Display device manufacturing method including forming a repair hole that penetrates a sealing layer
According to one embodiment, a method of manufacturing a display device, includes forming a plurality of display elements each including a lower electrode, an organic layer which covers the lower electrode and an upper electrode which covers the organic layer, forming a first sealing layer which seals the plurality of display elements, individually, inspecting the plurality of display elements to determine whether any of the plurality of display elements entails a defect and forming, when in the inspection, it is confirmed that there is a defective one of the display elements, a repair hole which penetrates the first sealing layer which seals the defective one of the display elements.
1 . A method of manufacturing a display device, comprising:
forming a plurality of display elements each including a lower electrode, an organic layer which covers the lower electrode and an upper electrode which covers the organic layer;
forming a first sealing layer which seals the plurality of display elements, individually;
inspecting the plurality of display elements to determine whether any of the plurality of display elements entails a defect; and
forming, when in the inspection, it is confirmed that there is a defective one of the display elements, a repair hole that penetrates the first sealing layer that seals the defective one of the display elements.
2 . The manufacturing method of claim 1 , wherein
the forming the plurality of display elements, includes:
forming the lower electrode;
forming the organic layer which covers the lower electrode; and
forming the upper electrode which covers the organic layer.
3 . The manufacturing method of claim 2 , further comprising:
forming a rib comprising pixel apertures which overlap the lower electrodes, after the forming of the lower electrode; and
forming a partition disposed on the rib between each pair of pixel apertures adjacent to each other, after the forming of the rib.
4 . The manufacturing method of claim 3 , wherein
the repair hole overlap a respective one of the pixel apertures, and
an area of the repair hole is smaller than an area of the respective one of the pixel apertures.
5 . The manufacturing method of claim 3 , wherein
the repair hole overlaps a respective one of the pixel apertures.
6 . The manufacturing method of claim 1 , further comprising:
forming a resin layer which covers the first sealing layer and fills the repair hole, after the forming of the repair hole.
7 . The manufacturing method of claim 6 , wherein
the resin layer includes a first filling portion located in the repair hole.
8 . The manufacturing method of claim 1 , wherein
the repair hole further penetrates the upper electrode.
9 . The manufacturing method of claim 8 , wherein
the repair hole further penetrates the organic layer.
10 . The manufacturing method of claim 1 , further comprising:
forming a resin layer which covers the first sealing layer, after the forming the first sealing layer,
wherein
the repair hole penetrates the resin layer and the first sealing layer.
11 . The manufacturing method of claim 1 , further comprising:
forming a second sealing layer which covers the resin layer after the forming of the resin layer,
wherein
the repair hole penetrates the second sealing layer, the resin layer and the first sealing layer.
12 . The manufacturing method of claim 11 , further comprising:
forming an adhesive layer which covers the second sealing layer and fills the repair hole, after the forming of the repair hole.
13 . The manufacturing method of claim 12 , wherein
the adhesive layer includes a second filling portion located in the repair hole.
14 . The manufacturing method of claim 1 , wherein
the forming of the repair hole comprises irradiating a laser beam toward the defective one of the display elements.
15 . The manufacturing method of claim 1 , wherein
the repair hole does not penetrate the lower electrode.
16 . The manufacturing method of claim 1 , wherein
the plurality of display elements each further comprises a cap layer which covers the upper electrode.
17 . The manufacturing method of claim 16 , wherein
the repair hole further penetrates the cap layer.
18 . The manufacturing method of claim 1 , wherein
the inspecting comprises determining that there is a display element having a defect when a display element in a bright spot state is detected.
19 . The manufacturing method of claim 1 , further comprising:
allowing moisture to enter the display element from the repair hole after the forming of the repair hole.
20 . The manufacturing method of claim 1 , wherein
the forming of the repair holes comprises forming a plurality of repair holes each identical to the repair hole in the defective one of the display elements.