Display device and method of manufacturing the same

Patent metadata

Field	Value
Publication number	US-11877480-B2
Application number	US-202217686885-A
Country	US
Kind code	B2
Filing date	Mar 4, 2022
Priority date	Nov 26, 2018
Publication date	Jan 16, 2024
Grant date	Jan 16, 2024

Abstract

A method of manufacturing a display device includes providing a transistor on a light-emitting area of a substrate, patterning a first organic layer covering the transistor to provide a first insulating layer, providing a pixel electrode connected to the transistor, and patterning a second organic layer covering the first insulating layer and the pixel electrode to provide a second insulating layer which defines the light-emitting area. The first insulating layer includes a first area corresponding to the light-emitting area, and a second area outside the light-emitting area and having a thickness which is less than a thickness of the first area, within the light-emitting area, the second insulating layer covers edges of the pixel electrode and covers external lateral surfaces of the first area of the first insulating layer, and a height of the second insulating layer decreases along a direction from the first area to the second area.

First claim

What is claimed is:

1. A method of manufacturing a display device, the method comprising:
providing a thin film transistor on a light-emitting area of a substrate;
providing a first organic material layer covering the thin film transistor, and patterning the first organic material layer to provide a first insulating layer;
providing a pixel electrode electrically connected to the thin film transistor; and
providing a second organic material layer covering the first insulating layer and the pixel electrode, and patterning the second organic material layer to provide a second insulating layer which defines the light-emitting area,
wherein
the first insulating layer comprises:
a first area corresponding to the light-emitting area, and
a second area disposed outside the light-emitting area, the second area having a thickness which is less than a thickness of the first area,

within the light-emitting area, the second insulating layer covers edges of the pixel electrode and covers external lateral surfaces of the first area of the first insulating layer, and
a height of the second insulating layer decreases along a direction from the first area to the second area.

2. The method of claim 1 , wherein
the providing the second insulating layer exposes the pixel electrode to outside the second insulating layer, and
the method further comprises:
providing an intermediate layer including an organic emission layer on the pixel electrode which is exposed to outside the second insulating layer, and
providing a common electrode on the intermediate layer.

3. The method of claim 2 , wherein
the providing the second insulating layer further exposes an upper surface of the second area of the first insulating layer to outside the second insulating layer, and
the providing the common electrode directly contacts the common electrode with the upper surface of the second area of the first insulating layer which is exposed to outside the second insulating layer.

4. The method of claim 3 , wherein the providing the second insulating layer disposes an end portion of the second insulating layer in the second area of the first insulating layer and having a concave curved surface.

5. The method of claim 1 , wherein
the providing the second insulating layer disposes an extension portion of the second insulating layer covering the second area of the first insulating layer, and
an upper surface of the extension portion which is furthest from the substrate, is closer to the substrate than an upper surface of the first area of the first insulating layer which is furthest from the substrate.

6. The method of claim 1 , wherein
an upper surface of the first area of the first insulating layer is planar, and
the providing the pixel electrode disposes the pixel electrode on the upper surface of the first area of the first insulating layer which is planar.

7. The method of claim 1 , wherein the patterning the first organic material layer comprises using a first halftone mask, and provides the first area and the second area of the first insulating layer simultaneously.

8. The method of claim 1 , wherein the patterning of the second organic material layer comprises:
using a second halftone mask, and
removing a portion of the second organic material layer corresponding to the second area of the first insulating layer.

9. The method of claim 2 , further comprising providing a first inorganic encapsulation layer, an organic encapsulation layer and a second inorganic encapsulation layer on the common electrode.

Assignees

• Samsung Display Co Ltd

Inventors

• JEON Bogeon
• Kim Jungi
• Jung Yangho
• Choi Seonhwa

Classifications

• H10K50/844

  Encapsulations · CPC title

• H10K59/126

  Shielding, e.g. light-blocking means over the TFTs · CPC title

• H10K59/124 Primary

  Insulating layers formed between TFT elements and OLED elements · CPC title

• H10K59/873

  Encapsulations · CPC title

• H10K59/8731

  multilayered coatings having a repetitive structure, e.g. having multiple organic-inorganic bilayers · CPC title