Display panel and method of manufacturing the same

A display panel includes a substrate, a thin-film transistor (TFT) disposed on the substrate, a first electrode electrically connected to the thin-film transistor, a roof layer disposed on the first electrode and a liquid crystal layer. The roof layer includes an organic insulating material, and defines a cavity that overlaps the first electrode. The liquid crystal layer is disposed in the cavity and is in direct contact with the roof layer.

CROSS-REFERENCE TO RELATED APPLICATION

This U.S. non-provisional application claims priority under 35 U.S.C. § 119 to Korean Patent Application No. 10-2014-0125851, filed on Sep. 22, 2014, and Korean Patent Application No. 10-2015-0041455, filed on Mar. 25, 2015, the disclosures of which are incorporated by reference herein in their entireties.

TECHNICAL FIELD

Exemplary embodiments of the present invention relate to a display panel and a method of manufacturing the same.

DISCUSSION OF RELATED ART

A display panel may include an array substrate, a color filter substrate and a liquid crystal layer disposed between the array substrate and the color filter substrate. The array substrate may include switching elements, and the color filter substrate may have color filters disposed thereon. The array substrate may include a first base substrate and the color filter substrate may include a second base substrate.

An embedded micro-cavity display panel may include switching elements and color filters on a single base substrate.

When the embedded micro-cavity display panel is manufactured, a sacrificial layer may be formed to form a tunnel-shaped cavity. The sacrificial layer may be hard-baked to harden the sacrificial layer and to remove gas included therein.

When a process temperature for hard-baking is increased, edges of the sacrificial layer may be disposed higher than a middle of the sacrificial layer due to thermal reflow. Thus, edges of the display panel corresponding to the edges of the sacrificial layer may be relatively dark and an aperture ratio may be decreased.

When layers are formed on the sacrificial layer without hard-baking to prevent thermal reflow, wrinkles may occur on an upper surface of the sacrificial layer. This may cause wrinkles on layers which are formed on the sacrificial layer.

SUMMARY

Exemplary embodiments of the present invention provide a display panel including a sacrificial layer and a roof layer including phase separable materials, which may increase an aperture ratio.

Exemplary embodiments of the present invention provide a method of manufacturing the display panel.

In accordance with an exemplary embodiment of the present invention, a display panel includes a substrate, a thin-film transistor (TFT) disposed on the substrate, a first electrode electrically connected to the thin-film transistor, a roof layer disposed on the first electrode and a liquid crystal layer. The roof layer includes an organic insulating material, and defines a cavity that overlaps the first electrode. The liquid crystal layer is disposed in the cavity and is in direct contact with the roof layer.

In an exemplary embodiment of the present invention, the cavity may have a tunnel shape.

In an exemplary embodiment of the present invention, the roof layer may be a color filter.

In an exemplary embodiment of the present invention, the display panel may further include a color filter overlapping the first electrode.

In an exemplary embodiment of the present invention, the display panel may further include a second electrode overlapping the first electrode and receiving a common voltage. The first electrode or the second electrode may include a plurality of slits.

In accordance with an exemplary embodiment of the present invention, a display panel includes a substrate, a thin-film transistor (TFT) disposed on the substrate, a first electrode electrically connected to the thin-film transistor, a roof layer disposed on the first electrode, an alignment layer and a liquid crystal layer. The roof layer includes an organic insulating material, and defines a cavity that overlaps the first electrode. The alignment layer is disposed in the cavity and is in direct contact with the roof layer. The liquid crystal layer is disposed in the cavity and is in direct contact with the alignment layer.

In accordance with an exemplary embodiment of the present invention, a method of manufacturing a display panel includes forming a thin-film transistor (TFT) and a first electrode electrically connected to the thin-film transistor on a substrate. A positive photoresist composition is deposited on the first electrode to form a sacrificial layer. The sacrificial layer is light-exposed and developed to form a sacrificial pattern. A negative photoresist composition is deposited on the sacrificial pattern to form a roof layer in direct contact with the sacrificial pattern. The sacrificial pattern is removed.

In an exemplary embodiment of the present invention, the positive photoresist composition may include a polyamide compound, a photosensitive quinone diazide compound and a first solvent.

In an exemplary embodiment of the present invention, the negative photoresist composition may include an acryl compound, a photo initiator and a second solvent. The roof layer may entirely cover the sacrificial pattern.

In an exemplary embodiment of the present invention, the polyamide compound may be insoluble in the second solvent. The acryl compound may be insoluble in the first solvent.

In an exemplary embodiment of the present invention, the first solvent may include propylene glycol monomethyl ether (PGME), cyclohexanone, ethyle lactate (EL), γ-butyrolactone (GBL) or N-methylpyrrolidione (NMP).

In an exemplary embodiment of the present invention, the second solvent may include propylene glycol methyl ether acetate (PGMEA).

In an exemplary embodiment of the present invention, the negative photoresist composition may include an acryl compound, a photo initiator, a coloring agent and a second solvent. The roof layer may be a color filter partially covering the sacrificial pattern.

In an exemplary embodiment of the present invention, a protection layer may be further formed to cover the color filter.

In an exemplary embodiment of the present invention, a color filter may be further formed under the first electrode

In an exemplary embodiment of the present invention, the tunnel may have a tunnel shape.

In an exemplary embodiment of the present invention, an amide stripper may be provided to the sacrificial pattern to remove the sacrificial pattern.

In an exemplary embodiment of the present invention, a liquid crystal may be injected into a space formed by removing the sacrificial pattern to form a liquid crystal layer.

DETAILED DESCRIPTION OF THE EMBODIMENTS

FIG. 1is a plan view illustrating a display panel in accordance with an exemplary embodiment of the present invention.

Referring toFIG. 1, a display panel may include a plurality of gate lines GL, a plurality of data lines DL and a plurality of pixels (e.g., pixels P1and P2).

The gate lines GL may extend in a first direction D1. The data lines DL may extend in a second direction substantially perpendicular to the first direction D1. The gate lines GL may extend in the second direction D2and the data lines DL may extend in the first direction D1.

The pixels may be disposed in a matrix shape. The pixels may be respectively disposed in areas defined by the gate lines GL and the data lines DL.

Each pixel may be connected to a corresponding gate line GL and a corresponding data line DL adjacent to the pixel.

Each pixel may have a rectangular shape extending in the second direction D2, a V-shape, or a Z-shape, for example.

FIG. 2is a plan view illustrating a pixel of the display panel inFIG. 1in accordance with an exemplary embodiment of the present invention.FIG. 3is a cross-sectional view taken along line I-I′ inFIG. 1in accordance with an exemplary embodiment of the present invention.

Referring toFIGS. 1 to 3, the display panel may include a substrate100, thin film transistors TFT, a gate insulating layer110, a data insulating layer120, a black matrix BM, a color filter130, a first electrode EL1, a passivation layer140, a second electrode EL2, a liquid crystal layer150and a roof layer160.

The substrate100may be a transparent insulating substrate. According to exemplary embodiments of the present invention, the transparent insulating substrate may be, but is not limited to, a glass substrate, or a plastic substrate.

The substrate100may include a plurality of pixel areas for displaying an image. The plurality of the pixel areas may be disposed in a matrix shape having a plurality of rows and a plurality of columns.

Each pixel may include a switching element. For example, the switching element may be the thin film transistor TFT. The switching element may be connected to the gate line GL and the data line DL adjacent to the switching element. The switching element may be disposed at a crossing area of the gate line GL and the data line DL.

A gate pattern may include a gate electrode GE and the gate line GL. The gate pattern may be disposed on the substrate100. The gate line GL may be electrically connected to the gate electrode GE.

The gate insulating layer110may be disposed on the substrate100and may cover the gate pattern. The gate insulating layer110may insulate the gate pattern.

A semiconductor pattern SM may be disposed on the gate insulating layer110. The semiconductor pattern SM may overlap the gate electrode GE.

A data pattern may include the data line DL, a source electrode SE and a drain electrode DE. The data pattern may be disposed on the semiconductor pattern SM, which may be disposed on the gate insulating layer110. The source electrode SE may overlap the semiconductor pattern SM. The source electrode SE may be electrically connected to the data line DL.

The drain electrode DE may be spaced apart from the source electrode SE on the semiconductor pattern SM. The semiconductor pattern SM may have a conductive channel between the source electrode SE and the drain electrode DE.

The thin film transistor TFT may include the gate electrode GE, the source electrode SE, the drain electrode DE and the semiconductor pattern SM.

The data insulating layer120may be disposed on the gate insulating layer110. The data insulating layer120may insulate the data pattern.

The gate insulating layer110and the data insulating layer120may include an organic insulating material or an inorganic insulating material. For example, the gate insulating layer110and the data insulating layer120may include silicon oxide (SiOX) and/or silicon nitride (SiNX).

A plurality of color filters130and a plurality of black matrices BM may be disposed on the data insulating layer120.

The color filters130may be disposed between adjacent data lines DL. The color of light may be changed by the color filters130and the light may penetrate the liquid crystal layer150.

Each color filter130may correspond to one of the pixel areas. For example, the color filters130may include a red color filter, green color filter and a blue color filter. The color filters130, which may be adjacent to each other, may have different colors from each other. For example, the color filters130may be spaced apart from a border between adjacent pixel areas.

The color filters130may be disposed in an island shape and may be spaced apart from each other. Alternatively, the color filters130may be adjacent to each other and may partially overlap each other at a border between adjacent pixel areas.

The display panel may include signal lines and black matrices BM. The signal lines may be connected to the thin film transistor TFT. The black matrices BM may overlap the signal lines and may block light.

The black matrices BM may be disposed on a border between adjacent pixel areas. For example, the black matrices BM may be disposed between adjacent color filters130.

The black matrices BM may be disposed on an area where the gate line GL, the data line DL and the switching element are disposed. For example, the black matrices BM may be disposed on a non-display area.

For example, the black matrices BM may include a photosensitive organic material including a pigment, such as carbon black.

The first electrode EL1may be disposed on the color filter130. The first electrode EL1may be disposed in the pixel area. The first electrode EL1may overlap the color filter130. The first electrode EL1may be electrically connected to the thin film transistor TFT. A grayscale voltage may be applied to the first electrode EL1through the thin film transistor TFT.

For example, the first electrode EL1may include a transparent conductive material, such as indium tin oxide (ITO), indium zinc oxide (IZO) and/or aluminum zinc oxide (AZO). The first electrode EL1may have a continuous plate shape.

The passivation layer140may be disposed on the first electrode EL1and the black matrices BM. The passivation layer140may cover the first electrode EL1and the black matrices BM. The passivation layer140may be formed on a whole surface of the substrate100.

The passivation layer140may include an organic insulating material or an inorganic insulating material. For example, the passivation layer140may include silicon oxide (SiOX) and/or silicon nitride (SiNX).

The second electrode EL2may be disposed on the passivation layer140. The passivation layer140may overlap the first electrode EL1.

For example, the second electrode EL2may include a transparent conductive material such as indium tin oxide (ITO), aluminum zinc oxide (AZO) and/or indium zinc oxide (IZO). For example, the second electrode EL2may have a slit pattern.

For example, a common voltage may be applied to the second electrode EL2. Thus, the first electrode EL1may function as a pixel electrode, and the second electrode EL2may function as a common electrode. In another exemplary embodiment, the second electrode EL2may be electrically connected to the thin film transistor TFT to receive the grayscale voltage, and the first electrode EL1may receive the common voltage. Furthermore, the first electrode EL1may have a slit pattern, and the second electrode EL2may have a continuous plate shape.

The liquid crystal layer150may be disposed on one or more of the color filters130and may overlap one or more of the color filters130.

The liquid crystal layers150may be disposed on adjacent pixel areas, and the liquid crystal layers150may be spaced apart from the data lines, which may be a border.

The liquid crystal layer150may include one or more liquid crystal molecules. The liquid crystal molecules may be aligned by an electric field applied between the first electrode EL1and the second electrode EL2. Therefore, a light transmittance of the pixel may be controlled.

The roof layer160may be disposed on the liquid crystal layer150. The roof layer160may be in direct contact with the liquid crystal layer150.

The roof layer160may cover the liquid crystal layer150. The roof layer may include a wall161disposed between the liquid crystal layers150. For example, the wall161may overlap with the data lines DL. The wall161may maintain a shape of the roof layer160. The roof layer160may include a plurality of walls.

The roof layer160may include an organic insulating material. For example, the organic insulating material may include a material capable of being hardened by exposure to light or heat. Thus, the roof layer160may be hardened by exposure to heat or light.

A stripper injecting hole may be formed in the roof layer160, thereby exposing the liquid crystal layer150. An encapsulating layer may also be disposed on the roof layer160. The encapsulating layer may cover the stripper injecting hole and may prevent the liquid crystal molecules from leaking.

FIGS. 4A, 4B, 4C, 4D, 4E and 4Fare cross-sectional views taken along the line I-I′ inFIG. 1illustrating a method of manufacturing a display panel in accordance with exemplary embodiments of the present invention.

Referring toFIGS. 1 to 4F, steps of manufacturing a display panel in accordance with an exemplary embodiment of the present invention are illustrated in more detail.

Referring toFIGS. 1 to 4C, the gate insulating layer110, the data line DL, the data insulating layer120, the color filter130, the black matrix BM, the first electrode EL1and the second electrode EL2may be formed on the substrate100. A sacrificial layer SL may be formed on the substrate100.

The gate pattern including the gate electrode GE and the gate line GL may be formed on the substrate100. A first conductive layer may be formed on the substrate100and may be patterned by a photolithograph process, thus forming the gate pattern.

The gate insulating layer110may be formed on the substrate100to cover the gate pattern. The gate insulating layer110may insulate the gate pattern.

The semiconductor pattern SM may be formed on the gate insulating layer110. The semiconductor pattern SM may overlap the gate electrode GE.

The data pattern including the data line DL, the source electrode SE and the drain electrode DE may be formed on the gate insulating layer110on which the semiconductor pattern SM may be formed. A second conductive layer may be formed on the gate insulating layer110and may be patterned by a photolithography process, thus forming the data pattern.

The drain electrode DE may be spaced apart from the source electrode SE with respect to the semiconductor pattern SM. The semiconductor pattern SM may have a conductive channel between the source electrode SE and the drain electrode DE.

The thin film transistor TFT may include the gate electrode GE, the source electrode SE, the drain electrode DE and the semiconductor pattern SM.

The data insulating layer120may be formed on the gate insulating layer110on which the data pattern may be formed.

The color filter130may be formed on the substrate100on which the data line DL may be formed. The color filter130may be disposed between adjacent data lines DL.

The black matrix BM may be formed on a border between adjacent pixel areas. For example, the black matrix BM may be disposed between adjacent color filter130. The black matrix BM may be disposed on an area where the gate line GL, the data line DL and the switching element are disposed. For example, the black matrix BM may include a photosensitive organic material including a pigment, such as carbon black. For example, the display panel may include a plurality of black matrices BM.

A positive photoresist composition may be deposited on the color filter130and the black matrix BM, thus forming the sacrificial layer SL.

The sacrificial layer SL may be partially removed, which may form a space for forming a cavity. Accordingly, the sacrificial layer SL may be formed at a position where the liquid crystal layer150is formed. The sacrificial layer SL may determine a width and height of the cavity.

The sacrificial layer SL may be formed by depositing the positive photoresist composition.

The positive photoresist composition will be described in more detail below with respect to a negative photoresist composition.

For example, the sacrificial layer SL may be formed by an inkjet process, or a spin-coating process.

The sacrificial layer SL may be soft-baked prior to being exposed to light. For example, the sacrificial layer SL may be soft-baked within a temperature range of about 120° C. to about 130° C.

The mask MASK may include a transparent part T and a blocking part B. The mask MASK may be disposed above the substrate100. The transparent part T may allow light to pass through it to the data line DL and the black matrix BM. The blocking part B may block light emitted toward the color filter130. The sacrificial layer SL may be exposed to light using the mask MASK.

An exposed portion of the sacrificial layer SL may be partially removed by using a developer, thus forming a sacrificial pattern SL′.

The developer may include an alkali solution. For example, the developer may be an amide solution.

Referring toFIG. 4D, the negative photoresist composition may be deposited on the sacrificial patter SL′ thus forming a roof layer160.

The roof layer160may be formed on the sacrificial pattern SL′. The roof layer160may be in direct contact with the sacrificial pattern SL′. The roof layer160may entirely cover the sacrificial pattern SL′.

Phases of the sacrificial pattern SL′ and the roof layer160may be separated from each other. The roof layer160may include the negative photoresist composition and the sacrificial pattern SL′ may include the positive photoresist composition, thus the roof layer160and the sacrificial pattern SL′ may not be mixed so that a separation between the roof layer160and the sacrificial pattern SL′ may be maintained.

For example, the positive photoresist composition may include a polyamide compound, a photosensitive quinone diazide compound and a first solvent.

For example, the polyamide compound may include polyamic acid, which is a precursor of polyimide. Polyamic acid may be cured to form a polyimide resin. For example, the polyamide compound may include a repeating unit represented by the following Chemical Formula 1.

R1 and R2 may be respectively an alkyl group (alkylene group) having 1 to 20 carbon atoms or an aromatic group, R3 and R4 may be respectively an alkyl group having 1 to 20 carbon atoms, an aromatic group or

R5 may be a hydrogen atom, a hydroxyl group, an alkyl group having 1 to 20 carbon atoms or an aromatic group.

The polyamide compound may be formed by a condensation reaction between a diamine compound and dianhydride compound.

A weight-average molecular weight of the polyamide compound may be in a range of about 3,000 to about 300,000. The polyamide compound having this range of weight-average molecular weight may have relatively high solubility in the first solvent.

The photosensitive quinone diazide compound may include naphthoquinone diazide or benzoquinone diazide.

The polyamide compound may be soluble in the first solvent.

For example, based on a total weight of the positive photoresist composition, the positive photoresist composition may include about 5 wt % to about 70 wt % of the polyamide compound, about 0.5 wt % to about 30 wt/o of the photosensitive quinone diazide compound and a remainder of the first solvent.

The negative photoresist composition may include an acryl compound, a photo initiator and a second solvent.

For example, the acryl compound may be polyacrylate resin, or poly methacrylate resin.

For example, the photo initiator may be a halogen-containing iminosulfonate photo initiator including a halogen, a diazonaphthoquinone-4-sulfonate photo acid generator, or a triazine photo initiator.

The acryl compound may be soluble in the second solvent.

For example, the second solvent may include propylene glycol methyl ether acetate (PGMEA).

For example, the polyamide compound may be insoluble in the second solvent.

The second solvent does not include a functional group capable of hydrogen bonding so that the polyamide compound having a polarity may be relatively insoluble in the second solvent.

For example, based on a total weight of the negative photoresist composition, the negative photoresist composition may include about 5 wt % to about 70 wt % of the acryl compound, about 1 wt % to about 35 wt % of the photo initiator and a remainder of the second solvent.

Thus, when the negative photoresist composition is deposited on the sacrificial pattern SL′, the sacrificial pattern SL′ and the negative photoresist composition are not mixed, thus separating phases thereof and maintaining a shape of the roof layer160.

Referring toFIGS. 1 to 4E, after forming the roof layer160, the sacrificial pattern SL′ may be removed using a stripper.

Prior to removing the sacrificial pattern SL′ using the stripper, a stripper injection hole may be formed. Furthermore, the substrate including the sacrificial pattern SL′ may be entirely exposed to a light to increase a solubility of the sacrificial pattern SL′ before the stripper is provided.

The stripper may be injected into the sacrificial pattern SL′ through the stripper injection hole. Thus, a cavity145may be formed in a position where the sacrificial pattern SL′ was formed. The cavity145may have a tunnel shape extending in a direction. For example, the cavity145may extend in a direction substantially parallel to the data line DL. The cavity145may overlap at least one of the first electrode EL1and the second electrode EL2.

The stripper may include an alkali solution. For example, the stripper may be an amide solution. The stripper including the amide solution may entirely remove the sacrificial pattern SL′, however a structure of the roof layer160may be maintained.

The removal of the sacrificial pattern SL′ by the developer may be performed at about 23° C. to about 26° C. The removal of the sacrificial pattern SL′ may be accelerated by increasing the processing temperature. For example, the sacrificial pattern SL′ may be removed by the developer at about 23° C. to about 80° C.

Referring toFIGS. 1 to 4F, liquid crystal may be injected into the cavity145, thus forming the liquid crystal layer150.

The liquid crystal may be in the form of a fluid. The liquid crystal may flow into the cavity145by capillary action. For example, the liquid crystal may be provided into the cavity145through the stripper injecting hole.

The liquid crystal may be provided into the cavity145by using an inkjet having a micropipette. Alternatively, the liquid crystal may be provided into the cavity145by using a vacuum injection apparatus.

An encapsulating layer may be disposed on the roof layer160so that the encapsulating layer may cover the stripper injecting hole to prevent the liquid crystal from leaking.

FIG. 5is a cross-sectional view taken along the line I-I′ inFIG. 1in accordance with an exemplary embodiment of the present invention.

Referring toFIG. 5, the display panel may include the substrate100, thin film transistors TFT, the gate insulating layer110, the data insulating layer120, the black matrix BM, the color filter130, the first electrode EL1, the passivation layer140, the second electrode EL2, the lower alignment layer AL1, the liquid crystal layer150, the upper alignment layer AL2and the roof layer160.

The display panel illustrated inFIG. 5may be substantially the same as that of the display panel illustrated inFIG. 3except for the lower alignment layer AL1and the upper alignment layer AL2, and thus repetitive explanations concerning the above elements may be omitted.

The lower alignment layer AL1may be disposed on the color filters130. For example, the lower alignment layer AL1may be disposed between the passivation layer140and the second electrode EL2.

The liquid crystal layer150may be disposed on the lower alignment layer AL1. The liquid crystal layer150may overlap the color filters130.

The upper alignment layer AL2may be disposed on the liquid crystal layer150.

The roof layer160may be in direct contact with the upper alignment layer AL2, thus covering the upper alignment layer AL2. For example, the roof layer160may include an organic insulating material.

The lower alignment layer AL1and the upper alignment layer AL2may pretilt the liquid crystal molecules of the liquid crystal layer150.

For example, the lower alignment layer AL1and the upper alignment layer AL2may have a thickness of about 10 μm to about 100 μm.

The lower alignment layer AL1and the upper alignment layer AL2may include an aligning composition.

The liquid crystal layer150may be exposed through the roof layer160by forming a stripper injection hole.

The aligning composition may be deposited in the cavity145through the stripper injection hole, and then the aligning composition may be dried to remove a solvent thereof. For example, the aligning composition may be dried at room temperature or may be heated.

While the sacrificial pattern SL′ and the roof layer160are formed on the color filter130in the above exemplary embodiment, a color filter may function as a roof layer in another exemplary embodiment.

FIGS. 6A, 6C, 6E, 6G, 6I, 6K and 6Lare cross-sectional views taken along line I-I′ inFIG. 1and illustrating a method of manufacturing a display panel in accordance with exemplary embodiments of the present invention.FIGS. 6B, 6D, 6F and 6Jare plan views illustrating a method of manufacturing a display panel in accordance with exemplary embodiments of the present invention. Particularly,FIG. 6Bis a plan view ofFIG. 6A.FIG. 6Dis a plan view ofFIG. 6C.FIG. 6Fis a plan view ofFIG. 6E.FIG. 6His a plan view ofFIG. 6G.FIG. 6Jis a plan view ofFIG. 6I.

A configuration of a thin film transistor of the display panel may be explained with reference toFIG. 2. The display panel may be substantially the same as the display panel illustrated inFIGS. 1, 2, and 5except for including a color filter functioning as a roof layer. Thus, any duplicated explanation may be omitted.

Referring toFIGS. 2, 6A and 6B, a gate pattern, a gate insulation layer210, a semiconductor pattern SM, a data pattern, a data insulation layer220, a first electrode EL1, a passivation layer230, a second electrode EL2and a black matrix BM are formed on a substrate200.

The gate pattern may include a gate line GL and a gate electrode GE connected to the gate line GL.

The gate insulation layer210may cover the gate pattern.

The semiconductor pattern SM may be formed on the gate insulation layer210. The semiconductor pattern SM overlaps the gate electrode GE.

The data pattern may include a source electrode SE, a drain electrode DE and a data line DL. The source electrode SE and the drain electrode DE contact the semiconductor pattern SM, and are spaced apart from each other. The data line GL is connected to the source electrode SE.

The data insulation layer220may cover the data pattern.

The first electrode EL1may be formed on the data insulation layer220. The passivation layer230may cover the first electrode EL1.

The second electrode EL2may be formed on the passivation layer230. The second electrode EL2includes a plurality of slits SP. For example, the slits SP may extend in a direction substantially parallel to the data line DL.

The black matrix BM may overlap the gate line GL. The black matrix BM may have a linear shape extending a direction substantially parallel to the gate line GL. The black matrix BM may be formed on the passivation layer230. In another exemplary embodiment, the black matrix BM may be formed on the data insulation layer220to be disposed between the data insulation layer220and the passivation layer230. In another exemplary embodiment, the black matrix BM may be omitted.

Referring toFIGS. 6C and 6D, a sacrificial pattern SL′ may be formed on the second electrode EL2. The sacrificial pattern SL′ may entirely cover the second electrode EL2. The sacrificial pattern SL′ may further cover the black matrix BM. The sacrificial pattern SL′ may be formed through a substantially same method as the sacrificial pattern SL′ illustrated in FIG.4C.

Referring toFIGS. 6E and 6F, a first color filter CF1may be formed on a first sacrificial pattern SL′. For example, a photoresist composition may be coated on the first sacrificial pattern SL′, and exposed to a light and developed to form the first color filter CF1. The photoresist composition may be a negative photoresist composition. The photoresist composition may include an acryl compound, a photo initiator, a coloring agent and a solvent.

Examples of the acryl compound may include polyacrylate resin or poly methacrylate resin. Examples of the photo initiator may include a halogen-containing iminosulfonate photo initiator, a diazonaphthoquinone-4-sulfonate photo acid generator, or a triazine photo initiator. The solvent may include propylene glycol methyl ether acetate (PGMEA).

For example, the photoresist composition may include about 5 wt % to about 70 wt % of the acryl compound, about 1 wt % to about 35 wt % of the photo initiator, about 1 wt % to about 30 wt % of the coloring agent and a remainder of the solvent.

The sacrificial pattern SL′ may include a positive photoresist composition. Thus, the sacrificial pattern SL′ may not be mixed with the negative photoresist composition for forming a color filter so that a separation between the sacrificial pattern SL′ and the color filter may be maintained.

The first color filter CF1has a specific color, and is formed in certain pixels of the entire pixels. For example, the first color filter CF1may include a red coloring agent. The photoresist composition may include the red coloring agent such as a red pigment to form a red color filter.

Referring toFIGS. 6G and 6H, a second color filter CF2may be formed on a second sacrificial pattern SL′. The second color filter CF2may be adjacent to the first color filter CF1, and may partially overlap the first color filter CF1. The second color filter CF2may include a coloring agent different from the first color filter CF1, for example, a green coloring agent. A photoresist composition including a green pigment may be used for forming a green color filter.

Even if not illustrated, at least one color filter having a different color from the first color filter CF1and the second color filter CF2may be further formed through a substantially same method as the first color filter CF1and the second color filter CF2. For example, a third color filter may be a blue filter. A fourth color filter may be a white filter, a yellow filter, a cyan filter or a magenta filter.

The color filters overlap the second electrode EL2. Thus, a portion of the sacrificial pattern SL′ may be uncovered by the color filters and exposed.

Referring toFIGS. 6I and 6J, the sacrificial pattern SL′ may be removed. A stripper is provided to remove the sacrificial pattern SL′. Furthermore, the substrate including the sacrificial pattern SL′ may be entirely exposed to a light to increase a solubility of the sacrificial pattern SL′ before the stripper is provided.

A portion of the sacrificial pattern SL′ is uncovered by the color filters. Thus, the sacrificial pattern SL′ may easily contact the stripper. When the sacrificial pattern SL′ is removed, a cavity245may be formed in a position where the sacrificial pattern SL′ was formed. The cavity245may have a tunnel shape extending in a direction. For example, the cavity245may extend in a direction substantially parallel to the data line DL. A plurality of cavities245may be spaced apart from each other in a direction parallel to the gate line GL. In a plan view, the data line DL may be disposed between adjacent cavities245.

The stripper may include an alkali solution. For example, the stripper may be an amide solution. The stripper including the amide solution may entirely remove the sacrificial pattern SL′ including the polyamide compound without damaging a structure of the color filters.

Referring toFIG. 6K, an alignment layer is formed in the cavity245. An aligning composition may be provided in the cavity245to form the alignment layer.

The alignment layer may include a lower alignment layer AL1covering the second electrode EL2, and an upper alignment layer AL2covering a lower surface of the color filter. While the lower alignment layer AL1and the upper alignment layer AL2are illustrated to be spaced apart from each other, the lower alignment layer AL1and the upper alignment layer AL2may be substantially connected to each other.

After the alignment layer is formed, a liquid crystal material may be provided in the cavity245to form a liquid crystal layer. Thus, the alignment layer may be in direct contact with the liquid crystal layer. If the alignment layer is omitted in another exemplary embodiment, the color filter may be in direct contact with the liquid crystal layer.

Referring toFIG. 6L, a protection layer250may be formed to cover the color filter. The protection layer250may protect the color filter, and may include an organic material or an inorganic material. Furthermore, the protection layer250may have a single-layered structure or a multiple-layered structure including an organic material layer and an inorganic material layer.

The display panel and the method for manufacturing the display panel according to exemplary embodiments of the present invention may be used for a liquid crystal display panel including one base substrate and a liquid crystal display apparatus having the same.

In accordance with exemplary embodiments of the present invention, a sacrificial layer and a roof layer may formed in phase separable materials so that the roof layer may be directly formed on an upper surface of the sacrificial layer without forming an inorganic layer on the sacrificial layer, thus reducing the number of masks. Therefore, a hard-baking process of the sacrificial layer may be skipped so that an aperture ratio is increased.