DISPLAY APPARATUS AND METHOD OF MANUFACTURING THE SAME

A display apparatus includes: a substrate including an opening area, a display area surrounding at least a portion of the opening area, and an intermediate area between the opening area and the display area; and a display element at the display area, and including a pixel electrode, an opposite electrode on the pixel electrode, and an intermediate layer between the pixel electrode and the opposite electrode. The intermediate layer includes a first common layer, a second common layer on the first common layer, and an emission layer between the first common layer and the second common layer, the first common layer and the second common layer extend to the intermediate area, and the second common layer is directly on the first common layer at the intermediate area.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority to and the benefit of Korean Patent Application No. 10-2021-0024227, filed on Feb. 23, 2021, in the Korean Intellectual Property Office, the entire content of which is hereby incorporated by reference.

BACKGROUND

Aspects of one or more embodiments relate to a display apparatus and a method of manufacturing the same, and more particularly, to a display apparatus having improved reliability and a method of manufacturing the same.

2. Description of the Related Art

Recently, the usage of display apparatuses has diversified. In addition, as display apparatuses have become thinner and lighter, their range of use has gradually been extended.

As the area occupied by a display area in the display apparatuses expands, various functions that are combined or associated with the display apparatuses have been added. In order to add various functions while expanding the display area, research is being carried out on display apparatuses in which various elements may be arranged in the display area.

SUMMARY

One or more embodiments are directed to a display apparatus having an improved reliability while including an area in which various suitable kinds of components may be arranged inside a display area, and a manufacturing method thereof. However, the aspects and features of the present disclosure are not limited thereto.

Additional aspects and features will be set forth, in part, in the description that follows, and in part, will be apparent from the detailed description, or may be learned by practicing one or more of the presented embodiments of the present disclosure.

According to one or more embodiments, a display apparatus includes: a substrate including an opening area, a display area surrounding at least a portion of the opening area, and an intermediate area between the opening area and the display area; and a display element at the display area, and including a pixel electrode, an opposite electrode on the pixel electrode, and an intermediate layer between the pixel electrode and the opposite electrode. The intermediate layer includes a first common layer, a second common layer on the first common layer, and an emission layer between the first common layer and the second common layer, the first common layer and the second common layer extend to the intermediate area, and the second common layer is directly on the first common layer at the intermediate area.

In an embodiment, the first common layer and the second common layer may each have an opening at the intermediate area.

In an embodiment, the display apparatus may further include: a thin-film encapsulation layer on the display element, and including at least one inorganic encapsulation layer and at least one organic encapsulation layer; and an inorganic insulating layer at the display area and the intermediate area, and located between the substrate and a first partition wall. The inorganic insulating layer may contact the inorganic encapsulation layer through the opening.

In an embodiment, the display apparatus may further include: a first partition wall at the intermediate area, and surrounding the opening area, and the opening may include a first opening between the first partition wall and the display area.

In an embodiment, the opening may further include a second opening between the first partition wall and the opening area.

In an embodiment, the display apparatus may further include: a second partition wall spaced from the first partition wall, and the opening may further include a third opening between the first partition wall and the second partition wall.

In an embodiment, the display apparatus may further include: a thin-film transistor at the display area; and an organic insulating layer on the thin-film transistor, and the opposite electrode may cover a lateral end portion of the organic insulating layer.

In an embodiment, the intermediate area may include a laser irradiation region, and the opposite electrode may not be located at the laser irradiation region.

In an embodiment, the display apparatus may further include: a capping layer on the opposite electrode, and the capping layer may not be located at the laser irradiation region.

In an embodiment, the display apparatus may further include: a wiring portion at a region of the display area that is adjacent to the intermediate area, the wiring portion bypassing the opening area; and a dummy emission layer on the wiring portion.

In an embodiment, the dummy emission layer may include a same material as that of the emission layer.

In an embodiment, the dummy emission layer may be between the first common layer and the second common layer.

In an embodiment, the dummy emission layer may include the same material as that of the emission layer.

In an embodiment, a thickness of the first common layer may be greater than a thickness of the second common layer.

According to one or more embodiments, a display apparatus includes: a substrate including an opening area, a display area surrounding at least a portion of the opening area, and an intermediate area between the opening area and the display area; a pixel electrode at the display area; an emission layer at the display area; an opposite electrode on the emission layer, and located at the display area and the intermediate area; a common organic material layer between the pixel electrode and the opposite electrode, and located at the display area and the intermediate area; and an inorganic encapsulation layer on the opposite electrode, and located at the display area and the intermediate area. The common organic material layer has an opening surrounding the opening area at the intermediate area, and the inorganic encapsulation layer directly contacts an inorganic layer exposed through the opening.

According to one or more embodiments, a method of manufacturing a display apparatus includes: providing a substrate including a first area, a display area surrounding at least a portion of the first area, and an intermediate area between the first area and the display area; forming a sacrificial metal layer at the intermediate area; forming a first common layer on an entire surface of the substrate to cover the sacrificial metal layer; forming a plurality of emission layer patterns on the first common layer at the display area; forming a second common layer on the entire surface of the substrate to cover the plurality of emission layer patterns; forming an opposite electrode on the entire surface of the substrate to cover the second common layer; removing the sacrificial metal layer, and portions of the first common layer and the second common layer on the sacrificial metal layer, by irradiating a laser to the substrate at the intermediate area; and forming a through hole at the first area, by irradiating a laser to the first area of the substrate.

In an embodiment, the removing of the portions of the first common layer and the second common layer may include removing the sacrificial metal layer by irradiating the laser, thereby removing the portions of the first common layer and the second common layer formed on the sacrificial metal layer.

In an embodiment, an opening may be formed in the first common layer by removing the sacrificial metal layer and the portion of the first common layer on the sacrificial metal layer.

In an embodiment, the method may further include forming an inorganic encapsulation layer on the opposite electrode, and the inorganic encapsulation layer may directly contact an inorganic layer exposed through the opening of the first common layer.

In an embodiment, the method may further include removing a portion of the opposite electrode by irradiating the laser to the substrate at the intermediate area.

In an embodiment, the portion of the opposite electrode may be removed concurrently with the removing of the sacrificial metal layer.

In an embodiment, the plurality of emission layer patterns may not be formed at the intermediate area during the forming of the plurality of emission layer patterns.

In an embodiment, the plurality of emission layer patterns may be formed by using a fine metal mask, and the fine metal mask may not include an opening in a portion thereof corresponding to the intermediate area.

These and/or other aspects and features of the present disclosure will become apparent and more readily appreciated from the following description of the presented embodiments, the accompanying drawings, and the claims and their equivalents.

These general and specific embodiments may be implemented by using a system, a method, a computer program, or a combination of a system, a method, and a computer program.

DETAILED DESCRIPTION

In the figures, the x-axis, the y-axis, and the z-axis are not limited to three axes of the rectangular coordinate system, and may be interpreted in a broader sense. For example, the x-axis, the y-axis, and the z-axis may be perpendicular to or substantially perpendicular to one another, or may represent different directions from each other that are not perpendicular to one another.

FIG. 1is a perspective view of a display apparatus1according to an embodiment.

Referring toFIG. 1, the display apparatus1includes an opening area OA (e.g., a transmission area or a first area), and a display area DA surrounding (e.g., around a periphery of) at least a portion of the opening area OA. The display apparatus1may display an image (e.g., a preset or predetermined image) by using light emitted from a plurality of pixels arranged at (e.g., in or on) the display area DA. The opening area OA may be partially or entirely surrounded (e.g., around a periphery thereof) by the display area DA. The opening area OA may be an area in which a component is arranged, which will be described in more detail below with reference toFIG. 2.

An intermediate area MA is arranged between the opening area OA and the display area DA. The display area DA may be surrounded (e.g., around a periphery thereof) by a peripheral area PA. The intermediate area MA and the peripheral area PA may be a kind of non-display area at (e.g., in or on) which pixels are not arranged. The intermediate area MA may be partially or entirely surrounded (e.g., around a periphery thereof) by the display area DA. The display area DA may be entirely surrounded (e.g., around a periphery thereof) by the peripheral area PA.

Hereinafter, an organic light-emitting display apparatus is described in more detail as an example of the display apparatus1according to an embodiment, but the present disclosure is not limited thereto. In another embodiment, the display apparatus1may be a quantum-dot light-emitting display. As an example, an emission layer of a display element of the display apparatus1may include an organic material, an inorganic material, quantum dots, an organic material and quantum dots, or an inorganic material and quantum dots.

FIG. 1shows one opening area OA having a circular shape, but the present disclosure is not limited thereto. In other embodiments, the number of opening areas OA may be two or more, and each of the opening areas OA may have various suitable shapes, for example, such as a circular shape, an elliptical shape, a polygonal shape, a diamond shape, a bar shape, or the like.

In addition, whileFIG. 1shows that the display apparatus1includes the display area DA having a plane surface, the present disclosure is not limited thereto, and at least a portion of the display apparatus1may be foldable, bendable, and/or rollable. In this case, at least a portion of the display area DA may have a curved surface.

FIG. 2is a cross-sectional view of the display apparatus1according to an embodiment, and may correspond to a cross-section of the display apparatus1taken along the line A-A′ ofFIG. 1.

Referring toFIG. 2, the display apparatus1may include a display panel10. An input sensing layer40and an optical functional layer50may be on the display panel10. The display panel10, the input sensing layer40, and the optical functional layer50may be covered by a window60. The display apparatus1may include (or may be included in) various suitable kinds of electronic apparatuses, for example, such as mobile phones, notebook computers, smartwatches, and the like.

The display panel10may display an image. The display panel10includes pixels arranged at (e.g., in or on) the display area DA. The pixels may include a display element, and a pixel circuit connected to the display element. The display element may include an organic light-emitting diode or a quantum-dot organic light-emitting diode, but the present disclosure is not limited thereto.

The input sensing layer40obtains coordinate information corresponding to an external input, for example, such as a touch event. The input sensing layer40may include a sensing electrode (e.g., a touch electrode), and trace lines connected to the sensing electrode. The input sensing layer40may be arranged on the display panel10. The input sensing layer40may sense an external input through a mutual capacitive method and/or a self-capacitive method.

The input sensing layer40may be directly formed on the display panel10, or may be separately formed and then connected to (e.g., coupled to or attached to) the display panel10through an adhesive layer, for example, such as an optical clear adhesive. As an example, the input sensing layer40may be successively formed on the display panel10after a process of forming the display panel10. In this case, the input sensing layer40may be understood as being a portion of the display panel10, and an adhesive layer may not be arranged between the input sensing layer40and the display panel10. WhileFIG. 2shows that the input sensing layer40is arranged between the display panel10and the optical functional layer50, in another embodiment, the input sensing layer40may be arranged on the optical functional layer50.

The optical functional layer50may include an anti-reflection layer. The anti-reflection layer may reduce a reflectivity of light (e.g., external light) incident toward the display panel10from the outside through the window60. The anti-reflection layer may include a retarder and a polarizer. In another embodiment, the anti-reflection layer may include a black matrix and color filters. In addition, the optical functional layer50may include a lens layer. The lens layer may improve a light-emission efficiency of the light emitted from the display panel10, or may reduce a color deviation. The optical functional layer50may include all of the above-described anti-reflection layer and the lens layer, or may include any suitable one of the anti-reflection layer or the lens layer.

In an embodiment, the optical functional layer50may be successively formed after a process of forming the display panel10and/or the input sensing layer40. In this case, an adhesive layer may not be arranged between the optical functional layer50and the display panel10, and/or between the optical functional layer50and the input sensing layer40.

The display panel10, the input sensing layer40, and/or the optical functional layer50may include an opening. For example, as shown inFIG. 2, the display panel10, the input sensing layer40, and the optical functional layer50may include first to third openings10H,40H, and50H, respectively, and the first to third openings10H,40H, and50H may overlap with one another. The first to third openings10H,40H, and50H are arranged to correspond to the opening area OA.

In another embodiment, at least one of the display panel10, the input sensing layer40, or the optical functional layer50may not include an opening. As an example, one or two from among the display panel10, the input sensing layer40, and the optical functional layer50may not include an opening.

The opening area OA may be a kind of component area (e.g., a sensor area, a camera area, a speaker area, and/or the like) in which a component20for adding various suitable functions to the display apparatus1is arranged as described above. For example, the component20may be arranged inside (e.g., within) the first to third openings10H,40H, and50H as shown inFIG. 2. As another example, the component20may be arranged below (e.g., underneath) the display panel10.

The component20may include an electronic element. As an example, the component20may be an electronic element that uses light or sound. As an example, the electronic element may include a sensor, for example, such as an infrared sensor that emits and/or receives light, a camera that receives light to capture an image, a sensor that outputs and senses light or sound to measure a distance or recognize a fingerprint, a small lamp that outputs light, a speaker that outputs sound, and/or the like. An electronic element that uses light may use light in various suitable wavelength bands, for example, such as visible light, infrared light, and/or ultraviolet light. In an embodiment, the opening area OA may be understood as a transmission area through which light and/or sound that is output from the component20to the outside or that progresses toward the component20from the outside may pass.

In another embodiment, in the case where the display apparatus1is used as (e.g., included in) a smartwatch or an instrument panel for an automobile, the component20may be a member, for example, such as clock hands or a needle indicating suitable information (e.g., predetermined information), for example, such as the time of day, the velocity of a vehicle, or the like. In the case where the display apparatus1includes clock hands or an instrument panel for an automobile, the component20may pass through the window60, and may be exposed to the outside. In this case, the window60may also include an opening that corresponds to the opening area OA.

The component20may include an element(s) related to the function of the display panel10as described above, or may include an element or the like, for example, such as an accessory that increases an aesthetic sense of the display panel10.

FIG. 3is a plan view of the display panel10according to an embodiment, andFIG. 4is an equivalent circuit diagram of a pixel of the display panel10according to an embodiment.

Referring toFIG. 3, the display panel10may include the opening area OA, the display area DA, the intermediate area MA, and the peripheral area PA. For convenience of description, it may be understood that a substrate100of the display panel10includes the opening area OA, the display area DA, the intermediate area MA, and the peripheral area PA.

The display panel10includes a plurality of pixels P arranged at (e.g., in or on) the display area DA. As shown inFIG. 4, each pixel P may include a pixel circuit PC, and an organic light-emitting diode OLED as a display element connected to the pixel circuit PC. The pixel circuit PC may include a first thin film transistor T1, a second thin film transistor T2, and a storage capacitor Cst. Each pixel P may emit, for example, a suitable one of red, green, blue, or white light from the organic light-emitting diode OLED.

The second thin-film transistor T2may be a switching thin-film transistor connected to a scan line SL and a data line DL, and may be configured to transfer a data voltage input from the data line DL to the first thin-film transistor T1according to (e.g., based on) a switching voltage input from the scan line SL. The storage capacitor Cst may be connected to the second thin-film transistor T2and a driving voltage line PL, and may be configured to store a voltage corresponding to a difference between a voltage transferred from the second thin-film transistor T2and a first power voltage ELVDD supplied to the driving voltage line PL.

The first thin-film transistor T1may be connected to the driving voltage line PL and the storage capacitor Cst, and may be configured to control a driving current flowing from the driving voltage line PL to the organic light-emitting diode OLED according to the voltage stored in the storage capacitor Cst. The organic light-emitting diode OLED may emit light having a desired brightness (e.g., a preset or predetermined brightness) based on the driving current. An opposite electrode (e.g., a cathode) of the organic light-emitting diode OLED may receive a second power voltage ELVSS.

WhileFIG. 4shows that the pixel circuit PC includes two thin-film transistors and one storage capacitor, the present disclosure is not limited thereto. The number of thin-film transistors and the number of storage capacitors may be variously modified depending on the design of the pixel circuit PC. As an example, the pixel circuit PC may include four or more thin-film transistors in addition to the two thin-film transistors. In an embodiment, the pixel circuit PC may include seven thin-film transistors and one storage capacitor.

Referring again toFIG. 3, the intermediate area MA may surround (e.g., around a periphery of) the opening area OA in a plan view (e.g., a view from a direction that is perpendicular to or substantially perpendicular to a surface (e.g., a top surface) of the relevant element, member, or layer (e.g., the display panel10)). The intermediate area MA is an area at (e.g., in or on) which a display element, for example, such as an organic light-emitting diode that emits light, is not arranged. Signal lines may pass across (or extend around) the intermediate area MA, the signal lines being configured to provide a signal to the pixels P arranged around (e.g., adjacent to) the opening area OA. A scan driver1100, a data driver1200, and main power wirings may be arranged at (e.g., in or on) the peripheral area PA. The scan driver1100may be configured to provide a scan signal to each of the pixels P, the data driver1200may be configured to provide a data signal to each of the pixels P, and the main power wiring may be configured to provide the first power voltage ELVDD and the second power voltage ELVSS. WhileFIG. 3shows that the data driver1200is arranged adjacent to one lateral side of the substrate100, the present disclosure is not limited thereto, and in another embodiment, the data driver1200may be arranged on a flexible printed circuit board (FPCB) that is electrically connected to a pad arranged on a side (e.g., on one side) of the display panel10.

FIG. 5is an enlarged plan view of a portion of the display panel10according to an embodiment, andFIGS. 6 and 7are enlarged plan views of the region D ofFIG. 5.

Referring toFIG. 5, the intermediate area MA may be arranged between the opening area OA and the display area DA. Unlike the display area DA, pixels P may not be arranged at (e.g., in or on) the intermediate area MA. In a plan view, the intermediate area MA may surround (e.g., around a periphery of) the opening area OA.

The pixels P are arranged at (e.g., in or on) the display area DA with the opening area OA between some of the pixels P. Some pixels P may be spaced apart from each other with the opening area OA therebetween, and the opening area OA may be defined between some of the pixels P. As an example, in a plan view, some of the pixels P may be vertically arranged around (e.g., adjacent to) the opening area OA, and some of the pixels P may be horizontally arranged around (e.g., adjacent to) the opening area OA.

Signal lines that are adjacent to the opening area OA from among the signal lines configured to supply a signal to the pixels P may detour around (e.g., may extend around a periphery of) the opening area OA. In this case, the signal lines that detour around the opening area OA may be arranged along an edge of the display area DA that is adjacent to the intermediate area MA. Hereinafter, an area in which the signal lines that detour around the opening area OA are arranged is defined as a wiring area WLA. The wiring area WLA may refer to an edge area of the display area DA that is adjacent to the intermediate area MA.

As shown inFIG. 5, in a plan view, one of the data lines DL passing across (e.g., extending across) the display area DA may extend in a y-direction to provide a data signal to the pixels P vertically arranged around the opening area OA, and may detour around the opening area OA and the intermediate area MA along the edge of the display area DA. In a plan view, one of the scan lines SL passing across (e.g., extending across) the display area DA may extend in an x-direction to provide a scan signal to the pixels P horizontally arranged around the opening area OA, and may detour around the opening area OA and the intermediate area MA along the edge of the display area DA.

A circuitous portion or a bypass portion SL-D of the scan line SL may be arranged at (e.g., in or on) the same layer as that of an extension portion SL-L that passes across (e.g., that extends across) the display area DA, and these portions may be formed as one body. A bypass portion DL-D1of at least one of the data lines DL may be formed at (e.g., in or on) a layer different from that of an extension portion DL-L1of the at least one data line DL that passes across (e.g., that extends across) the display area DA, and may be connected to the extension portion DL-L1through a contact hole CNT. A bypass portion DL-D2of at least one other of the data lines DL may be arranged at (e.g., in or on) the same layer as that of an extension portion DL-L2of the at least one other data line DL, and these portions may be formed as one body.

Referring toFIGS. 5 and 6, at least one partition wall PW may be arranged at (e.g., in or on) the intermediate area MA. In a plan view, each partition wall PW has a closed curve shape, for example, such as a ring shape that surrounds (e.g., around a periphery of) the opening area OA. In the case where the partition wall PW is provided in a plurality of partition walls PW1and PW2, the partition walls PW1and PW2may be spaced apart from each other. As shown inFIGS. 5 and 6, two partition walls PW1and PW2may be arranged at (e.g., in or on) the intermediate area MA. The partition walls PW1and PW2arranged at (e.g., in or on) the intermediate area MA may prevent or substantially prevent an organic encapsulation layer320(e.g., seeFIG. 8) from overflowing to the opening area OA.

The intermediate area MA is an area configured to prevent or substantially prevent foreign substances and/or moisture that may be introduced from the opening area OA to the display area, and may include an inorganic contact region ICR at (e.g., in or on) at least a portion thereof. In the inorganic contact region ICR, because a lower inorganic layer contacts an upper inorganic layer with the organic light-emitting diode OLED therebetween, an organic layer is not arranged between the lower inorganic layer and the upper inorganic layer. Thus, foreign substances and/or moisture that may be introduced or transmitted through the organic layer may be prevented or substantially prevented. In an embodiment, the lower inorganic layer may include at least one of a buffer layer201, a gate insulating layer203, a first interlayer insulating layer205, and/or a second interlayer insulating layer207, and the upper inorganic layer may include a first inorganic encapsulation layer310of a thin-film encapsulation layer300.

Referring toFIG. 6, pixels Pr, Pg, and Pb may be arranged at (e.g., in or on) the display area DA. The pixels Pr, Pg, and Pb may include emission layers222br,222bg, and222bb, respectively. Each of the emission layers222br,222bg, and222bbmay include an emission area P-EA that emits or substantially emits light in a region defined through a corresponding opening215OP of a pixel-defining layer215.

Dummy emission layers222dmmay be arranged at (e.g., in or on) the wiring area WLA that is arranged along the edge of the display area DA. The dummy emission layers222dminclude the same materials as those of the emission layers222br,222bg, and222bbarranged at (e.g., in or on) the display area DA, but may not emit or substantially emit light. Because a pixel electrode and a pixel circuit are not arranged below the dummy emission layers222dm, the dummy emission layers222dmmay not serve or substantially serve as pixels. The dummy emission layers222dmmay be concurrently (e.g., simultaneously) formed during a process of forming the emission layers222br,222bg, and222bb. A portion of the dummy emission layers222dmmay overlap with wirings WL (e.g., the signal lines) that detour around the intermediate area MA at (e.g., in or on) an outer portion thereof.

However, the present disclosure is not limited thereto, and the dummy emission layers222dmshown inFIG. 6may be omitted. For example, as shown inFIG. 7, in another embodiment, the dummy emission layers222dmmay not be provided.

As described above, the dummy emission layers222dmmay not be arranged or may be arranged at (e.g., in or on) the wiring area WLA as needed or desired (e.g., depending on the design or manufacturing process of the display panel10). In both cases, the dummy emission layers222dmmay not be arranged at (e.g., in or on) the intermediate area MA.

FIG. 8is a cross-sectional view of a portion of the display area DA of the display apparatus1according to an embodiment.FIG. 9is a cross-sectional view of a portion of the display area DA and the intermediate area MA of the display apparatus1according to an embodiment.FIGS. 10A and 10Bare enlarged cross-sectional views of the region E ofFIG. 9.

First, a cross-sectional structure of the display area DA is described in more detail with reference to the display panel10ofFIG. 8.FIG. 8may correspond to a cross-section of the display area DA taken along the line B-B′ ofFIG. 5.

The substrate100may include glass or a polymer resin. In an embodiment, the substrate100may include a plurality of layers. As an example, the substrate100may have a structure in which at least one organic layer and at least one inorganic layer are alternately arranged (e.g., are alternately stacked on one another).

The buffer layer201may be formed on the substrate100. The buffer layer201may prevent or substantially prevent impurities from penetrating into a semiconductor layer Act of a thin-film transistor TFT. The buffer layer201may include an inorganic insulating material, for example, such as silicon nitride, silicon oxynitride, and/or silicon oxide. The buffer layer201may include a single layer or multi-layers.

The pixel circuit PC may be arranged on the buffer layer201. The pixel circuit PC includes the thin-film transistor TFT and the storage capacitor Cst. The thin-film transistor TFT may include the semiconductor layer Act, a gate electrode GE, a source electrode SE, and a drain electrode DE. The thin-film transistor TFT shown inFIG. 8may be the first thin-film transistor T1described above with reference toFIG. 4, and may correspond to a driving thin-film transistor. The data line DL of the pixel circuit PC is electrically connected to a switching thin-film transistor (e.g., the second thin-film transistor T2ofFIG. 4) of the pixel circuit PC, which is not shown inFIG. 8. WhileFIG. 8shows an embodiment of a top-gate type thin-film transistor TFT in which the gate electrode GE is arranged above the semiconductor layer Act with the gate insulating layer203therebetween, the present disclosure is not limited thereto, and in another embodiment, the thin-film transistor TFT may be a bottom gate type thin-film transistor.

The semiconductor layer Act may include polycrystalline silicon. In other examples, the semiconductor layer Act may include amorphous silicon, an oxide semiconductor, or an organic semiconductor.

The gate electrode GE may include a low-resistance metal material. The gate electrode GE may include a conductive material including molybdenum (Mo), aluminum (Al), copper (Cu), and/or titanium (Ti), and may include a single layer or multi-layers.

The gate insulating layer203between the semiconductor layer Act and the gate electrode GE may include an inorganic insulating material including silicon oxide, silicon nitride, silicon oxynitride, aluminum oxide, titanium oxide, tantalum oxide, and/or hafnium oxide. The gate insulating layer203may include a single layer or multi-layers including one or more of the above materials.

The source electrode SE and the drain electrode DE, which are connection electrodes that are electrically connected to the semiconductor layer Act, may be arranged at (e.g., in or on) the same layer as that of the data line DL, and may include the same material as that of the data line DL. The source electrode SE, the drain electrode DE, and the data line DL may include a material having excellent conductivity. The source electrode SE and the drain electrode DE may include a conductive material including molybdenum (Mo), aluminum (Al), copper (Cu), and/or titanium (Ti), and may include a single layer or multi-layers. In an embodiment, the source electrode SE, the drain electrode DE, and the data line DL may include a multi-layered structure of Ti/Al/Ti.

The storage capacitor Cst may include a bottom electrode CE1and a top electrode CE2overlapping with each other with the first interlayer insulating layer205therebetween. The storage capacitor Cst may overlap with the thin-film transistor TFT. For example, as shown inFIG. 8, the gate electrode GE of the thin-film transistor TFT may be (or may serve as) the bottom electrode CE1of the storage capacitor Cst. In another embodiment, the storage capacitor Cst may not overlap with the thin-film transistor TFT. The storage capacitor Cst may be covered by the second interlayer insulating layer207. The top electrode CE2of the storage capacitor Cst may include a conductive material including molybdenum (Mo), aluminum (Al), copper (Cu), and/or titanium (Ti), and may include a single layer or multi-layers including one or more of the above materials.

The first interlayer insulating layer205and the second interlayer insulating layer207may include an inorganic insulating material including silicon oxide, silicon nitride, silicon oxynitride, aluminum oxide, titanium oxide, tantalum oxide, and/or hafnium oxide. The first interlayer insulating layer205and the second interlayer insulating layer207may each include a single layer or multi-layers including one or more of the above materials.

A first organic insulating layer209and a second organic insulating layer211may be arranged on the second interlayer insulating layer207. The first organic insulating layer209and the second organic insulating layer211may include a flat or substantially flat (e.g., an approximately flat) upper surface.

The pixel circuit PC may be electrically connected to a pixel electrode221. As an example, as shown inFIG. 8, a contact metal layer CM may be arranged between the pixel circuit PC and the pixel electrode221. The contact metal layer CM may be connected to the pixel circuit PC through a contact hole defined in the first organic insulating layer209, and the pixel electrode221may be connected to the contact metal layer CM through a contact hole defined in the second organic insulating layer211that is on the contact metal layer CM. The contact metal layer CM may include a conductive material including molybdenum (Mo), aluminum (Al), copper (Cu), and/or titanium (Ti), and may include a single layer or multi-layers including one or more of the above materials. In an embodiment, the contact metal layer CM may include a multi-layered structure of Ti/Al/Ti.

The first organic insulating layer209and the second organic insulating layer211may include a general-purpose polymer, for example, such as polymethylmethacrylate (PMMA) or polystyrene (PS), polymer derivatives having a phenol-based group, an acryl-based polymer, an imide-based polymer, an aryl ether-based polymer, an amide-based polymer, a fluorine-based polymer, a p-xylene-based polymer, a vinyl alcohol-based polymer, and/or a blend thereof. In an embodiment, the first organic insulating layer209and the second organic insulating layer211may include polyimide.

The pixel electrode221may be formed on the second organic insulating layer211. The pixel electrode221may include a conductive oxide, for example, such as indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO), indium oxide (In2O3), indium gallium oxide (IGO), or aluminum zinc oxide (AZO). In another embodiment, the pixel electrode221may include a reflective layer including silver (Ag), magnesium (Mg), aluminum (Al), platinum (Pt), palladium (Pd), gold (Au), nickel (Ni), neodymium (Nd), iridium (Ir), chrome (Cr), or a compound thereof. In another embodiment, the pixel electrode221may further include a layer on and/or under the reflective layer, for example, such as a layer including ITO, IZO, ZnO, or In2O3. As an example, the pixel electrode221may include a multi-layered structure of ITO/Ag/ITO.

The pixel-defining layer215may be formed on the pixel electrode221. The pixel-defining layer215may include an opening that exposes the upper surface of the pixel electrode221, and may cover the edges of the pixel electrode221. The pixel-defining layer215may include an organic insulating material. As another example, the pixel-defining layer215may include an inorganic insulating material, for example, such as silicon nitride (SiNx), silicon oxynitride (SiON), or silicon oxide (SiOx). As another example, the pixel-defining layer215may include an organic insulating material and an inorganic insulating material.

An intermediate layer222may be on the pixel electrode221, and may include an emission layer222b. The emission layer222bmay include a polymer or a low-molecular weight organic material that emits light having a suitable color (e.g., a preset or predetermined color). As another example, the intermediate layer222may include at least one organic material layer under and/or on the emission layer222b. In an embodiment, the intermediate layer222may include a first common layer222aunder (e.g., underneath) the emission layer222band/or a second common layer222con the emission layer222b.

The first common layer222amay include a single layer or multi-layers. For example, in the case where the first common layer222aincludes a polymer material, the first common layer222amay include a hole transport layer (HTL), which has a single-layer structure, including poly(3,4-ethylenedioxythiophene) (PEDOT) or polyaniline (PANI). In the case where the first common layer222aincludes a low molecular weight material, the first common layer222amay include a hole injection layer (HIL) and a hole transport layer (HTL).

In the case where the first common layer222aand the emission layer222binclude a polymer material, the second common layer222cmay be formed. The second common layer222cmay include a single layer or multi-layers. The second common layer222cmay include an electron transport layer (ETL) and/or an electron injection layer (EIL). However, the present disclosure is not limited thereto, and the second common layer222cmay be omitted depending on a structure of the intermediate layer222.

In an embodiment, the thickness (e.g., in a z-direction) of the first common layer222amay be thicker than the thickness of the second common layer222c. As an example, the thickness of the first common layer222amay be about 1100 Å to about 2200 Å, and the thickness of the second common layer222cmay be about 350 Å to about 2200 Å.

The emission layer222bof the intermediate layer222may be separately arranged for each pixel at (e.g., in or on) the display area DA. In other words, the emission layer222bmay be patterned to correspond to the pixel electrode221of each pixel. The emission layer222bmay include an emission material layer and an auxiliary layer. The emission material layer may include a polymer organic material or a low-molecular weight organic material that emits light having a suitable color (e.g., a preset or predetermined color) The auxiliary layer may assist a resonance distance of the emission material layer. The auxiliary layer may include, for example, a hole transport material such as poly (3, 4-ethylenedioxythiophene) (PEDOT) or polyaniline (PANI). The emission material layer and the auxiliary layer may have different thicknesses from each other depending on a color of the light emitted by the corresponding pixel.

Unlike the emission layer222b, the first common layer222aand/or the second common layer222cof the intermediate layer222may be provided at (e.g., in or on) the intermediate area MA as well as at (e.g., in or on) the display area DA.

An opposite electrode223may be on the intermediate layer222, and may include a conductive material having a low work function. As an example, the opposite electrode223may include a (semi) transparent layer including silver (Ag), magnesium (Mg), aluminum (Al), platinum (Pt), palladium (Pd), gold (Au), nickel (Ni), neodymium (Nd), iridium (Ir), chrome (Cr), lithium (Li), calcium (Ca), or an alloy thereof. As another example, the opposite electrode223may further include a layer on the (semi) transparent layer including one or more of the above materials, and the layer may include ITO, IZO, ZnO, or In2O3. The opposite electrode223may be formed at (e.g., in or on) the intermediate area MA as well as at (e.g., in or on) the display area DA. The first common layer222a, the second common layer222c, and the opposite electrode223may be formed through thermal deposition.

A capping layer230may be arranged on the opposite electrode223. As an example, the capping layer230may include lithium fluoride (LiF), and may be formed through thermal deposition. However, the present disclosure is not limited thereto, and in an embodiment, the capping layer230may be omitted.

A spacer217may be formed on the pixel-defining layer215. The spacer217may include an organic insulating material, for example, such as polyimide. As another example, the spacer217may include an inorganic insulating material, or may include an organic insulating material and an inorganic insulating material.

The spacer217may include a material that is different from that of the pixel-defining layer215, or may include the same material as that of the pixel-defining layer215. As an example, the pixel-defining layer215and the spacer217may be concurrently (e.g., simultaneously) formed during a mask process that uses a half-tone mask. In an embodiment, the pixel-defining layer215and the spacer217may include polyimide.

The organic light-emitting diode OLED may include the pixel electrode221, the intermediate layer222, and the opposite electrode223. The organic light-emitting diode OLED may be covered by the thin-film encapsulation layer300. The thin-film encapsulation layer300may include at least one organic encapsulation layer and at least one inorganic encapsulation layer. For example,FIG. 8shows that the thin-film encapsulation layer300includes first and second inorganic encapsulation layers310and330, and the organic encapsulation layer320therebetween. However, the present disclosure is not limited thereto, and in other embodiments, the number of organic encapsulation layers, the number of inorganic encapsulation layers, and a stacking order thereof may be variously modified.

The first and second inorganic encapsulation layers310and330may include at least one inorganic material from among aluminum oxide, titanium oxide, tantalum oxide, hafnium oxide, zinc oxide, silicon oxide, silicon nitride, and silicon oxynitride. The first and second inorganic encapsulation layers310and330may include a single layer or multi-layers including one or more of the above materials.

The organic encapsulation layer320may include a polymer-based material. The polymer-based material may include an acryl-based resin, an epoxy-based resin, polyimide, and/or polyethylene. In an embodiment, the organic encapsulation layer320may include acrylate.

The thicknesses (e.g., in the z-direction) of the first and second inorganic encapsulation layers310and330may be different from each other. For example, the thickness of the first inorganic encapsulation layer310may be greater than the thickness of the second inorganic encapsulation layer330. As another example, the thickness of the second inorganic encapsulation layer330may be greater than the thickness of the first inorganic encapsulation layer310. However, the present disclosure is not limited thereto, and the thickness of the first inorganic encapsulation layer310may be the same or substantially the same as the thickness of the second inorganic encapsulation layer330.

The wiring area WLA and the intermediate area MA are described in more detail hereinafter with reference toFIG. 9.

The first organic insulating layer209and the second organic insulating layer211may also be arranged at (e.g., in or on) the wiring area WLA. In an embodiment, the wiring area WLA may denote an edge region of the display area DA that is adjacent to the intermediate area MA. In addition, in an embodiment, the display area DA may be defined as an area at (e.g., in or on) which the first organic insulating layer209and/or the second organic insulating layer211, which are organic layers, are arranged as described above.

The wirings WL may be arranged at (e.g., in or on) the wiring area WLA. The wirings WL may correspond to the signal lines that are configured to supply a signal to the pixels P. The wirings WL may include (e.g., may be) the data line DL and/or the scan line SL, and may correspond to the bypass portions DL-D1, DL-D2, and SL-D of the data lines DL and the scan lines SL shown inFIG. 5.

In an embodiment, the wirings WL at (e.g., in or on) the wiring area WLA may be alternately arranged with an insulating layer therebetween. As an example, one of the wirings WL that is adjacent to another one of the wirings WL may be arranged under (e.g., underneath) the insulating layer (e.g., under the first organic insulating layer209), and the other one of the wirings WL may be arranged on the insulating layer (e.g., on the first organic insulating layer209). In the case where the wirings WL are alternately arranged with the insulating layer therebetween, a distance Δd (e.g., a pitch) between data lines DL may be reduced.

A portion of a multi-layered structure may extend on the insulating layers arranged at (e.g., in or on) the wiring area WLA. The multi-layered structure may include a portion of some of the layers forming the organic light-emitting diode OLED. For example, the multi-layered structure may include the first common layer222a, the second common layer222c, and the opposite electrode223, as well as the capping layer230. Furthermore, in an embodiment, the multi-layered structure may further include the dummy emission layers222dmbetween the first common layer222aand the second common layer222c. The dummy emission layers222dmmay each include at least one of a red emission material, a green emission material, or a blue emission material. As shown inFIG. 6, the dummy emission layers222dmmay be patterned and spaced apart from each other by a suitable interval (e.g., by a preset or predetermined interval). The dummy emission layers222dmmay include the emission materials, but may not emit light or may not substantially emit light, unlike the emission layers of the organic light-emitting diodes OLED.

The dummy emission layers222dmmay have the same or substantially the same structure as that of the emission layer222b. In other words, the dummy emission layer222dmmay include the emission material layer and the auxiliary layer, the emission material layer including a polymer organic material or a low-molecular weight organic material configured to emit light having a suitable color (e.g., a preset or predetermined color), and the auxiliary layer assisting a resonance distance of the emission material layer. The emission material layer and the auxiliary layer may have different thicknesses from each other depending on a color of light that may be emitted. Because the dummy emission layer222dmdoes not emit light or does not substantially emit light, but is concurrently (e.g., simultaneously) formed during a process of forming the emission layer222b, the dummy emission layer222dmmay have the same or substantially the same structure as that of the emission layer222b.

According to a comparative example, the dummy emission layers are also arranged at (e.g., in or on) the intermediate area. In this case, during a process of removing the multi-layered structure (e.g., the first common layer, the emission layer, the second common layer, the opposite electrode, and the capping layer) arranged at (e.g., in or on) the intermediate area, process foreign substances may be excessively generated due to the dummy emission layers. On the other hand, in an embodiment, because the dummy emission layers222dmare not arranged at (e.g., in or on) the intermediate area MA during a manufacturing process, the generation of process foreign substances may be reduced while the multi-layered structure is removed.

As described above, because the dummy emission layer222dmis not arranged at (e.g., in or on) the intermediate area MA, the second common layer222cmay be arranged directly on the first common layer222aat (e.g., in or on) the intermediate area MA. In other words, another layer may not be arranged between the first common layer222aand the second common layer222cat (e.g., in or on) the intermediate area MA. The first common layer222amay directly contact the second common layer222cat (e.g., in or on) an entirety of (e.g., an entire surface of) the intermediate area MA.

In an embodiment, a portion of the first common layer222aand/or the second common layer222carranged at (e.g., in or on) the intermediate area MA at (e.g., in or on) which the dummy emission layer222dmis not arranged may be provided to have a thickness (e.g., in the z-direction) that is thicker than that of the first common layer222aand/or the second common layer222carranged at (e.g., in or on) the display area DA. In other words, the first common layer222aand/or the second common layer222cmay be arranged such that the thickness thereof corresponding to the display area DA is different from the thickness thereof corresponding to the intermediate area MA. This may be for reducing a thickness variation with respect to the display area DA at (e.g., in or on) which the dummy emission layer222dmand/or the emission layer222bare arranged.

The intermediate area MA is a region between the display area DA and the opening area OA, and may include at least one partition wall (e.g., a first partition wall PW1) and at least one inorganic contact region ICR. The intermediate area MA may prevent or substantially prevent foreign substances and/or moisture from penetrating to the display area DA through the opening area OA.

The first partition wall PW1may be arranged at (e.g., in or on) the intermediate area MA. The first partition wall PW1may be arranged on the inorganic insulating layer IL extending to the intermediate area MA. In another embodiment, a sub-partition wall may be further arranged on the second organic insulating layer211of the wiring area WLA. The first partition wall PW1may prevent or substantially prevent the organic encapsulation layer320of the thin-film encapsulation layer300from overflowing to the opening area OA.

In an embodiment, the first partition wall PW1may include first to third layers211PW1,215PW1, and217PW1. The first layer211PW1of the first partition wall PW1may include the same material as that of the first organic insulating layer209or the second organic insulating layer211. The second layer215PW1may include the same material as that of the pixel-defining layer215. The third layer217PW1may include the same material as that of the spacer217.

The first common layer222aand the second common layer222cmay be arranged on the first partition wall PW1. The first common layer222aand the second common layer222cmay extend to the opening area OA, and may cover the upper surface and the lateral surfaces of the first partition wall PW1. The first and second inorganic encapsulation layers310and330may be arranged on the second common layer222con the first partition wall PW1.

At least one inorganic contact region ICR may be arranged at (e.g., in or on) the intermediate area MA. The inorganic contact region ICR may be provided in a closed curve shape along a shape of the opening area OA as shown inFIG. 5. The inorganic contact region ICR may be a region in which only the inorganic insulating layer IL is arranged between the first inorganic encapsulation layer310and the substrate100. In other words, the inorganic insulating layer IL is arranged on the substrate100to correspond to the inorganic contact region ICR, and the first inorganic encapsulation layer310may directly contact the inorganic insulating layer IL.

In an embodiment, the first common layer222aand the second common layer222cmay have at least one opening corresponding to the inorganic contact region ICR. In other words, the inorganic contact region ICR may be defined as the opening. It is shown inFIG. 9that the first common layer222aand the second common layer222cinclude a first opening OP1and a second opening OP2, respectively, each corresponding to one of the inorganic contact regions ICR. The first opening OP1may be arranged between the first partition wall PW1and the display area DA, and the second opening OP2may be arranged between the first partition wall PW1and the opening area OA.

A portion of the inorganic insulating layer IL at (e.g., in or on) the intermediate area MA may be exposed through the first opening OP1and the second opening OP2. Because the upper surfaces of the inorganic insulating layer IL that are exposed through the first opening OP1and the second opening OP2contact the first inorganic encapsulation layer310, the first opening OP1and the second opening OP2may constitute a plurality of inorganic contact regions ICR. Because the inorganic contact regions ICR are provided in a plurality as shown inFIG. 9, the inorganic contact regions ICR may gradually block moisture transmission from the opening area OA to the display area DA.

FIGS. 10A and 10Bare enlarged cross-sectional views of the region E ofFIG. 9, or in other words, the inorganic contact region ICR at the first opening OP1. Referring toFIG. 10A, a residual material layer R may remain on the inorganic insulating layer IL exposed through the first opening OP1. The residual material layer R may be a remnant that is not completely removed while the first opening OP1is formed. The first opening OP1(and the second opening OP2) may be formed by removing a portion of the first and second common layers222aand222c, which may include forming a sacrificial metal layer (e.g., seeFIG. 15A) under (e.g., underneath) the first common layer222aand removing the sacrificial metal layer, where a portion of the first and second common layers222aand222con the sacrificial metal layer are concurrently (e.g., simultaneously) removed. Accordingly, a remnant that is left after the sacrificial metal layer is removed during the manufacturing process may remain as the residual material layer R inside the inorganic contact region ICR.

However, the present disclosure is not limited thereto, and in another embodiment, the residual material layer R may not remain, and may be completely removed from the inorganic contact region ICR as shown inFIG. 10B.

The intermediate area MA may include a laser irradiation region LIR. The laser irradiation region LIR may be a region to which a laser is irradiated to remove a portion or all of the multi-layered structure, or in other words, the first common layer222a, the second common layer222c, the opposite electrode223, and the capping layer230arranged at (e.g., in or on) the intermediate area MA during the manufacturing process. The laser irradiation region LIR may be the same or substantially the same as or less than the intermediate area MA. The inorganic contact region ICR may be arranged inside the laser irradiation region LIR. The opposite electrode223and the capping layer230extending to the intermediate area MA may be removed from the laser irradiation region LIR. In other words, the opposite electrode223and the capping layer230may not be arranged at (e.g., in or on) the laser irradiation region LIR.

As described above, because the opposite electrode223and the capping layer230are removed from the laser irradiation region LIR arranged at (e.g., in or on) the intermediate area MA, and the first common layer222aand the second common layer222c, which are organic material layers, are removed from the inorganic contact region ICR, foreign substances and/or moisture that may be introduced to the display area DA through the opening area OA may be effectively blocked.

In addition, as described above, the dummy emission layer222dmis not arranged at (e.g., in or on) the intermediate area MA, or in other words, the laser irradiation region LIR. As a comparative example, during a process of removing the opposite electrode and the capping layer by irradiating a laser to the laser irradiation region LIR, the dummy emission layer may be arranged in the relevant region. In this case, because laser energy is absorbed in the dummy emission layer before the laser energy is transferred to the opposite electrode, evaporation of the dummy emission layer occurs. Due to the expansion of the dummy emission layer, the opposite electrode may be broken down or torn down before the opposite electrode is removed, which becomes a cause for increasing foreign substances due to the laser process in the laser irradiation region, or in other words, the intermediate area. In the case where the process foreign substances that occurs in this manner remains in the inorganic contact region, cracks or peeling due to the foreign substances may occur to the inorganic layer, and thus, the inorganic layer may be vulnerable to moisture transmission.

In contrast, in the display apparatus according to one or more embodiments, because the dummy emission layer222dmis not arranged at (e.g., in or on) the intermediate area MA, or in other words, the laser irradiation region LIR, foreign substance generation in the relevant region may be suppressed or reduced during the laser process.

FIGS. 11 and 12are cross-sectional views of a portion of a display panel according to one or more embodiments.FIGS. 11 and 12show modified example embodiments of the embodiment ofFIG. 9.

A cross-sectional structure ofFIG. 11may correspond toFIG. 6.FIG. 11may be different fromFIG. 9, in that a plurality of partition walls including the first partition wall PW1and the second partition wall PW2are arranged at (e.g., in or on) the intermediate area MA. Hereinafter, differences between the embodiments ofFIG. 11andFIG. 9may be mainly described, and redundant description may not be repeated.

Referring toFIG. 11, the first partition wall PW1and the second partition wall PW2may be arranged at (e.g., in or on) the intermediate area MA. The first partition wall PW1is spaced apart from the second partition wall PW2by a suitable interval (e.g., a preset or predetermined interval). The first partition wall PW1and the second partition wall PW2may be arranged on the inorganic insulating layer IL extending to the intermediate area MA. The first partition wall PW1and the second partition wall PW2may prevent or substantially prevent the organic encapsulation layer320of the thin-film encapsulation layer300from overflowing to the opening area OA.

In an embodiment, the first partition wall PW1may include the first to third layers211PW1,215PW1, and217PW1. In addition, similar to the first partition wall PW1, the second partition wall PW2may include first to third layers211PW2,215PW2, and217PW2. The first layers211PW1and211PW2of the first partition wall PW1and the second partition wall PW2may include the same material as that of the first organic insulating layer209or the second organic insulating layer211. The second layers215PW1and215PW2may include the same material as that of the pixel-defining layer215. The third layers217PW1and217PW2may include the same material as that of the spacer217.

The first common layer222aand the second common layer222cmay be arranged on the first partition wall PW1and the second partition wall PW2. The first common layer222aand the second common layer222cmay extend to the opening area OA, and may cover the upper surfaces and the lateral surfaces of the first partition wall PW1and the second partition wall PW2. The first and second inorganic encapsulation layers310and330may be arranged on the second common layer222con the first partition wall PW1and the second partition wall PW2.

At least one inorganic contact region ICR may be arranged at (e.g., in or on) the intermediate area MA. InFIG. 11, the inorganic contact region ICR may be provided in a plurality with the first partition wall PW1and the second partition wall PW2therebetween. The inorganic contact regions ICR may be arranged between the first partition wall PW1and the display area DA, between the first partition wall PW1and the second partition wall PW2, and between the second partition wall PW2and the opening area OA.

In an embodiment, the first common layer222aand the second common layer222cmay include the first opening OP1, the second opening OP2, and a third opening OP3corresponding to the inorganic contact regions ICR, respectively. In an embodiment, the first opening OP1may be arranged between the first partition wall PW1and the display area DA. The second opening OP2may be arranged between the second partition wall PW2and the opening area OA. The third opening OP3may be arranged between the first partition wall PW1and the second partition wall PW2. The inorganic insulating layer IL at (e.g., in or on) the intermediate area MA may be exposed through the first to third openings OP1, OP2, and OP3. As described above, the inorganic insulating layer IL exposed through the first to third openings OP1, OP2, and OP3contacts the first inorganic encapsulation layer310, and thus, the first to third openings OP1, OP2, and OP3may constitute the inorganic contact regions ICR. Because the inorganic contact regions ICR are provided in a plurality, moisture transmission through the opening area OA may be gradually blocked.

FIG. 12shows the intermediate area MA and a pixel P arranged at (e.g., in or on) the display area DA. A cross-sectional structure ofFIG. 12may correspond to the structure ofFIG. 7. In other words, the dummy emission layers222dmare not provided in the embodiment ofFIG. 12. WhileFIGS. 9 and 11show that the dummy emission layers222dmare arranged at (e.g., in or on) the wiring area WLA, which is an edge region of the display area DA,FIG. 12shows that the dummy emission layers222dmare not arranged at (e.g., in or on) the wiring area WLA. Accordingly, the emission layer222bmay be provided at only a portion in which a pixel P is formed or substantially formed.

Referring to the intermediate area MA ofFIG. 12, the dummy emission layers222dmare not arranged at (e.g., in or on) the intermediate area MA, for example, the laser irradiation region LIR, like the above embodiments. In the display apparatus according to one or more embodiments, the dummy emission layers222dmare not arranged at (e.g., in or on) the intermediate area MA, for example, the laser irradiation region LIR, and thus, foreign substance generation in the relevant region may be suppressed or reduced during the laser process.

FIGS. 13 and 14are experimental graphs showing results of measuring the number of foreign substances after a laser process that occur from a display panel according to one or more embodiments.

Hereinafter, the experimental results ofFIGS. 13 and 14are described with reference to the above-described embodiments.

FIG. 13shows results obtained by measuring the number of foreign substances per unit area in a region A, andFIG. 14shows results obtained by measuring the number of foreign substances per unit area in a region B. In the experiments ofFIGS. 13 and 14, the region A is a region that is adjacent to the opening area OA, and the region B is a region at (e.g., in or on) which the first partition wall PW1is arranged.

InFIGS. 13 and 14, the experiments have been carried out based on an Embodiment 1, an Embodiment 2, an Embodiment 3, and a Comparative example. Embodiment 1 is a case where the second common layer222cis not provided and only the first common layer222ais provided. In this case, the thickness of the first common layer222ahas been set to about 1170 Å. In addition, Embodiment 2 is a case where both the first common layer222aand the second common layer222care provided, and the thicknesses thereof have been set to about 1530 Å. In addition, Embodiment 3 is a case where the second common layer222cis not provided and only the first common layer222ais provided, and the thickness of the first common layer222ahas been set to about 2340 Å. Embodiments 1 to 3 are cases where the dummy emission layers222dmare not arranged at (e.g., in or on) the intermediate area MA, for example, the laser irradiation region LIR. Unlike Embodiments 1 to 3, the Comparative example is a case where the dummy emission layers222dmare also arranged at (e.g., in or on) the intermediate area MA. In the Comparative example, an average thickness of the first common layer222a, the dummy emission layer222dm, and the second common layer222chas been set to about 2197 Å.

Referring toFIG. 13, the number of foreign substances generated in the region A according to the Comparative example has been measured as 41.6. In contrast, the number of foreign substances generated in the region A according to the Embodiments 1, 2, and 3 have been measured as 7.2, 10.7, and 15, respectively. The number of foreign substances has been measured as an average value through repeated experiments.

Referring toFIG. 14, the number of foreign substances generated in the region B according to the Comparative example has been measured as 15.9. In contrast, the number of foreign substances generated in the region B according to the Embodiments 1, 2, and 3 have been measured as 2.8, 4.7, and 2, respectively. The number of foreign substances has been measured as an average value through repeated experiments.

As described above, in summarizing the experimental results ofFIGS. 13 and 14, it is revealed that foreign substances of a remarkably low level is observed in the cases of Embodiments 1 to 3 where the dummy emission layer222dmis not formed at (e.g., in or on) the intermediate area MA, for example, the laser irradiation region LIR, compared to that of the Comparative example. Accordingly, in the display apparatus according to one or more embodiments, foreign substances that are generated during the laser process in the intermediate area MA are reduced, and thus, the reliability of the display apparatus may be improved.

While the display apparatus has been mainly described, the present disclosure is not limited thereto. As an example, a method of manufacturing the display apparatus also falls within the spirit and scope of the present disclosure.

FIGS. 15A to 15Dare cross-sectional views showing some processes of a method of manufacturing a display apparatus according to an embodiment.

The display apparatus according to one or more embodiments may be generally formed in a stacking order in the +z-direction on the substrate100as shown in the cross-sectional views ofFIGS. 9, 11, and 12. Hereinafter, inFIGS. 15A to 15D, redundant description as those of the above may not be repeated, and characteristics of a manufacturing process are mainly described with reference to the above cross-sectional views.

Referring toFIG. 15A, the substrate100including the opening area OA, the display area DA surrounding (e.g., around a periphery of) at least a portion of the opening area OA, and the intermediate area MA between the opening area OA and the display area DA may be prepared. InFIG. 15A, the through hole10H ofFIG. 9and the like is not formed in the opening area OA, and the opening area OA is denoted by a first area OA′.

The inorganic insulating layer IL may be formed on the entire surface of the substrate100, and an organic insulating layer OL may be formed to correspond to the display area DA. The inorganic insulating layer IL may include at least one of the buffer layer201, the gate insulating layer203, the first interlayer insulating layer205, and the second interlayer insulating layer207ofFIG. 9and the like. The organic insulating layer OL may be the first organic insulating layer209and/or the second organic insulating layer211ofFIG. 9and the like.

A sacrificial metal layer SML may be formed on the inorganic insulating layer IL corresponding to the intermediate area MA. The sacrificial metal layer SML may be provided to remove the first common layer222aand the second common layer222c. A region in which the sacrificial metal layer SML is formed may correspond to the inorganic contact region ICR ofFIG. 9and the like in the display apparatus.

Although the partition wall is omitted from the intermediate area MA ofFIGS. 15A to 15Dfor convenience of illustration, the partition wall may be arranged between the sacrificial metal layers SML.

The first common layer222amay be arranged to cover the sacrificial metal layer SML. The first common layer222amay be formed on the entire surface of the substrate100by using an open mask.

Then, the dummy emission layers222dmmay be formed on the first common layer222a. The dummy emission layers222dmmay be formed through the same process as a process of forming the emission layer222bof the display area DA ofFIG. 12and the like. In an embodiment, the dummy emission layer222dmmay be formed to constitute a pattern by a mask having an opening M-OP, for example, a fine metal mask FMM.

In an embodiment, the dummy emission layer222dmis not formed at (e.g., in or on) the intermediate area MA. In other words, the dummy emission layer222dmmay not be formed at (e.g., in or on) the intermediate area MA and then removed. Accordingly, a mask M for forming the emission layer222bmay not have an opening in a portion corresponding to the intermediate area MA. As shown inFIG. 15A, a portion of the mask M corresponding to the intermediate area MA may have a closed shape without an opening formed therein.

As described above, because the dummy emission layer222dmis not formed at (e.g., in or on) the intermediate area MA, the generation of foreign substances may be reduced while the opposite electrode223and the capping layer230are removed during the laser irradiation process shown inFIG. 15C, which is described in more detail below.

Referring toFIG. 15B, the second common layer222c, the opposite electrode223, and the capping layer230may be sequentially formed to cover the dummy emission layer222dm. Like the first common layer222a, the second common layer222c, the opposite electrode223, and the capping layer230may be formed on the entire surface of the substrate100by using an open mask.

Then, referring toFIG. 15C, a laser L may be irradiated to the substrate100corresponding to the laser irradiation region LIR. Accordingly, metal layers such as the opposite electrode223and the capping layer230arranged at (e.g., in or on) the laser irradiation region LIR may be removed. In an embodiment, the laser L may be an infrared (IR) laser.

The sacrificial metal layer SML is formed as shown inFIG. 15Ato remove the first common layer222aand the second common layer222c, which are organic material layers, in this laser irradiation process. In other words, the first common layer222aand the second common layer222con the sacrificial layer SML may be concurrently (e.g., simultaneously) removed during a process of removing the sacrificial metal layer SML. As shown inFIG. 15C, the sacrificial layer SML may be removed by the laser L, and a portion of the first common layer222aand the second common layer222ccorresponding to (e.g., overlapping with) the sacrificial metal layer SML may be concurrently (e.g., simultaneously) removed.

Openings OP may be formed in the first common layer222aand the second common layer222ccorresponding to the portions of the sacrificial metal layer SML that are removed. The inorganic insulating layer IL may be exposed through the openings OP. These openings OP may disconnect the first common layer222aand the second common layer222c, which are the organic material layers. Because the organic material layers are vulnerable to impurities and/or moisture transmission, impurities or moisture may be easily blocked by disconnecting the first common layer222aand the second common layer222cthrough the openings OP, such that the impurities and/or moisture may not be introduced to the display area DA through the organic material layers.

Referring toFIG. 15D, the first inorganic encapsulation layer310may be formed on the capping layer230. The first inorganic encapsulation layer310may be formed on the entire surface of the substrate100. The first inorganic encapsulation layer310may contact the inorganic insulating layer IL exposed through the openings OP. Accordingly, the inorganic contact regions ICR may be formed to correspond to the openings OP.

Then, as shown inFIG. 12, the organic encapsulation layer320and the second inorganic encapsulation layer330are sequentially formed on the first inorganic encapsulation layer310. Then, the first region OA′ ofFIG. 15Dis laser-cut to form the hole10H in the opening area OA as shown inFIG. 12and the like.

According to one or more embodiments, a display apparatus having an improved reliability while having an area in which various kinds of components may be arranged inside a display area, and a manufacturing method thereof may be implemented. However, the spirit and scope of the present disclosure is not limited thereto.