Display apparatus and manufacturing method thereof

• US 9,846,323 B2
• Filed: 04/18/2011
• Issued: 12/19/2017
• Est. Priority Date: 09/10/2010
• Status: Active Grant

• Current Assignee: Samsung Display Company Limited (Samsung Electronics Co. Ltd.)
• Original Assignee: Samsung Display Company Limited (Samsung Electronics Co. Ltd.)
• Inventors: Kim, Yeun Tae, Lee, Hee-Keun, Kwon, Pilsook, Kim, Sangil, Choi, Nakcho
• Primary Examiner(s): Glick, Edward
• Assistant Examiner(s): CHUNG, DAVID Y
• Application Number:
  US13/089,046
• Publication Number:
  US 20120062448A1
• Time in Patent Office: 2,437 Days
• Field of Search: 349156, 349 43, 349 58, 349 86, 349153, 216 23, 216 39, 438 30, 438666
• CPC Class Codes: G02F 1/133377 Cells with plural compartments or having plurality of liquid crystal microcells partitioned by walls, e.g. one microcell per pixel
• CPC Class Codes: G02F 1/1681 having two or more microcells partitioned by walls, e.g. of microcup type

Abstract

A display apparatus includes a plurality of pixel units and each pixel unit includes a substrate, a first electrode, a second electrode, an image display part and a protective layer. The first electrode is formed on the substrate. The second electrode is formed over the first electrode while interposing a first insulating layer therebetween to define a TSC (tunnel-shaped cavity) extending in a first direction between the first and second electrodes. The image display part is provided in the TSC to display an image according to an electric field generated by the first and second electrodes. The protective layer covers the second electrode and seals the TSC. The display apparatus having the above structure is manufactured by forming the first electrode, a sacrificial layer and the second electrode and forming the image display part by removing the sacrificial layer.

Claims

1. A display apparatus including a pixel, comprising:

a base layer;

an electrode part configured to generate an electric field;

a first insulating layer disposed on the base layer and including a contact portion contacted with the base layer and a cavity portion entirely spaced apart from the base layer in a first direction to provide a cavity extending in the first direction, the contact portion and the cavity portion integrally formed in an inseparable single body, the first insulating layer terminating at a first edge of the cavity portion and a second edge of the cavity portion facing each other in the first direction, the first edge of the cavity portion and the second edge of the cavity portion spaced apart from the base layer;

an image display part provided in the cavity; and

a protective layer covering the first insulating layer and configured to seal the cavity at the first and second edges of the cavity in the first direction.

2. The display apparatus of claim 1, wherein the electrode part comprises first and second electrodes insulated from each other.

3. The display apparatus of claim 2, wherein the first and second electrodes are separated from each other with the image display part interposed between the first electrode and the second electrode.

4. The display apparatus of claim 3, wherein the second electrode is disposed on the first insulating layer.

5. The display apparatus of claim 4, wherein the first insulating layer and the second electrode have a same shape as each other and overlap with each other when viewed in a plan view.

6. The display apparatus of claim 4, wherein the base layer is disposed under the image display part to cover the first electrode.

7. The display apparatus of claim 2, wherein the first and second electrodes are provided under the image display part and separated from each other.

8. The display apparatus of claim 7, wherein the base layer is disposed under the image display part to overlap with the first and second electrodes.

9. The display apparatus of claim 2, wherein the pixel is provided in a plural number and the first electrode is provided in a plural number in one-to-one corresponding to the pixels, and

wherein the first insulating layer is provided in a plural number and the second electrode is provided in a plural number.

10. The display apparatus of claim 9, wherein the pixels are arranged in a matrix form with columns extending in the first direction and rows extending in a second direction crossing the first direction, and

each of the first insulating layers is integrally formed in an inseparable single body according to each row.

11. The display apparatus of claim 10, wherein the first insulating layers are spaced apart from each other according to the first direction.

12. The display apparatus of claim 10, wherein each of the second electrodes is integrally formed in an inseparable single body according to the each row.

13. The display apparatus of claim 12, wherein the second electrodes are spaced apart from each other according to the first direction.

14. The display apparatus of claim 1, wherein the image display part includes a liquid crystal material or an electrophoretic material.

15. The display apparatus of claim 1, wherein the image display part is the liquid crystal layer and the liquid crystal layer comprises a nematic liquid crystal, a blue-phase liquid crystal, or a cholesteric liquid crystal.

16. The display apparatus of claim 15, further comprising an alignment layer provided on an interior surface of the cavity.

17. The display apparatus of claim 1, further comprising a color filter disposed on the base layer.

18. The display apparatus of claim 17, wherein the color filter is disposed on the image display part.

19. The display apparatus of claim 17, wherein the color filter is disposed between the base layer and the image display part.

20. A display apparatus comprising first and second pixels adjacent to each other, comprising:

a base layer;

electrode parts corresponding to the first and second pixels, respectively;

a first insulating layer disposed on the base layer and including a contact portion contacted with the base layer and a cavity portion entirely spaced apart from the base layer in a first direction to provide a cavity extending in the first direction, the first insulating layer terminating at a first edge of the cavity portion and a second edge of the cavity portion facing each other in the first direction;

the first edge of the cavity portion and the second edge of the cavity portion spaced apart from the base layer;

an image display part provided in the cavity; and

a protective layer covering the first insulating layer and configured to seal the cavity at the first and second edges of the cavity in the first direction,

wherein the contact portion and the cavity portion are integrally formed in an inseparable single body in an area corresponding to the first and second pixels.

21. The display apparatus of claim 20, wherein each of the electrode parts comprise first and second electrodes insulated from each other to generate an electric field.

22. The display apparatus of claim 21, wherein the first and second electrodes are separated from each other with the image display part interposed between the first electrode and the second electrode.

23. The display apparatus of claim 22, wherein the second electrode is disposed on the first insulating layer.

24. The display apparatus of claim 23, wherein the first insulating layer and the second electrode have a same shape as each other and overlap with each other when viewed in a plan view.

25. The display apparatus of claim 23, wherein the base layer is disposed under the image display part to cover the first electrode.

26. The display apparatus of claim 21, wherein the first and second electrodes are provided under the image display part and separated from each other.

27. The display apparatus of claim 26, wherein the base layer is disposed under the image display part to overlap with the first and second electrodes.

28. The display apparatus of claim 20, wherein the image display part includes a liquid crystal material or an electrophoretic material.

29. The display apparatus of claim 20, wherein the image display part is the liquid crystal layer and the liquid crystal layer comprises a nematic liquid crystal, a blue-phase liquid crystal, or a cholesteric liquid crystal.

30. The display apparatus of claim 29, further comprising an alignment layer provided on an interior surface of the cavity.

31. The display apparatus of claim 20, further comprising a color filter disposed on the base layer.

32. The display apparatus of claim 31, wherein the color filter is disposed on the image display part.

33. The display apparatus of claim 31, wherein the color filter is disposed between the base layer and the image display part.

34. A display apparatus including a pixel comprising:

a base layer;

an electrode part configured to generate an electric field;

a first insulating layer disposed on the base layer and including a contact portion contacted with the base layer and a cavity portion entirely spaced apart from the base layer in a first direction to provide a cavity extending in the first direction, the contact portion and the cavity portion integrally formed in an inseparable single body, the first insulating layer terminating at a first edge of the cavity portion and a second edge of the cavity portion facing each other in the first direction;

the first edge of the cavity portion and the second edge of the cavity portion spaced apart from the base layer;

an image display part provided in the cavity;

a color filter on the first insulating layer; and

a protective layer covering the first insulating layer and configured to seal the cavity at both ends of the cavity in the first direction.

35. The display apparatus of claim 34, wherein the color filter is provided between the first insulating layer and the protective layer.

36. The display apparatus of claim 35, wherein the pixel is provided in a plural number and the color filter is provided in a plural number in one-to-one corresponding to the pixels.

37. The display apparatus of claim 36, wherein the color filters comprise a red color filter, a green color filter, and a blue color filter, and each pixel one-to-one corresponds to one of the red color filter, the green color filter, and the blue color filter.

38. The display apparatus of claim 36, further comprising a black matrix disposed on the substrate and overlapping with a portion of the color filters.

39. The display apparatus of claim 38, wherein the black matrix overlaps with the color filters at a boundary region of adjacent two color filters in a plan view.

40. The display apparatus of claim 38, wherein the black matrix overlaps with both ends of the first insulating layer in the first direction.

41. The display apparatus of claim 38, wherein the black matrix is disposed on the color filters.

42. The display apparatus of claim 38, wherein the black matrix is disposed between the color filters and the base layer.

43. The display apparatus of claim 34, wherein the image display part includes a liquid crystal material or an electrophoretic material.

44. The display apparatus of claim 34, wherein the image display part is the liquid crystal layer and the liquid crystal layer comprises a nematic liquid crystal, a blue-phase liquid crystal, or a cholesteric liquid crystal.

45. The display apparatus of claim 44, further comprising an alignment layer provided on an interior surface of the cavity.

46. A display apparatus comprising:

a substrate extending in a plane defined by crossing first and second directions;

a first electrode disposed on the substrate;

a second electrode disposed over the first electrode, the second electrode being insulated from the first electrode;

a spacing between the first and second electrodes, the spacing defining a TSC (tunnel-shaped cavity) extending in the first direction, the TSC having a floor parallel to the plane, a ceiling overlapping the floor, opposed first side boundaries extending from the floor to the ceiling and facing each other along the second direction, the TSC having opposed second side boundaries facing each other along the first direction, the second electrode not draping down over the opposed second side boundaries to seal off the TSC at the opposite second side boundaries;

an image display part provided in the TSC to define part of a to-be-displayed image according to an electric field formed by the first and second electrodes; and

a protective layer overlapping the ceiling of the TSC and the second electrode and extending down along the opposed second side boundaries so as to seal the TSC closed at the opposed second side boundaries of the TSC.

47. The display apparatus of claim 46, further comprising a black matrix provided on the second electrode, wherein the black matrix overlaps with both of opposed first ends of the first electrode, the opposed first ends of the first electrode being opposed along the second direction.

48. The display apparatus of claim 47, wherein the black matrix comprises an extension portion that overlaps with both of opposed second ends of the first electrode, the opposed second ends of the first electrode being opposed along the first direction.

49. The display apparatus of claim 46, wherein the image display part includes an electrophoretic material.

50. The display apparatus of claim 46, wherein the image display part includes a liquid crystal layer and the liquid crystal layer comprises a nematic liquid crystal, a blue-phase liquid crystal, or a cholesteric liquid crystal.

51. The display apparatus of claim 46, wherein the image display part includes a liquid crystal layer and further comprises a first insulating layer covering the first electrode in the TSC and an alignment layer disposed on the first insulating layer.

52. The display apparatus of claim 46, further comprising a polarizing plate provided on the protective layer.

53. The display apparatus of claim 46, further comprising a color filter provided between the second electrode and the protective layer.

54. The display apparatus of claim 53, further comprising a second insulating layer disposed on the color filter to cover the color filter.

55. The display apparatus of claim 46, further comprising a color filter disposed between the substrate and the first electrode.

56. The display apparatus of claim 55, further comprising a third insulating layer disposed on the second electrode to cover the second electrode.

57. A display apparatus comprising:

a substrate extending in a plane defined by crossing first and second directions;

an electrode part including a first electrode formed on the substrate and a second electrode spaced apart from the first electrode, the first and second electrodes being insulated from each other such that the first and second electrodes generate an electric field extending between them;

a first insulating layer disposed over the electrode part;

a spacing between the electrode part and the first insulating layer, the spacing defining a TSC (tunnel-shaped cavity) extending in the first direction, the TSC having a floor parallel to the substrate plane, a ceiling overlapping the floor, opposed first side boundaries extending from floor to ceiling and facing each other along the second direction, the TSC having opposed second side boundaries facing each other along the first direction, the first insulating layer being absent at the opposed second side boundaries of the TSC for sealing off the opposed second side boundaries;

an image display part provided in the TSC between the opposed second side boundaries, the image display part being configured to define a corresponding part of a to-be-displayed image according to an electric field formed by the first and second electrodes; and

a protective layer overlapping the ceiling of the TSC and the first insulating layer and extending down along the opposed second side boundaries so as to seal the TSC closed at the opposed second side boundaries of the TSC.

58. The display apparatus of claim 57, further comprising a second insulating layer under the image display part to cover the electrode part,

wherein a portion of the first insulating layer makes contact with the second insulating layer.

59. The display apparatus of claim 57, wherein the image display part comprises a nematic liquid crystal, a blue-phase liquid crystal, or a cholesteric liquid crystal.

60. The display apparatus of claim 57, further comprising a color filter on the first insulating layer.

61. The display apparatus of claim 60, wherein the color filter is provided between the first insulating layer and the protective layer.

62. A display apparatus comprising:

a base layer;

a first insulating layer disposed on the base layer and including a first cavity portion entirely spaced apart from the base layer in a first direction to provide a first cavity extending in the first direction, a second cavity portion entirely spaced apart from the base layer in the first direction to provide a second cavity extending in the first direction, and a contact portion contacted with the base layer and connecting the first cavity portion and the second cavity portion in a second direction crossing the first direction, the first cavity portion, the second cavity portion, and the contact portion being integrally formed in an inseparable single body;

first and second image display parts provided in the first and second cavities, respectively; and

a protective layer covering the first insulating layer and configured to seal the first and second cavities,

wherein the first insulating layer terminates at a first edge of the first and second cavity portions and a second edge of the first and second cavity portions facing each other in the first direction, and

the first edge of the first and second cavity portions and the second edge of the first and second cavity portions are spaced apart from the base layer.

63. A display apparatus including a pixel, comprising:

a base layer;

a first cavity define insulating layer disposed on the base layer and including a first contact portion contacted with the base layer and a first cavity portion entirely spaced apart from the base layer in a first direction to provide the first cavity extending in a first direction, the first contact portion and the first cavity portion integrally formed in an inseparable single body, the first cavity define insulating layer terminating at a first edge of the first cavity portion and a second edge of the first cavity portion facing each other in the first direction, the first edge of the first cavity portion and the second edge of the first cavity portion spaced apart from the base layer;

a second cavity define insulating layer spaced apart from the first cavity define insulating layer and disposed on the base layer and including a second contact portion contacted with the base layer and a second cavity portion entirely spaced apart from the base layer in the first direction to provide a second cavity extending in the first direction, the second contact portion and the second cavity portion integrally formed in an inseparable single body, the second cavity define insulating layer terminating at a first edge of the second cavity portion and a second edge of the second cavity portion facing each other in the first direction, the first edge of the second cavity portion and the second edge of the second cavity portion spaced apart from the base layer;

first and second image display parts provided in the first and second cavities, respectively; and

a protective layer covering the first cavity define insulating layer and the second cavity define insulating layer and configured to seal the first and second cavities.