Mold and method of manufacturing display device

• US 20070202709A1
• Filed: 02/07/2007
• Published: 08/30/2007
• Est. Priority Date: 02/08/2006
• Status: Active Grant

• Current Assignee: Samsung Display Company Limited (Samsung Electronics Co. Ltd.)
• Original Assignee: Samsung Electronics Co. Ltd.
• Inventors: Hong, Mun-pyo, Chang, Jae-hyuk, Roh, Nam-seok, Bae, Jung-mok
• Granted Patent: US 8,040,474 B2
• Time in Patent Office: Days
• US Class Current: 438/758
• CPC Class Codes: G02F 1/133504 Diffusing, scattering, diffracting elements associated to illuminating devices G02F1/133606
• CPC Class Codes: G02F 1/133555 Transflectors
• CPC Class Codes: G02F 1/133565 inside the LC elements, i.e. between the cell substrates
• CPC Class Codes: G02F 2201/123 pixel

Abstract

A mold for a display device, comprising a supporting frame; at least one pattern forming part provided on a surface of the supporting frame; and a protrusion projecting from the supporting frame and disposed along the circumference of the pattern forming part, an inside wall of the protrusion toward the pattern forming part standing upright from the surface of the supporting frame.

Claims

1. A mold for a display device, comprising:

a supporting frame;

at least one pattern forming part provided on a surface of the supporting frame; and

a protrusion projecting from the supporting frame and disposed along the circumference of the pattern forming part, an inside wall of the protrusion toward the pattern forming part standing upright from the surface of the supporting frame.

2. The mold according to claim 1, wherein a flat part is formed around the pattern forming part, and the protrusion is disposed on a boundary region between the flat part and the pattern forming part.

3. The mold according to claim 2, wherein an outside wall of the protrusion inclines to the surface of the supporting frame so that a cross-sectional area of the protrusion taken along transversely becomes smaller further from the supporting frame.

4. The mold according to claim 2, further comprising a mask placed on an opposite surface of the supporting frame and having an opening corresponding to the pattern forming part.

5. The mold according to claim 2, wherein the pattern forming part has a concavo-convex pattern.

6. The mold according to claim 4, wherein the angle between the inside wall of the protrusion and the surface of the supporting frame is substantially in the range of 80 degrees to 100 degrees.

7. The mold according to claim 4, wherein the width of the protrusion is substantially in the range of 5 μ

m to 20 μ

m.

8. The mold according to claim 7, wherein the supporting frame and the protrusion comprises polydimethylsiloxane (PDMS).

9. A manufacturing method for a display device comprising:

providing an insulating substrate;

forming a passivation layer on the insulating substrate;

aligning a mold provided with a pattern forming part according to claim 1 on the passivation layer; and

pressing the mold to form pattern corresponding to the pattern forming part on the passivation layer.

10. The manufacturing method according to claim 9, further comprising curing the passivation layer while pressing the mold.

11. The manufacturing method according to claim 10, wherein the passivation layer comprises organic polymer and is cured by at least one of heat and light.

12. The manufacturing method according to claim 9, further comprising removing the mold;

and

exposing and developing the passivation layer with a mask which has a light-transmitting opening corresponding to a pattern forming part provided in the mold and is disposed over the passivation layer and removing an unpatterned portion of the passivation layer.

13. The manufacturing method according to claim 9, wherein the mold further comprises a mask having an opening corresponding to the pattern forming part and placed on an opposite surface of a supporting frame provided in the mold,

the manufacturing method further comprising exposing and developing the passivation layer and removing an unpatterned portion of the passivation layer after pressing the mold.

14. The manufacturing method according to claim 12, further comprising forming a gate wiring and a data wiring insulatedly crossing the gate wiring to define a pixel region on the insulating substrate before forming the passivation layer;

and

forming a thin film transistor at an intersection area where the gate wiring and the data wiring cross each other,

wherein the pattern forming part is disposed to correspond to at least a portion of the pixel region.

15. The manufacturing method according to claim 14, further comprising forming a pixel electrode on the passivation layer and forming a reflective layer at least on a portion of the pixel electrode after removing the mold.

16. The manufacturing method according to claim 14, wherein a flat part is formed around the pattern forming part, and

the protrusion is disposed on a boundary region between the flat part and the pattern forming part.

17. The manufacturing method according to claim 16, wherein an outside wall of the protrusion inclines to the surface of the supporting frame so that a cross-sectional area of the protrusion taken along transversely becomes smaller as it moves far from the supporting frame.

18. The manufacturing method according to claim 16, wherein the pattern forming part has a concavo-convex pattern.

19. The manufacturing method according to claim 18, wherein the angle between the inside wall of the protrusion and the surface of the supporting frame is substantially in the range of 80 degrees to 100 degrees.

20. The manufacturing method according to claim 18, wherein the width of the protrusion is substantially in the range of 5 μ

m to 20 μ

m.

21. The manufacturing method according to claim 20, wherein the supporting frame and the protrusion comprises polydimethylsiloxane (PDMS).