Mother substrate for display panel, method of cutting the same, and display panel prepared by the method

A display panel includes a display area, a non-display area, a first substrate with first and second edges extending in first and second directions and forming a vertex, a second substrate facing the first substrate, a seal pattern between the first and second substrates to surround a display area with first and second seal patterns extending in the first and second directions and forming a vertex, and dummy spacers disposed on the first substrate within the non-display area. The non-display area includes a first non-display area between the first seal pattern and the first edge, a second non-display area between the second seal pattern and the second edge, a vertex area that abuts on the first and second non-display areas and is adjacent to the vertex of the first substrate, and an average arrangement density of the dummy spacers is smaller in the vertex area than in the non-display area.

This application claims priority from and the benefit of Korean Patent Application No. 10-2016-0024016, filed on Feb. 29, 2016, which is hereby incorporated by reference for all purposes as if fully set forth herein.

BACKGROUND

Field

Exemplary embodiments relate to a mother substrate for a display panel, a method of cutting the mother substrate for the display panel, and a display panel manufactured by the method of cutting the mother substrate.

Discussion of the Background

In order to improve the yield in the manufacture of a display panel, a mother substrate with a large area including an upper substrate and a lower substrate is manufactured, and thereafter, the mother substrate is cut into a plurality of unit panels having a smaller area, thereby manufacturing the display panel. A method for cutting the mother substrate, such as a scribe and break process, may be adopted.

For example, after forming a scribing line, i.e., a crack on the surfaces of the upper substrate and the lower substrate of the mother substrate may be made by a cutter, the mother substrate may be cut by applying a uniform impact or load to the scribing line, and thus a unit panel of a desired size may be manufactured.

SUMMARY

As the thicknesses of the upper substrate and the lower substrate become gradually thinner, in order to reduce the weight and thickness of the display device, the upper substrate and/or lower substrate may be bent in the process of forming the scribing line using a cutter. Thus, there is a problem of an occurrence of cracks in an unintended direction, e.g., cracks which make the scribing line uneven.

Furthermore, when there are cracks along the uneven scribing line, impurities such as debris and dust may be generated due to the uneven cut surface, and defective pixels of the display panel may be caused by such impurities. In addition, such a failure may increase with an increase in the area of the mother substrate.

Exemplary embodiments provide a mother substrate and a method for forming a uniform scribing line for cutting the mother substrate.

Exemplary embodiments provide a display panel in which the defective pixel caused by impurities generated in the process of cutting the mother substrate is minimized.

According to an exemplary embodiment of the present disclosure, a display panel includes a display area comprising a plurality of pixels, a non-display area surrounding the display area, a first substrate comprising a first edge extending in a first direction, a second edge extending in a second direction which intersects with the first direction and forms a vertex with the first edge, a second substrate that faces the first substrate, a seal pattern that comprises a first seal pattern extending in the first direction, and a second seal pattern which extends in the second direction and forms a vertex with the first seal pattern, the seal pattern being located between the first substrate and the second substrate and surrounding the display area, and one or more dummy spacers disposed on the first substrate within the non-display area. The non-display area includes a first non-display area between the first seal pattern and the first edge, a second non-display area between the second seal pattern and the second edge, a vertex area that abuts on the first non-display area and the second non-display area and is adjacent to the vertex of the first substrate, and an average arrangement density of the dummy spacers in the vertex area is smaller than an average arrangement density of the dummy spacers in the non-display area or 0.

According to another exemplary embodiment of the present disclosure, the mother substrate includes a plurality of active areas arranged in a matrix form, a grid-shaped surrounding area of the active areas, a second substrate that faces the first substrate to be spaced apart, a plurality of seal pattern that is located between the first substrate and the second substrate and surrounds each of the active areas, and a plurality of dummy spacers disposed on the first substrate within the surrounding area. The surrounding area includes a first surrounding area which extends in the first direction and a second surrounding area which extends in a second direction intersecting with the first direction, wherein an average arrangement density of the dummy spacers in an area in which the first surrounding area and the second surrounding area intersect with each other is smaller than an average arrangement density of the dummy spacers in the surrounding area or 0.

According to yet another exemplary embodiment of the present disclosure, a method of cutting a mother substrate includes preparing a mother substrate. The mother substrate includes a plurality of active areas arranged in matrix form, a grid-shaped surrounding area of the active areas, a first substrate, a second substrate that faces the first substrate to be spaced apart, and a plurality of dummy spacers disposed on the first substrate within the surrounding area. The surrounding area includes a first surrounding area which extends in the first direction and a second surrounding area which extends in a second direction intersecting with the first direction, wherein an average arrangement density of the dummy spacers in an area in which the first surrounding area and the second surrounding area intersect with each other is smaller than an average arrangement density of the dummy spacers in the surrounding area. The method also includes forming a first scribing line extending in the first direction on one side of the second substrate within the first surrounding area and forming a second scribing line extending in a second direction intersecting with the first direction on one side of the second substrate within the second surrounding area, wherein upon forming the second scribing line, forming the second scribing line so that an intersection in which the second scribing line and the first scribing line intersect with each other is located within an area in which the first surrounding area and the second surrounding area intersect with each other.

According to the mother substrate, and method of cutting the mother substrate according to an exemplary embodiment of the present disclosure, by disposing one or more dummy spacers in a surrounding area of the mother substrate, and by forming a scribing line on one side of the substrate to overlap the dummy spacers or to penetrate between the two dummy spacers contiguously spaced apart from each other, there is an effect capable of alleviating the bending of the substrate in the process of forming the scribing line, thereby suppressing the cracks that occur in the horizontal direction with respect to the substrate surface.

At the same time, by setting an average arrangement density of the dummy spacers in an cross area of the surrounding area of the mother substrate to be smaller than an average arrangement density of the dummy spacers within an entire surrounding area, or by forming the intersection of a plurality of scribing lines to overlap the cross area without disposing the dummy spacer in the cross area, it is possible to improve the uniformity of the scribing line in the vicinity of the intersection.

Further, by suppressing the generation of the impurities to a minimum in the cutting process of the mother substrate, it is possible to provide a display panel with improved reliability.

DETAILED DESCRIPTION OF THE ILLUSTRATED EMBODIMENTS

Various exemplary embodiments are described herein with reference to sectional illustrations that are schematic illustrations of idealized exemplary embodiments and/or intermediate structures. As such, variations from the shapes of the illustrations as a result, for example, of manufacturing techniques and/or tolerances, are to be expected. Thus, exemplary embodiments disclosed herein should not be construed as limited to the particular illustrated shapes of regions, but are to include deviations in shapes that result from, for instance, manufacturing. Thus, the regions illustrated in the drawings are schematic in nature and their shapes are not intended to illustrate the actual shape of a region of a device and are not intended to be limiting.

FIG. 1is an exploded perspective view of a mother substrate according to an embodiment of the present disclosure.FIG. 2is a layout diagram of a mother substrate ofFIG. 1.

Referring toFIGS. 1 and 2, a plurality of active areas AA and a surrounding area SA are defined on the mother substrate1. The active area AA is an area that includes a plurality of pixel areas to achieve an image, and the surrounding area SA is a surrounding area that surrounds the active areas AA.

The plurality of active areas AA may be aligned in a first direction (X1, a row direction) and a second direction (X2, a column direction) and is disposed in a substantially matrix form, and the first direction X1and the second direction X2may be orthogonal to each other. Each active area AA may include a plurality of pixel areas, and a pixel electrode is disposed for each pixel area. The active areas AA of the mother substrate1may correspond to the display area of the display panel.

The surrounding area SA may be an area that excludes an area occupied by the active areas AA from the mother substrate1. The surrounding area SA may include an area (not illustrate) in which a circuit pattern for providing an electrical signal to the pixel electrode of the active area AA, and an area in which a scribing line to be described later is formed. When a plurality of active areas AA is disposed in a matrix form, the surrounding area SA may be an area in the grid form that is formed by a plurality of first surrounding areas SA1extending in the first direction X1and a plurality of second surrounding areas SA2extending in the second direction X2. A single first surrounding area SA1and a single second surrounding area SA2may intersect with each other to define a cross area CA.

The mother substrate1may include a first substrate10including a plurality of dummy spacers51and52, a second substrate20that faces the first substrate10to be spaced apart from each other, and a plurality of seal patterns40which is located between first substrate10and the second substrate20.

In an exemplary embodiment, the second substrate20may be a substrate that includes a second base substrate (not illustrated) and the pixel electrode disposed on the second base substrate, and the first substrate10may be a counter substrate that includes a first base substrate (not illustrated) and dummy spacers51and52and is disposed to face second substrate20to be spaced apart from each other.

A plurality of seal patterns40may be located between the first substrate10and the second substrate20. The seal patterns40may be a sealing member for bonding the first substrate10and the second substrate20together. Specifically, a single seal pattern40may have a square band shape that is located in the surrounding area SA to surround the single active area AA. In each active area AA that is sealed by the first substrate10, the second substrate20, and the seal pattern40, elements for obtaining an image, e.g., one or more thin film transistors, one or more pixel electrodes, a liquid crystal, and/or an organic light emitting element may be disposed.

The plurality of dummy spacers51and52may be disposed in the surrounding area SA. The plurality of dummy spacers may alleviate the problem of bending of the first substrate and the second substrate bend, in the process of forming a scribing line to be described later, by maintaining a separated distance between the first substrate10and the second substrate20. The function of the dummy spacer will be described below in detail withFIGS. 11 to 17relating to the method of cutting the mother substrate.

The plurality of dummy spacers may include one or more first dummy spacers51that are located in the first surrounding area SA1and extend approximately in the first direction X1, and one or more second dummy spacers52that are located in the second surrounding area SA2and extend approximately in the second direction X2.FIGS. 1 and 2illustrate a case where the three first dummy spacers51spaced apart in the second direction X2in the first surrounding area SA1are repeatedly disposed in the first direction X1, and a single second dummy spacer52disposed in a single second surrounding area SA2is repeatedly disposed in the second direction X2. However, the present disclosure is not limited thereto, and the number of the first and second dummy spacers may be provided by being modified. In another exemplary embodiment, a plurality of dummy spacers may be disposed on the substrate on which the pixel electrode is disposed.

Hereinafter, the shape and arrangement of the components of the mother substrate1according to an exemplary embodiment of the present disclosure will be described in detail with reference toFIGS. 3 and 4.FIG. 3is an enlarged layout diagram of an area A ofFIG. 2.FIG. 4is an enlarged perspective view of the dummy spacer ofFIG. 3.

Referring toFIGS. 1 to 4, the cross area CA may be an area of an approximately square shape. In this case, the length in the first direction (X1, a horizontal direction) of the cross area CA may correspond to the width of the second surrounding area SA2, and the length in the second direction (X2, a vertical direction) of the cross area CA may correspond to the width of the first surrounding area SA1.

In an exemplary embodiment, a length WSA2in the first direction X1of the cross area CA may be approximately 4 mm or more, or approximately 8 mm or more, and a length WSA1in the second direction X2may be approximately 4 mm or more, or approximately 8 mm or more. That is, the cross area CA may include an area of a square shape in which the length of one side is 4 mm or more.

Further, an average arrangement density of the dummy spacers51and52in the cross area CA may be zero. That is, the dummy spacers51and52may not be located in the cross area CA. In this example, the average arrangement density of the dummy spacers means the ratio of the area on a plane occupied by the dummy spacers to the unit area on the plane. Specifically, the first dummy spacers51may extend in the first direction X1within the first surrounding area SA1, and the second dummy spacers52may extend in the second direction X2within the second surrounding area SA2, but the first dummy spacers51and the second dummy spacers52may be spaced apart from each other, without intersecting with each other. The extension length of the first dummy spacers51may be substantially the same as the length in the first direction X1of the adjacent seal pattern40, and the extension length of the second dummy spacer52may be substantially the same as the length in the second direction X2of the adjacent seal pattern40.

In the scribing process as described below with reference toFIGS. 11 to 17, the scribing line extending in one direction (e.g., the first direction) and the scribing line extending in the other direction (e.g., the second direction) intersecting with the one direction may form an intersection within the cross area CA, and there may be an effect capable of ensuring the uniformity of the scribing lines in the area near the intersection, by preventing the dummy spacer from being located in the area near the intersection.

Meanwhile, each of the first and second dummy spacers51and52may have a structure in which a plurality of pattern layers is laminated. For example, the first dummy spacer51may include a first base pattern51aas a linear pattern that is disposed on the first base substrate (not illustrated), is located in the first surrounding area SA1and extends in the first direction X1, and first support patterns51bas a plurality of protrusion-like patterns of a dot shape that are disposed on the first base pattern51aand are spaced apart in the first direction X1. In an exemplary embodiment, the first base pattern51ais formed of the same material as the light-shielding member in the active area AA but may be thicker than the thickness of the light-shielding member, and the first support pattern51bis formed of the same material as the color filter in the active area AA but may be thicker than the thickness of the color filter. By forming the thicknesses of the base pattern and the support pattern to be thicker than the thicknesses of the light-shielding member and the color filter of the active area, the base pattern and the support pattern may function as a spacer.

Each of the width W1of the first dummy spacer and the width W2of the second dummy spacer may be approximately 0.8 mm to 1.1 mm, respectively. The width W1of the first dummy spacer may be equal to the width W1aof the first base pattern, and the width W2of the second dummy spacer may be equal to the width of the second base pattern. In an exemplary embodiment, the width W1of the first dummy spacer and the width W2of the second dummy spacer may be different from each other. For example, the width W1of the first dummy spacer may be approximately 1.1 mm, and the width W2of the second dummy spacer may be approximately 0.8 mm. If the width WSA1of the first surrounding area SA1is larger than the width WSA2of the second surrounding area SA2, by setting the width W1of the first dummy spacer51to be larger than the width W2of the second dummy spacer52, it is possible to more effectively alleviate bending of the substrates.

The shortest separation distance l1between the first dummy spacer51and the seal pattern40, and the shortest separation distance l2between the second dummy spacer52and seal pattern40may be approximately 0.001 times to 0.004 times the width of the dummy spacer, respectively. For example, the shortest separation distance l1between the first dummy spacer51and the seal pattern40, and the shortest separation distance l2between the second dummy spacer52and the seal pattern40may be 2 to 3 μm or approximately 2.5 to 2.9 μm, respectively.

A separation distance l3between the two first dummy spacers51spaced apart in the second direction X2within the surrounding area SA1may be approximately 2 times to 3.5 times the width W1of the first dummy spacer51. For example, the separation distance l3between the first dummy spacers may be approximately 0.5 to 2.5 mm or approximately 2 mm. Although it is not illustrated in the drawings, when the plurality of second dummy spacers are disposed to be spaced apart in the first direction X1within the second surrounding area SA2, the separation distance between the second dummy spacers may also be approximately 0.5 to 2.5 mm or approximately 2 mm. If the ratio of the separation distance of the dummy spacers to the width of dummy spacer is 2 or more, it is possible to form a uniform scribing line, and if the ratio is 3.5 or less, it is possible to effectively alleviate the problem of bending of substrates.

The height h1of the first and second dummy spacers51and52may be smaller than the height of the adjacent seal pattern40. For example, the height h1of the first and second dummy spacers may be approximately 2 to 3 μm, respectively. Herein, the height of the dummy spacer means a vertical length from the substrate surface on which the dummy spacers are disposed to the highest point of the dummy spacers. For example, if the dummy spacers are made up of the base pattern and the support pattern disposed on base pattern, the height of the dummy spacers may be a vertical length from the bottom surface of the base pattern to the highest portion of the support pattern. By setting the height of the first and second dummy spacers51and52within the aforementioned range, the dummy spacers may serve as spacers that reduce the distance between the highest portion of the first substrate10and the lowest portion of the second substrate20in the portion in which the dummy spacers are disposed, which makes it possible to alleviate the problem of bending of the substrates.

The first support pattern51bmay have a regular octagonal pyramid shape which has a regular octagonal bottom surface, but the present disclosure is not limited thereto. The width W1bof the first support pattern may be approximately 20 to 150 μm, and the separation distance d1bbetween the first support patterns may be approximately 100 μm to 1 mm. Meanwhile, because the second dummy spacer52may have substantially the same or similar shape and configuration as the first dummy spacer51, the detailed description thereof will not be provided.

Hereinafter, a mother substrate according to another exemplary embodiment of the present disclosure will be described. However, in order not to obscure the essence of the present disclosure, the description of the configuration that is substantially identical or similar to the mother substrate according to the exemplary embodiment will not be provided, and this may be clearly understood by a person of ordinary skill in the art from the accompanying drawings.

FIG. 5is a layout diagram of a mother substrate according to another exemplary embodiment of the present disclosure.

Referring toFIG. 5, first base patterns53aaccording to the present exemplary embodiment extends in the first direction X1within the first surrounding area SA1, and second base patterns54aextends in the second direction X2within the second surrounding area SA2. However, the first and second base patterns of the present exemplary embodiment are different from the first and second base patterns of the exemplary embodiments, according toFIGS. 1 to 4, in that an extension length of the first base pattern53ais less than the length in the first direction X1of the adjacent seal pattern40, and an extension length of the second base pattern54ais also less than the length in the second direction X2of the adjacent seal pattern40.

That is, the dummy spacers including the first and second base patterns53aand54amay not be located within the cross area CA, and may not be located in areas adjacent to one side and the other side in the first direction X1of the cross area CA and in areas adjacent to one side and the other side in the second direction X2. The areas in which the dummy spacers are not located may be approximately cross-shaped (+) areas.

In an exemplary embodiment, the maximum length l4in the first direction X1of the cross-shaped area is approximately 4 mm or more, or approximately 8 mm or more, and the maximum length l5in the second direction X2may be approximately 4 mm or more, or approximately 8 mm or more.

By setting the length l4in the first direction and the length l5in the second direction length of the area in which the dummy spacers are not disposed to be included within the aforementioned range, it may be possible to ensure uniformity in the area near the intersection between the scribing lines, it may also be possible to reduce the width of the first surrounding area SA1, the width of the second surrounding area SA2, and the area on the plane of the cross area CA, thereby improving the yield of the unit display panel manufactured from the mother substrate.

FIG. 6is a layout diagram of a mother substrate according to still another exemplary embodiment of the present disclosure.

Referring toFIG. 6, first base patterns55aaccording to the present disclosure may extend in the first direction X1in the first surrounding area SA1, but may be different from the first dummy spacer of the exemplary embodiments, according toFIGS. 1 to 4, in that the extension length of the first base pattern55amay be longer than the length in the first direction X1of the adjacent seal pattern40, and the average arrangement density of the dummy spacers in the cross area CA may be smaller than the average arrangement density of the dummy spacers in the entire surrounding area SA.

That is, some of the first dummy spacers including the first base pattern55amay be located in the cross area CA, but the first dummy spacer and the second dummy spacer may be spaced apart from each other without intersecting with each other. Unlike the configuration illustrated in the drawings, the first base pattern55ain the cross area CA located on the left side and the first base pattern in the cross area CA located on the right side may abut on each other rather than being spaced apart from each other.

The plurality of first dummy spacers extending in the first direction X1and the second dummy spacers extending in the second direction X2may be located in the surrounding area SA. Meanwhile, only some of the first dummy spacers extending in the first direction X1may be located in the cross area CA. Accordingly, a local decrease in arrangement density of the dummy spacers may occur in the cross area CA. Thus, the scribing lines may form the intersection in the cross area CA in which the arrangement density of the dummy spacers is lower than the periphery, and it may be possible to secure the uniformity of the scribing lines in the area near the intersection.

FIG. 7is a layout diagram of a mother substrate according to still another exemplary embodiment of the present disclosure.FIG. 8is an enlarged perspective view of the dummy spacer ofFIG. 7.

Referring toFIGS. 7 and 8, first and second dummy spacers57and58according to the present disclosure have a structure in which a plurality of pattern layers is laminated. The first and second dummy spacers57and58of the present disclosure may be different from the first and second dummy spacers of the exemplary embodiments according toFIGS. 1 to 4in that the first dummy spacer57may include a first base pattern57aas a linear pattern that is disposed on the first base substrate (not illustrated), may be located on the first surrounding area SA1and extend in the first direction X1, and a first support pattern57bas a linear pattern that may be disposed on the first base pattern57aand extends in the first direction X1.

In an exemplary embodiment, a width W7aof the first base pattern57amay be larger than a width W7bof the second support pattern57b. For example, the width W7Aof the first base pattern may be approximately 0.8 to 1.1 mm, and the width W7bof the first support pattern may be approximately 20 μm to 1.1 mm. In another exemplary embodiment, the width of the upper surface of the first base pattern may be substantially the same as the width of the lower surface of the first support pattern. In this case, the cross-sectional shape in the direction perpendicular to the extending direction of the first dummy spacers may be rectangular or trapezoidal shape. Meanwhile, the second dummy spacers58may have a shape and configuration that are substantially identical or similar to the first dummy spacers57.

When the first and second dummy spacers57and58have a structure in which a plurality of pattern layers are laminated but an upper pattern layer (a support pattern) is a linear pattern, sufficient scribing intensity may be imparted to the first and second dummy spacers. Thus, by forming the scribing lines to overlap the dummy spacer or to penetrate between the two dummy spacers contiguously spaced apart from each other in a scribing process to be described later, it is possible to form a uniform scribing line without a problem of bending of the substrate.

FIG. 9is a layout diagram of a mother substrate according to still another exemplary embodiment of the present disclosure.FIG. 10is an enlarged layout view of an area B inFIG. 9.

Referring toFIGS. 9 and 10, the dummy spacer according to the present embodiment is different from the dummy spacers of the exemplary embodiments according toFIGS. 1 to 4in that the former includes a plurality of first dummy spacers59as a dot-shaped protrusion-like pattern that is located in the first surrounding area SA1, spaced apart from each other in the first direction X1and the second direction X2and aligned in a matrix form, and second dummy spacers60as a dot-shaped protrusion-like pattern that is located in the second surrounding area SA2, spaced apart from each other in the first direction X1and the second direction X2and aligned in a matrix form.

Specifically, the first and second dummy spacers59and60may have a regular octagonal pyramid shape having a regular octagonal bottom surface, but are not limited thereto, and the first and second dummy spacers59and60may have a shape such a pillar, a cone, a pyramid and a hemisphere having a circular or polygonal bottom surface.

A width W9of the first dummy spacer59is approximately 20 to 150 μm, a separation distance d9between the adjacent first dummy spacers in the first direction X1may be approximately 100 μm to 1 mm, and a separation distance l6between the adjacent first dummy spacers in the second direction X2may be approximately 0.5 to 2.5 mm or approximately 2 mm. A width W10of the second dummy spacer60may be approximately 20 to 150 μm, and a separation distance d10between the adjacent second dummy spacers in the second direction X2may be approximately 100 μm to 1 mm.

Unlike the configuration illustrated inFIG. 9or the like, in some exemplary embodiments, the first dummy spacers may also be protrusion-like patterns which are aligned to be spaced apart in the first direction and the third direction. In this case, an angle formed between the first direction and the third direction may be approximately 30 to 75°. That is, the first dummy spacers may be not be aligned in a matrix, and the adjacent three dummy spacers may be aligned in the approximately triangular form.

Hereinafter, a method for cutting the mother substrate according to an exemplary embodiment of the present disclosure will be described.

FIGS. 11 to 14are diagrams for explaining a method for cutting a mother substrate according to an exemplary embodiment of the present disclosure. Specifically,FIG. 11is a layout diagram of a mother substrate in which the scribing lines are formed,FIG. 12is an enlarged layout diagram of an area C ofFIG. 12,FIG. 13is a cross-sectional view taken from the line XIII-XIII′ ofFIG. 12, andFIG. 14is a cross-sectional view taken from the line XIV-XIV′ ofFIG. 12.

The method of cutting the mother substrate according to an exemplary embodiment of the present disclosure may include the step of preparing the mother substrate1, the step of forming the first scribing line SL1extending in the first direction X1on one side of the second substrate20of the mother substrate1, and the step of forming the second scribing line SL2extending in the second direction X2on one side of the second substrate20of the mother substrate1.

First, referring toFIGS. 11 and 12, the mother substrate1according to the aforementioned exemplary embodiments ofFIGS. 1 to 4may be prepared. Since the arrangement, the shape and the like of the components included in the mother substrate1, has been described above withFIGS. 1 to 4, detailed descriptions thereof will not be provided.

Next, referring toFIGS. 11 to 13, the first scribing line SL1is formed on one side of the second substrate20. In this specification, the scribing line means a line on which cracks formed in a direction perpendicular to the substrate surface extend in one direction. The first scribing line SL1may be formed by extending in the first direction X1within the first surrounding area SA1of the mother substrate1.

In an exemplary embodiment, the first scribing line SL1may be formed by extending in the first direction X1to overlap any one of the three first dummy spacers51spaced apart in the second direction X2within the first surrounding area SA1.

In this case, although the surface of the second substrate20may receive a pressure in the vertical direction by a cutter900for forming the first scribing line SL1, because the first scribing line SL1overlaps the first dummy spacers51, the first dummy spacer51may support the second substrate20from the lower side of the first scribing line SL1, which makes it possible to alleviate bending of the second substrate20. Further, other first dummy spacers adjacent to the first dummy spacers overlapping the first scribing line SL1may also support the second substrate20on at least one side of the first scribing line SL1.

Next, referring toFIGS. 11, 12, and 14, a second scribing line SL2may be formed on one side of the second substrate20. The second scribing line SL2may extend in the second direction X2within the second surrounding area SA2of the mother substrate1, and may be formed such that an intersection cp intersecting with the first scribing line SL1is located within the cross area CA in which the first surrounding area SA1and the second surrounding area SA2intersect with each other.

In an exemplary embodiment, the second scribing line SL2may be formed by extending in the second direction X2to overlap the second dummy spacers52located in the second surrounding area SA2.

If the second scribing line SL2is formed to intersect with the already formed first scribing line SL1, as the cracks are formed in the other direction by the second scribing line in addition to the cracks formed in one direction by the first scribing line, cracks in another unintended direction may be caused in the area near the intersection. Furthermore, because the cracks are already formed by the first scribing line, the second substrate of the area near the intersection is vulnerable to the vertical bending. Accordingly, in the process of the second scribing line intersecting with the intersection, the substrate may be bent and a non-uniform second scribing line may be formed.

According to the mother substrate and the method of cutting the mother substrate according to an exemplary embodiment of the present disclosure, by locating the intersection cp between the first scribing line SL1and the second scribing line SL2within the cross area CA in which the first and second dummy spacers51and52are not located or the average arrangement density of the dummy spacers is a smaller than the entire surrounding area SA, it may be possible to ensure the uniformity of the scribing line in the area near the intersection cp. This may be due to the fact that, because of a change in the arrangement density of the dummy spacers in accordance with the direction of extension of the scribing lines, the vertical depth of the cracks of the scribing line change, but the present disclosure is not limited thereto.

In this case, the shortest separation distance l7between the intersection cp and the adjacent first dummy spacer51, and the shortest separation distance l8between the intersection cp and the adjacent second dummy spacer52may be approximately 2 mm or more and 4 mm or less, respectively. If the separation distances l7and l8between the intersection cp and the dummy spacer is 2 mm or more, it is possible to secure a sufficient arrangement density difference capable of minimizing the scribing line failure in the area near the intersection cp. Further, if the separation distance is 4 mm or less, the dummy spacers may support the substrate to alleviate bending of the substrate, and it is possible to improve the yield of the unit display panel manufacture from the mother substrate.

Although not illustrated in the drawings, after the step of forming the scribing line on one side of the second substrate20, a step of forming a plurality of scribing lines on one side of the first substrate10, and/or a step of applying an impact or load to the vicinity of the scribing line using a brake bar or the like may be further included.

FIGS. 15 to 17are diagrams for explaining a method of cutting a mother substrate according to another exemplary embodiment of the present disclosure. Specifically,FIG. 15is an enlarged layout diagram of the mother substrate in which the scribing line is formed,FIG. 16is a cross-sectional view taken from the line XVI-XVI′ ofFIG. 15, andFIG. 17is a cross-sectional view taken from the line XVII-XVII′ ofFIG. 15.

Referring toFIGS. 15 and 16, a first scribing line SL3is formed on one side of the second substrate20. The first scribing line SL3may be formed to extend in the first direction X1within the first surrounding area SA1of the mother substrate1.

In an exemplary embodiment, the first scribing line SL3may be formed to extend in the first direction X1to penetrate between any two of the three first dummy spacers spaced apart in the second direction X251within the first surrounding area SA1.

In this case, although the surface of the second substrate20may receive a pressure in the vertical direction by the cutter900for forming the first scribing line SL3, because the first scribing line SL3is formed to penetrate between the two adjacent first dummy spacers51, the two first dummy spacers51may support the second substrate20on both sides of the first scribing line SL3, which makes it possible to alleviate bending of the second substrate20.

Next, referring toFIGS. 15 and 17, the second scribing line SL4is formed on one side of the second substrate20. The second scribing line SL4may extend in the second direction X2within the second surrounding area SA2of the mother substrate1, and may be formed so that the intersection cp intersecting with the first scribing line SL3may be located within the cross area CA in which the first surrounding area SA1and the second surrounding area SA2intersect with each other.FIG. 17illustrates a case where the second scribing line SL4is formed to extended in the second direction X2to be directly adjacent to the second dummy spacer52, but the present disclosure is not limited thereto, and the second scribing line extends in the second direction X2to overlap the second dummy spacer, or when the plurality of second dummy spacers is disposed to be spaced apart in the first direction X1within the second surrounding area SA2, the second scribing line may be formed by extending in the second direction X2to penetrate between the two adjacent second dummy spacers.

In this case, the shortest separation distance l9between the intersection cp and the adjacent first dummy spacer51, and the shortest separation distance between the intersection cp and the adjacent second dummy spacer52may be approximately 2 mm or more and 4 mm or less. By setting the separation distance of the intersection cp and the first and second dummy spacers within the aforementioned range, it is possible to secure a sufficient arrangement density difference that is capable of minimizing the scribing line failure in the area near the intersection cp.

Hereinafter, a display panel according to an exemplary embodiment of the present disclosure manufactured by the method of cutting the mother substrate will be described.

FIG. 18is a layout diagram of a display panel according to an exemplary embodiment of the present disclosure.FIG. 19is a comparative cross-sectional view in which the cross-section of the non-display area NA1ofFIG. 18is compared to the cross-section of the pixel areas PX.

The display panel is a module that displays an image, and may be a liquid crystal display panel, an electrophoretic display panel, an organic light-emitting display panel, a plasma display panel or the like. Hereinafter, although the liquid crystal display panel will be described as an example of the display panel according to an exemplary embodiment of the present disclosure, the display panel is not limited to the liquid crystal display panel. Various display panels and display devices may be used, which may be clearly understood to those of ordinary skill in the art.

Referring toFIGS. 18 and 19, a display panel700according to an exemplary embodiment of the present disclosure includes a first substrate100, a second substrate200that includes a plurality of dummy spacers510and520and faces the first substrate100to be spaced apart from each other, a liquid crystal layer300that is interposed between the first substrate100and the second substrate200and includes a liquid crystal layer, and a seal pattern400that bonds both the substrates100and200and seals the liquid crystal layer300.

The first substrate100and the second substrate200may include a first edge E1that extends in the first direction X1, and a second edge E2that extends in the second direction X2and forms a single vertex V with the first edge E1. In the exemplary embodiment, the first substrate100and the second substrate200may be an approximately rectangular-shaped substrate that includes two long sides (e.g., a first edge) and two short sides (e.g., a second edge).

The display area DA, and the non-display area NA that surrounds the display area DA are defined in the display panel700. The display area DA may be an area in which an image is visually recognized, and the non-display area NA is an area in which no image is visible. The outer shell of the display area DA is surrounded by the non-display area NA.

The seal pattern400may be a sealing member for bonding the first substrate100and the second substrate200. The seal pattern400may have a shape that corresponds to the shape of the first substrate100and/or the second substrate200. In an exemplary embodiment, the seal pattern400may include a first seal pattern410which is located in the non-display area NA and extends in the first direction X1to be adjacent to the first edge E1and a second seal pattern420that is located in the non-display area NA and extends in the second direction X2to be adjacent to the second edge E2to a single vertex with the first seal pattern410. The seal pattern400may have a shape that surrounds the display area DA.

The display area DA includes a plurality of pixel areas PX. The plurality of pixel areas PX is disposed in the first direction X1and the second direction X2, and may be disposed in a substantially matrix form. Each pixel area PX may uniquely display one of the primary colors to achieve a color display. Examples of the primary colors may include red, green, and blue. Further, a switching element (not illustrated) and a pixel electrode230may be disposed in each pixel area PX.

The non-display area NA may be a light-shielding area. For example, the non-display area NA may be shielded by overlapping a front chassis (not illustrated) of a display device including the display panel700. In the second substrate200of the non-display area NA, a gate driver (not illustrated) that provides a gate signal to the switching element in the pixel area PX of the display area DA and a data driver (not illustrated) that provides a data signal may be disposed. The non-display area NA may include a first non-display area NA1between the first seal pattern410and the first edge E1, a second non-display area NA2between the second seal pattern420and the second edge E2, and a vertex area VA that abuts on the first non-display area NA1and the second non-display area NA2and is adjacent to the vertex V.

Hereinafter, the shape and arrangement of the components in the display panel700will be described in more detail.

The first substrate100may include a first base substrate101, a light-shielding member111, a color filter121, a first dummy spacer510, and a second dummy spacer520.

The first base substrate101may be a transparent insulating substrate. For example, the first base substrate101may be a silicon substrate, a glass substrate, or a plastic substrate. The light-shielding member111may be disposed on the first base substrate101. For example, the light-shielding member111may be a black matrix. The light-shielding member111may be disposed in a boundary area between the plurality of pixel areas PX. The color filter121may be disposed on the light-shielding member111to overlap each pixel area PX. The color filter121may be configured to include a substance through which light of a specific wavelength band selectively transmits. For example, the color filter121may selectively transmit any one light of red, green or blue, and the color filters that transmit light of different wavelength bands may be disposed for each of the adjacent pixel areas.

A plurality of dummy spacers510and520may be disposed in the non-display area NA of the first base substrate101. The plurality of dummy spacers may include one or more first dummy spacers510which are located in the first non-display area NA1and extend approximately in the first direction X1, and one or more second dummy spacers520which are located in the second non-display area NA2and extend approximately in the second direction X2. Although it is not illustrated in the drawings, a plurality of first dummy spacers may be disposed to be spaced apart in the second direction X2within the first non-display area NA1, or a plurality of second dummy spacers may be disposed to be spaced part in the first direction X1within the second non-display area NA2. In this case, the separation distance in the second direction X2between the first dummy spacers, and the separation distance in the first direction X1between the second dummy spacers may be approximately 0.5 to 2.5 mm or approximately 2 mm.

The average arrangement density of the dummy spacers510and520in the vertex area VA may be zero. That is, the dummy spacers may not be located in the vertex area VA. Specifically, the first dummy spacer510may extend in the first direction X1within the first non-display area NA1, and the second dummy spacer520may extend in the second direction X2within the second non-display area NA2, but the first dummy spacer510and the second dummy spacer520may be spaced apart from each other without intersecting with each other. The extension length of the first dummy spacer510may be substantially equal to the length of the first seal pattern410, and the extension length of the second dummy spacers520may be substantially equal to the length of the second seal pattern420.

In an exemplary embodiment, if the first dummy spacer510includes a first base pattern510awhich is disposed on the first base substrate101and extends in the first direction X1, and a first support pattern510bdisposed on the first base pattern510a, the first base pattern510amay be formed of the same material as the light-shielding member111through an integral process, and the first support pattern510bmay be formed of the same material as the color filter121through an integral process.

Specifically, after providing the light-shielding member material on the first base substrate101, by patterning the light-shielding member material, the first base pattern510aand the light-shielding member111pattern may be formed. The patterning may utilize a mask process, and may utilize other methods capable of forming a pattern. In this case, the thickness of the first pattern layer510amay be greater than the thickness of the light-shielding member111, but the thickness of the first pattern layer510amay be equal to or smaller than the thickness of the light-shielding member111. Further, after providing the color filter material thereon, by patterning the color filter material, the first support pattern510band the color filter121pattern may be formed. In this case, the thickness of the first support pattern510bmay be greater than the thickness of the color filter121, and the thickness of the first support pattern510bmay be equal to or smaller than the thickness of the color filter121.

However, the present disclosure is not limited thereto, and in some exemplary embodiments, the dummy spacers may be formed of the same material as a column spacer (not illustrated) in the pixel area PX, may further include other layers such as a protective layer/an insulating layer/an electrode layer, or may be a single layer structure.

The length l10in the first direction X1of the vertex area VA may approximately 2 mm or more or 4 mm or more, and the length l11in the second direction X2may be approximately 2 mm or more or 4 mm or more. Specifically, the vertex area VA may include an area in which the distance from the vertex V is less than 2 mm, that is, an area of an approximately quadrant shape having a radius of 2 mm.

Further, the shortest separation distance between the first dummy spacer510and the first seal pattern410may be approximately 2 to 3 μm or approximately 2.5 to 2.9 μm, and the shortest separation distance l12between the first dummy spacer510and the first edge E1may be approximately 1 mm or less. In another exemplary embodiment, the first dummy spacer and the first edge may be located to abut on each other. Further, the shortest separation distance between the second dummy spacers520and the second seal pattern420may be approximately 2 to 3 μm or approximately 2.5 to 2.9 μm, and the second dummy spacers520and the second edge E2may be located to abut on each other. In another exemplary embodiment, the second dummy spacer and the second edge may also be spaced apart from each other.

Each of the width of the first dummy spacer and the width of the second dummy spacer may be 0.8 to 1.1 mm. In an exemplary embodiment, the width of the first dummy spacer and the width of the second dummy spacer may be different from each other. For example, the width of the first dummy spacer may be approximately 1.1 mm, and the width of the second dummy spacer may be approximately 0.8 mm.

A plurality of dummy spacers510and520according to the present exemplary embodiment may be understood such that that when the mother substrate1including the dummy spacers described withFIGS. 1 to 4is cut by the method of cutting the mother substrate described above withFIG. 15or the like, and at least some of the dummy spacers are left on the display panel. Thus, the specific description of the shape and the size of the first and second dummy spacers510and520will not be provided.

Next, the second substrate200will be described. The second substrate200may include a second base substrate201, a gate line210, a data line220a switching element (not illustrated), and a pixel electrode230.

The second base substrate201may be the same transparent insulating substrate as the first base substrate101. The gate line210and the data line220may be disposed on the second base substrate201. The gate line210may extend approximately in the first direction X1, and may electrically connect a control terminal and a gate driver of each switching element within the plurality of pixel areas PX arranged along the first direction X1. The data line220may extend approximately in the second direction X2, and may electrically connect an input terminal and a data driver of each switching element within a plurality of pixel areas PX arranged along the second direction X2. Further, the output terminal of the switching element may be electrically connected to the pixel electrode230. The pixel electrodes230may be disposed in each pixel area PX, and each pixel electrode230may be in a state of being electrically insulated.

A liquid crystal layer300including a liquid crystal may be disposed between the first substrate100and the second substrate200inside the seal pattern400. In an exemplary embodiment, the pixel electrode230of the second substrate200may generate an electric field together with a common electrode (not illustrated) of the first substrate100, and may achieve the display color of the pixel area PX by controlling the alignment direction of the liquid crystal in the liquid crystal layer300.

FIG. 20is a layout diagram of a display panel according to another exemplary embodiment of the present disclosure.

Referring toFIG. 20, the first base pattern530aaccording to the present exemplary embodiment may extend in the first direction X1within the first non-display area NA1, and the second base pattern540amay extend in the second direction X2within the second non-display area NA2. However, the first base pattern530aand the second base pattern540aare different from the first and second base patterns of the exemplary embodiment according toFIG. 18in that the extension length of the first base pattern530ais less than the length of the adjacent first seal pattern410, and the extension length of the second base pattern540ais less than the length of the adjacent second seal pattern420.

That is, the dummy spacers including the first and second base patterns530aand540amay not be located within the vertex area VA, and may not be located in an area adjacent to the first direction X1of vertex area VA and an area adjacent to the second direction X2. The area in which the dummy spacers530and540are not located may have a shape of approximately “┌”, “┐”, “┘” or “└”. For example, a length l13in the first direction X1of the “┌” shape may be approximately 2 mm or more or approximately 4 mm or more, and a length l14in the second direction X2may be approximately 2 mm or more or approximately 4 mm or more.

The plurality of dummy spacers according to the present exemplary embodiment may be understood such that that when the mother substrate described withFIG. 5is cut, and at least some of the dummy spacers are left on the display panel.

FIG. 21is a layout diagram of a display panel according to still another exemplary embodiment of the present disclosure.

Referring toFIG. 21, a first base pattern550aaccording to the present exemplary embodiment extends in the first direction X1within the first non-display area NA1, but is different from the first dummy spacer of the exemplary embodiment according toFIG. 18in that the extension length of the first base pattern550ais longer than the length of the adjacent first seal pattern410, and the average arrangement density of the dummy spacers in the vertex area VA is smaller than the average arrangement density of the dummy spacers in the entire non-display area NA.

That is, some of the first dummy spacers including the first base pattern550amay be located in the vertex area VA, but the first dummy spacers and the second dummy spacers may be spaced apart from each other, without mutually intersecting.

Meanwhile, the plurality of dummy spacers according to the present exemplary embodiment may be understood such that that when the mother substrate described withFIG. 6is cut and at least some of the dummy spacers are left on the display panel.

FIG. 22is a layout diagram of a display panel according to still another exemplary embodiment of the present disclosure.

Referring toFIG. 22, each of first and second dummy spacers570and580according to the present exemplary embodiment may have a structure in which a plurality of pattern layers is laminated, and, for example, is different from the first and second dummy spacers of the exemplary embodiment according toFIG. 18in that the first dummy spacer570includes a first base pattern570aas a linear pattern which is disposed on the first base substrate (not illustrated), is located in the first non-display area NA1and extends in the first direction X1, and a first support pattern570bas a linear pattern which is disposed on the first base pattern570aand extends in the first direction X1.

In an exemplary embodiment, a width W70aof the first base pattern570amay be larger than a width W70bof the first support pattern570b. For example, the width W70aof the first base pattern may be approximately 0.8 to 1.1 mm, and the width W70bof the first support pattern may be approximately 20 μm to 1.1 mm. In another exemplary embodiment, the width of the upper surface of the first base pattern may also be substantially the same as the width of the lower surface of the first support pattern. For example, the cross-sectional shape in the direction perpendicular to the extending direction of the first dummy spacer may be a rectangular or trapezoidal shape. Meanwhile, the second dummy spacer580may have a shape and a configuration that are substantially identical or similar to those of the first dummy spacer570.

A plurality of dummy spacers570and580according to the present exemplary embodiment may be understood such that that when the mother substrate mentioned withFIG. 7is cut, and at least some of the dummy spacers are left on the display panel.

FIG. 23is a layout diagram of a display panel according to still another exemplary embodiment of the present disclosure.

Referring toFIG. 23, the dummy spacer according to the present exemplary embodiment is different from the dummy spacer of the exemplary embodiment according toFIG. 18in that the former includes a plurality of first dummy spacers590as a dot-shaped protrusion-like pattern that is located in the first non-display area NA1and spaced apart in the first direction X1, and a plurality of second dummy spacers600as a dot-shaped protrusion-like pattern that is located in the second non-display area NA2and spaced apart in the second direction X2.

Specifically, the first and second dummy spacers590and600may have an octagonal pyramid shape having a regular octagonal bottom surface, but are not limited thereto, and may have a shape such a pillar, a cone, a pyramid and a hemisphere having a circular or polygonal bottom surface.

Further, a width W90of the first dummy spacer590may be approximately 20 to 150 μm, a separation distance d90between the adjacent first dummy spacers in the first direction X1may be approximately 100 μm or more. Further, a width W100of the second dummy spacer600may be approximately 20 to 150 μm, and a separation distance d100between the adjacent second dummy spacers in the second direction X2may be approximately 100 μm or more.

Meanwhile, the plurality of dummy spacers590and600according to the present exemplary embodiment may be understood such that that when the mother substrate described withFIG. 9is cut, and at least some of the dummy spacers are left on the display panel.

Unlike the configuration illustrated inFIG. 23, in some exemplary embodiments, the first dummy spacers may be arranged in a matrix form while being spaced apart in the first direction X1and the second direction X2, and/or the second dummy spacers may also be arranged in a matrix form while being spaced apart in the first direction X1and the second direction X2. In this case, the separation distance between the adjacent first dummy spacers in the second direction X2may be approximately 0.5 to 2.5 mm or approximately 2 mm, and the separation distance between the adjacent second dummy spacers in the first direction X1may be approximately 0.5 to 2.5 mm or approximately 2 mm.

FIG. 24is a comparative view in which the cross-section of the non-display area of the display panel is compared to the cross-section of the pixel areas according to still another exemplary embodiment of the present disclosure.

Referring toFIG. 24, a first dummy spacer610and a second dummy spacer (not illustrated) according to the present exemplary embodiment are different from the first and second dummy spacers according to exemplary embodiment ofFIG. 19in that the first dummy spacer610and the second dummy spacers are disposed on the second base substrate201, and at least some of the first dummy spacer610does not overlap the first base substrate101.

In an exemplary embodiment, each of the first substrate (the upper substrate) and the second substrate (200′, the lower substrate) is a substrate of a rectangular shape including two long sides and two short sides, and the second substrate200′ may have an area on a plane that is larger than the first substrate.

Further, the first substrate may include a first base substrate101, and the second substrate200′ includes a second base substrate201, a gate line (not illustrated), a data line (not illustrated), a switching element (not illustrated), a color filter122, a light-shielding member112, and a pixel electrode230. Specifically, a color filter122may be disposed on the second base substrate201to overlap each pixel area PX, and the pixel electrode230may be disposed on the color filter122. Further, on the pixel electrode230, the light-shielding member112may be disposed at the boundary between the respective pixel areas PX.

If the first dummy spacer610includes a first base pattern610awhich is disposed on the second base substrate201and extends in the first direction X1, and a first support pattern610bdisposed on the first base pattern610a, the first base pattern610amay be formed of the same material as the color filter122through an integral process, and the first support pattern610bmay be formed of the same material as the light-shielding member112through an integral process. Further, a plurality of first dummy spacers610may be disposed to be spaced apart in the second direction X2between the first edge of the second substrate200′ and the first seal pattern, and at least some of the first dummy spacers may not overlap the first substrate.