode 4), shows that the work function of ZnO is 5.8 eV, while the work function of ITO (indium tin oxide) conventionally used as a transparent electrode is 7.0 eV. In contrast, since the work function of the zinc-based material used as the n-type semiconductor particles 21 of the phosphor layer 3 is 5 to 6 eV, the work function of ZnO, which is closer to the work function of a zinc-based material in comparison with that of ITO, provides an advantage that the electron injecting property to the phosphor layer 3 is improved. This advantage is also obtained when a zinc-based material, such as AZO and GZO, is used as the transparent electrode 2 (or the back electrode 4).
As shown in
In contrast, in the comparative example, the transparent electrode is made of ITO that is not a zinc-based material, as shown in
As described above, in a case where a zinc-based material, such as ZnS and ZnSe, is used as the n-type semiconductor particles 21 of the phosphor layer 3, by combining it with the transparent electrode 2 (or the back electrode 4) made of a zinc oxide-based material, it becomes possible to provide a display device with superior light-emitting efficiency.
In the above-mentioned example, an explanation has been given by exemplifying AZO doped with aluminum and GZO doped with gallium as the material for the transparent electrode 2 (or the back electrode 4) containing zinc; however, the same effects can be obtained even when zinc oxide, doped with at least one kind of material selected from the group consisting of aluminum, gallium, titanium, niobium, tantalum, tungsten, copper, silver and boron, is used.
The following description will discuss one example of a method for manufacturing the display device 10 in accordance with eleventh embodiment.
(1) First, a glass substrate is prepared as a transparent substrate 1.
(2) On the glass substrate 1, a black matrix 19 is formed by using a resin material containing carbon black through a photolithography method. The black matrix 19 is disposed virtually in a lattice shape by using a plurality of linear patterns that extend in a first direction in parallel with the surface of the glass substrate 1 with predetermined intervals and a plurality of linear patterns that extend in a direction orthogonal to the first direction with predetermined intervals.
(3) Next, by using color resists, colored patterns are formed between adjacent matrix lines of the black matrix 19 by a photolithography method. These processes are repeatedly carried out for each of the colors of R, G and B so that a color filter 17 is formed.
(4) Next, a protective layer 18 is formed on each of the colored patterns of the color filter 17, and a transparent electrode 2 is formed on the protective layer 18 by a sputtering method. As the material for the transparent electrode 2, ITO is used, and the transparent electrode 2 is formed in a manner so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the first direction.
(5) Next, a phosphor layer 3 having a flat face is formed on the protective layer 18 and the transparent electrode 2 of the color filter 17. The phosphor layer 3 is formed in the following manner. First, powdered ZnS and Cu2S are respectively charged into a plurality of evaporating sources, and an electron beam is applied to each of the materials under vacuum (about 10−6 Torr) so as to be film-formed on the substrate 1 as the phosphor layer 3. At this time, the substrate temperature is set to 200° C. so that ZnS and Cu2S are commonly vapor deposited.
(6) After forming the film, this is subjected to a firing process at 700° C. for about one hour in a sulfur atmosphere. By examining this film by using the X-ray diffraction and the SEM, the polycrystal structure with minute ZnS crystal grains and the segregated portion of CuxS can be observed. Although the reason for this has not been clarified, it is considered that a phase separation occurs between ZnS and CuxS, with the result that the above-mentioned segregated structure is formed (
(7) Next, a YAG laser beam 24 having a virtually linear shape is intermittently applied to the black matrix 19 that extends in the first direction from above the phosphor layer 3 so that the phosphor layer 3 is patterned (
(8) Next, a back electrode 4 is formed on the phosphor layer 3 by a sputtering method. As the material for the back electrode 4, Pt is used, and the back electrode 4 is formed in a manner so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the second direction. As a result, the transparent electrode 2 and the back electrode 4 are made orthogonal to each other on the colored patterns of the color filter 17, and also made face to face with each other with the phosphor layer 3 interposed therebetween.
(9) Next, an insulating protective layer 11 is formed on the phosphor layer 3 and the back electrode 4.
By using the above-mentioned processes, a display device 10 of the present embodiment is obtained.
Additionally, the spot shape of the laser 24 may be formed into a virtually dot shape. In this case, the patterning process of the phosphor layer 3 can be carried out by scanning the laser spot in the first direction as well as in the second direction (
Moreover, a mask pattern having an opening through which an area to be irradiated with the laser 24 is exposed is superposed on the phosphor layer 3 so that the area covering a plurality of pixels and a plurality of electrodes may be subjected to a laser irradiation at one time from above the mask pattern.
In the display device in accordance with eleventh embodiment, by removing the phosphor layer 3 located in an interpixel region between adjacent pixels over the same plane of the phosphor layer 3, a non-pixel region 3b having a higher resistance than that of the phosphor layer 3 of the pixel region 3a is formed. With this arrangement, even with a display device using a low resistance phosphor layer 3 that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
The following description will discuss one example of a method for manufacturing the display device 10c in accordance with twelfth embodiment.
(1) A phosphor layer 3 is formed on a glass substrate 1 in a solid state in the same manner as in the method for manufacturing the display device in accordance with the aforementioned first embodiment (
(2) Next, a virtually linear excimer laser 24 is applied to an area that is virtually in parallel with the stripe-shaped transparent electrode 2 and located between adjacent transparent electrodes 2 from above the phosphor layer 3 so that the phosphor layer 3 is patterned (
(3) Next, in the same manner as in the manufacturing method for the display device of the aforementioned eleventh embodiment, a back electrode 4 and a protective layer 11 are formed on the phosphor layer 3. The back electrode 4 and the transparent electrode 2 are made orthogonal to each other on the colored patterns of the color filter 17, and also made face to face with each other with the phosphor layer 3 interposed therebetween.
By using the above-mentioned processes, the display device 10c of the present embodiment is obtained.
Additionally, the spot shape of the laser 24 may be formed into a virtually dot shape. In this case, the patterning process of the phosphor layer 3 can be carried out by scanning the laser spot 24 in the first direction as well as in the second direction (
Moreover, a mask pattern having an opening through which an area to be irradiated with the laser 24 is exposed is superposed on the phosphor layer 3 so that the area covering a plurality of pixels and a plurality of electrodes may be subjected to a laser irradiation at one time from above the mask pattern.
In the display device 10c of the present embodiment, by removing the phosphor layer 3 located in an interpixel region between adjacent pixels over the same plane of the phosphor layer 3, an area that makes the phosphor layer 3 disconnected is formed so that a non-pixel region 3b having a higher resistance than that of the phosphor layer 3 of the pixel region 3a is formed. With this arrangement, even with a display device using a low resistance phosphor layer that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
As the barrier plate 26, a material having higher resistance in comparison with the phosphor layer 3 can be used. The barrier plate 26 may be formed by using, for example, an organic material, an inorganic material and the like. Examples of the organic material include polyimide resin, acrylic resin, epoxy resin and urethane resin. Moreover, examples of the inorganic material include SiO2, SiNx, alumina and the like, or a composite structure, such as a laminated structure and a mixed structure (for example, a binder in which an inorganic filler is dispersed) of these materials, may be used. The shape of the barrier plate 26 is not particularly limited, but the height of the barrier plate 26 is preferably set to about 0.5 to 1.5 times the film thickness of the phosphor layer 3. Moreover, the width of the barrier plate 26 is preferably set to 0.5 to 1.5 times the interval between the adjacent transparent electrodes.
The following description will discuss one example of a method for manufacturing a display device 10d in accordance with thirteenth embodiment.
(1) In the same manner as in the method for manufacturing the display device of the aforementioned eleventh embodiment, a color filter 17 is formed on a glass substrate 1, and a first protective layer 18 is formed thereon. Moreover, a transparent electrode 2 is formed on the first protective layer 18. The transparent electrode 2 is formed so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the first direction (
(2) Next, barrier plates 26 are formed on the first protective layer 18. The barrier plates 26 are formed in the following manner. First, a glass paste in which alumina powder is dispersed is formed into a stripe pattern by a screen printing process, with each stripe being located between the adjacent transparent electrodes 2 so as to extend in a first direction. Then, this is fired to obtain barrier plates 26 formed into a desired pattern (
(3) Next, in the same manner as in the method for manufacturing the display device relating to the aforementioned eleventh embodiment, a phosphor layer 3 is formed on the transparent electrode 2. The barrier plates 26 are shield by using a metal mask (
(4) Next, in the same manner as in the method for manufacturing the display device relating to the aforementioned eleventh embodiment, a back electrode 4 and a second protective layer 11 are formed on the phosphor layer 3. The back electrode 4 is made orthogonal to the transparent electrode 2 on the colored patterns of the color filter 17, and also made face to face therewith, with the phosphor layer 3 interposed therebetween.
By using the above-mentioned processes, a display device 10d of the present embodiment is obtained.
Additionally, the pattern shape of the barrier plates 26 may be formed into a virtually lattice shape. In this case, each of the barrier plates 26 located in a manner so as to extend in the second direction is positioned between the adjacent back electrodes 4 (
Moreover, the method for forming the barrier plates 26 is not intended to be limited by the screen printing method, and other methods, such as etching by the photolithography method, a sand-blasting method and an ink-jet method, may be used.
In the display device 10d of the present embodiment, each of the barrier plates 26, mainly made of an insulating resin, is formed in an interpixel region between adjacent pixels 3a over the same plane of the phosphor layer 3 so that a non-pixel region 3b having a higher resistance than that of the phosphor layer 3 of the pixel region 3a is formed. With this arrangement, even with a display device using a low resistance phosphor layer 3 that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
(1) In the same manner as in the method for manufacturing the display device of the aforementioned eleventh embodiment, a transparent electrode 2 is formed on a glass substrate 1. The transparent electrode 2 is formed in a manner so as to be located between adjacent lines of the black matrix 19 and to extend virtually in parallel therewith, with predetermined intervals between one another, relative to the matrix lines of the black matrix 19 that extend in the first direction.
(2) Thereafter, in the same manner as in the method for manufacturing the display device relating to the aforementioned eleventh embodiment, a phosphor layer 3 is formed thereon in a solid state, and this is then subjected to a photolithography method by using a photosensitive resist so that a mask pattern 28 is formed. This mask pattern 28 is designed so as to be located between adjacent transparent electrodes, and to extend in the first direction in parallel therewith, with openings formed therein with predetermined intervals from one another (
(3) Next, the exposed portions of the phosphor layer 3 are etched by using a dry etching method so as to have a desired thickness (
(4) Next, the mask pattern 28 made of the photosensitive resist is removed (
(5) Thereafter, in the same manner as in the method for manufacturing the display device relating to the aforementioned eleventh embodiment, a back electrode 4 and a protective layer 11 are formed on the phosphor layer 3. The back electrode 4 and the transparent electrode 2 are made orthogonal to each other on the colored patterns of the color filter 17, and also made face to face with each other, with the phosphor layer 3 interposed therebetween.
The display device 10e of the present example is obtained by the above-mentioned processes.
Additionally, the pattern shape of the mask pattern 28 made of the photosensitive resist for use in the etching process is not limited by the above-mentioned stripe shape, but may be formed into a virtually lattice shape. In this case, the openings that are located to extend in the second direction, each being positioned between the adjacent back electrodes 4, are also placed in parallel with one another with predetermined intervals therebetween (
Moreover, the etching method is not intended to be limited by the dry etching and another method, such as a wet-etching method and a sand-blasting method, may be used.
Furthermore,
In the display device of the present embodiment, an area having a higher resistance than that of the pixel region 3a is formed in an interpixel region 3b between the adjacent pixels over the same plane of the phosphor layer 3. Thus, even with a display device using a low resistance phosphor layer 3 that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
On the other hand, not limited to the above-mentioned structure, for example, another structure may be used in which a plurality of phosphor layers 3 are formed, both of the first and second electrode are prepared as the transparent electrodes, the back electrode 4 is prepared as a black-colored electrode, or a structure for sealing the entire portion or one portion of the display device 20 by the protective layer 11 is further provided. When the light emission from the phosphor layer 3 corresponds to a white-color light ray, a structure that eliminates the necessity of the color conversion layer 16 is also available.
The following description will discuss one example of a method for manufacturing a display device 20 in accordance with fifteenth embodiment.
(1) First, a glass substrate is prepared as a substrate 1.
(2) Next, a back electrode 4 is formed on the substrate 1 by using a sputtering method. In this case, Pt is used as the back electrode 4, and the back electrode 4 is formed as a plurality of linear patterns that extend in a first direction in parallel with the surface of the glass substrate 1, in parallel with one another, with predetermined intervals being formed therebetween.
(3) Next, a phosphor layer 3 is formed in a solid state from the glass substrate 1 to the back electrode 4, in the same manner as in eleventh embodiment.
(4) Next, by applying a laser annealing process only to the pixel region 3a corresponding to the pixels on the phosphor layer 3, a crystalline distribution pattern in which the pixel region 3a forms a crystalline phase while the interpixel regions 3b form amorphous phase is formed within the in-plane of the phosphor layer 3.
(5) Next, a transparent electrode 2 is formed on the phosphor layer 3 by a sputtering method. As the material for the transparent electrode 2, ITO is used, and the transparent electrode 2 is formed as a linear pattern having a plurality of lines that are located in parallel with the surface of the glass substrate and extend in a second direction virtually orthogonal to the aforementioned first direction, in parallel with one another with predetermined intervals between one another.
(6) Next, after film-forming SiN as a protective layer 18 from the phosphor layer 3 or the transparent electrode 2, a black matrix 19 is formed by a photolithography method by using a resin material containing carbon black. The black matrix 19 is disposed virtually in a lattice shape by using a plurality of linear patterns that extend in the first direction in parallel with the surface of the glass substrate 1, between gaps of the back electrodes 4, and a plurality of linear patterns that extend in the second direction between gaps of the adjacent transparent electrodes 2.
(7) Next, after forming the color conversion layer 16 by inkjet method, by using color resists, colored patterns are formed between adjacent matrix lines of the black matrix 19 by a photolithography method. These processes are repeatedly carried out for the respective colors of R, G and B so that a color filter 17 is formed.
(8) Next, an insulating protective layer 11 is formed on the color filter 17 by using an epoxy resin.
By using the above-mentioned processes, a top-emission-type display device 20 of the present embodiment is obtained.
Additionally, as shown in
In the display device in accordance with the present embodiment, over the same plane of the phosphor layer 3, the phosphor layer 3b in the interpixel region between the adjacent pixel regions 3a is made to have higher resistance than that of the phosphor layer 3a in the pixel region so that even with a display device using a low resistance phosphor layer that exhibits electroluminescent light emission, it is possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
In the same manner as in the display device of eleventh embodiment, the display device 20b makes it possible to greatly reduce crosstalk at the time of a displaying operation, and consequently to improve the display quality.
Although the present invention has been described above in detail by way of preferred embodiments thereof, the invention is not limited to the above embodiments, and various changes and modifications as would be obvious to one skilled in the art are intended to be included within the technical scope of the following claims.
The display device of the present invention, which uses a light-emitting element that can be driven at a low voltage, and has high luminance and high efficiency, makes it possible to provide a display device that can prevent crosstalk and achieve high display quality. The present invention is effectively used for providing a high-quality display device, such as a high-quality television.
This application claims priority on Japanese Patent Application No. 2007-43956 filed in Japan on Feb. 23, 2007 and Japanese Patent Application No. 2007-46986 filed in Japan on Feb. 27, 2007, the entire contents of which are hereby incorporated by reference.
| Number | Date | Country | Kind |
|---|---|---|---|
| 2007-043956 | Feb 2007 | JP | national |
| 2007-046986 | Feb 2007 | JP | national |
| Filing Document | Filing Date | Country | Kind | 371c Date |
|---|---|---|---|---|
| PCT/JP2008/000293 | 2/21/2008 | WO | 00 | 8/19/2009 |
