Display apparatus and method of manufacturing the same

A method of manufacturing a display apparatus is provided as follows. A substrate having a display portion on an upper surface of the substrate is prepared. A protection film having an opening is attached to a lower surface of the substrate so that the protection film overlaps the display portion. A support film is attached to the lower surface so that the support film is disposed within the opening of the protection film. A driving circuit chip is attached to the upper surface so that the driving chip is spaced apart from the display portion and the opening. At least a part of the support film is removed. The substrate is bent along a longitudinal direction of the opening.

CROSS-REFERENCE TO RELATED APPLICATION

This application claims priority under 35 U.S.C. § 119 to Korean Patent Application No. 10-2016-0054692, filed on May 3, 2016, in the Korean Intellectual Property Office, the disclosure of which is incorporated by reference herein in its entirety.

TECHNICAL FIELD

The present invention relates to a display apparatus and a method of manufacturing the same.

DISCUSSION OF RELATED ART

Display apparatuses include a substrate divided into a display area and a non-display area. In the display area, gate lines and data lines are insulated from each other and pixel areas are defined by the gate lines and the data lines that cross one another. Thin film transistors (TFTs) and pixel electrodes provided in the in the pixel areas in the display area are electrically connected to one another. Various conductive layers such as wirings transmitting electrical signals to the display area are provided in the display area.

SUMMARY

According to an exemplary embodiment of the present invention, a method of manufacturing a display apparatus is provided as follows. A substrate having a display portion on an upper surface of the substrate is prepared. A protection film having an opening is attached to a lower surface of the substrate so that the protection film overlaps the display portion. A support film is attached to the lower surface so that the support film is disposed within the opening of the protection film. A driving circuit chip is attached to the upper surface so that the driving chip is spaced apart from the display portion and the opening. At least a part of the support film is removed. The substrate is bent along a longitudinal direction of the opening.

According to an exemplary embodiment of the present invention, a display apparatus is provided as follows. A substrate having a first area, a second area and a bending area between the first area and the second area is provided. The bending area is bent to have a curved lower surface. A display portion is disposed on an upper surface of the first area of the substrate. A protection film is disposed on a lower surface of the first area of the substrate and comprises a protection film base and a first adhesive layer. A second adhesive layer is disposed on the curved lower surface of the bending area of the substrate. A hardness of the second adhesive layer is higher than a hardness of the first adhesive layer. The protection film has an opening exposing the curved lower surface of the bending area of the substrate.

According to an exemplary embodiment of the present invention, a method of manufacturing a display apparatus is provided as follows. A substrate having a display portion on an upper surface of the substrate is prepared. A protection film having an opening is attached to a lower surface of the substrate so that the protection film overlaps the display portion. The protection film comprises a protection film base and a first adhesive layer. A support film is attached to the lower surface so that the support film is disposed within the opening of the protection film. The support film comprises a support film base and a second adhesive layer. A driving circuit chip is attached to the upper surface of the substrate so that the driving chip is spaced apart from the display portion and the opening. The support film is removed to expose the second adhesive layer so that the second adhesive layer is exposed through the opening of the protection film. The substrate is bent along a longitudinal direction of the opening so that the substrate has a curved surface overlapping the opening of the protection film. A first hardening process is performed on the exposed second adhesive layer.

DETAILED DESCRIPTION OF EXEMPLARY EMBODIMENTS

Exemplary embodiments of the present invention will be described below in detail with reference to the accompanying drawings. However, the present invention may be embodied in different forms and should not be construed as limited to the embodiments set forth herein. In the drawings, the thickness of layers and regions may be exaggerated for clarity. It will also be understood that when an element is referred to as being “on” another element or substrate, it may be directly on the other element or substrate, or intervening layers may also be present. It will also be understood that when an element is referred to as being “coupled to” or “connected to” another element, it may be directly coupled to or connected to the other element, or intervening elements may also be present. Like reference numerals may refer to the like elements throughout the specification and drawings.

Sizes of components in the drawings may be exaggerated for convenience of explanation. In other words, since sizes and thicknesses of components in the drawings are arbitrarily illustrated for convenience of explanation, the present invention is not limited thereto.

A display apparatus is an apparatus displaying images, for example, a liquid crystal display apparatus, an electrophoretic display apparatus, an organic light-emitting display apparatus, an inorganic light-emitting display apparatus, a field emission display apparatus, a surface-conduction electron-emitter display apparatus, a plasma display apparatus, a cathode ray display apparatus, or the like.

Hereinafter, the organic light-emitting display apparatus will be described as an example of a display apparatus according to an embodiment. However, the display apparatus according to the present inventive concept is not limited thereto and may include various types of display apparatus.

FIG. 1is a schematic perspective view partially showing a display apparatus according to an exemplary embodiment. The display apparatus includes a substrate100that are partially bent as shown inFIG. 1.

The substrate100of the display apparatus includes a bending area BA extending in a first direction (a+y direction). The bending area BA is located between a first area1A and a second area2A, in a second direction (a+x direction) crossing the first direction. The substrate100is bent with respect to a bending axis BAX extending in the first direction (the +y direction). The substrate100may include various materials having flexible or bendable characteristics, for example, a polymer resin such as polyethersulfone (PES), polyarylate (PAR), polyetherimide (PEI), polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polyphenylene sulfide (PPS), polyimide (PI), polycarbonate (PC), or cellulose acetate propionate (CAP). The substrate100may have a single-layer or multi-layer structure. The present invention is not limited thereto. For example, the substrate100may have variously modified structures such as a structure in which a resin layer including a resin and a barrier layer including an inorganic material such as silicon oxide or silicon nitride are alternately stacked, a structure further including an intermediate layer including amorphous silicon between the resin layer and the barrier layer, etc.

The bending area BA has a curved surface along the bending axis BAX. For example, the bending area BA has a curved lower surface along the bending axis BAX.

FIG. 2Ais a plan view illustrating a mother substrate of a display apparatus according to an exemplary embodiment of the present invention.FIGS. 2B, 2C, 2D, 3, 4A, 4B, 5, 6, 7, 8, 9A, 9B, 9C, 10, 11 and 12are schematic cross-sectional views for describing processes of manufacturing the display apparatus ofFIG. 1.

As shown inFIG. 2A, a plurality of display portions DU is formed on an upper surface of a mother substrate100M. Other processes may be performed before the plurality of display portions DU are formed. For example, a process of forming a buffer layer on an entire surface of the mother substrate100M, etc. may be performed. In addition, when the plurality of display portions DU is formed, electronic devices such as thin film transistors that may be electrically connected to display devices, etc. may also be formed. The electronic devices may also be formed in peripheral areas outside a display area in which display devices are positioned. When the plurality of display portions DU is formed, an encapsulation layer for protecting display devices may also be formed. A detailed configuration of the display portion DU will be described below.

When the plurality of display portions DU is formed as shown inFIG. 2A, the plurality of display portions DU may be formed on the mother substrate100M. The mother substrate100M is positioned on a carrier substrate CS as shown inFIG. 2B. The carrier substrate CS may include, for example, glass having a sufficient thickness to support the mother substrate100in the manufacturing process of the display apparatus ofFIG. 1. The carrier substrate CS may have a sufficient hardness to prevent the mother substrate100M including a flexible or bendable characteristic from being bent or deformed during the manufacturing process of the display apparatus ofFIG. 1. For example, the mother substrate100M may be formed on the carrier substrate CS having the sufficient hardness, and the plurality of display portions DU may be formed on the mother substrate100M.

After the display portions DU are formed as described above, the mother substrate100M is separated from the carrier substrate CS and as shown inFIG. 2C, a temporary protection film20is attached to a lower surface of the mother substrate100M from which the carrier substrate CS is separated in a z direction. The temporary protection film20may serve to prevent the lower surface of the mother substrate100M from being damaged during the manufacturing process of the display apparatus ofFIG. 1. The temporary protection film20may be removed during the manufacturing process as will be described below, and thus adhesion between the temporary protection film20and the mother substrate100M need not be strong.

After the temporary protection film20is attached to the lower surface of the mother substrate100M, the mother substrate100M and the temporary protection film20may be simultaneously cut. For example, the mother substrate100M and the temporary protection film20may be cut so that each of the plurality of display portions DU is separated from each other. In this case, the mother substrate100M is separated into a plurality of substrates100as shown inFIG. 2D. Each of the display portions DU may form a display panel and thus a plurality of display panels may be obtained through the cutting operation of the temporary protection film20and the substrate100M. The mother substrate100M and the temporary protection film20may be cut using various methods, for example, by irradiating a laser beam on the mother substrate100M and/or the temporary protection film20or by placing a cutting wheel in contact with the mother substrate100M and/or the temporary protection film20.

FIG. 3is a schematic cross-sectional view of a part of one of a plurality of display panels obtained through the cutting operation described above.

The first area1A of the substrate100includes a display area DA. The first area1A also includes a part of a non-display area outside the display area DA as shown inFIG. 3. The second area2A includes the non-display area. A display portion including a display device such as an organic light-emitting diode (OLED)300or a thin film transistor (TFT)210, etc. is in the first area1A. The display portion may include elements disposed within the display area DA and may also include elements belonging to the first area1A and disposed inside the non-display area. The substrate100includes the bending area BA between the first area1A and the second area2A. The substrate100may be bent in the bending area BA afterward and may have the shape illustrated inFIG. 1.

A plurality of pixels may be disposed in the display area DA of the display panel so that an image may be displayed. The display area DA may include devices such as the display device such as the OLED300, the TFT210, and a capacitor, etc. The display area DA may further include signal wirings such as a gate line for transferring a gate signal, a data line for transferring a data signal, a driving power line for supplying power, a common power line, etc. A pixel may be formed by electrically coupling the TFT210, the capacitor, the display device such as the OLED300, etc. that are connected to the gate line, the data line, and the driving power line so that an image may be displayed. The pixel may emit light with brightness corresponding to a driving current passing through the OLED300in response to the data signal according to driving power and common power supplied to the pixel. A plurality of pixels may be configured and disposed in various ways, such as a stripe layout, a PenTile layout, etc.

A configuration in which the OLED300is electrically connected to the TFT210may be construed as a configuration in which a pixel electrode310is electrically connected to the TFT210. A TFT (not shown) may also be disposed in a peripheral area outside the display area DA of the substrate100when needed. The TFT disposed in the peripheral area may be, for example, a part of a circuit portion for controlling an electric signal applied to the display area DA.

The TFT210may include a semiconductor layer211, a gate electrode213, a source electrode215a, and a drain electrode215b. The semiconductor layer211may include amorphous silicon, polycrystalline silicon, an oxide semiconductor, or an organic semiconductor material

The gate electrode213may be connected to a gate wiring (not shown) for sending on and off signals are to the TFT210. The gate electrode213may include a low-resistive conductive material. For example, the gate electrode213may be a single layer or a multilayer including a conductive material including, for example, molybdenum (Mo), aluminum (Al), copper (Cu), titanium (Ti) or a combination thereof.

Each of the source electrode215aand the drain electrode215bmay be a single layer or a multilayer including a conductive material having high conductivity. The source electrode215aand the drain electrode215bmay be respectively connected to a source area and a drain area of the semiconductor layer211. For example, each of the source electrode215aand the drain electrode215bmay be a single layer or a multilayer including a conductive material including, for example, Al, Cu, Ti or a combination thereof.

The source electrode215aand the drain electrode215bmay be connected to the semiconductor layer211via contact holes C1and C2. The contact holes C1and C2may be formed by simultaneously etching an interlayer insulating layer130and a gate insulating layer120.

The TFT210is a top gate type TFT in which the gate electrode213is disposed on an upper surface of the semiconductor layer211. The upper surface of the semiconductor layer211faces toward the OLED300. The present invention is not limited thereto. For example, the TFT210may be a bottom gate type TFT in which the gate electrode213is disposed on a bottom surface of the semiconductor layer211. The bottom surface of the semiconductor layer211faces toward the substrate100.

To obtain an insulating property between the semiconductor layer211and the gate electrode213, the gate insulating layer120may include an inorganic material such as silicon oxide, silicon nitride, silicon oxynitride or a combination thereof. The gate insulating layer120may be disposed between the semiconductor layer211and the gate electrode213. In addition, the interlayer insulating layer130including an inorganic material such as silicon oxide, silicon nitride, silicon oxynitride or a combination thereof may be disposed on the gate electrode213. The source electrode215aand the drain electrode215bmay be disposed on the interlayer insulating layer130. The insulating layer including the inorganic material described above may be formed by a chemical vapor deposition (CVD) process or an atomic layer deposition (ALD) process. The same applies to the embodiments described below and modifications thereof.

A buffer layer110including an inorganic material such as silicon oxide, silicon nitride, silicon oxynitride or a combination thereof may be disposed between the TFT210having the above structure and the substrate100. The buffer layer110may have a single-layer or multi-layer structure. The buffer layer110may increase smoothness of an upper surface of the substrate100. The buffer layer110may also serve to prevent or minimize infiltration of impurities from the substrate100, etc. into the semiconductor layer211of the TFT210.

A planarization layer140may be disposed on the TFT210. For example, when the OLED300is disposed on the TFT210as shown inFIG. 3, the planarization layer140may cover the TFT210, providing a planarized surface for manufacturing the OLED300on the TFT210. The planarization layer140may include an organic material, for example, benzocyclobutene (BCB) or hexamethyldisiloxane (HMDSO). The planarization layer140ofFIG. 3has a single-layered structure. The present invention is not limited thereto. For example, the planarization layer140may have variously modified structures such as a multi-layered structure.

The planarization layer140has an opening O1outside the display area DA so that a portion of the planarization layer140within the display area DA and a portion of the planarization layer140outside the display area DA are physically separated from each other through the opening O1. For example, the planarization layer140includes an inner planarization layer140A disposed within the display area DA and an outer planarization layer140B disposed outside the display area DA. The inner planarization layer140A and the outer planarization layer140B are separated from each other by the opening O1which is interposed between the inner and outer planarization layers140A and140B.

Thus, impurities from the outer planarization layer140B may be prevented from infiltrating the display area DA by the opening O1. The outer planarization layer140B is partially disposed with the second area2A.

In the display area DA of the substrate100, the OLED300including a pixel electrode310, an opposite electrode330, and an intermediate layer320disposed between the pixel electrode310and the opposite electrode330. The intermediate layer320may include an emission layer. The OLED300is positioned on the planarization layer140. The pixel electrode310may be electrically connected to the TFT210by contacting one of the source electrode215aand the drain electrode215bvia an opening formed in the inner planarization layer140A.

A pixel defining layer150may be disposed on the planarization layer140. The pixel defining layer150may have an opening O2corresponding to each of sub-pixels. For example, the opening O2of the pixel defining layer150exposes at least a center portion of the pixel electrode310to define a pixel. The pixel defining layer150may increase a distance between an edge of the pixel electrode310and the opposite electrode330above the pixel electrode310to prevent an electric arc from being generated from an end portion310E of the pixel electrode310. For example, the opening O2of the pixel defining layer150increases upwardly so that the distance between the end portion310E of the pixel electrode310and the opposite electrode330increase upwardly along the opposite electrode330. The pixel defining layer150may include, for example, an organic material such as PI or HMDSO.

The intermediate layer320of the OLED300may include a low-molecular weight material or a polymer material. When the intermediate layer320includes the low-molecular weight material, the intermediate layer320may have a single or multiple-layered structure including a hole injection layer (HIL), a hole transport layer (HTL), an emission layer (EML), an electron transport layer (ETL), and an electron injection layer (EIL) and may include various organic materials including copper phthalocyanine (CuPc), N,N′-Di(naphthalene-1-yl)-N,N′-diphenyl-benzidine (NPB), and tris-8-hydroxyquinoline aluminum (Alq3). The layers may be formed by using a vacuum deposition method.

When the intermediate layer320includes the polymer material, the intermediate layer320may have a structure including an HTL and an EML. In this regard, the HTL may include Poly(3,4-ethylenedioxythiphene):poly(4-styrenesulfonate) (PEDOT:PSS), and the EML may include a polymer material such as a poly-phenylenevinylene (PPV)-based material and a polyfluorene-based material. The intermediate layer320may be formed using a screen printing method, an inkjet printing method, a laser induced thermal imaging (LITI) method, or the like.

The present invention is not limited thereto. For example, the intermediate layer320may include a layer that is continuously formed on a plurality of pixel electrodes310or a layer that is patterned to correspond to each of the plurality of pixel electrodes310.

The opposite electrode330may be disposed on the display area DA, covering the display area DA. The opposite electrode330may be continuously formed in a plurality of OLEDs and thus may overlap the plurality of pixel electrodes310.

Since the OLED300may be easily damaged by external moisture or oxygen, an encapsulation layer400covers and protects the OLED300. The encapsulation layer400covers the display area DA and extend to the outside of the display area DA. The encapsulation layer400may include a first inorganic encapsulation layer410, an organic encapsulation layer420, and a second inorganic encapsulation430.

The first inorganic encapsulation layer410covers the opposite electrode330. The first inorganic encapsulation layer410may include silicon oxide, silicon nitride, silicon oxynitride or a combination thereof. Other layers such as a capping layer may be disposed between the first inorganic encapsulation layer410and the opposite electrode330. Since the first inorganic encapsulation layer410is conformally formed on the opposite electrode330, an upper surface of the first inorganic encapsulation layer410need not be flat as shown inFIG. 3. The organic encapsulation layer420covers the first inorganic encapsulation layer410. Unlike the first inorganic encapsulation layer410, an upper surface of the organic encapsulation layer420is flat. For example, the organic encapsulation layer420has a flat upper surface at a portion corresponding to the display area DA. For example, the organic encapsulation layer420fills the opening of the pixel defining layer150. The organic encapsulation layer420may include PET, PEN, PC, PI, polyethylene sulfonate, polyoxymethylene, PAR, or HMDSO.

The second inorganic encapsulation layer430is disposed on the organic encapsulating layer420, covering the organic encapsulation layer420. The second inorganic encapsulation layer430may include silicon oxide, silicon nitride, silicon oxynitride or a combination thereof. In an exemplary embodiment, an edge of the second inorganic encapsulation layer430outside the display area DA may contact the first inorganic encapsulation layer410so that the organic encapsulation layer420is not exposed to the outside.

Since the encapsulation layer400includes the first inorganic encapsulation layer410, the organic encapsulation layer420, and the second inorganic encapsulation layer430, a crack created in the encapsulation layer400need not propagate between the first inorganic encapsulation layer410and the organic encapsulation layer420or between the organic encapsulation layer420and the second inorganic encapsulation layer430. Accordingly, formation of a path through which external moisture or oxygen infiltrates into the display area DA may be prevented or minimized. The formation of the path may be formed when the crack is propagated through the encapsulation layer400.

A polarization plate520is attached to the encapsulation layer400by using an optically clear adhesive (OCA)510. The polarization plate520may reduce reflection of external light. For example, when the external light having passed through the polarization plate520is reflected from an upper surface of the opposite electrode330and then passes through the polarization plate520again, a phase of the reflected external light may be changed as the incoming external light passes through the polarization plate520twice. As a result, a phase of reflected external light may be different from the phase of the incoming external light entering the polarization plate520to the extent that a destructive interference occurs, and accordingly, the reflection of external light may be reduced to increase visibility. The OCA510and the polarization plate520may cover the opening O2of the planarization layer140. The present invention is not limited thereto. For example, the polarization plate520may be omitted or other configurations of the polarization plate520may be used. For example, if the polarization plate520is omitted, a black matrix and a color filter may serve to reduce the reflection of incoming external light.

A process of forming a touch electrode of various patterns for a touch screen function or a touch protection layer for protecting the touch electrode over the encapsulation layer400may be further performed.

The buffer layer110, the gate insulating layer120, and the interlayer insulating layer130, all of which include an inorganic insulating material, may be referred to as an inorganic insulating layer900. For example, the inorganic insulating layer may include silicon oxide or silicon nitride.FIG. 3, the inorganic insulating layer may have a flat upper surface which overlaps an organic material layer160that will be described below.

The display apparatus includes a first conductive layer215cdisposed on the inorganic insulating layer. The first conductive layer215cis disposed on the first area1A, the second area2A and the bending area BA. The first conductive layer215cmay serve as a wiring via which an electrical signal is transmitted to the display area DA. The first conductive layer215cmay be formed simultaneously with the source electrode215aor the drain electrode215bby using the same material as a material of the source electrode215aor the drain electrode215b.

The display apparatus includes the organic material layer160. The organic material layer160is disposed between the interlayer insulating layer130and the first conductive layer215cand may overlap with the bending area BA. The interlayer insulating layer130may include an inorganic insulating material. The organic material layer160may buffer or absorb a tensile stress created when the substrate100and the inorganic insulating layer900are bent through the bending area BA. The tensile stress transferred to the first conductive layer215cis minimized.

A stacked structure of the first conductive layer215c, the organic material layer160and the inorganic insulating layer900is formed on the bending area BA. For example, the first conductive layer215c, the organic material layer160and the inorganic insulating layer900are stacked on each other in the listed order to prevent a crack from propagating to OLED300, for example.

Without the organic material layer160, the first conductive layer215cis in contact with the inorganic insulating layer900. The tensile stress created when the substrate100is bent may be, without being reduced by the organic material layer160, applied to the first conductive layer215c. The inorganic insulating layer900has a higher hardness than a hardness of the organic material layer160, and accordingly, a crack is more likely to occur and propagate in the inorganic insulating layer900in the bending area BA. When a crack occurs in the inorganic insulating layer900, the crack may propagate into the first conductive layer215c. Accordingly, a defect such as a disconnection in the first conductive layer215cmay occur due to the crack in the first conductive layer215c.

According to an exemplary embodiment, such crack propagation into the first conductive layer215cdue to the bent of the substrate100may be prevented by using the organic material layer160interposed between the first conductive layer215cand the inorganic insulating layer900in the bending area BA. The organic material layer160may serve to buffer or absorb the tensile stress which is generated when the substrate100and the inorganic insulating layer900are bent. The tensile stress transferred to the first conductive layer215cmay be minimized by the organic material layer160. Accordingly, the occurrence of a crack in a portion of the first conductive layer215cthat corresponds to the bending area BA, wherein the first conductive layer215cis positioned on the organic material layer160, may be prevented or minimized.

The organic material layer160overlaps the bending area BA, covering a portion of a non-bending area. For example, the organic material layer160having a predetermined width ORW is formed on the inorganic insulating layer, covering the bending area BA. For example, the organic material layer160completely covers the bending area BA. In this case, the width ORW of the organic material layer160is greater than a width of the bending area BA. A thickness of a portion of the organic material layer160that overlaps with the bending area BA may be greater than a thickness of a non-overlapping area thereof. The thickness difference may be set considering the stress generated due to the bending. The organic material layer160may include PI, acryl, BCB, HMDSO or a combination thereof.

The display apparatus further includes second conductive layers213aand213band a third conductive layer215d. The third conductive layer215dmay be disposed in the same layer level as a layer of the first conductive layer215c. The second conductive layers213aand213bare disposed in the first area1A and the second area2A, respectively. The second conductive layers213aand213bare located at a different layer level from a layer of the first conductive layer215c. The second conductive layers213aand213bmay be electrically connected to the first conductive layer215cor the third conductive layer215d.

The second conductive layers213aand213bmay be located at the same layer level as a layer of the gate electrode213of the TFT210. For example, the second conductive layers213and213bare in contact with the gate insulating layer120and include the same material as a material of the gate electrode213. The first conductive layer215cmay contact the second conductive layer213adisposed in the first area1A via a contact hole formed in the interlayer insulating layer130. The third conductive layer215dis connected to the second conductive layer213blocated in the second area2A. The first conductive layer215cis connected to the second conductive layer213alocated in the first area1A.

The second conductive layer213alocated in the first area1A may be electrically connected to a TFT in the display area DA, and thus, the first conductive layer215cmay be electrically connected to the TFT in the display area DA via the second conductive layer213a. The second conductive layer213blocated in the second area2A may also be electrically connected to the TFT in the display area DA. As described above, the second conductive layers213aand213blocated outside the display area DA may be electrically connected to components located in the display area DA. The present invention is not limited thereto. The second conductive layers213aand213bmay extend toward the display area DA so as to be located at least partially in the display area DA.

The first conductive layer215cthat extends across the bending area BA may include a material having a elongation rate to the extent that the occurrence of a crack in the first conductive layer215cor a defect such as a disconnection in the first conductive layer215cmay be prevented.

The second conductive layers213aand213bmay include a material having a lower elongation rate than an elongation rate of the first conductive layer215cand electrical/physical characteristics different from electrical/physical characteristics of the first conductive layer215c. The second conductive layers213aand213bmay be formed in the first area1A and the second area2A, respectively. Accordingly, efficiency of transmitting an electrical signal in the display apparatus may increase, or a defect rate during the manufacturing processes may be reduced. For example, the second conductive layers213aand213bmay include molybdenum, and the first conductive layer215cmay include aluminum. The first conductive layer215cand the second conductive layers213aand213bmay have multi-layered structures.

The first conductive layer215cand the third conductive layer215dmay be simultaneously formed when the source electrode215aand the drain electrode215bare formed. The second conductive layers213aand213bmay be simultaneously formed when the gate electrode213is formed.

The temporary protection film20may be removed before a protection film175and a support film175S that will be described below are attached to a lower surface (−z direction) of the substrate100. The temporary protection film20may be configured as an adhesive and a temporary protection film base so that the temporary protection film base may be attached to the lower surface of the substrate100by using the adhesive. Thus, when the temporary protection film20is removed from the substrate100, the temporary protection film20may be wholly removed, and the adhesive may partially remain.

As shown inFIGS. 4A and 4B, the protection film175and the support film175S are prepared. The protection film175and the support film175S are supported by a lower film195. The protection film175and the support film175S may be attached to one surface of the substrate100. The support film175S may be attached to the bending area BA of the substrate100. According to an exemplary embodiment, the support film175S and the protection film175may be formed of different materials from each other.

FIGS. 4A and 4Billustrate a method of manufacturing the protection film175and the support film175S according to an exemplary embodiment. Referring toFIG. 4A, a preparatory protection film175pmay be formed on the lower film195. For example, the preparatory protection film175pmay be attached to the lower film195by using a third adhesive layer191. The preparatory protection film175pmay include a preparatory protection film base170pand a preparatory adhesive layer180p. A protection film (not shown) may be further formed on the preparatory adhesive layer180pto protect the preparatory adhesive layer180pduring a manufacturing procedure.

The preparatory protection film175pformed on the lower film195may be cut along a cutting line CL by using a blade BL and/or laser. As shown inFIG. 4B, the preparatory protection film175pis separated into the protection film175and the support film175S. Since the preparatory protection film175pis cut, the protection film175includes an opening175OP. The support film175S is disposed in the opening175OP. The support film175S is spaced apart from sidewalls of the opening175OP at predetermined gaps g1and g2. The gaps g1and g2may be determined by a width of the blade BL or a laser beam. For example, the gaps g1and g2may range from several micrometer (um) to several tens um. The support film175S may be attached to the bending area BA of the substrate100later. An area of the support film175S and an area of the opening175OP may be greater than an area of the bending area BA. For example, a width175OPW of the opening175OP is greater than a width of the bending area BA inFIG. 4.

The opening175OP may be extended along the y-axis in parallel to the bending axis BAX ofFIG. 1. For example, the opening175OP may be extended along the opening's longitudinal direction (y-axis, for example).

Since the preparatory protection film175pis cut, the protection film175includes a protection film base170and a first adhesive layer180, and the support film175S includes a support film base171and a second adhesive layer181. The support film175S may include the same material as a material of the protection film175. The protection film base170and the support film base171may be attached to a lower surface of the substrate100by using the first adhesive layer180and the second adhesive layer181, respectively.

The protection film base170and the support film base171may include PET (Polyethylene terephtahalate) or PI (Polymide), PMMA (Poly(methyl methacrylate)) or PC (Polycarbonate). According to an exemplary embodiment, the protection film base170and the support film base171may be formed of different materials. The first adhesive layer180and the second adhesive layer181may include a pressure sensitive adhesive (PSA). The PSA may include acrylics, silicon rubbers, butyl rubber, ethylene-vinyl acetate or styrene block copolymers. The first adhesive layer180and the second adhesive layer181may include different properties. For example, the first adhesive layer180and the second adhesive layer181may be different in adhesion, hardness, and/or colors, etc. To make the first adhesive layer180and the second adhesive layer181have different properties, a hardening process may be performed on the second adhesive layer181. The hardening process may use an ultraviolet (UV) rays, a laser beam or a heat treatment. Hereinafter, the hardening process performed on the second adhesive layer181may be referred to as a first hardening process.

The preparatory adhesive layer180pis formed and then separated into the first adhesive layer180and the second adhesive layer181. The present invention is not limited thereto. For example, the protection film base170and the support film base171may be formed on the lower film195and then the first adhesive layer180and the second adhesive layer181may be individually formed on the protection film base170and the support film base171, respectively. In this case, the first adhesive layer180and the second adhesive layer181may also have different properties.

The preparatory protection film175pis cut by the blade BL and is separated into the protection film175and the support film175S. The present invention is not limited to. For example, the preparatory protection film175pmay be cut by a laser or a combination of a blade cutting process and a laser cutting process. The preparatory protection film175pmay also be separated into the protection film175and the support film175S by using an etching process.

The protection film175and the support film175S are supported by the lower film195as shown inFIG. 5. In this case, the temporary protection film20attached to the lower surface of the substrate100of the display panel may be removed and then the protection film175and the support film175S may be attached. The lower surface of the substrate100is a surface in an opposite direction (a −z direction) to a direction (a +z direction) in which a display portion is to be positioned.

The protection film175and the support film175S are attached to the lower surface of the substrate100. The lower film195is attached to the protection film175and the support film175S using the third adhesive layer191. An attaching process described above may be performed by pressing a lower surface of the lower film195in a direction (+z direction) of an upper surface of the substrate100by using a roller, etc. The protection film175and the support film175S may be respectively attached to the lower surface of the substrate100by the first adhesive layer180and the second adhesive layer181. As described above, the support film175S is attached to the bending area BA of the substrate100.

InFIG. 6, the protection film175and the support film175S are respectively attached to the lower surface of the substrate100via the lower film195. A driving circuit chip810and/or a printed circuit board (PCB)820may be attached to the second area2A. The driving circuit chip810and/or the PCB820may be connected to the first conductive layer215c, the second conductive layer213b, and the third conductive layer215dthat are disposed in the second area2A and/or other conductive layers electrically connected to the first conductive layer215c, the second conductive layer213b, and the third conductive layer215d. The driving circuit chip810and/or the PCB820may provide driving signals to the display area DA through the above conductive layers. The driving signals may represent various signals driving the display apparatus such as a driving voltage, a gate signal, a data signal, etc. The driving circuit chip810is mounted in an end of the first conductive layer215c, and the PCB820is connected to an edge of the third conductive layer215d. The present invention is not limited thereto. For example, the driving circuit chip810and the PCB820may be connected to the second conductive layer213bor other conductive layers.

The driving circuit chip810and/or the PCB820may be attached to the above conductive layers by applying pressure and heat thereto by a pressure bonding apparatus PB. In this case, an anisotropic conducting film (ACF) may be used as an adhesive for the driving circuit chip810and/or the PCB820. The ACF may include an adhesive agent cured by heat. The AFC may be configured as a double-sided tape including fine conducting particles containing the adhesive agent. The fine conducting particles are mixed and distributed in the double-sided tape. Thus, if pressure is applied to upper and lower portions of the ACF, the fine conducting particles may burst and the adhesive agent in the fine conducting particles may cover the double-sided tape so that the ACF may simultaneously have conductive and adhesive properties.

The support film175S may serve to minimize deformation of the substrate100during a process of bonding the driving circuit chip810and/or the PCB820. During the bonding process, a heat treatment may be applied so that without the support film175S, the substrate100may droop in the direction (−z direction) in which the display portion is not disposed. If the drooped substrate100is hardened with the temperature cooled down, the drooped substrate100may have a curvature to the extent that a crack occurs in the bending area BA in a bending process later. If a bending protection layer (BPL)600that will be described below is formed on the drooped substrate100, the thickness of the BPL600may be ununiform, and thus the radius of curvature need not be uniformly formed and a crack occurs in the bending area BA when the substrate100is bent.

The support film175S is attached to the lower surface of the substrate100in the bending area BA, thereby preventing or minimizing drooping of the substrate100in the process of bonding the driving circuit chip810and/or the PCB820.

Referring toFIG. 7, the BPL600is formed on an upper surface of the substrate100, overlapping the bending area BA. The BPL600may be formed after the process of bonding the driving circuit chip810and/or the PCB820is performed. The present invention is not limited thereto. For example, the BPL600may be formed before the process of bonding the driving circuit chip810and/or the PCB820is performed.

The BPL600is formed on a portion of the first conductive layer215c. The portion of the first conductive layer215coverlaps the bending area BA. When the stack structure ofFIG. 7is bent, there is a stress neutral plane in the stack structure. If the BPL600does not exist, as will be described below, an excessive tensile stress may be applied, when the substrate100is bent, to the first conductive layer215cin the bending area BA because the first conductive layer215cneed not be in the stress neutral plane.

The location of the stress neutral plane may be adjusted to be around the first conductive layer215cby forming the BPL600. For example, the thickness and modulus of the BPL600may be controlled so that the location of the stress neutral plane in the stack structure including the substrate100, the first conductive layer215c, the BPL600, etc. may be around the first conductive layer215c. Accordingly, a tensile stress applied to the first conductive layer215cmay be minimized, thereby protecting a bending portion in the bending area BA.

The BPL600is in contact with the polarization plate520without covering the polarization plate520as shown inFIG. 7. The present invention is not limited thereto. For example, an end of the BPL600may partially cover an upper surface at an edge of the polarization plate520. For example, the end of the BPL600in the direction (the −x direction) toward the display area DA need not contact the polarization plate520and/or a light-transmitting adhesive510.

The BPL600may be formed by applying and hardening a liquid phase material or a paste-type material. The volume of the BPL600may be reduced during a hardening process. The BPL600is in contact with the polarization plate520and/or the light-transmitting adhesive510to the extent that the BPL600is fixed at the boundary between the BPL600and the polarization plate520, and thus, the volume reduction occurs in the remaining portion of the BPL600which is not in contact with the polarization plate520. As a result, a thickness of the portion of the BPL600in the direction (−x direction) toward the display area DA may be greater than thicknesses of the remaining portions of the BPL600.

Referring toFIGS. 8 and 9, the lower film195and the support film175S attached to the lower surface of the substrate100are removed. For example, the lower film195may be separated and removed from the protection film175and the support film175S and then the support film base171that is a part of the support film175S is removed.

The support base film171may be removed by using an isolation tape. In this case, an adhesive force of the isolation tape may be higher than an adhesive force of the second adhesive layer181to the extent that the support film base171may be more strongly combined with the isolation tape than the support film base171is attached to the substrate100by using the second adhesive layer181. Accordingly, when the isolation tape is pulled off from the support film base171, the support film base171may be separated from the substrate100. In this case, the second adhesive layer181remains on the lower surface of the substrate100. The present invention is not limited thereto. For example, at least a part of the second adhesive layer181may be separated from the support film base171, remaining on the lower surface of the substrate100. in this case, only a part of the second adhesive layer181may be detached along with the support film base171.

FIGS. 9B and 9Care enlarged views of part A ofFIG. 9Aand illustrate various shapes of an inner portion of the opening175OP of the protection film175. Referring toFIG. 9B, a thickness t2of at least a part of the second adhesive layer181is smaller than a thickness t1of the first adhesive layer180. The thickness difference may be made when only a part of the second adhesive layer181is detached in a thickness direction when the support film base171is detached or a thickness of the second adhesive layer181may be smaller than that of the first adhesive layer180before the support film170sis attached to a lower surface of the substrate100.

Referring toFIG. 9C, the second adhesive layer181does not remain in an inner portion of the opening1750OP of the protection film175. In this case, the second adhesive layer181and the support film base171completely removed. In an exemplary embodiment, the second adhesive layer181need not be formed before the support film170S is attached to the lower surface of the substrate100.

As described with reference toFIGS. 8 and 9A, the lower film195and the support film base171are sequentially removed. The present invention is not limited thereto. For example, the lower film195and the support film base171may be simultaneously removed. In this case, adhesion of the second adhesive layer181may be weaker than adhesion of the first adhesive layer180and adhesion of the third adhesive layer191. The second adhesive layer181may include a material having a different adhesion characteristic from a material of the first adhesive layer180. The second adhesive layer181may include the same material as a material of the first adhesive layer180and may have a different adhesion characteristic from adhesion characteristic of the first adhesive layer180by performing later a process of weakening the adhesion of the second adhesive layer181. The adhesion of the first adhesive layer180may be the same as or stronger than that of the third adhesive layer191.

For example, the adhesion of the second adhesive layer181may be weaker than the adhesion of the first adhesive layer180by irradiating ultraviolet (UV) rays on the second adhesive layer181. For reference, the adhesion of a PSA may be generally weakened when UV rays are irradiated thereon. The amplitude of the UV rays irradiated to the second adhesive layer181so as to weaken the adhesion of the second adhesive layer181may be less than the amplitude of the UV rays irradiated to the first adhesive layer180so as to increase hardness of a specific part of the second adhesive layer181, which will be described later.

As described above, when the adhesion of the second adhesive layer181is weaker than the adhesion of the third adhesive layer191, the support film base171may be removed simultaneously with the lower film195using an isolation tape. The present invention is not limited thereto. For example, the support film base171may be removed by irradiating a laser beam or by an etching process.

After the lower film195and the support film base171are removed, the substrate100, etc. may be bent in the bending area BA to have a resulting structure as shown inFIG. 1.

Hereinafter, it will be described that the second adhesive layer181remains in the opening175OP of the protection film175for the convenience of description. The description that will be made below may be also applicable when as described with reference toFIGS. 9B and 9C, the second adhesive layer181is partially disposed or is not disposed.

FIG. 10is a schematic cross-sectional view of the substrate100and the protection film175of the display apparatus ofFIG. 1. The substrate100is in the status of being bent in the bending area BA. The protection film base170of the protection film175may have rigidity sufficient to protect a lower surface of the substrate100in the process of bending the substrate100. However, if the protection film has the rigidity sufficient to protect the lower surface of the substrate100, the protection film base170, if not having the opening175OP, may be separated from the substrate100in the process of bending the substrate100. The opening175OP overlapping the bending area BA may prevent the protection film base170from being separated from the substrate100in the process of bending the substrate100.

The bending area BA has a curved surface along a longitudinal direction of the opening175OP. For example, the bending area BA has a lower curved surface along the longitudinal direction of the opening175OP.

The second adhesive layer181is disposed in the opening175OP, spaced apart from the first adhesive layer180by the predetermined gaps g1and g2. For example, the second adhesive layer181overlaps the bending area BA.

Hardness of the second adhesive layer181may be adjusted after the second adhesive layer181is bent in the process of bending the substrate100. The hardness of the second adhesive layer181may be adjusted by using various methods. For example, an UV ray or a laser beam may be irradiated to the second adhesive layer181or a heat treatment process may be applied to the second adhesive layer181. For reference, a general PSA has increased hardness when an UV ray or a laser beam is irradiated or heat is applied thereto. Accordingly, the hardness of the second adhesive layer181may be greater than the hardness of the first adhesive layer180. The second adhesive layer181may have the increased hardness to the extent that the substrate100bent after the process of bending the substrate100keeps the bent shape ofFIG. 10. For example, the second adhesive layer181may have the increased hardness sufficient to prevent or minimize returning of the substrate100to a state before being bent. For example, the second adhesive layer has a hardness to the extent that the substrate is prevented from losing a curved surface formed after the bending area BA is bent.

Since the UV ray or the laser beam is irradiated to the second adhesive layer181, adhesion and/or a color of the second adhesive layer181may also be changed differently from adhesion and/or a color of the first adhesive layer180.

InFIG. 11, a cushion layer190is formed in an area between the first area1A and the second area2A. For example, the cushion layer190is in contact with a part of the first area1A and a part of the second area2A of the protection film base170. The cushion layer190fills a space between the first area1A and the second area2A to support a display panel and buffer an external shock applied to the substrate100. The cushion layer190may include an elastic material to the extent that the cushion layer190protects the substrate100from the external shock by absorbing the external shock. According to an exemplary embodiment, the cushion layer190may be formed of polyurethane or other polymer to absorb the external shock.

InFIG. 12, a filler193is formed in the opening175OP of the protection film175. The filler193may be formed by injecting and hardening a liquid phase material or a paste-type material into the opening175OP of the protection film175. The filler193may be hardened by irradiating an UV ray or applying a heat treatment thereto. The filler193may include a material having adhesion. Since the filler193is hardened by irradiating the UV ray or applying heat, deformation of the substrate100by restoring force that restores the substrate100to a state before being bent may be effectively prevented or minimized in collaboration with the second adhesive layer181. If the second adhesive layer181does not exist in the opening175OP, the filler193may prevent or minimize the returning of the substrate100to a state before being bent. Hereinafter, the hardening process performed on the filler may be referred to as a second hardening process.

The filler193is injected after the substrate100, etc. is bent inFIG. 12. The present invention is not limited thereto. For example, as shown inFIGS. 13A through 13C, after the support film base171is removed and then a liquid phase or paste-type filler193is injected (FIG. 13A) and before the liquid phase or paste-type filler193is hardened, the substrate100, etc. may be bent as shown inFIG. 13B. Thereafter, the liquid phase filler193may be hardened to form the filler193by a second hardening process including irradiating an UV ray or applying heat to the liquid phase filler193. For example, as shown inFIG. 13C, the cushion layer190may be disposed and then the liquid phase filler193may be hardened. According to an exemplary embodiment, the liquid phase filler193may be formed of acryl-based polymer. The liquid pahse filler193may also include a hardner.

FIGS. 14A through 14Dare schematic cross-sectional views of a shape of the support film175S according to an exemplary embodiment. Referring toFIG. 14A, a surface of the support film175S attached to the substrate100may have a convex shape in a direction (+z direction) of an upper surface of the substrate100. For example, an upper surface of the support film175S has the convex shape.

Since the upper surface of the175S has the convex shape, an inorganic insulating layer and a conductive layer formed in the bending area BA of the substrate100may have convex shapes before the substrate100is bent, thereby minimizing cracks that may occur when the substrate100is bent.

In some embodiments, the upper surface of the support film175S may have a uniform radius of curvature with respect to a bending axis. In some embodiments, a first radius of curvature of the upper surface of the support film175S with respect to the bending axis may be greater than a second radius of curvature of the substrate100. Accordingly, after the substrate100is bent, the bending area BA may have a curved shape with the second radius of curvature.

As shown inFIG. 14B, the support film175S may include a different material from a material of the protection film175. In this case, after the opening175OP of the protection film175is formed, the support film175S may be inserted into the opening175OP.

Various modifications may be made such as the support film175S may be configured as only the support film base171as shown inFIG. 14C, and the second adhesive layer181of the support film175S may have a smaller thickness than that of the first adhesive layer180of the protection film175as shown inFIG. 14D. In this case, the support film base171may include the same material as or a different material from a material of the protection film base170.

InFIGS. 14B through 14D, the upper surface of the support film175S is flat. The present invention is not limited thereto. For example, the upper surface of the support film175S may have the convex shape as shown inFIG. 14A.

A case where the protection film175includes the opening175OP corresponding to the bending area BA and is attached to a lower surface of the substrate100in the first area1A and the second area2A is described above but the inventive concept is not limited thereto. For example, the protection film175may correspond to only at least a part of the first area1A of the substrate100. For example, as shown inFIG. 15Athat is a schematic cross-sectional view of a part of a display apparatus according to an exemplary embodiment, the protection film175is not be formed in the second area2A of the substrate100.

For example, as shown inFIG. 15B, the protection film175is formed on the first area1A, and the support film175S is formed on the bending area BA and the second area2A. The support film base171may be removed before the substrate100, etc. is bent, and then the substrate100, etc. may be bent in the bending area BA. Accordingly, the structure shown inFIG. 15Amay be obtained after the substrate100is bent. In this case, the second adhesive layer181is spaced apart from the first adhesive layer180by the predetermined gap g1and disposed in the bending area BA and the second area2A. As described above, the second adhesive layer181may have a different property from a property of the first adhesive layer180. For example, the second adhesive layer181may be different from the first adhesive layer180in adhesion, hardness, or colors, etc. In the display apparatus according to the present embodiment, the filler193and/or the cushion layer190described above may also be formed.

The substrate100is bent along a bending axis so that a part of a lower surface of the first area1A and at least a part of a lower surface of the second area2A face each other inFIGS. 1, 10 through 12, 13B, 13C, and 15. The present invention is not limited thereto. For example, the substrate100may be bent to the extent that the lower surface of the second area2A need not face the lower surface of the first area1A. In this case, a curvature of the bending area BA is smaller than the curvature of the bending area as shown inFIGS. 1, 10 through 12, 13B, 13C, and 15or an area of the bending area BA may be small.

InFIG. 16, the BPL600may extend to an end of the substrate100of a display apparatus, covering the first conductive layer215c, the second conductive layer213b, and/or other conductive layers electrically connected to the first and second conductive layers215cand213bwhich are not covered at least partially by the interlayer insulating layer130or the planarization layer140, etc. but may be electrically connected to the driving circuit chip810or the PCB820, etc. The electrically connected portions covered by the BPL600may be protected from impurities such as external moisture. In this case, the BPL600may serve as a protection layer of the electrically connected portions. The BPL600also covers the driving circuit chip810and a part of the PCB820. The present invention is not limited thereto. For example, the BPL600may cover the driving circuit chip810without covering the PCB820. According to an exemplary embodiment, the BPL600may be formed of acryl-based polymer.

FIG. 17Ais a schematic cross-sectional view partially showing a display apparatus according to an exemplary embodiment.FIG. 17Ais a schematic cross-sectional view of a periphery of the bending area BA. The inorganic insulating layer900including the buffer layer110, the gate insulating layer120and the interlayer insulating layer130may include a groove800at a location corresponding to the bending area BA.

The buffer layer110is continuously formed throughout the first area1A, the bending area BA, and the second area2A. The gate insulating layer120has an opening120acorresponding to the bending area BA. The interlayer insulating layer130has an opening130acorresponding to the bending area BA. Accordingly, the inorganic insulating layer900including the buffer layer110, the gate insulating layer120, and the interlayer insulating layer130have a groove800formed of the openings120aand130a. The groove800is formed on the bending area BA so that the groove800overlaps the bending area BA.

The inorganic insulating layer900may include a groove of a different type. For example, an upper surface of the buffer layer110(in +z direction) may be partially removed, or a lower surface of the gate insulating layer120(in −z direction) may remain. With reference toFIGS. 17A and 3, the groove900may be formed simultaneously with a patterning process for forming the contact holes C1and C2for connecting the source electrode215aand the drain electrode215bof the TFT210to the semiconductor layer211.

Referring back toFIG. 17A, an area of the groove800may be greater than an area of the bending area BA. In this case, a width GW of the groove800is shown to be greater than a width of the bending area BA inFIG. 17A. In this regard, the area of the groove may be defined as an area of the opening having the smallest area, between the openings120aand130ain the gate insulating layer120and the interlayer insulating layer130. For example, the area of the groove800is defined by the area of the opening120ain the gate insulating layer120. In the display apparatus according to the present embodiment, the organic material layer160may be disposed between the inorganic insulating layer and the first conductive layer215cand may fill the groove800.

AlthoughFIG. 17Ashows that the display apparatus is not bent for convenience of description, the display apparatus according to an exemplary embodiment may be in a state in which the substrate100, etc. is bent in the bending area BA as shown inFIG. 1. During manufacturing processes, the display apparatus may be manufactured in a state in which the substrate100is flat, and then, the substrate100, etc. may be bent in the bending area BA so that the display apparatus may have the shape as shown inFIG. 1. In this regard, a tensile stress may be applied to the first conductive layer215cwhile the substrate100, etc. is bent at the bending area BA, but in the display apparatus according to an exemplary embodiment, the inorganic insulating layer900may have the groove800in the bending area BA, and a portion of the first conductive layer215cthat corresponds to the bending area BA may be located on the organic material layer160at least partially filling the groove in the inorganic insulating layer900. Accordingly, the occurrence of cracks in the portion of the first conductive layer215cthat corresponds to the bending area BA may be prevented or minimized. The first conductive layer215cis located on the organic material layer160.

Since the inorganic insulating layer900has a higher hardness than the organic material layer160, the inorganic insulating layer900in the bending area BA is highly likely to have cracks. When the inorganic insulating layer cracks, there is a high possibility that the cracks may spread to the first conductive layer215c. Although the organic material layer160may block the cracks from spreading, the groove formed in the inorganic insulating layer may further reduce the possibility of the inorganic insulating layer having cracks. Therefore, a minimum amount of tensile stress may concentrate on the first conductive layer215c.

FIG. 17Bis a schematic cross-sectional view partially showing a display apparatus according to an exemplary embodiment. Referring toFIG. 17B, an inorganic insulating layer900includes an opening800′ at a location corresponding to the bending area BA. For example, the opening800′ overlap the bending area BA or the second adhesive layer181.

Referring toFIG. 17B, the buffer layer110, the gate insulating layer120, and the interlayer insulating layer130may respectively have the openings110a,120a, and130acorresponding to the bending area BA. That an opening800′ overlaps the bending area BA or the second adhesive layer181. In this regard, an area of the opening may be greater than that of the bending area BA. For example, the width GW of the opening is shown to be greater than a width of the bending area BA inFIG. 17B. In this regard, the area of the opening may be defined as an area of the opening having the smallest area, between the openings110a,120a, and130ain the gate insulating layer120and the interlayer insulating layer130. For example, inFIG. 17B, the area of the opening is defined by the area of the opening110ain the buffer layer110.

When a display portion described above is formed, the organic material layer160filling at least a part of the opening800′ of the inorganic insulating layer900may be formed. The inorganic insulating layer900has the opening800′ in the bending area BA, and a portion of the first conductive layer215cthat corresponds to the bending area BA may be located on the organic material layer160at least partially filling the opening800′ in the inorganic insulating layer900. Since the inorganic insulating layer900has the opening800′ in the bending area BA, there is a very low possibility that cracks occur in the inorganic insulating layer900. Due to a characteristic of the organic material layer160including an organic material, there is a low possibility that cracks occur in the organic material layer160. Thus, the occurrence of cracks in the portion of the first conductive layer215cthat corresponds to the bending area BA, wherein the first conductive layer215cis located on the organic material layer160, may be prevented or minimized. Since the organic material layer160has a lower hardness than the inorganic insulating layer900, the organic material layer160may buffer a tensile stress generated by bending the substrate100, etc., thereby effectively minimizing an amount of the tensile stress that concentrates on the first conductive layer215c.

FIG. 17Cis a schematic cross-sectional view partially showing a display apparatus according to an exemplary embodiment. Referring toFIG. 17C, the organic material layer160may have a corrugated surface160sat least partially in an upper surface thereof (+z direction). Since the organic material layer160includes the corrugated surface160s, the first conductive layer215clocated on the organic material layer160may have an upper surface and/or a lower surface having a shape corresponding to the corrugated surface160sof the organic material layer160.

As described above, since tensile stress may be applied to the first conductive layer215cwhen the substrate100, etc. is bent at the bending area BA during a manufacturing process, the upper surface and/or the lower surface of the first conductive layer215cmay have the shape corresponding to the corrugated surface160sof the organic material layer160, and thus an amount of the tensile stress applied to the first conductive layer215cmay be minimized. That is, the tensile stress which may be generated during a bending process may be reduced via deformation of the shape of the organic material layer160having a smaller hardness. In this regard, the first conductive layer215chaving a corrugated shape at least before the bending process is performed may be deformed with the organic material layer160in the bending process. Accordingly, the occurrence of a defect such as a disconnection in the first conductive layer215cmay be prevented.

The corrugated surface160smay be formed at least partially in the upper surface of the organic material layer160(+z direction), and thus, a surface area of the upper surface of the organic material layer160and a surface area of the upper and lower surfaces of the first conductive layer215cin a first opening may be increased. Increased surface areas of the upper surface of the organic material layer160and the upper and lower surfaces of the first conductive layer215cincrease a deformation margin so that the tensile stress caused due to the bending of the substrate100may be reduced.

For reference, since the first conductive layer215cis located over the organic material layer160, the lower surface of the first conductive layer215cmay have a shape corresponding to the corrugated surface160sof the organic material layer160. However, the present invention is not limited thereto. For example, the upper surface of the first conductive layer215cmay have a corrugate surface which does not match with the corrugated surface160sof the organic material layer160.

The description may be applied to an example in which an inorganic insulating layer having an corrugated surface includes an opening, an example in which the inorganic insulating layer has a flat upper surface at an area overlapping the organic material layer160, and an example in which the inorganic insulating layer has a groove.

In a display apparatus according to the above-described embodiments, structures, manufacturing methods, and features that are described in the above-described embodiments regarding the protection film175including the protection film base170and the first adhesive layer180and the second adhesive layer181may be applied.

When the organic material layer160is not formed, structures, manufacturing methods, and features that are described in the above-described embodiments regarding the protection film175including the protection film base170and the first adhesive layer180and the second adhesive layer181may also be applied.

In one or more embodiments, a plurality of display panels are formed by forming a plurality of display portions on a mother substrate and simultaneously cutting the mother substrate and a temporary protection film but one or more embodiments are not limited thereto. For example, the plurality of display panels may not be simultaneously formed but a substrate including a material having a flexible or bendable characteristic may be formed over a carrier substrate and one display portion may be formed on the substrate. Thereafter, various modifications may be made such as the carrier substrate may be removed from the substrate and a protection film and a support film may be attached to a lower surface of the substrate.