Method of manufacturing display apparatus

Patent metadata

Field	Value
Publication number	US-11527581-B2
Application number	US-202017136690-A
Country	US
Kind code	B2
Filing date	Dec 29, 2020
Priority date	May 18, 2020
Publication date	Dec 13, 2022
Grant date	Dec 13, 2022

Abstract

A method of manufacturing a display apparatus includes: forming a display element layer above a lower substrate, where the display element layer includes first to third display elements; forming an encapsulation layer on the display element layer; forming first partition walls on the encapsulation layer to define first to third color regions, where the first to third color regions overlap the first to third display elements, respectively, in a view in a direction perpendicular to the lower substrate; forming second partition walls on the first partition walls; forming a quantum dot layer, which includes forming a second color quantum dot layer in the second color region and forming a third color quantum dot layer in the third color region; and removing the second partition walls.

First claim

What is claimed is:

1. A method of manufacturing a display apparatus, the method comprising:
forming a display element layer above a lower substrate, wherein the display element layer comprises first to third display elements;
forming an encapsulation layer on the display element layer;
forming first partition walls on the encapsulation layer to define first to third color regions, wherein the first to third color regions overlap the first to third display elements, respectively, in a view in a direction perpendicular to the lower substrate;
forming second partition walls on the first partition walls;
forming a quantum dot layer, which comprises forming a second color quantum dot layer in the second color region and forming a third color quantum dot layer in the third color region; and
removing the second partition walls.

2. The method of claim 1 , wherein the forming of the quantum dot layer comprises:
injecting a second color quantum dot layer material into the second color region and injecting a third color quantum dot layer material into the third color region;
volatilizing a portion of a material included in the second color quantum dot layer material and a portion of a material included in the third color quantum dot layer material; and
curing the second color quantum dot layer material and the third color quantum dot layer material.

3. The method of claim 2 , wherein the portion of the material included in the second color quantum dot layer material is a portion of a material other than quantum dots in the second color quantum dot layer material, and the portion of the material included in the third color quantum dot layer material is a portion of a material other than quantum dots in the third color quantum dot layer material.

4. The method of claim 3 , wherein the volatilizing comprises volatilizing the portion of the material comprised in the second color quantum dot layer material and the portion of the material comprised in the third color quantum dot layer material such that a distance from an upper surface of the encapsulation layer to an upper surface of the second color quantum dot layer material and a distance from the upper surface of the encapsulation layer to an upper surface of the third color quantum dot layer material each are equal to or less than a preset distance in a thickness direction of the lower substrate.

5. The method of claim 4 , wherein the preset distance is a distance from the upper surface of the encapsulation layer to an upper surface of the first partition wall in the thickness direction.

6. The method of claim 5 , wherein the volatilizing comprises providing thermal energy to the second color quantum dot layer material and the third color quantum dot layer material.

7. The method of claim 1 , wherein upper surfaces of the second partition walls are hydrophobic.

8. The method of claim 1 , further comprising forming a reflective plate covering an upper surface of the encapsulation layer and the first partition walls,
wherein the forming of the second partition walls comprises forming the second partition walls on portions of the reflective plate covering the first partition walls.

9. The method of claim 8 , further comprising removing a portion of the reflective plate that does not cover the first partition walls.

10. The method of claim 1 , wherein the first to third display elements comprise a first color emission layer configured to emit light of a wavelength in a first wavelength band.

11. The method of claim 10 , wherein the second color quantum dot layer is configured to convert the light of the wavelength in the first wavelength band into light of a wavelength in a second wavelength band, and the third color quantum dot layer is configured to convert the light of the wavelength in the first wavelength band into light of a wavelength in a third wavelength band.

12. The method of claim 11 , wherein the first to third display elements comprise:
first to third pixel electrodes, respectively; and
an opposite electrode corresponding to the first to third pixel electrodes, respectively,
wherein the first color emission layer is between the opposite electrode and each of the first to third pixel electrodes.

13. A method of manufacturing a display apparatus, the method comprising:
forming a color filter layer on a first surface of an upper substrate;
forming a protective layer on the color filter layer;
forming first partition walls on the protective layer, wherein the first partition walls define first to third color regions;
forming second partition walls on the first partition walls;
forming a quantum dot layer, which comprises forming a second color quantum dot layer in the second color region and forming a third color quantum dot layer in the third color region; and
removing the second partition walls.

14. The method of claim 13 , wherein the forming of the quantum dot layer comprises:
injecting a second color quantum dot layer material into the second color region and injecting a third color quantum dot layer material into the third color region;
volatilizing a portion of a material included in the second color quantum dot layer material and a portion of a material included in the third color quantum dot layer material; and
curing the second color quantum dot layer material and the third color quantum dot layer material.

15. The method of claim 14 , wherein the portion of the material included in the second color quantum dot layer material is a portion of a material other than quantum dots in the second color quantum dot layer material, and the portion of the material included in the third color quantum dot layer material is a portion of a material other than quantum dots in the third color quantum dot layer material.

16. The method of claim 15 , wherein the volatilizing comprises volatilizing the portion of the material included in the second color quantum dot layer material and the portion of the material included in the third color quantum dot layer material such that a distance from an upper surface of the protective layer to an upper surface of the second color quantum dot layer material and a distance from the upper surface of the protective layer to an upper surface of the third color quantum dot layer material each are equal to or less than a preset distance in a thickness direction of the upper substrate.

17. The method of claim 16 , wherein the preset distance is a distance from the upper surface of the protective layer to an upper surface of the first partition wall in the thickness direction.

18. The method of claim 13 , wherein upper surfaces of the second partition walls are hydrophobic.

19. The method of claim 13 , further comprising forming a reflective plate covering an upper surface of the protective layer and the first partition walls,
wherein the forming of the second partition walls comprises forming the second partition walls on portions of the reflective plate covering the first partition walls.

20. The method of claim 12 , further comprising forming a display element layer above a lower substrate, wherein the display element layer comprises first to third display elements,
wherein the first to third display elements comprise a first color emission layer configured to emit light in a first wavelength band,
wherein the second color quantum dot layer is configured to convert the light in the first wavelength band into light in a second wavelength band, and the third color quantum dot layer is configured to convert the light in

Assignees

• Samsung Display Co Ltd

Inventors

• Kang Shintack
• Kim Yujin
• Kim Hyunseok
• Jo Kunhee

Classifications

• G02B5/201

  in the form of arrays · CPC title

• H01L27/3244

  Electricity · mapped topic

• H01L27/322 Primary

  Electricity · mapped topic

• H01L51/5253

  Electricity · mapped topic

• H01L2227/323

  Electricity · mapped topic