Method of manufacturing display device

Patent metadata

Field	Value
Publication number	US-10529956-B2
Application number	US-201816031246-A
Country	US
Kind code	B2
Filing date	Jul 10, 2018
Priority date	Dec 18, 2017
Publication date	Jan 7, 2020
Grant date	Jan 7, 2020

Abstract

A method of manufacturing a display device includes forming a pixel-defining layer including an opening corresponding to a pixel electrode and a bank defining the opening, forming a first non-photosensitive layer on the pixel-defining layer, forming a temporary layer including a second non-photosensitive material different from a material of the first non-photosensitive layer on a portion of the first non-photosensitive layer, forming an inorganic material layer on the first non-photosensitive layer using the temporary layer such that the inorganic material layer includes a first open region corresponding to the opening, forming a second open region overlapping the first open region in the first non-photosensitive layer, wherein a width of the second open region is greater than a width of the first open region, and forming an intermediate layer on the pixel electrode by using the first non-photosensitive layer and the inorganic material layer as a template.

First claim

What is claimed is:

1. A method of manufacturing a display device, the method comprising:
forming a pixel electrode;
forming a pixel-defining layer including an opening corresponding to the pixel electrode and a bank portion defining the opening;
forming a first non-photosensitive layer on the pixel-defining layer;
forming a temporary layer on a portion of the first non-photosensitive layer, the temporary layer including a second non-photosensitive material different from a material of the first non-photosensitive layer;
forming an inorganic material layer on the first non-photosensitive layer by using the temporary layer to block a formation of the inorganic material layer on the portion of the first non-photosensitive layer on which the temporary layer is formed, such that the inorganic material layer includes a first open region corresponding to the opening in the pixel defining layer;
forming a second open region in the first non-photosensitive layer, the second open region overlapping the first open region, and a width of the second open region being greater than a width of the first open region; and
forming an intermediate layer on the pixel electrode by using the first non-photosensitive layer and the inorganic material layer as a template.

2. The method as claimed in claim 1 , further comprising:
forming a conductive layer on the intermediate layer.

3. The method as claimed in claim 2 , wherein in forming the conductive layer, the first non-photoconductive layer and the inorganic material layer, respectively including the second open region and the first open region, is used as a template.

4. The method as claimed in claim 1 , wherein the temporary layer including the second non-photosensitive material has an undercut structure in which a width of a lower portion thereof is less than a width of an upper portion thereof.

5. The method as claimed in claim 4 , wherein:
the lower portion of the temporary layer includes the second non-photosensitive material, and
the upper portion of the temporary layer includes a material different from the material of the lower portion of the temporary layer.

6. The method as claimed in claim 5 , wherein the upper portion of the temporary layer includes a photosensitive material.

7. The method as claimed in claim 1 , wherein,
in forming the inorganic material layer, an end of the inorganic material layer adjacent to the first open region is spaced apart from a lower portion of the temporary layer by a preset interval, and
forming the second open region in the first non-photosensitive layer includes removing the temporary layer and a portion of the first non-photosensitive layer overlapping the temporary layer.

8. The method as claimed in claim 1 , wherein a width of the second open region of the first non-photosensitive layer is greater than a width of the pixel electrode exposed through the opening of the pixel-defining layer.

9. The method as claimed in claim 1 , wherein, in forming the intermediate layer, a material forming the intermediate layer is incident obliquely with respect to a direction perpendicular to an upper surface of the pixel electrode such that the intermediate layer is formed on the pixel electrode and the bank portion adjacent to the pixel electrode.

10. The method as claimed in claim 1 , wherein the first non-photosensitive layer includes a fluorine-based non-photosensitive material.

11. A method of manufacturing a display device, the method comprising:
forming a pixel electrode;
forming an insulating layer including an opening corresponding to the pixel electrode and a bank portion defining the opening;
forming a first non-photosensitive layer on the insulating layer;
forming a temporary layer on a portion of the first non-photosensitive layer, the temporary layer including a material different from a material of the first non-photosensitive layer and having an undercut structure;
forming a shadow layer on the first non-photosensitive layer by using the temporary layer as a template, the shadow layer including a first open region corresponding to the opening;
forming a second open region in the first non-photosensitive layer, the second open region overlapping the first open region of the shadow layer and having a width greater than a width of the first open region;
forming a material layer on the pixel electrode by using the first non-photosensitive layer and the shadow layer respectively as a template including the second open region and the first open region; and
removing the first non-photosensitive layer and the shadow layer.

12. The method as claimed in claim 11 , wherein the temporary layer includes a second non-photosensitive material.

13. The method as claimed in claim 11 , wherein the shadow layer includes at least one of metal and an inorganic insulating material.

14. The method as claimed in claim 11 , wherein, in forming the shadow layer, an end of the shadow layer adjacent to the first open region is spaced apart from a lower portion of the temporary layer by a preset interval.

15. The method as claimed in claim 14 , wherein forming the second open region in the first non-photosensitive layer includes removing the temporary layer.

16. The method as claimed in claim 11 , wherein the material layer is a conductive layer or an intermediate layer including an emission layer.

17. The method as claimed in claim 11 , wherein the material layer is formed by thermal evaporation.

18. The method as claimed in claim 11 , wherein the first non-photosensitive layer includes a fluorine-based non-photosensitive material.

19. The method as claimed in claim 11 , wherein, in forming the second open region in the first non-photosensitive layer, an end of the shadow layer adjacent to the first open region extends farther toward a center of the first open region than an end of the first non-photosensitive layer adjacent to the second open region.

20. The method as claimed in claim 19 , wherein, in forming the material layer, a material forming the material layer is incident obliquely with respect to a direction perpendicular to an upper surface of the pixel electrode such that the material layer is formed on the pixel electrode and the bank portion adjacent to the pixel electrode.

Assignees

• Samsung Display Co Ltd

Inventors

• Kwon Younggil
• Choung Jiyoung

Classifications

• H01L27/3246

  Electricity · mapped topic

• H01L51/56 Primary

  Electricity · mapped topic

• H01L2227/323

  Electricity · mapped topic

• H10K71/00 Primary

  Manufacture or treatment specially adapted for the organic devices covered by this subclass · CPC title

• H10K59/122 Primary

  Pixel-defining structures or layers, e.g. banks · CPC title