Display apparatus and method of manufacturing the same

• US 9,825,056 B2
• Filed: 07/15/2015
• Issued: 11/21/2017
• Est. Priority Date: 02/06/2015
• Status: Active Grant

• Current Assignee: Samsung Display Company Limited (Samsung Electronics Co. Ltd.)
• Original Assignee: Samsung Display Company Limited (Samsung Electronics Co. Ltd.)
• Inventors: Kwak, Wonkyu, Lee, Jaeyong
• Primary Examiner(s): Lee, Kyoung
• Application Number:
  US14/800,521
• Publication Number:
  US 20160233248A1
• Time in Patent Office: 860 Days
• CPC Class Codes: H01L 27/1218 with a particular composition or structure of the substrate
• CPC Class Codes: H01L 27/1248 with a particular composition or shape of the interlayer dielectric specially adapted to the circuit arrangement
• CPC Class Codes: H01L 27/1262 with a particular formation, treatment or coating of the substrate
• CPC Class Codes: H01L 27/1266 the substrate on which the devices are formed not being the final device substrate, e.g. using a temporary substrate
• CPC Class Codes: H10K 50/8426 Peripheral sealing arrangements, e.g. adhesives, sealants
• CPC Class Codes: H10K 50/844 Encapsulations
• CPC Class Codes: H10K 59/122 Pixel-defining structures or layers, e.g. banks
• CPC Class Codes: H10K 59/124 Insulating layers formed between TFT elements and OLED elements
• CPC Class Codes: H10K 71/00 Manufacture or treatment specially adapted for the organic devices covered by this subclass
• CPC Class Codes: H10K 71/851 Division of substrate

Abstract

A display apparatus includes a substrate partitioned into a central area and a peripheral area disposed adjacent to the central area. The central area includes a display area; a first insulating layer corresponding to the peripheral area of the substrate; at least one slit corresponding to a region of the first insulating layer; and a cladding layer, which covers the at least one slit, on the first insulating layer.

Claims

1. A display apparatus comprising:

a substrate partitioned into a central area and a peripheral area disposed adjacent to the central area, the central area comprising a display area;

a first insulating layer disposed in the peripheral area of the substrate;

at least one slit corresponding to a region of the first insulating layer; and

a cladding layer on the first insulating layer and covering the at least one slit in the peripheral area, wherein at least one encapsulating layer on the display area is spaced apart from the cladding layer.

2. The display apparatus of claim 1, further comprising one or more insulating layers in the display area, and wherein the cladding layer includes a same material as a material of the one or more insulating layers.

3. The display apparatus of claim 1, wherein a depth of the at least one slit is less than or equal to a thickness of the first insulating layer.

4. The display apparatus of claim 1, wherein the cladding layer extends in one direction and is parallel to an edge of the substrate.

5. The display apparatus of claim 1, wherein a width of the cladding layer is greater than a width of the at least one slit.

6. The display apparatus of claim 1, wherein a length of the cladding layer is longer than a length of the at least one slit.

7. The display apparatus of claim 1, wherein the first insulating layer extends to the display area.

8. The display apparatus of claim 1, wherein the first insulating layer extends to an edge of the substrate.

9. The display apparatus of claim 1, further comprising a barrier layer between the substrate and the first insulating layer.

10. The display apparatus of claim 9, wherein the barrier layer extends to the display area.

11. The display apparatus of claim 1, further comprising a second insulating layer on the first insulating layer, and wherein the at least one slit extends through the second insulating layer.

12. The display apparatus of claim 11, wherein the second insulating layer extends to the display area.

13. The display apparatus of claim 1, wherein the at least one slit is spaced apart from at least one edge of the substrate.

14. The display apparatus of claim 1, wherein the at least one slit overlaps with at least one edge of the substrate.

15. The display apparatus of claim 1, wherein the cladding layer is spaced apart from at least one edge of the substrate.

16. The display apparatus of claim 1, wherein the cladding layer overlaps with at least one edge from among edges of the substrate.

17. The display apparatus of claim 1, wherein a plurality of slits are spaced apart from each other in one direction.

18. The display apparatus of claim 17, wherein the plurality of slits are disposed in a direction that crosses the one direction.

19. The display apparatus of claim 17, wherein, among the plurality of slits, a width of a slit most adjacent to an edge of the substrate is greater than a width of each of slits other than the slit most adjacent to the edge of the substrate.

20. The display apparatus of claim 17, wherein, among the plurality of slits, a width of a slit furthest from an edge of the substrate is greater than a width of each of slits other than the slit furthest from the edge of the substrate.

21. The display apparatus of claim 17, wherein, among the plurality of slits, a width of a middle slit located between a slit furthest from an edge of the substrate and a slit most adjacent to the edge of the substrate is greater than a width of each of slits other than the middle slit.

22. The display apparatus of claim 1, wherein at least one edge from among edges of the substrate is defined as a cutting line.

23. The display apparatus of claim 1, wherein the substrate comprises a flexible material.

24. The display apparatus of claim 1, wherein the substrate comprises an organic material.

25. The display apparatus of claim 1, wherein the substrate comprises multiple layers.

26. The display apparatus of claim 25, wherein the substrate further comprises a first layer comprising an organic material, a second layer comprising an organic material, and an insertion layer between the first layer and the second layer.

27. The display apparatus of claim 1, further comprising a particle that remains in the at least one slit, and wherein the cladding layer is formed to cover the particle.

28. The display apparatus of claim 1, wherein the at least one encapsulating layer extends to the peripheral area.

29. The display apparatus of claim 1, wherein the at least one encapsulating layer comprises one or more inorganic encapsulating layers or one or more organic encapsulating layers.

30. The display apparatus of claim 1, further comprising a plurality of thin-film transistors (TFTs) in the central area of the substrate, each of the plurality of TFTs comprising an active layer, a gate electrode, a source electrode, and a drain electrode,

wherein one or more insulating layers are adjacent to at least one of the active layer, the gate electrode, the source electrode, and the drain electrode, and

wherein the cladding layer and the one or more insulating layers include a same material.

31. The display apparatus of claim 30, wherein the first insulating layer extends to the central area and is disposed between the substrate and the plurality of TFTs.

32. The display apparatus of claim 30, further comprising a passivation layer on the source electrode and the drain electrode, and wherein the cladding layer and the passivation layer are formed of a same material.

33. The display apparatus of claim 30, further comprising a second insulating layer between the gate electrode and the active layer, and wherein the second insulating layer is on the first insulating layer and extends to the peripheral area so as to correspond to the at least one slit.

34. The display apparatus of claim 30, further comprising an interlayer insulating layer between the gate electrode and the source and drain electrodes, and wherein the interlayer insulating layer is on the first insulating layer and extends to the peripheral area so as to correspond to the at least one slit.

35. The display apparatus of claim 30, further comprising:

a first electrode electrically connected to at least one of the plurality of TFTs; and

a pixel defining layer covering a portion of the first electrode and defining a pixel area.

36. The display apparatus of claim 35, further comprising:

a second electrode facing the first electrode; and

an intermediate layer between the first electrode and the second electrode and comprising an organic emission layer.

37. The display apparatus of claim 35, wherein the cladding layer and the pixel defining layer include a same material.

38. The display apparatus of claim 1, wherein the cladding layer surrounds the display area.

39. The display apparatus of claim 1, wherein the cladding layer corresponds to edges of the display area, except for one of the edges.

40. The display apparatus of claim 1, wherein the cladding layer comprises one or more main portions corresponding to edges of the substrate, and comprises a corner portion connecting two adjacent main portions.

41. The display apparatus of claim 1, further comprising a pad area in the peripheral area of the substrate, wherein the cladding layer is near the pad area and comprises curved portions that correspond to the pad area and are curved toward the display area or are curved away from the display area.

42. A method of manufacturing a display apparatus comprising a substrate partitioned into a central area and a peripheral area adjacent to the central area, the central area comprising a display area, the method comprising:

forming a first insulating layer to correspond to the peripheral area of the substrate;

forming at least one slit by partially removing a vertical portion of the first insulating layer, wherein the at least one slit corresponds to a region of the first insulating layer;

forming a plurality of thin-film transistors (TFTs) in the central area of the substrate, wherein each of the plurality of TFTs comprises an active layer, a gate electrode, a source electrode, and a drain electrode; and

forming a cladding layer contacting the first insulating layer, wherein the cladding layer covers the at least one slit.

43. The method of claim 42, further comprising forming one or more insulating layers in the display area, and wherein the cladding layer includes a same material as the one or more insulating layers formed in the display area.

44. The method of claim 42, further comprising forming a passivation layer on the source electrode and the drain electrode, wherein forming the passivation layer comprises forming a via hole in the passivation layer so as to expose a region of at least one of the source electrode and the drain electrode, and wherein the cladding layer includes a same material as the passivation layer, and is simultaneously patterned with the forming of the via hole.

45. A method of manufacturing a display apparatus comprising a central area and a peripheral area adjacent to the central area, by using a mother substrate, the method comprising:

cutting the mother substrate along cutting lines,

forming a first insulating layer to correspond to the peripheral area;

forming at least one slit by partially removing a vertical portion of the first insulating layer, wherein the at least one slit corresponds to a region of the first insulating layer;

forming a cladding layer on the first insulating layer, wherein the cladding layer covers the at least one slit; and

performing a cutting process along the cutting lines, and thus, separating one or more display apparatuses formed on the mother substrate.

46. The method of claim 45, wherein, during the cutting process, the cutting lines are spaced apart from the cladding layer.

47. The method of claim 45, wherein, during the cutting process, the cutting lines overlap with the cladding layer.

48. A display apparatus comprising:

a substrate partitioned into a central area and a peripheral area disposed adjacent to the central area, the central area comprising a display area;

a first insulating layer corresponding to the peripheral area of the substrate;

a second insulating layer on the first insulating layer;

at least one slit corresponding to a region of the first insulating layer and extending through the second insulating layer; and

a cladding layer on the first and second insulating layers and covering the at least one slit.

49. A display apparatus comprising:

a substrate partitioned into a central area and a peripheral area disposed adjacent to the central area, the central area comprising a display area;

a first insulating layer corresponding to the peripheral area of the substrate;

at least one slit corresponding to a region of the first insulating layer and overlapping with at least one edge of the substrate; and

a cladding layer on the first insulating layer and covering the at least one slit.

50. A display apparatus comprising:

a substrate partitioned into a central area and a peripheral area disposed adjacent to the central area, the central area comprising a display area;

a first insulating layer corresponding to the peripheral area of the substrate;

at least one slit corresponding to a region of the first insulating layer; and

a cladding layer on the first insulating layer and covering the at least one slit, wherein the cladding layer overlaps with at least one edge from among edges of the substrate.

51. A display apparatus comprising:

a substrate partitioned into a central area and a peripheral area disposed adjacent to the central area, the central area comprising a display area;

a first insulating layer corresponding to the peripheral area of the substrate;

at least one slit corresponding to a region of the first insulating layer;

a cladding layer on the first insulating layer and covering the at least one slit; and

a particle that remains in the at least one slit,

wherein the cladding layer is formed to cover the particle.

52. A display apparatus comprising:

a substrate partitioned into a central area and a peripheral area disposed adjacent to the central area, the central area comprising a display area;

a first insulating layer corresponding to the peripheral area of the substrate;

at least one slit corresponding to a region of the first insulating layer; and

a cladding layer on the first insulating layer and covering the at least one slit,

wherein the cladding layer surrounds the display area.