DISPLAY PANEL AND MANUFACTURING METHOD OF THE SAME

A display panel includes a pixel defining layer including first and second light-emitting openings, a conductive partition disposed on the pixel defining layer and including first and second partition openings and respectively corresponding to the first and second light-emitting openings, a first light-emitting element disposed in the first partition opening, a second light-emitting element disposed in the second partition opening, and a conductive pattern disposed on the conductive partition. The first light-emitting element includes a first anode, a first organic layer, and a first cathode contacting the conductive partition, and the second light-emitting element includes a second anode, a second organic layer, and a second cathode contacting the conductive partition. A conductive pattern opening corresponding to the second light-emitting opening is included in the conductive pattern.

CROSS-REFERENCE TO RELATED APPLICATIONS

This application claims priority to and benefits of Korean Patent Application No. 10-2022-0174087 under 35 U.S.C. § 119, filed on Dec. 13, 2022 in the Korean Intellectual Property Office, the entire contents of which are incorporated herein by reference.

BACKGROUND

1. Technical Field

The disclosure herein relates to a display panel and a method for manufacturing the same, and, to a display panel with improved process reliability and a method of manufacturing the same.

2. Description of the Related Art

A display device is activated according to an electrical signal. The display device may include a display panel to display an image. Regarding the display panel, an organic light-emitting display panel has low power consumption, a high luminance, and a high response speed.

Among display panels, the organic light-emitting display panel may include an anode, a cathode, and a light-emitting pattern. The light-emitting pattern is separated for each light-emitting region and the cathode provides a common voltage to each of light-emitting regions.

SUMMARY

The disclosure provides a display panel including a light-emitting element which is formed without using a metal mask.

The disclosure also provides a light-emitting element with improved process reliability and a display panel including the same.

The technical objectives to be achieved by the disclosure are not limited to those described herein, and other technical objectives that are not mentioned herein would be clearly understood by a person skilled in the art from the description of the disclosure.

An embodiment provides a display panel that may include a pixel defining layer disposed above a base layer and including a first light-emitting opening and a second light-emitting opening; a conductive partition disposed on the pixel defining layer and including a first partition opening and a second partition opening and respectively corresponding to the first light-emitting opening and the second light-emitting opening; a first light-emitting element including a first anode at least partially exposed by the first light-emitting opening, a first organic layer, and a first cathode at least partially disposed in the first partition opening and contacting the conductive partition; a second light-emitting element including a second anode at least partially exposed by the second light-emitting opening, a second organic layer, and a second cathode at least partially disposed in the second partition opening and contacting the conductive partition; and a conductive pattern disposed on the conductive partition and including a conductive pattern opening and corresponding to the second light-emitting opening.

In an embodiment, the conductive pattern may surround the second light-emitting opening and have a substantially closed-line shape.

In an embodiment, the display panel may further include a first dummy pattern disposed on the conductive partition, containing a same material as the first organic layer, and including a first dummy opening and corresponding to the first light-emitting opening; and a second dummy pattern spaced apart from the first dummy pattern, containing a same material as the second organic layer, and including a second dummy opening and corresponding to the second light-emitting opening, wherein the conductive pattern may be disposed between the conductive partition and the second dummy pattern.

In an embodiment, an outer side surface of the conductive pattern may be disposed closer to a center of the second anode than an outer side surface of the second dummy pattern.

In an embodiment, the display panel may further include a first lower inorganic encapsulation pattern overlapping the first light-emitting opening in a plan view and disposed on the first light-emitting element and the first dummy pattern; and a second lower inorganic encapsulation pattern overlapping the second light-emitting opening in a plan view, spaced apart from the first lower inorganic encapsulation pattern, and disposed on the second light-emitting element and the second dummy pattern.

In an embodiment, the conductive pattern may contain a transparent conductive oxide.

In an embodiment, the display panel may further include a third light-emitting element including a third anode, a third organic layer, and a third cathode electrically contacting the conductive partition; a third light-emitting opening spaced apart from the first light-emitting opening and the second light-emitting opening and exposing at least a portion of the third anode in the pixel defining layer; a third partition opening spaced apart from the first partition opening and the second partition opening and including the third cathode in the conductive partition; and, the conductive pattern may not overlap the third light-emitting opening in a plan view and may surround only the second light-emitting opening in a plan view.

In an embodiment, the conductive partition may have a substantially undercut shape, the first cathode may electrically contact an inner side surface of the conductive partition including the first partition opening, and the second cathode may electrically contact an inner side surface of the conductive partition including the second partition opening.

In an embodiment, a method for manufacturing a display panel may include providing a preliminary display panel including a base layer, a first anode disposed above the base layer, a pixel defining layer disposed above the base layer and including a first light-emitting opening and exposing a portion of the first anode, and a conductive partition disposed on the pixel defining layer and including a first partition opening and corresponding to the first light-emitting opening; depositing a first organic material to form a first light-emitting pattern at least partially disposed in the first light-emitting opening and the first partition opening and a first dummy layer spaced apart from the first light-emitting pattern and disposed on the conductive partition; depositing a first conductive material to form a first cathode at least partially disposed in the first partition opening; forming a first mask pattern, overlapping the first light-emitting opening in a plan view and contains a second conductive material, on the conductive partition; patterning the first dummy layer by the first mask pattern to form a first dummy pattern from the first dummy layer; and depositing the second conductive material to form a first conductive layer from the first mask pattern, wherein, in the depositing of the second conductive material, the first conductive layer may cover an outer side surface of the first dummy pattern.

In an embodiment, the method may further include forming a first photoresist layer overlapping the first light-emitting opening in a plan view after the depositing of the first conductive material to form the first cathode and before the forming of the first mask pattern; and removing the first photoresist layer after the forming of the first mask pattern and before the etching of the first dummy layer, wherein the forming of the first mask pattern may be performed through etching of the first photoresist layer.

In an embodiment, the method may further include forming a preliminary first lower inorganic encapsulation layer on the first cathode and the conductive partition after the depositing of the first conductive material and before the forming of the first mask pattern; and patterning the preliminary first lower inorganic encapsulation layer by the first mask pattern to form a first lower inorganic encapsulation pattern, overlapping the first light-emitting opening in a plan view, from the preliminary first lower inorganic encapsulation layer after the forming of the first mask pattern and before the etching of the first dummy layer.

In an embodiment, after the depositing of the second conductive material to form the first conductive layer, the method may further include forming a first conductive opening in the first conductive layer; forming a second partition opening corresponding to the first conductive opening in the conductive partition; forming a second light-emitting opening corresponding to the second partition opening in the pixel defining layer; depositing a second organic material to form a second light-emitting pattern at least partially disposed in the second light-emitting opening and the second partition opening and a second dummy layer spaced apart from the second light-emitting pattern and disposed on the conductive partition; depositing the first conductive material to form a second cathode at least partially disposed in the second partition opening; forming a second mask pattern, overlapping the second light-emitting opening in a plan view and may include the second conductive material, on the conductive partition; patterning the second dummy layer by the second mask pattern to form a second dummy pattern from the second dummy layer; and depositing the second conductive material to form a second conductive layer from the first conductive layer and the second mask pattern, wherein in the providing of the preliminary display panel, the preliminary display panel may further include a second anode spaced apart from the first anode; in the forming of the first conductive opening, the first conductive opening may overlap the second anode in a plan view; and in the depositing of the second conductive material to form the second conductive layer, the second conductive layer may cover the outer side surface of the second dummy pattern.

In an embodiment, the forming of the second partition opening in the conductive partition may include etching the conductive partition by dry etching to form a preliminary second partition opening overlapping the second anode in a plan view; and etching the conductive partition by wet etching method to form the second partition opening from the preliminary second partition opening.

In an embodiment, in the providing of the preliminary display panel, a preliminary second partition opening overlapping the second anode in a plan view may be further included in the preliminary conductive partition, and in the forming of the second partition opening in the conductive partition, the conductive partition may be etched by wet etching.

In an embodiment, the second mask pattern may overlap the first conductive layer in a plan view.

In an embodiment, the second conductive layer may include a first portion disposed on the second dummy pattern; a second portion disposed between the conductive partition and the second dummy pattern; and a third portion connecting the first portion to the second portion and covering the outer side surface of the second dummy pattern.

In an embodiment, the second mask pattern may not overlap the first conductive layer in a plan view, and the second dummy pattern may be entirely contact an upper surface of the conductive partition.

In an embodiment, in the providing of the preliminary display panel, the preliminary display panel may further include a first sacrificial pattern disposed on the first anode and including a first sacrificial opening and a second sacrificial pattern disposed on the second anode, and the method may further include forming a second photoresist layer, including a first photoresist opening and overlapping the second anode in a plan view, on the first conductive layer after the depositing of the second conductive material to form the first conductive layer and before the forming of the first conductive opening in the first conductive layer; forming a second sacrificial opening corresponding to the second light-emitting opening in the second sacrificial pattern after the forming of the second light-emitting opening in the pixel defining layer and before the depositing of the second organic material; and removing the second photoresist layer after the forming of the second sacrificial opening and before the depositing of the second organic material.

In an embodiment, the method may include forming a third photoresist layer overlapping the second light-emitting opening in a plan view after the depositing of the first conductive material to form the second cathode and before the forming of the second mask pattern; and removing the third photoresist layer after the forming of the second mask pattern and before the patterning of the second dummy layer, wherein the forming of the second mask pattern may be performed through etching by the third photoresist layer.

In an embodiment, after the depositing of the second conductive material to form the second conductive layer, the method may further include forming a second conductive opening in the second conductive layer; forming a third partition opening corresponding to the second conductive opening in the conductive partition; forming a third light-emitting opening corresponding to the third partition opening in the pixel defining layer; etching the second conductive layer; depositing a third organic material to form a third light-emitting pattern at least partially disposed in the third light-emitting opening and the third partition opening and a third dummy layer spaced apart from the third light-emitting pattern and disposed on the conductive partition; depositing the first conductive material to form a third cathode at least partially disposed in the third partition opening; forming a third mask pattern, which overlaps the third light-emitting opening and may include the second conductive material, on the conductive partition; patterning the third dummy layer by the third mask pattern to form a third dummy pattern from the third dummy layer; and removing the third mask pattern, wherein, in the providing of the preliminary display panel, the preliminary display panel may further include a third anode spaced apart from the first anode and the second anode, and in the forming of the second conductive opening, the second conductive opening may overlap the third anode in a plan view.

In an embodiment, in the depositing of the second conductive material to form the second conductive layer, the second conductive layer may include a first portion disposed on the second dummy pattern; a second portion disposed between the conductive partition and the second dummy pattern; and a third portion connecting the first portion to the second portion and covering the outer side surface of the second dummy pattern, and in the etching of the second conductive layer, the second portion and the third portion may be removed, and a conductive pattern may be formed from a remaining first portion.

In an embodiment, the conductive pattern may surround the second light-emitting opening and have a substantially closed-line shape in a plan view.

In an embodiment, a portion of the conductive pattern may be removed together in the removing of the third mask pattern, the outer side surface of the conductive pattern may be disposed closer to a center of the second anode than the outer side surface of the second dummy pattern.

In an embodiment, in the etching of the second conductive layer, the second conductive layer may be entirely removed.

In an embodiment, in the providing of the preliminary display panel, the preliminary display panel may further include a third sacrificial pattern disposed on the third anode, and in the etching of the second conductive layer, a third sacrificial opening corresponding to the third light-emitting opening may be formed in the third sacrificial pattern.

In an embodiment, the method may further include forming a fourth photoresist layer including a second photoresist opening and overlapping the third anode in a plan view after the depositing of the second conductive material and before the forming of a second conductive opening in the second conductive layer; and removing the fourth photoresist layer after the forming of the third light-emitting opening in the pixel defining layer and before the etching of the second conductive layer.

In an embodiment, the method may further include forming a fifth photoresist layer overlapping the third light-emitting opening in a plan view after the depositing of the first conductive material to form the third cathode and before the forming of the third mask pattern; and removing the fifth photoresist layer after the forming of the third mask pattern and before the etching of the third dummy layer, wherein the forming of the third mask pattern may be performed through etching by the fifth photoresist layer.

In an embodiment, prior to the providing of the preliminary display panel, the method may further include forming a preliminary first partition opening in the preliminary conductive partition layer by dry-etching a preliminary conductive partition layer including sequentially stacked a first layer and a second layer; and forming the first partition opening from the preliminary first partition opening by wet-etching the first layer and the second layer to form the conductive partition from the preliminary conductive partition layer, wherein an inner side surface of the second layer defining the second region of the first partition opening may be closer to a center of the first anode than an inner side surface of the first layer defining the first region of the first partition opening.

In an embodiment, the preliminary display panel may further include a second anode disposed above the base layer, and in the forming of the preliminary first partition opening in the preliminary conductive partition layer, a preliminary second partition opening overlapping the second anode in a plan view may be formed together in the preliminary conductive partition layer.

In an embodiment, the second conductive material may include a transparent conductive oxide.

DETAILED DESCRIPTION OF THE EMBODIMENTS

In this specification, it will be understood that when an element (or region, layer, portion, etc.) is referred to as being “on”, “connected to” or “coupled to” another element, it can be directly on, connected or coupled to the other element, or intervening elements may be present.

Like reference numerals refer to like elements throughout. In the drawings, the thicknesses, ratios, and dimensions of elements are exaggerated for effective description of the technical contents.

It will be understood that, although the terms first, second, etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. For example, a first element could be termed a second element without departing from the scope of the disclosure. Similarly, the second element may also be referred to as the first element.

In addition, terms, such as “below”, “lower”, “above”, “upper” and the like, are used herein for ease of description to describe one element's relation to another element(s) as illustrated in the figures. The above terms are relative concepts and are described based on the directions indicated in the drawings.

For the purposes of this disclosure, the phrase “at least one of A and B” may be construed as A only, B only, or any combination of A and B. Also, “at least one of X, Y, and Z” and “at least one selected from the group consisting of X, Y, and Z” may be construed as X only, Y only, Z only, or any combination of two or more of X, Y, and Z. The term “overlap” or “overlapped” means that a first object may be above or below or to a side of a second object, and vice versa.

FIG.1Ais a perspective view of a display device according to an embodiment.FIG.1Bis an exploded perspective view of the display device according to an embodiment.FIG.2is a schematic cross-sectional view of a display panel according to an embodiment.

In an embodiment, the display device DD may be a large electronic device such as a television, a monitor, or an external billboard. The display device DD may be a small or medium-sized electronic device such as a personal computer, a notebook computer, a personal digital terminal, a car navigation unit, a game machine, a smart phone, a tablet, or a camera. These are presented only as examples and the display device DD may be employed as other display devices within the spirit and the scope of the disclosure. In this embodiment, a smart phone is illustrated as an example of the display device DD.

Referring toFIGS.1A,1B, and2, the display device DD may display an image IM toward a third direction DR3on a display surface FS parallel to each of a first direction DR1and a second direction DR2. The image IM may include a still image as well as a dynamic image.FIG.1Aillustrates a watch window and icons as an example of the image IM. The display surface FS on which the image IM is displayed may correspond to the front surface of the display device DD.

In this embodiment, the front surface (or upper surface) and the rear surface (or lower surface) of each member are defined based on a direction in which the image IM is displayed. The front surface and the rear surface may face each other in the third direction DR3, and a normal direction of each of the front surface and the rear surface may be parallel to the third direction DR3. Directions indicated by the first to third directions DR1, DR2, and DR3are relative concepts and may be converted into other directions. In this specification, the expression “on a plane” may mean a state when viewed in the third direction DR3.

As illustrated inFIG.1B, the display device DD according to this embodiment may include a window WP, a display module DM, and a housing HAU. The window WP and the housing HAU may be coupled (or connected) to each other to form the exterior of the display device DD.

The window WP may contain an optically transparent insulating material. For example, the window WP may contain glass or plastic. The front surface of the window WP may define the display surface FS of the display device DD. The display surface FS may include a transmission region TA and a bezel region BZA. The transmission region TA may be an optically transparent region. For example, the transmission region TA may have a visible light transmittance of about 90% or more.

The bezel region BZA may have a relatively low light transmittance, compared to the transmission region TA. The bezel region BZA may define the shape of the transmission region TA. The bezel region BZA may be adjacent to and surround the transmission region TA. This is illustrated as an example, and in the window WP according to an embodiment, the bezel region BZA may be omitted. The window WP may include at least any one functional layer among an anti-fingerprint layer, a hard coating layer, or an anti-reflection layer, and the disclosure is not limited to any one embodiment.

The display module DM may be disposed below the window WP. The display module DM may be a component that substantially generates an image IM. The image IM generated by the display module DM is displayed on the display surface IS of the display module DM and is visually recognized by a user from the outside through the transmission region TA.

As illustrated inFIG.2, the display module DM according to this embodiment may include a display panel DP and an input sensor INS. Although not separately illustrated, the display device DD according to an embodiment may further include a protective member disposed on the lower surface of the display panel DP or an anti-reflection member and/or a window member disposed on the upper surface of the input sensor INS.

The display panel DP may be a light-emitting display panel and is not particularly limited thereto. For example, the display panel DP may be an organic light-emitting display panel or an inorganic light-emitting display panel. A light-emitting layer in the organic light-emitting display panel contains an organic light-emitting material. A light-emitting layer in the inorganic light-emitting display panel contains quantum dots, quantum rods, or micro LEDs. Hereinafter, the display panel DP will be described as an organic light-emitting display panel.

The display panel DP may include a base layer BL, a circuit element layer DP-CL disposed on the base layer BL, a display element layer DP-OLED, and a thin film encapsulation layer TFE. The input sensor INS may be disposed directly on the thin film encapsulation layer TFE. In this specification, the expression “component A is disposed directly on component B” means that no adhesive layer is disposed between component A and component B.

The base layer BL may include at least one plastic film. The base layer BL may be a flexible substrate and include a plastic substrate, a glass substrate, a metal substrate, or an organic/inorganic composite material substrate. In this specification, it may be considered that the display region DA and the non-display region NDA are defined in the base layer BL. It may be considered that components disposed on the base layer BL are disposed to overlap the display region DA or the non-display region NDA.

The circuit element layer DP-CL may include at least one insulating layer and a circuit element. The insulating layer may include at least one inorganic layer and at least one organic layer. The circuit element may include signal lines, a pixel driving circuit, and the like within the spirit and the scope of the disclosure.

The display element layer DP-OLED may include a conductive partition and a light-emitting element. The light-emitting element may include an anode, a light-emitting pattern, and a cathode, and the light-emitting pattern may include at least a light-emitting layer.

The thin film encapsulation layer TFE may include thin films. Some or a number of thin films are disposed to improve optical efficiency, and some or a number of thin films are disposed to protect organic light-emitting diodes.

The input sensor INS acquires the coordinate information of an external input. The input sensor INS may have a multi-layered structure. The input sensor INS may include a single-layered or multi-layered conductive layer. The input sensor INS may include a single-layered or multi-layered insulating layer. The input sensor INS may sense an external input, for example, in a capacitive manner. In the disclosure, the operation manner of the input sensor INS is not particularly limited, and in an embodiment, the input sensor INS may sense an external input in an electromagnetic induction manner or a pressure-sensing manner. In an embodiment, the input sensor INS may be omitted.

As illustrated inFIG.1B, the housing HAU may be coupled (or connected) to the window WP. The housing HAU may be coupled (or connected) to the window WP to provide a selectable internal space. The display module DM may be accommodated in the internal space.

The housing HAU may contain a material having relatively high rigidity. For example, the housing HAU may include frames and/or plates composed of glass, plastic, or metal, or a combination thereof. The housing HAU may stably protect the components of the display device DD, which are accommodated in the internal space, from an external impact.

FIG.3is a schematic plan view of the display panel according to an embodiment.

Referring toFIG.3, the display panel DP may include a base layer BL divided into a display region DA and a non-display region NDA which are described with reference toFIG.2.

The display panel DP may include pixels PX disposed in the display region DA and signal lines SGL electrically connected to the pixels PX. The display panel DP may include a driving circuit GDC and a pad portion PLD disposed in the non-display region NDA.

The pixels PX may be arranged (or disposed) in the first and second directions DR1and DR2. The pixels PX may include pixel rows extending in the first direction DR1and arranged in the second direction DR2and pixel columns extending in the second direction DR2and arranged in the first direction DR1.

The signal lines SGL may include gate lines GL, data lines DL, a power line PL, and a control signal line CSL. Each of the gate lines GL may be connected to a corresponding pixel of the pixels PX, and each of the data lines DL may be connected to a corresponding pixel of the pixels PX. The power line PL may be electrically connected to the pixels PX. The control signal line CSL may be connected to the driving circuit GDC to provide control signals thereto.

The driving circuit GDC may include a gate driving circuit. The gate driving circuit may generate gate signals and sequentially output the generated gate signals to the gate lines GL. The gate driving circuit may further output another control signal to the pixel driving circuit.

The pad portion PLD may be a portion to which a flexible circuit board is connected. The pad portion PLD may include pixel pads D-PD, and the pixel pads D-PD may be pads for connecting the flexible circuit board to the display panel DP. Each of the pixel pads D-PD may be connected to a corresponding signal line among the signal lines SGL. The pixel pads D-PD may be connected to corresponding pixels PX through the signal lines SGL. Any one of the pixel pads D-PD may be connected to the driving circuit GDC.

The pad portion PLD may further include input pads. The input pads may be pads for connecting the flexible circuit board to the input sensor INS (seeFIG.2). Without being limited thereto, however, the input pads may be disposed in the input sensor INS (seeFIG.2) and connected to the pixel pads D-PD and a separate circuit board. By way of example, the input sensor INS (seeFIG.2) may be omitted and may not further include the input pads.

FIG.4is an enlarged schematic plan view of a portion of a display region of the display panel according to an embodiment.FIG.4illustrates a plane of the display module DM (seeFIG.2) viewed from the display surface IS (seeFIG.2) of the display module DM (seeFIG.2), and an arrangement of light-emitting regions PXA-R, PXA-G, and PXA-B.

Referring toFIG.4, the display region DA may include first to third light-emitting regions PXA-R, PXA-G and PXA-B and a peripheral region NPXA surrounding the first to third light-emitting regions PXA-R and PXA-G, and PXA-B. The first to third light-emitting regions PXA-R, PXA-G, and PXA-B may respectively correspond to regions from which light provided from light-emitting elements ED1, ED2, and ED3(seeFIG.5B) is emitted. The first to third light-emitting regions PXA-R, PXA-G, and PXA-B may be classified according to the color of light emitted toward the outside of the display module DM (seeFIG.2).

The first to third light-emitting regions PXA-R, PXA-G, and PXA-B may respectively provide first to third color lights having different colors. For example, the first color light may be red light (R), the second color light may be green light (G), and the third color light may be blue light (B). However, the first to third color lights are not necessarily limited to the above examples.

Each of the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may be defined as a region in which an upper surface of the anode is exposed by a light-emitting opening to be described later. The peripheral region NPXA may determine boundaries between the first to third light-emitting regions PXA-R, PXA-G, and PXA-B, and prevent color-mixing between the first to third light-emitting regions PXA-R, PXA-G, and PXA-B.

Each of the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may be provided in plurality and the plurality thereof may be repeatedly arranged in a selectable arrangement form in the display region DA. For example, the first and third light-emitting regions PXA-R and PXA-B may be alternately arranged along the first direction DR1to form a ‘first group’. The second light-emitting regions PXA-G may be arranged along the first direction DR1to form a ‘second group’. Each of the ‘first group’ and the ‘second group’ may be provided in plurality, and the ‘first groups’ and the ‘second groups’ may be alternately arranged along the second direction DR2.

One second light-emitting region PXA-G may be disposed to be spaced apart from one first light-emitting region PXA-R or one third light-emitting region PXA-B in a fourth direction DR4. The fourth direction DR4may be defined as a direction between the first and second directions DR1and DR2.

FIG.4illustrates an arrangement of the first to third light-emitting regions PXA-R, PXA-G, and PXA-B, but the embodiment is not limited thereto, and the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may be arranged in various forms. In an embodiment, the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may have a PENTILE™ arrangement form as illustrated inFIG.4. By way of example, the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may have a stripe arrangement form or a Diamond Pixel™ arrangement form.

The first to third light-emitting regions PXA-R, PXA-G, and PXA-B may have various shapes on a plane. For example, the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may have a polygonal shape, a circular shape, or an elliptical shape.FIG.4illustrates, on a plane, the first and third light-emitting regions PXA-R and PXA-B having a quadrangular shape (or a diamond shape) and the second light-emitting region PXA-G having an octagonal shape.

On a plane, the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may have the same shape as each other, or at least some or a number of them may have different shapes.FIG.4illustrates, on a plane, the first and third light-emitting regions PXA-R and PXA-B having the same shape as each other and the second light-emitting region PXA-G having a shape different from those of the first and third light-emitting regions PXA-R and PXA-B.

At least some or a number of the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may have areas different from each other on a plane. In an embodiment, the area of the first light-emitting region PXA-R that emits red light may be larger than the area of the second light-emitting region PXA-G that emits green light and smaller than the area of the third light-emitting region PXA-B that emits blue light. However, the size relationship between the areas of the first to third light-emitting regions PXA-R, PXA-G, and PXA-B according to the color of emitted light is not limited thereto and may vary depending on the design of the display module DM (seeFIG.2). The embodiment is not limited thereto, and the first to third light-emitting regions PXA-R, PXA-G, and PXA-B may have the same area as each other on a plane.

The shape, area, and arrangement of the first to third light-emitting regions PXA-R, PXA-G, and PXA-B of the display module DM (seeFIG.2) according to the disclosure may be designed in various ways according to the color of emitted light or the size and configuration of the display module DM (seeFIG.2) and are not limited to the embodiment illustrated inFIG.4.

FIG.5is a schematic cross-sectional view of the display panel according to an embodiment taken along line I-I′ ofFIG.4.FIG.6is an enlarged schematic plan view of a configuration of the display panel according to an embodiment.

Referring toFIGS.5and6, the display panel DP according to this embodiment may include a base layer BL, a circuit element layer DP-CL, a display element layer DP-OLED, and a thin film encapsulation layer TFE.

The display panel DP may include insulating layers, semiconductor patterns, conductive patterns, signal lines, and the like within the spirit and the scope of the disclosure. An insulating layer, a semiconductor layer, and a conductive layer are formed by coating, deposition, or the like within the spirit and the scope of the disclosure. Hereafter, the insulating layer, the semiconductor layer, and the conductive layer may be selectively patterned by photolithography and etching processes. In this way, the semiconductor patterns, the conductive patterns, the signal lines, and the like included in the circuit element layer DP-CL and the display element layer DP-OLED are formed.

The circuit element layer DP-CL is illustrated as a single layer, but this is for example, and the circuit element layer DP-CL may include an insulating layer, a semiconductor pattern, a conductive pattern, and the like for forming various elements.

The pixel driving circuit in the circuit element layer DP-CL may be provided in plurality, and the pixel driving circuits may be respectively connected to and independently control the light-emitting elements ED1, ED2, and ED3. Each of the pixel driving circuits may include transistors to drive the connected light-emitting elements, at least one capacitor, and signal lines to connect them.

The display element layer DP-OLED may be disposed on the circuit element layer DP-CL. According to this embodiment, the display element layer DP-OLED may include light-emitting elements ED1, ED2, and ED3, a pixel defining layer PDL, a conductive partition PW, dummy patterns D1, D2, and D3, additional dummy patterns D1a, D2a, and D3a, and a conductive pattern CDP.

The light-emitting elements ED1, ED2, and ED3include a first light-emitting element ED1, a second light-emitting element ED2, and a third light-emitting element ED3, and each of the first to third light-emitting elements ED1ED2and ED3may include an anode (or first electrode), a cathode (or second electrode), and a light-emitting pattern disposed between the anode and the cathode. The first light-emitting element ED1may include a first anode AE1, a first cathode CE1, and a first light-emitting pattern EL1, the second light-emitting element ED2may include a second anode AE2, a second cathode CE2, and a second light-emitting pattern EL2, and the third light-emitting element ED3may include a third anode AE3, a third cathode CE3, and a third light-emitting pattern EL3.

The first to third anodes AE1, AE2, and AE3(or 1-1st, 1-2nd, and 1-3th electrodes) may be provided in patterns. The first to third anodes AE1, AE2, and AE3may have conductivity. For example, each of the anodes AE1, AE2, and AE3may be formed of various materials, such as a metal, a transparent conductive oxide (TCO), or a conductive polymer material, as long as they have conductivity. For example, the metal may include gold (Au), silver (Ag), aluminum (Al), magnesium (Mg), lithium (Li), molybdenum (Mo), copper (Cu), or an alloy. The transparent conductive oxide may include an indium tin oxide (ITO), an indium zinc oxide (IZO), a zinc oxide, an indium oxide, an indium gallium oxide, or an aluminum zinc oxide.

Each of the first to third anodes AE1, AE2, and AE3is illustrated as a single layer, but this is an example, and each of the first to third anodes AE1, AE2, and AE3may have a multi-layered structure. Any one of the first to third anodes AE1, AE2, and AE3may have a single-layered structure, and one of them may have a multi-layered structure, and the disclosure is not limited to any one embodiment.

The first to third light-emitting patterns EL1, EL2, and EL3may be respectively disposed on the first to third anodes AE1, AE2, and AE3. The first to third light-emitting patterns EL1, EL2, and EL3may be patterned by a tip portion defined in the conductive partition PW, which will be described later.

In an embodiment, the first light-emitting pattern EL1may provide red light, the second light-emitting pattern EL2may provide green light, and the third light-emitting pattern EL3may provide blue light.

Each of the first to third light-emitting patterns EL1, EL2, and EL3may include a light-emitting layer containing a light-emitting material. Each of the first to third light-emitting patterns EL1, EL2, and EL3may further include a hole injection layer (HIL) and a hole transport layer (HTL) which are disposed between a corresponding anode among the first to third anodes AE1, AE2, and AE3and the light-emitting layer and may further include an electron transport layer (ETL) and an electron injection layer (EIL) which are disposed on the light-emitting layer. The first to third light-emitting patterns EL1, EL2, and EL3may be respectively referred to as ‘first to third organic layers’ or ‘first to third intermediate layers’.

The first to third cathodes CE1, CE2, CE3(or 2-1st, 2-2nd, and 2-3rd electrodes) may be disposed on a corresponding light-emitting pattern among the first to third light-emitting patterns EL1, EL2, and EL3. The first to third cathodes CE1, CE2, and CE3may have conductivity. For example, each of the cathodes CE1, CE2, and CE3may be formed of various materials, such as a metal, a transparent conductive oxide (TCO), or a conductive polymer material, as long as they have conductivity. The first to third cathodes CE1, CE2, and CE3may be patterned by a tip portion defined in the conductive partition PW, which will be described later.

The pixel defining layer PDL may be disposed on an insulating layer disposed on the uppermost side of the circuit element layer DP-CL. First to third light-emitting openings OP1-E, OP2-E, and OP3-E may be defined in the pixel defining layer PDL. The first to third light-emitting openings OP1-E, OP2-E, and OP3-E may respectively overlap the first to third anodes AE1, AE2, and AE3. The pixel defining layer PDL may expose at least a portion of each of the anodes AE1, AE2, and AE3through the light-emitting openings OP1-E, OP2-E, and OP3-E.

The first light-emitting region PXA-R is defined as a region of the upper surface of the first anode AE1exposed by the first light-emitting opening OP1-E, the second light-emitting region PXA-G is defined as a region of the upper surface of the second anode AE2exposed by the second light-emitting opening OP2-E, and the third light-emitting region PXA-B is defined as a region of the upper surface of the third anode AE3exposed by the third light-emitting opening OP3-E.

The pixel defining layer PDL may be an inorganic insulating film. For example, the pixel defining layer PDL may contain a silicon oxide, a silicon nitride, or a combination thereof. For example, the pixel defining layer PDL may have a two-layer structure in which a silicon oxide layer and a silicon nitride layer may be sequentially stacked each other. However, this is described as an example, and as long as the pixel defining layer PDL can be an inorganic insulating layer, the material and structure of the pixel defining layer PDL, whether it is single-layered or multi-layered, may be variously changed, and the disclosure is not limited to any one embodiment.

According to an embodiment, the display panel DP may further include first to third sacrificial patterns SP1, SP2, and SP3. The first to third sacrificial patterns SP1, SP2, and SP3may be respectively disposed on the upper surfaces of the first to third anodes AE1, AE2, and AE3. The sacrificial patterns SP1, SP2, and SP3may be covered by the pixel defining layer PDL. Each of the sacrificial patterns SP1, SP2, and SP3exposes at least a portion of a corresponding anode AE1, AE2, or AE3. The sacrificial patterns SP1, SP2, and SP3may be respectively disposed at positions that do not overlap the light-emitting openings OP1-E, OP2-E, and OP3-E.

In case that the display panel DP further may include the sacrificial patterns SP1, SP2, and SP3, the upper surfaces of the anodes AE1, AE2, and AE3may be spaced apart from the pixel defining layer PDL on a cross section with the corresponding sacrificial patterns SP1, SP2, and SP3interposed therebetween. Accordingly, it is possible to protect the anodes AE1, AE2, and AE3from being damaged in the process of forming the light-emitting openings OP1-E, OP2-E and OP3-E.

In an embodiment, sacrificial openings OP1-S, OP2-S, OP3-S respectively corresponding to the light-emitting openings OP1-E, OP2-E, and OP3-E may be defined in the sacrificial patterns SP1, SP2, and SP3. Each of the sacrificial openings OP1-S, OP2-S, and OP3-S may have a larger area than a corresponding light-emitting opening OP1-E, OP2-E, or OP3-E. Without being limited thereto, however, the inner side surfaces of the sacrificial patterns SP1, SP2, and SP3defining the sacrificial openings OP1-S, OP2-S, and OP3-S may be substantially aligned with the inner side surface of the pixel defining layer PDL defining the corresponding light-emitting openings OP1-E, OP2-E, and OP3-E. Each of the light-emitting regions PXA-R, PXA-G, and PXA-B may be considered to be a region of an anode AE1, AE2, or AE3exposed from a corresponding sacrificial opening OP1-S, OP2-S, or OP3-S.

The conductive partition PW is disposed on the pixel defining layer PDL. First to third partition openings OP1-P, OP2-P, and OP3-P may be defined in the conductive partition PW. The first to third partition openings OP1-P, OP2-P, and OP3-P may respectively correspond to the first to third light-emitting openings OP1-E, OP2-E, and OP3-E. Each of the partition openings OP1-P, OP2-P, and OP3-P may expose at least a portion of a corresponding anode AE1, AE2, or AE3.

The conductive partition PW may have an undercut shape on a cross section. Each of the side surfaces defining the partition openings OP1-P, OP2-P, and OP3-P of the conductive partition PW may have an undercut shape on a cross section. The conductive partition PW may include layers sequentially stacked each other, and at least one layer of the layers may be recessed compared to adjacent stacked layers. Accordingly, the conductive partition PW may include a tip portion.

The light-emitting patterns EL1, EL2, and EL3may be separated by the tip portion of the conductive partition PW, and each thereof may be formed in each of the light-emitting openings OP1-E, OP2-E, and OP3-E and the partition openings OP1-P and OP2-P, and OP3-P. For example, at least a portion of the first light-emitting pattern EL1may be disposed in the first light-emitting opening OP1-E and the first partition opening OP1-P, at least a portion of the second light-emitting pattern EL2may be disposed in the second light-emitting opening OP2-E and the second partition opening OP2-P, and at least a portion of the third light-emitting pattern EL3may be disposed in the third light-emitting opening OP3-E and the third partition opening OP3-P. In an embodiment including the first to third sacrificial patterns SP1, SP2, and SP3, portions of the first to third light-emitting patterns EL1, EL2, and EL3may be respectively disposed in the first to third sacrificial openings OP1-S, OP2-S, and OP3-S.

The cathodes CE1, CE2, and CE3may be separated by the tip portion of the conductive partition PW and formed in the partition openings OP1-P, OP2-P, and OP3-P. For example, at least a portion of the first cathode CE1may be disposed in the first partition opening OP1-P, at least a portion of the second cathode CE2may be disposed in the second partition opening OP2-P, and at least a portion of the third cathode CE3may be disposed in the third partition opening OP3-P. In an embodiment, according to the thickness of the first to third light-emitting patterns EL1, EL2, and EL3or the thickness of the pixel defining layer PDL, portions of the first to third cathodes CE1, CE2, and CE3may be respectively disposed in the first to third light-emitting openings OP1-E, OP2-E, and OP3-E.

According to this embodiment, the conductive partition PW may include a first layer L1and a second layer L2disposed on the first layer L1. The first layer L1may be disposed on the pixel defining layer PDL. The first layer L1may be relatively recessed compared to the second layer L2with respect to the light-emitting regions PXA. For example, the first layer L1may be formed by undercutting the second layer L2.

In this embodiment, each of the partition openings OP1-P, OP2-P, and OP3-P defined in the conductive partition PW may include a first region A1(seeFIG.7C) and a second region A2(seeFIG.7C). The first layer L1may include inner side surfaces defining the first region A1(seeFIG.7C) of each of the partition openings OP1-P, OP2-P, and OP3-P, and the second layer L2may include inner side surfaces defining the second region A2(seeFIG.7C) of each of the partition openings OP1-P, OP2-P, and OP3-P.

Each of the inner side surfaces of the first layer L1may be recessed relatively more inward than the inner side surface of the second layer L2with respect to a corresponding light-emitting region PXA-R, PXA-G, or PXA-B. For example, the inner side surface of the first layer L1may be formed by undercutting the inner side surface of the second layer L2. A portion of the second layer L2protruding from the first layer L1toward each of the light-emitting regions PXA-R, PXA-G, and PXA-B may define a tip portion.

In an embodiment, the first layer L1may contain a conductive material. The conductive material may include a metal, a transparent conductive oxide (TCO), or a combination thereof. For example, the metal may include gold (Au), silver (Ag), aluminum (Al), magnesium (Mg), lithium (Li), molybdenum (Mo), titanium (Ti), copper (Cu), or an alloy. The transparent conductive oxide may include an indium tin oxide (ITO), an indium zinc oxide (IZO), a zinc oxide, an indium oxide, an indium gallium oxide, an indium Gallium zinc oxide (IGZO), or an aluminum zinc oxide.

In an embodiment, the second layer L2may include a metal or non-metal. For example, the metal may include gold (Au), silver (Ag), aluminum (Al), magnesium (Mg), lithium (Li), molybdenum (Mo), titanium (Ti), copper (Cu), or an alloy. The non-metal may include silicon (Si), a silicon oxide (SiOx), a silicon nitride (SiNx), a silicon oxynitride (SiON), a metal oxide, a metal nitride, or a combination thereof, wherein the metal oxide may include a transparent conductive oxide (TCO).

According to an embodiment, the conductive partition PW may include layers disposed below the first layer L1, above the second layer L2, or between the first layer L1and the second layer L2. The additionally disposed layers may contain at least one of a conductive material or an inorganic material.

The conductive partition PW may receive a bias voltage. As the cathodes CE1, CE2, and CE3are in direct contact with the conductive partition PW, they may be electrically connected to each other and receive the bias voltage from the conductive partition PW.

In this embodiment, the first layer L1may have a relatively greater thickness than the second layer L2. The first layer L1may be in direct contact with the first to third cathodes CE, CE2, and CE3. As the first to third cathodes CE, CE2, and CE3are physically separated by the second layer L2forming a tip portion, formed in the respective light-emitting openings OP1-E, OP2-E, and OP3-E, and in contact with the first layer L1, they may be electrically connected to each other and receive a common voltage. Since the first layer L1has a relatively higher electrical conductivity and a larger thickness than the second layer L2, the contact resistance of the first to third cathodes CE1, CE2, and CE3may be reduced. Accordingly, a common cathode voltage may be uniformly provided to the light-emitting regions PXA-R, PXA-G, and PXA-B.

According to the disclosure, first light-emitting patterns EL1may be patterned and deposited in pixel units by tip portions defined in the conductive partition PW. For example, the first light-emitting patterns EL1are commonly formed by using an open mask, but may be readily divided into the pixel units by the conductive partitions PW.

On the other hand, in case that the first light-emitting patterns are patterned by using a fine metal mask (FMM), a support spacer protruding from the conductive partition should be provided to support the fine metal mask. Since the fine metal mask is spaced apart from a base surface, on which patterning is performed, by the height of the partition and the spacer, there may be limitation in implementing high resolution. As the fine metal mask is in contact with the spacer, foreign substances may remain on the spacer after a patterning process of the first light-emitting patterns EL1, or the spacer may be damaged by being stabbed by the fine metal mask. Accordingly, a defective display panel may be formed. The description thereabout may be identically applied to the case of making the second emission patterns EP2subject to patterning and the case of making the third emission patterns EP3subject to patterning.

According to this embodiment, since the display panel may include the conductive partition PW, physical separation between the light-emitting elements ED1, ED2, and ED3may be readily achieved. Accordingly, it is possible not only to prevent a current leakage or a driving error between adjacent light-emitting regions PXA-R, PXA-G, and PXA-B, but also to drive each of the light-emitting elements ED1, ED2, and ED3independently.

By way of example, by patterning the first light-emitting patterns EL1without a mask in contact with an internal component in the display region DA (seeFIG.2), a defect rate may be reduced, thus making it possible to provide the display panel DP having improved process reliability. The description thereabout may be identically applied to the case of making the second emission patterns EP2subject to patterning and the case of making the third emission patterns EP3subject to patterning. Since patterning is possible even in case that a separate support spacer protruding from the conductive partition PW is not provided, the areas of the light-emitting regions PXA-R, PXA-G, and PXA-B may be minimized and therefore, it is possible to provide the display panel DP capable of readily achieving high resolution.

In manufacturing the display panel DP having a large area, a process cost may be reduced by omitting the manufacture of a mask having a large area, and by not being affected by a defect occurring in the large-area mask, the display panel DP having improved process reliability may be provided.

AlthoughFIG.5illustrates that the light-emitting patterns EL1, EL2, and EL3are also in direct contact with the second layer L2, they may not be in contact with the second layer L2.

According to an embodiment, the display panel DP may further include capping patterns. The capping patterns may be respectively disposed in the partition openings OP1-P, OP2-P, and OP3-P and disposed on the cathodes CE1, CE2, and CE3. The capping patterns may be patterned by a tip portion formed in the conductive partition PW.

Dummy patterns D1, D2, and D3may be disposed on the conductive partition PW. The dummy patterns D1, D2, and D3may include a first dummy pattern D1, a second dummy pattern D2, and a third dummy pattern D3.

Each of the dummy patterns D1, D2, and D3may contain an organic material. For example, the first to third dummy patterns D1, D2, and D3may contain the same material as the first to third light-emitting patterns EL1, EL2, and EL3, respectively. One dummy pattern may be formed simultaneously with a corresponding light-emitting pattern through one process and may be formed separately from the corresponding light-emitting pattern by the undercut shape of the conductive partition PW.

First to third dummy openings OP1-D, OP2-D, and OP3-D may be defined in the first to third dummy patterns D1, D2, and D3, respectively. The first to third dummy openings OP1-D, OP2-D, and OP3-D may correspond to the first to third light-emitting openings OP1-E, OP2-E, and OP3-E, respectively. On a plane, the first to third dummy patterns D1, D2, and D3may surround the first to third light-emitting regions PXA-R, PXA-G, and PXA-B, respectively, and each of the dummy patterns D1, D2, and D3may have a closed-line shape.

FIG.5illustrates that the inner side surface of the first dummy pattern D1defining the first dummy opening OP1-D is aligned with the inner side surface of the second layer L2defining the second region A2(seeFIG.7C) of the first partition opening OP1-P, but the embodiment is not limited thereto, and the first dummy pattern D1may cover the inner side surface of the second layer L2. This description may be similarly applied to the second and third dummy patterns D2and D3.

Additional dummy patterns D1a, D2a, and D3amay be disposed on the dummy patterns D1, D2, and D3. The additional dummy patterns D1a, D2a, and D3amay include a first additional dummy pattern D1a, a second additional dummy pattern D2a, and a third additional dummy pattern D3a.

Each of the additional dummy patterns D1a, D2a, and D3amay contain a conductive material. For example, the first to third additional dummy patterns D1a, D2a, and D3amay contain the same material as the first to third cathodes CE1, CE2, and CE3, respectively. One additional dummy pattern may be formed simultaneously with a corresponding cathode through one process and may be formed separately from the corresponding cathode by the undercut shape of the conductive partition PW.

Openings corresponding to the first to third light-emitting openings OP1-E, OP2-E, and OP3-E may be respectively defined in the first to third additional dummy patterns D1a, D2a, and D3a. The first to third additional dummy patterns D1a, D2a, and D3amay surround the first to third light-emitting regions PXA-R, PXA-B, and PXA-G, respectively.

The conductive pattern CDP may be disposed on the conductive partition PW. In this embodiment, the conductive pattern CDP may be disposed between the conductive partition PW and the second dummy pattern D2. A conductive pattern opening OP-CDP corresponding to the second partition opening OP2-P may be defined in the conductive pattern CDP.

AlthoughFIG.5illustrates that an inner side surface of the conductive pattern CDP and an inner side surface of the second dummy pattern D2are aligned with each other, the second dummy pattern D2may cover the inner side surface of the conductive pattern CDP.

An outer side surface OS1of the conductive pattern CDP may be recessed inward toward the second light-emitting region PXA-G, compared to an outer side surface OS2of the second dummy pattern D2. In an etching process of one component, a portion of the conductive pattern CDP may be removed along with the component and therefore, the conductive pattern CDP may be recessed inward, which will be described in detail later.

FIG.6is a schematic plan view illustrating the conductive pattern CDP provided in plurality, and for the convenience of description, the first to third light-emitting regions PXA-R, PXA-G, and PXA-B are illustrated together. As illustrated inFIG.6, the conductive patterns CDP may surround the second light-emitting regions PXA-G on a plane. Each of the conductive patterns CDP may have a closed-line shape. In this embodiment, the conductive patterns CDP may not overlap the first and third light-emitting regions PXA-R and PXA-B and may be disposed only around the second light-emitting regions PXA-G. Without being limited thereto, however, the conductive patterns CDP may be disposed only around the first light-emitting regions PXA-R or only around the third light-emitting regions PXA-B.

According to the disclosure, the conductive pattern CDP may be formed from a conductive layer provided to cover an organic pattern (for example, first and second dummy patterns D1and D2) having a side surface exposed in a manufacturing process of the display panel DP. After etching processes performed after the forming of the conductive layer, a portion of the conductive layer may remain in a final product without being etched, and the conductive pattern CDP may correspond to a residue of the conductive layer.

According to the disclosure, as the side surface of the exposed organic pattern is covered, damage may be prevented in a subsequent process, and thus the display panel DP with improved process reliability may be provided. A detailed description of this will be given later.

According to an embodiment, the conductive pattern CDP may not be formed depending on a manufacturing process. A detailed description of this will be given later.

The thin film encapsulation layer TFE may be disposed on the display element layer DP-OLED. The thin film encapsulation layer TFE may include a first lower inorganic encapsulation pattern LIL1, a second lower inorganic encapsulation pattern LIL2, a third lower inorganic encapsulation pattern LIL3, an organic encapsulation layer OL, and an upper inorganic encapsulation layer UIL.

The first lower inorganic encapsulation pattern LIL1may be disposed to overlap the first light-emitting opening OP1-E. The first lower inorganic encapsulation pattern LIL1may cover the first light-emitting element ED1and the first dummy pattern D1, and a portion thereof may be disposed inside the first partition opening OP1-P. According to an embodiment, the first lower inorganic encapsulation pattern LIL1may be in contact with the inner side surface of the first layer L1defining the first region A1(seeFIG.7C) of the first partition opening OP1-P.

The second lower inorganic encapsulation pattern LIL2may be disposed to overlap the second light-emitting opening OP2-E. The second lower inorganic encapsulation pattern LIL2may cover the second light-emitting element ED2and the second dummy pattern D2, and a portion thereof may be disposed inside the second partition opening OP2-P. According to an embodiment, the second lower inorganic encapsulation pattern LIL2may be in contact with the inner side surface of the first layer L1defining the first region of the second partition opening OP2-P.

The third lower inorganic encapsulation pattern LIL3may be disposed to overlap the third light-emitting opening OP3-E. The third lower inorganic encapsulation pattern LIL3may cover the third light-emitting element ED3and the third dummy pattern D3, and a portion thereof may be disposed inside the third partition opening OP3-P. According to an embodiment, the third lower inorganic encapsulation pattern LIL3may be in contact with the inner side surface of the first layer L1defining the first region of the third partition opening OP3-P.

The organic encapsulation layer OL may cover the first to third lower inorganic encapsulation patterns LIL1, LIL2, and LIL3and provide a flat upper surface. The upper inorganic encapsulation layer UIL may be disposed on the organic encapsulation layer OL.

The first to third lower inorganic encapsulation patterns LIL1, LIL2, and LIL3and the upper inorganic encapsulation layer UIL may protect the display element layer DP-OLED from moisture/oxygen, and the organic encapsulation layer OL may protect the display element layer DP-OLED from foreign substances such as dust particles.

FIGS.7A to7Jare schematic cross-sectional views illustrating steps of a method of manufacturing a display panel according to an embodiment.FIGS.8A to8Jare schematic cross-sectional views illustrating steps of the method of manufacturing the display panel according to an embodiment.FIGS.9A to9Jare schematic cross-sectional views illustrating steps of the method of manufacturing the display panel according to an embodiment. In the description with reference toFIGS.7A to9J, same/similar reference numerals will be used for the same/similar components as those described inFIGS.1A to5, and duplicate descriptions may be omitted.

The method of manufacturing the display panel according to the disclosure may include: providing a preliminary display panel including a base layer, a first anode disposed above the base layer, a pixel defining layer disposed above the base layer and having a first light-emitting opening defined therein and exposing a portion of the first anode, and a conductive partition disposed on the pixel defining layer and having a first partition opening defined therein and corresponding to the first light-emitting opening; depositing a first organic material so as to form a first light-emitting pattern at least partially disposed in the first light-emitting opening and the first partition opening and a first dummy layer spaced apart from the first light-emitting pattern and disposed on the conductive partition; depositing a first conductive material so as to form a first cathode at least partially disposed in the first partition opening; forming a first mask pattern, which overlaps the first light-emitting opening and contains a second conductive material, on the conductive partition; patterning the first dummy layer by using the first mask pattern so as to form a first dummy pattern from the first dummy layer; and depositing the second conductive material so as to form a first conductive layer from the first mask pattern.

The method of manufacturing the display panel according to the disclosure may include a first group process, a second group process, a third group process, and a fourth group process. The first to third group processes may respectively form components of the first to third light-emitting elements ED1, ED2, and ED3(seeFIG.9I) and the thin film encapsulation layer TFE (seeFIG.9I). The fourth group process may be a process of completing the display panel DP (seeFIG.9J) by forming the remaining components of the thin film encapsulation layer TFE (seeFIG.9J).

In this embodiment, the first light-emitting element ED1(seeFIG.7J) and the first lower inorganic encapsulation pattern LIL1(seeFIG.7J) covering the first light-emitting element ED1(seeFIG.7J) may be formed through the first group process. Hereinafter, the first group process will be described with reference toFIGS.7A to7J.

Referring toFIG.7A, the first group process according to this embodiment may include forming an initial photoresist layer PR-I on a preliminary first display panel DP-I1.

The preliminary first display panel DP-I1provided in this embodiment may include a base layer BL, a circuit element layer DP-CL, first to third anodes AE1, AE2, and AE3, first to third sacrificial patterns SP1, SP2, and SP3, a preliminary pixel defining layer PDL-I, and a preliminary conductive partition layer PW-I.

The circuit element layer DP-CL may be formed through a process of manufacturing a selectable circuit element. In the process, an insulating layer, a semiconductor layer, and a conductive layer may be formed by a method such as coating or deposition, and the insulating layer, the semiconductor layer, and the conductive layer may be selectively patterned through photolithography and etching processes to form semiconductor patterns, conductive patterns, signal lines, and the like within the spirit and the scope of the disclosure.

The anodes AE1, AE2, and AE3and the sacrificial patterns SP1, SP2, and SP3may be formed through a same patterning process. The preliminary pixel defining layer PDL-I may cover all of the anodes AE1, AE2, and AE3and the sacrificial patterns SP1, SP2, and SP3.

The preliminary conductive partition layer PW-I may include a first layer L1and a second layer L2disposed on the first layer L1. The first layer L1may have a first conductivity and a first thickness, and the second layer L2may have a second conductivity lower than the second conductivity and a second thickness smaller than the first thickness.

The initial photoresist layer PR-I may be formed by forming a preliminary photoresist layer on the preliminary conductive partition layer PW-I and patterning the preliminary photoresist layer by using a photo mask. Through the patterning process, an initial opening OP-I overlapping the first anode AE1may be formed in the initial photoresist layer PR-I.

Hereafter, referring toFIGS.7B and7C, the first group process according to this embodiment may include forming a conductive partition, in which a first partition opening is defined, from the preliminary conductive partition layer through a first etching process.

First, as illustrated inFIG.7B, the first etching process may include forming a preliminary first partition opening OP1-PI in the preliminary conductive partition layer PW-I by using the initial photoresist layer PR-I as a mask and dry-etching the first and second layers L1and L2. The dry etching of the first etching process may be performed in an etching environment in which the etching selectivities of the first and second layers L1and L2are substantially the same as each other. Accordingly, the inner side surface of the first layer L1and the inner side surface of the second layer L2defining the preliminary first partition opening OP1-PI may be substantially aligned with each other.

Hereafter, as illustrated inFIG.7C, the first etching process may include forming a first partition opening OP1-P from the preliminary first partition opening OP1-PI by using the initial photoresist layer PR-I as a mask and wet-etching the first and second layers L1and L2. Through this, the conductive partition PW may be formed from the preliminary conductive partition layer PW-I in which the preliminary first partition opening OP1-PI is defined.

The wet etching process in the first etching process may be performed in an environment in which the etching selectivity between the first and second layers L1and L2is high. Accordingly, the inner side surface of the conductive partition PW defining the first partition opening OP1-P may have an undercut shape on a cross section. For example, as the etch rate of the first layer L1with respect to an etching solution is greater than that of the second layer L2, the first layer L1may be mainly etched. Accordingly, the first partition opening OP1-P may include the first region A1and the second region A2, and the inner side surface of the first layer L1defining the first region A1of the first partition opening OP1-P may be formed to be recessed more inward than the inner side surface of the second layer L2defining the second region A2of the first partition opening OP1-P. The inner side surface of the second layer L2defining the second region A2of the first partition opening OP1-P may be closer to the center of the first anode AE1than the inner side surface of the first layer L1defining the first region A1of the first partition opening OP1-P. A tip portion may be formed in the conductive partition PW by a portion of the second layer L2protruding from the first layer L1.

Referring toFIG.7D, the first group process according to this embodiment may include forming a pixel defining layer PDL, in which the first light-emitting opening OP1-E is defined, by patterning the preliminary pixel defining layer PDL-I (seeFIG.7C) through a second etching process. The second etching process may be performed by a dry etching method and may be performed by using the initial photoresist layer PR-I (seeFIG.7C) and the conductive partition PW (for example, the second layer L2) as a mask.

The first group process according to this embodiment may include forming a first sacrificial opening OP1-S in the first sacrificial pattern SP1so as to expose at least a portion of the first anode AE1through a third etching process. The third etching process may be performed by a wet etching method and may be performed by using, as a mask, the initial photoresist layer PR-I (seeFIG.7C) and the pixel defining layer PDL in which the first light-emitting opening OP1-E is defined.

The inner side surface of the first sacrificial pattern SP1defining the first sacrificial opening OP1-S may be formed to be recessed more inward than the inner side surface of the pixel defining layer PDL defining the light-emitting opening OP1-E. This is illustrated as an example, and the inner side surface of the first sacrificial pattern SP1may be aligned with the inner side surface of the pixel defining layer PDL, but the disclosure is not limited to any one embodiment.

The third etching process may be performed in an environment in which the etching selectivity between the first sacrificial pattern SP1and the first anode AE1is high, and through this, it is possible to prevent the second anode AE1from being etched together. For example, by disposing the first sacrificial pattern SP1, which has a higher etch rate than the first anode AE1, between the pixel defining layer PDL and the first anode AE1, it is possible to prevent the first anode AE1from being etched together and damaged during an etching process.

The third etching process may be performed as an etching process separate from the second etching process or may be performed as the same etching process as the second etching process.

Hereafter, the first group process according to this embodiment may include removing the initial photoresist layer PR-I (seeFIG.7C). In this specification, it may be considered that a preliminary second display panel DP-I2(preliminary display panel in claims) is provided after the removing of the initial photoresist layer PR-I (seeFIG.7C). For example, the preliminary second display panel DP-I2may include a base layer BL, a circuit element layer DP-CL, first to third anodes AE1, AE2, and AE3, a first sacrificial pattern SP1having a first sacrificial opening OP1-S defined therein, second and third sacrificial patterns SP2and SP3, a pixel defining layer PDL having a first light-emitting opening OP1-E defined therein, and a conductive partition PW having a first partition opening OP1-P defined therein.

Referring toFIG.7E, the first group process according to this embodiment may include depositing a first organic material so as to form a first light-emitting pattern EL1, depositing a first conductive material so as to form a first cathode CE1, and forming a preliminary first lower inorganic encapsulation layer LIL1-I.

In an embodiment, the depositing of the first organic material may be performed through a thermal evaporation process, and the depositing of the first conductive material may be performed through a sputtering process, but the embodiment is not limited thereto.

The first light-emitting pattern EL1may be separated by the tip portion formed in the conductive partition PW, and at least a portion thereof may be disposed in the first light-emitting opening OP1-E and the first partition opening OP1-P. The first cathode CE1may be separated by the tip portion formed in the conductive partition PW, and at least a portion thereof may be disposed in the first partition opening OP1-P. The first cathode CE1may be provided at a higher incident angle than the first light-emitting pattern EL1and may be formed to be in contact with the inner side surface of the first layer L1.

In the forming of the first light-emitting pattern EL1, a first dummy layer D1-I may be formed together on the conductive partition PW. In the forming of the first cathode CE1, an additional first dummy layer D1a-I may be formed on the conductive partition PW.

The preliminary first lower inorganic encapsulation layer LIL1-I may be formed through a chemical vapor deposition (CVD) process. The preliminary first lower inorganic encapsulation layer LIL1-I may be formed on the conductive partition PW and the first cathode CE1, and a portion of the preliminary first lower inorganic encapsulation layer LIL1-I may be formed inside the first partition opening OP1-P.

The method of manufacturing the display panel according to this embodiment may further include forming a capping pattern between the forming of the first cathode CE1and the forming of the preliminary first lower inorganic encapsulation layer LIL1-I. The capping pattern may be formed through a deposition process, and the capping pattern may be separated by the tip portion formed in the conductive partition PW and disposed in the first partition opening OP1-P.

Referring toFIGS.7F and7G, the first group process according to this embodiment may include forming a first mask pattern MP1. The forming of the first mask pattern MP1may include forming a preliminary first mask layer MP1-I on the preliminary first lower inorganic encapsulation layer LIL1-I, forming a first photoresist layer PR1on the preliminary first mask layer MP1-I, and forming a first mask pattern MP1from the preliminary first mask layer MP1-I.

First, as illustrated inFIG.7F, the preliminary first mask layer MP1-I may be formed through a deposition process. For example, the preliminary first mask layer MP1-I may be formed through a sputtering process, but the embodiment is not limited thereto. The preliminary first mask layer MP1-I may contain a second conductive material. In an embodiment, the second conductive material may include a transparent conductive oxide. For example, the second conductive material may be an indium zinc oxide (IZO) or an indium tin oxide (ITO).

The first photoresist layer PR1may be formed by forming a preliminary photoresist layer on the preliminary first mask layer MP1-I and patterning the preliminary photoresist layer by using a photo mask. Through the patterning process, the first photoresist layer PR1may be formed in a pattern shape overlapping the first light-emitting opening OP1-E.

Hereafter, as illustrated inFIG.7G, the first mask pattern MP1may be formed from the preliminary first mask layer MP1-I through a fourth etching process.

The fourth etching process may remove a portion of the preliminary first mask layer MP1-I overlapping the second and third anodes AE2and AE3by using the first photoresist layer PR1as a mask and wet-etching the preliminary first mask layer MP1-I. The first mask pattern MP1overlapping the first light-emitting opening OP1-E may be formed from the preliminary first mask layer MP1-I, a portion of which is removed.

Referring toFIGS.7H and7I, the first group process according to this embodiment may include removing the first photoresist layer PR1(seeFIG.7G), patterning the preliminary first lower inorganic encapsulation layer LIL1-I through a fifth etching process, and patterning the first dummy layer D1-I through a sixth etching process.

According to this embodiment, the process of removing the first photoresist layer PR1(seeFIG.7G) may be performed prior to the patterning process of the preliminary first lower inorganic encapsulation layer LIL1-I and the patterning process of the first dummy layer D1-I.

According to the disclosure, as the first mask pattern MP1is provided, the first mask pattern MP1may be used as a mask in subsequent patterning processes. Accordingly, the first photoresist layer PR1(seeFIG.7G) may be removed prior to the patterning process of the preliminary first lower inorganic encapsulation layer LIL1-I and the first dummy layer D1-I. For example, the first photoresist layer PR1may be removed before the inside (for example, the outer side surface of the first dummy pattern D1) of the first dummy layer D1-I is exposed, and a portion of the first dummy pattern D1may be prevented from being melted together and damaged by a material used to remove the photoresist layer. Through this, it is possible to prevent a lifting phenomenon between the first dummy pattern D1and the first lower inorganic encapsulation pattern LIL1and also prevent moisture and foreign substances from entering between the first dummy pattern D1and the first lower inorganic encapsulation pattern LIL1, thus preventing the occurrence of defects in the first light-emitting element ED1. Accordingly, it is possible to provide the first light-emitting element ED1having improved process reliability and the display panel DP (seeFIG.9J) including the same.

Through the fifth etching process, the first lower inorganic encapsulation pattern LIL1may be formed from the preliminary first lower inorganic encapsulation layer LIL1-I, and through the sixth etching process, the first dummy pattern D1may be formed from the first dummy layer D1-I.

In the fifth etching process, a portion of the preliminary first lower inorganic encapsulation layer LIL1-I overlapping the second and third anodes AE2and AE3may be patterned so as to be removed by using the first mask pattern MP1as a mask and dry-etching the preliminary first lower inorganic encapsulation layer LIL1-I. The first lower inorganic encapsulation pattern LIL1overlapping the first light-emitting opening OP1-E may be formed from the preliminary first lower inorganic encapsulation layer LIL1-I, a portion of which is removed. A portion of the first lower inorganic encapsulation pattern LIL1may be disposed in the first partition opening OP1-P to cover the first light-emitting element ED1, and another portion of the first lower inorganic encapsulation pattern LIL1may be disposed on the conductive partition PW.

In the sixth etching process, a portion of the first dummy layer D1-I overlapping the second and third anodes AE2, and AE3may be patterned so as to be removed by using the first mask pattern MP1as a mask and dry-etching the first dummy layer D1-I. On a plane, the first dummy pattern D1having a closed-line shape surrounding the first light-emitting region PXA-R (seeFIG.5) may be formed from the first dummy layer D1-I, a portion of which is removed.

In the sixth etching process, a portion of the additional first dummy layer D1a-I overlapping the second and third anodes AE2and AE3may be patterned so as to be removed by dry-etching the additional first dummy layer D1a-I. On a plane, the first additional dummy pattern D1ahaving a closed-line shape surrounding the first light-emitting region PXA-R (seeFIG.5) may be formed from the additional first dummy layer D1a-I, a portion of which is removed. The embodiment is not limited thereto, and the dry etching of the additional first dummy layer D1a-I may be performed as a process separate from the dry etching process of the first dummy layer D1-I.

Referring toFIGS.7I and7J, the first group process according to this embodiment may include depositing a second conductive material so as to form a first conductive layer CL1from the first mask pattern MP1. For example, the second conductive material may be deposited through a sputtering process, but the embodiment is not limited thereto.

In this embodiment, since the same material as that of the first mask pattern MP1is deposited on the first mask pattern MP1, the first mask pattern MP1and the newly deposited second conductive material may form the first conductive layer CL1. The first conductive layer CL1may overlap all of the first to third anodes AE1, AE2, and AE3.

According to this embodiment, the outer side surface of the first dummy pattern D1is exposed through the sixth etching process, but as the depositing of the second conductive material is included after the sixth etching process, the exposed outer side surface of the first dummy pattern D1may be covered by the first conductive layer CL1. Accordingly, damage to the first dummy pattern D1may be prevented in a subsequent step of removing a photoresist layer.

After the first group process, a second group process may be performed. In this embodiment, a second light-emitting element ED2(seeFIG.8J) and a second lower inorganic encapsulation pattern LIL2(seeFIG.8J) covering the second light-emitting element ED2(seeFIG.8J) may be formed through the second group process. Hereinafter, the second group process will be described with reference toFIGS.8A to8J.

Referring toFIG.8A, the second group process according to this embodiment may include forming a second photoresist layer PR2on the first conductive layer CL1. A first photo opening OP1-R overlapping the second anode AE2may be defined in the second photoresist layer PR2.

Referring toFIG.8B, the second group process according to this embodiment may include forming a first conductive opening OP1-C in the first conductive layer CL1through a first etching process. In the first etching process, the first conductive opening OP1-C in the first conductive layer CL1may be formed by using the second photoresist layer PR2as a mask and dry-etching the first conductive layer CL1. The first conductive opening OP1-C may correspond to the first photo opening OP1-R and overlap the second anode AE2.

Referring toFIGS.8C and8D, the second group process according to this embodiment may include forming a second partition opening OP2-P in the conductive partition PW through a second etching process.

First, as illustrated inFIG.8C, the second etching process may include forming a preliminary second partition opening OP2-PI in the conductive partition PW by using the second photoresist layer PR2as a mask and dry-etching the first and second layers L1and L2.

Hereafter, as illustrated inFIG.8D, the second etching process may include forming the second partition opening OP2-P from the preliminary second partition opening OP2-PI by using the second photoresist layer PR2as a mask and wet-etching the first and second layers L1and L2. Regarding the dry etching and wet etching of the first and second layers L1and L2, the aforementioned description thereof will be similarly applied. The inner side surface of the conductive partition PW defining the second partition opening OP2-P may have an undercut shape on a cross section.

Referring toFIG.8D, the second group process according to this embodiment may include forming a second light-emitting opening OP2-E in the pixel defining layer PDL through a third etching process and forming the second sacrificial opening OP2-S in the second sacrificial pattern SP2through a fourth etching process. At least a portion of the second anode AE2may be exposed by the second light-emitting opening OP2-E and the second sacrificial opening OP2-S.

Each of the second light-emitting opening OP2-E and the second sacrificial opening OP2-S may be formed in a manner similar to the forming of the first light-emitting opening OP1-E (seeFIG.7D) and the first sacrificial opening OP1-S (seeFIG.7D) in the first group process. In the second group process, the third etching process may be performed by using the second photoresist layer PR2and the conductive partition PW (for example, the second layer L2) as a mask, and the fourth etching process may be performed by using, as a mask, the pixel defining layer PDL in which the second light-emitting opening OP2-E is defined.

Referring toFIG.8E, the second group process according to this embodiment may include removing the second photoresist layer PR2(seeFIG.8D). In this embodiment, the outer side surface of the first dummy pattern D1may be provided in a state of being covered by the first conductive layer CL1, and therefore, it is possible to prevent the first dummy pattern D1from being damaged by a material injected to remove the second photoresist layer PR2(seeFIG.8D). Accordingly, the lifting phenomenon of the first lower inorganic encapsulation pattern LIL1may be prevented so that damage to the first light-emitting element ED1may be prevented.

Referring toFIG.8F, the second group process according to this embodiment may include depositing a second organic material so as to form a second light-emitting pattern EL2, depositing a first conductive material so as to form a second cathode CE2, and forming a preliminary second lower inorganic encapsulation layer LIL2-I.

The depositing of the second organic material may be performed in a manner similar to the depositing of the first organic material so as to form the first light-emitting pattern EL1(seeFIG.7E) in the first group process. The depositing of the first conductive material so as to form the second cathode CE2may be performed in a manner similar to the depositing of the first conductive material so as to form the first cathode CE1(seeFIG.7E) in the first group process. The preliminary second lower inorganic encapsulation layer LIL2-I may be formed in a manner similar to the forming of the preliminary first lower inorganic encapsulation layer LIL1-I (seeFIG.7E) in the first group process.

In the depositing of the second organic material, a second dummy layer D2-I spaced apart from the second light-emitting pattern EL2may be formed together. In the depositing of the first conductive material, an additional second dummy layer D2a-I spaced apart from the second cathode CE2may be formed together. The second dummy layer D2-I and the additional second dummy layer D2a-I may be disposed on the first conductive layer CL1.

Referring toFIGS.8G and8H, the second group process according to this embodiment may include forming a second mask pattern MP2. The forming of the second mask pattern MP2may include forming a preliminary second mask layer MP2-I on the preliminary second lower inorganic encapsulation layer LIL2-I, forming a third photoresist layer PR3on the preliminary second mask layer MP2-I, forming a second mask pattern MP2from the preliminary second mask layer MP2-I, and removing the third photoresist layer PR3.

First, as illustrated inFIG.8G, the preliminary second mask layer MP2-I may contain a second conductive material and be formed in a manner similar to the forming of the preliminary first mask layer MP1-I (seeFIG.7F) in the first group process.

The third photoresist layer PR3may be formed as a pattern overlapping the second light-emitting opening OP2-E in a manner similar to the forming of the first photoresist layer PR1(seeFIG.7F) in the first group process.

Hereafter, as illustrated inFIG.8H, a second mask pattern MP2may be formed from the preliminary second mask layer MP2-I through a fifth etching process. The forming of the second mask pattern MP2may be performed in a manner similar to the forming of the first mask pattern MP1(seeFIG.7G) in the first group process. A portion of the preliminary second mask layer MP2-I overlapping the first and third anodes AE1and AE3is removed, and the second mask pattern MP2may be formed as a pattern overlapping the second light-emitting opening OP2-E. Hereafter, the third photoresist layer PR3may be removed.

Referring toFIGS.8H and8I, the second group process according to this embodiment may include patterning the preliminary second lower inorganic encapsulation layer LIL2-I through a sixth etching process and patterning the second dummy layer D2-I through a seventh etching process. Through the sixth etching process, the second lower inorganic encapsulation pattern LIL2may be formed from the preliminary second lower inorganic encapsulation layer LIL2-I, and through the seventh etching process, the second dummy pattern D2may be formed from the second dummy layer D2-I.

The patterning of the preliminary second lower inorganic encapsulation layer LIL2-I may be performed in a manner similar to the patterning of the preliminary first lower inorganic encapsulation layer LIL1-I (seeFIG.7H) in the first group process. The patterning of the second dummy layer D2-I may be performed in a manner similar to the patterning of the first dummy layer D1-I (seeFIG.7H) in the first group process. In the sixth etching process and the seventh etching process, the second mask pattern MP2may be used as a mask.

The second lower inorganic encapsulation pattern LIL2may be disposed to overlap the second light-emitting opening OP2-E. A portion of the second lower inorganic encapsulation pattern LIL2may be disposed in the second partition opening OP2-P to cover the second light-emitting element ED2, and another portion of the second lower inorganic encapsulation pattern LIL2may be disposed on the conductive partition PW and the first conductive layer CL1. On a plane, the second dummy pattern D2may have a closed-line shape surrounding the second light-emitting region PXA-G (seeFIG.5).

In the seventh etching process, as the additional second dummy layer D2a-I is dry-etched together, a second additional dummy pattern D2ahaving a closed-line shape surrounding the second light-emitting region PXA-G (seeFIG.5) on a plane may be formed.

Referring toFIGS.8I and8J, the second group process according to this embodiment may include depositing a second conductive material so as to form a second conductive layer CL2from the first conductive layer CL1and the second mask pattern MP2. For example, the second conductive material may be deposited through a sputtering process, but the embodiment is not limited thereto.

In this embodiment, as the same material as that of the first conductive layer CL1and the second mask pattern MP2is deposited, the first conductive layer CL1, the second mask pattern MP2, and the newly deposited second conductive material may form the second conductive layer CL2. The second conductive layer CL2may overlap all of the first to third anodes AE1, AE2, and AE3.

According to this embodiment, the outer side surface of the second dummy pattern D2is exposed through the seventh etching process, but as the depositing of the second conductive material is included after the seventh etching process, the exposed outer side surface of the second dummy pattern D2may be covered by the second conductive layer CL2. Accordingly, it is possible to prevent damage to the second dummy pattern D2in a subsequent step of removing a photoresist layer.

In this embodiment, the second conductive layer CL2may include a first cover portion PP1covering the first dummy pattern D1and the first lower inorganic encapsulation pattern LIL1, a second cover portion PP2covering the second dummy pattern D2and the second lower inorganic encapsulation pattern LIL2, and a third cover portion PP3covering an upper surface of the conductive partition PW which is the remaining portion thereof excluding the first and second cover portions PP1and PP2.

The first cover portion PP1may include a first portion disposed on the first lower inorganic encapsulation pattern LIL1and a second portion covering the outer side surface of the first dummy pattern D1. Damage to the first dummy pattern D1may be prevented by the second portion of the first cover portion PP1. In this embodiment, the first cover portion PP1may not be disposed between the conductive partition PW and the first dummy pattern D1. For example, the first dummy pattern D1may be disposed to be in contact with the upper surface of the conductive partition PW.

The second cover portion PP2may include a first portion C1disposed on the second lower inorganic encapsulation pattern LIL2, a second portion C2disposed between the conductive partition PW and the second dummy pattern D2, and a third portion C3connecting the first portion C1and the second portion C2to each other and covering the outer side surface of the second dummy pattern D2. Damage to the second dummy pattern D2may be prevented by the third portion C3of the second cover portion PP2. In this embodiment, the second portion C2may be disposed to be in contact with the upper surface of the conductive partition PW and the lower surface of the second dummy pattern D2.

After the second group process, a third group process may be performed. In this embodiment, a third light-emitting element ED3(seeFIG.9H) and a third lower inorganic encapsulation pattern LIL3(seeFIG.9H) covering the third light-emitting element ED3(seeFIG.9H) may be formed through the third group process. Hereinafter, the third group process will be described with reference toFIGS.9A to9H.

Referring toFIG.9A, the third group process according to this embodiment may include forming a fourth photoresist layer PR4on the second conductive layer CL2. A second photo opening OP2-R overlapping the third anode AE3may be defined in the fourth photoresist layer PR4.

Referring toFIG.9B, the third group process according to this embodiment may include forming a second conductive opening OP2-C in the second conductive layer CL2through a first etching process. The forming of the second conductive opening OP2-C may be performed in a manner similar to the forming of the first conductive opening OP1-C (seeFIG.8B) in the second group process. The first etching process may use the fourth photoresist layer PR4as a mask, and the second conductive opening OP2-C may correspond to the second photo opening OP2-R and overlap the third anode AE3.

Hereafter, the third group process according to this embodiment may include forming a third partition opening OP3-P in the conductive partition layer PW through a second etching process and forming a third light-emitting opening OP3-E in the pixel defining layer PDL through a third etching process.

The forming of the third partition opening OP3-P may be performed in a manner similar to the forming of the second partition opening OP2-P (seeFIG.8D) in the second group process. In this embodiment, the second etching process may include: forming a preliminary third partition opening in the conductive partition PW by using the fourth photoresist layer PR4as a mask and dry-etching the first and second layers L1and L2; and forming a third partition opening OP3-P from the preliminary third partition opening by using the fourth photoresist layer PR4as a mask and wet-etching the first and second layers L1and L2. The inner side surface of the conductive partition PW defining the third partition opening OP3-P may have an undercut shape on a cross section.

The forming of the third light-emitting opening OP3-E may be performed in a manner similar to the forming of the second light-emitting opening OP2-E (seeFIG.8D) in the second group process. The third etching process may be performed by using the fourth photoresist layer PR4and the conductive partition PW (for example, the second layer L2) as a mask.

Referring toFIG.9C, the third group process according to this embodiment may include removing the fourth photoresist layer PR4. In this embodiment, each of the outer side surface of the first dummy pattern D1and the outer side surface of the second dummy pattern D2may be provided in a state of being covered by the second conductive layer CL2, and therefore, the first and second dummy patterns D1and D2may be prevented from being damaged by a material injected to remove the fourth photoresist layer PR4. Accordingly, the lifting phenomenon of the first and second lower inorganic encapsulation patterns LIL1and LIL2may be prevented, and therefore, damage to the first and second light-emitting elements ED1and ED2may be prevented.

Referring toFIGS.9C and9D, the third group process according to this embodiment may include removing at least a portion of the second conductive layer CL2through a fourth etching process. The fourth etching process may be performed by a wet etching method.

Referring toFIGS.9C,9D, and8Jtogether, in this embodiment, the first cover portion PP1, the first and third portions C1and C3of the second cover portion PP2, and the third cover portion PP3among the second conductive layer CL2may be removed. For example, the second portion C2of the second cover portion PP2among the second conductive layer CL2may not be removed because it is covered by the second dummy pattern D2and the second lower inorganic encapsulation pattern LIL2. The second portion C2remaining after the fourth etching process may form a conductive pattern CDP.

In this embodiment, the patterning of a third sacrificial pattern SP3may be performed together through the fourth etching process. A third sacrificial opening OP3-S may be formed in the third sacrificial pattern SP3so as to expose at least a portion of the third anode AE3. The etching process of the third sacrificial pattern SP3may use the conductive partition PW (for example, the second layer L2) as a mask.

Compared to the second group process, the third group process may include removing the second conductive layer CL2after the forming of the third light-emitting opening OP3-E in order to minimize the residue of the second conductive material remaining in a final product.

As the third sacrificial pattern SP3including a transparent conductive oxide may be etched simultaneously with the second conductive material, the forming of the third sacrificial opening OP3-S may be performed simultaneously with the removing of the second conductive layer CL2so that the process may be relatively simplified.

Referring toFIG.9E, the third group process according to this embodiment may include depositing a third organic material so as to form a third light-emitting pattern EL3, depositing a first conductive material so as to form a third cathode CE3, and forming a preliminary third lower inorganic encapsulation layer LIL3-I.

The depositing of the third organic material may be performed in a manner similar to the depositing of the first organic material so as to form the first light-emitting pattern EL1(seeFIG.7E) in the first group process. The depositing of the first conductive material so as to form the third cathode CE3may be performed in a manner similar to the depositing of the first conductive material so as to form the first cathode CE1(seeFIG.7E) in the first group process. The preliminary third lower inorganic encapsulation layer LIL3-I may be formed in a manner similar to the forming of the preliminary first lower inorganic encapsulation layer LIL1-I (seeFIG.7E) in the first group process.

In the depositing of the third organic material, a third dummy layer D3-I spaced apart from the third light-emitting pattern EL3may be formed together. In the depositing of the first conductive material, an additional third dummy layer D3a-I spaced apart from the third cathode CE3may be formed together. In the third group process, the third dummy layer D3-I and the additional third dummy layer D3a-I may be disposed on the conductive partition PW and cover the first dummy pattern D1, the first lower inorganic encapsulation pattern LIL1, the second dummy pattern D2, and the second lower inorganic encapsulation pattern LIL2.

Referring toFIGS.9F and9G, the third group process according to this embodiment may include forming a third mask pattern MP3. The forming of the third mask pattern MP3may include forming a preliminary third mask layer MP3-I on the preliminary third lower inorganic encapsulation layer LIL3-I, forming a fifth photoresist layer PR5on the preliminary third mask layer MP3-I, forming a third mask pattern MP3from the preliminary third mask layer MP3-I, and removing the fifth photoresist layer PR5.

First, as illustrated inFIG.9F, the preliminary third mask layer MP3-I may include a second conductive material and be formed in a manner similar to the forming of the preliminary first mask layer MP1-I (seeFIG.7F) in the first group process.

The fifth photoresist layer PR5may be formed as a pattern overlapping the third light-emitting opening OP3-E in a manner similar to the forming of the first photoresist layer PR1(seeFIG.7F) in the first group process.

Hereafter, as illustrated inFIG.9G, a third mask pattern MP3may be formed from the preliminary third mask layer MP3-I through a fifth etching process. The forming of the third mask pattern MP3may be performed in a manner similar to the forming of the first mask pattern MP1(seeFIG.7G) in the first group process. As a portion of the preliminary third mask layer MP3-I overlapping the first and second anodes AE1and AE2is removed, the third mask pattern MP3may be formed as a pattern overlapping the third light-emitting opening OP3-E. Hereafter, the fifth photoresist layer PR5may be removed.

Referring toFIGS.9G and9H, the third group process according to this embodiment may include patterning the preliminary third lower inorganic encapsulation layer LIL3-I through a sixth etching process and patterning the third dummy layer D3-I through a seventh etching process. Through the sixth etching process, the third lower inorganic encapsulation pattern LIL3may be formed from the preliminary third lower inorganic encapsulation layer LIL3-I, and through the seventh etching process, the third dummy pattern D3may be formed from the third dummy layer D3-I.

The patterning of the preliminary third lower inorganic encapsulation layer LIL3-I may be formed in a manner similar to the patterning of the preliminary first lower inorganic encapsulation layer LIL1-I (seeFIG.7H) in the first group process. The patterning of the third dummy layer D3-I may be performed in a manner similar to the patterning of the first dummy layer D1-I (seeFIG.7H) in the first group process. In the sixth etching process and the seventh etching process, the third mask pattern MP3may be used as a mask.

The third lower inorganic encapsulation pattern LIL3may be disposed to overlap the third light-emitting opening OP3-E. A portion of the third lower inorganic encapsulation pattern LIL3may be disposed in the third partition opening OP3-P to cover the third light-emitting element ED3, and another portion of the third lower inorganic encapsulation pattern LIL3may be disposed on the conductive partition PW. On a plane, the third dummy pattern D3may have a closed-line shape surrounding the third light-emitting region PXA-B (seeFIG.5).

In the seventh etching process, as the additional third dummy layer D3a-I is dry-etched together, a third additional dummy pattern having a closed-line shape surrounding the third light-emitting region PXA-B (seeFIG.5) on a plane (D3a) may be formed.

Referring toFIGS.9H and9I, the third group process according to this embodiment may include removing the third mask pattern MP3through an eighth etching process. The eighth etching process may be performed by a wet etching method.

In an embodiment, since the conductive pattern CDP may include the same material as the third mask pattern MP3, a portion of the conductive pattern CDP may be removed together with the third mask pattern MP3during the eighth etching process. For example, as the outer side portion of the conductive pattern CDP is exposed from the second dummy pattern D2, the outer side portion of the conductive pattern CDP may be partially removed. Accordingly, the outer side surface of the conductive pattern CDP may be disposed closer to the center of the second anode AE2than the outer side surface of the second dummy pattern D2. The embodiment is not limited thereto, and the conductive pattern CDP may not be removed during the eighth etching process.

Through the first to third group processes, the first to third light-emitting elements ED1, ED2, and ED3and the first to third lower inorganic encapsulation patterns LIL1, LIL2, and LIL3may be formed. Hereafter, a fourth group process may be performed, and the display panel DP (seeFIG.9J) including a thin film encapsulation layer TFE (seeFIG.9J) may be completed through the fourth group process.

Referring toFIG.9J, the fourth group process according to this embodiment may include forming an organic encapsulation layer OL on the conductive partition PW and the first to third lower inorganic encapsulation patterns LIL1, LIL2, and LIL3and forming an upper inorganic encapsulation layer UIL on the organic encapsulation layer OL. Through this, the display panel DP including a base layer BL, a circuit element layer DP-CL, a display element layer DP-OLED, and a thin film encapsulation layer TFE may be formed.

FIGS.10A to101are schematic cross-sectional views illustrating steps of the method of manufacturing the display panel according to an embodiment. According to the method of manufacturing the display panel according to this embodiment, no residue of the second conductive material used during the manufacturing process may be left. Hereinafter, a detailed description will be given with reference toFIGS.10A to101. Same/similar reference numerals will be used for the same/similar elements as those described inFIGS.7A to9J, duplicate descriptions may be omitted, and differences will be described.

Referring toFIGS.10A and10B, differences in the first group process compared to the embodiment described above inFIGS.7A to7Jwill be described.

First, referring toFIG.10A, the first group process according to this embodiment may include forming a first initial photoresist layer PR-I1on the preliminary first display panel DP-I1(seeFIG.7A). In the first initial photoresist layer PR-I1, first to third initial openings OP-I1, OP-I2, and OP-I3respectively overlapping the first to third anodes AE1, AE2, and AE3may be defined.

Hereafter, the first group process according to this embodiment may include forming preliminary first to third partition openings OP1-PI, OP2-PI, and OP3-PI on the preliminary conductive partition layer PW-I.

A 1-1st etching process may be performed by a dry etching method by using the first initial photoresist layer PR-I1as a mask. The dry etching of the 1-1st etching process may be performed in an etching environment in which the etching selectivities of the first layer L1and the second layer L2are substantially the same as each other. Accordingly, the inner side surface of the first layer L1and the inner side surface of the second layer L2respectively defining the preliminary first to third partition openings OP1-PI, OP2-PI, and OP3-PI may be substantially aligned with each other.

Referring toFIGS.10A and10B, the first group process according to this embodiment may include removing the first initial photoresist layer PR-I1and forming a second initial photoresist layer PR-I2. A fourth initial opening OP-I4corresponding to the preliminary first partition opening OP1-PI may be defined in the second initial photoresist layer PR-I2.

The first group process according to this embodiment may include forming a first partition opening OP1-P from the preliminary first partition opening OP1-PI through a 1-2nd etching process.

The 1-2nd etching process may be performed by a wet etching method by using the second initial photoresist layer PR-I2as a mask. The wet etching of the 1-2nd etching process may be performed in an environment in which the etching selectivity between the first layer L1and the second layer L2is high. Accordingly, the inner side surface of the first layer L1defining the first region A1of the first partition opening OP1-P may be formed to be recessed more inward than the inner side surface of the second layer L2defining the second region A2of the first partition opening OP1-P, and a tip portion may be formed in the conductive partition PW.

According to this embodiment, the preliminary first to third partition openings OP1-PI, OP2-PI, and OP3-PI may be simultaneously formed by using one photoresist layer. Accordingly, the preliminary second display panel DP-I2according to this embodiment may include a base layer BL, a circuit element layer DP-CL, first to third anodes AE1, AE2, and AE3, a pixel defining layer PDL having a first light-emitting opening OP1-E defined therein, and a conductive partition PW having a first partition opening OP1-P and preliminary second and third partition openings OP2-PI and OP3-PI defined therein.

Referring toFIGS.10C to10G, differences in the second group process compared to the embodiment described above inFIGS.8A to8Jwill be described.

FIG.10Cillustrates forming a second photoresist layer PR2on the first conductive layer CL1during the second group process. A first photo opening OP1-R overlapping the second anode AE2may be defined in the second photoresist layer PR2.

In this embodiment, the second photoresist layer PR2may expose a portion of the first conductive layer CL1disposed on the upper surface of the conductive partition PW through the first photo opening OP1-R.

In the second group process,FIG.10Dillustrates forming a first conductive opening OP1-C in the first conductive layer CL1through the first etching process and forming a second partition opening OP2-P in the conductive partition PW through the second etching process.

In this embodiment, a portion of the upper surface of the conductive partition PW may be exposed from the first conductive layer CL1through the first conductive opening OP1-C.

According to this embodiment, in the forming of the second partition opening OP2-P in the conductive partition PW, as the preliminary second partition opening OP2-PI is provided to the conductive partition PW in a state in which the preliminary second partition opening OP2-PI has been formed in the conductive partition PW, the second etching process may be performed only through a wet etching process of the conductive partition PW. The second partition opening OP2-P may be formed from the preliminary second partition opening OP2-PI through the wet etching process of the conductive partition PW.

FIGS.10E and10Fillustrate forming a second mask pattern MP2, patterning a preliminary second lower inorganic encapsulation layer LIL2-I, and patterning a second dummy layer D2-I in the second group process.

The forming of the second mask pattern MP2may include forming a preliminary second mask layer MP2-I, forming a third photoresist layer PR3, forming a second mask pattern MP2from the preliminary second mask layer MP2-I, and removing the third photoresist layer PR3.

As illustrated inFIG.10E, in this embodiment, the third photoresist layer PR3may entirely overlap the first conductive opening OP1-C. For example, the third photoresist layer PR3may be formed to non-overlap the first conductive layer CL1on a plane. Accordingly, as illustrated inFIG.10F, the second mask pattern MP2according to this embodiment may be formed to non-overlap the first conductive layer CL1on a plane.

In the patterning of the second dummy layer D2-I, a second dummy pattern D2may be formed from the second dummy layer D2-I, the first conductive layer CL1may not be disposed below the second dummy pattern D2, and the second dummy pattern D2may be entirely in contact with the upper surface of the conductive partition PW.

FIGS.10F and10Gillustrate depositing a second conductive material in the second group process so as to form a second conductive layer CL2from the second mask pattern MP2.

The second conductive layer CL2may include: a first cover portion PP1covering the first dummy pattern D1and the first lower inorganic encapsulation pattern LIL1; a second cover portion PP2covering the second dummy pattern D2and the second lower inorganic encapsulation pattern LIL2; and a third cover portion PP3covering the upper surface of the conductive partition PW, the inner side surface thereof defining the preliminary third partition opening OP3-PI, and the upper surface of the pixel defining layer PDL exposed through the preliminary third partition opening OP3-PI, which are the remaining portions thereof excluding the first and second cover portions PP1and PP2.

In this embodiment, the second cover portion PP2may include a first portion C1disposed on the second lower inorganic encapsulation pattern LIL2and a second portion C2covering the outer side surface of the second dummy pattern D2. The second cover portion PP2ofFIG.10Gmay not include a third portion C3(seeFIG.8J) in case that compared to the second cover portion PP2ofFIG.8J. For example, the second cover portion PP2may not be disposed below the second dummy pattern D2.

Referring toFIG.10H, differences in the third group process compared to the embodiment described above inFIGS.9A to9Iwill be described.FIG.10Hillustrates removing at least a portion of the second conductive layer CL2(seeFIG.10G) through the fourth etching process in third group process. In this embodiment, as the second conductive layer CL2(seeFIG.10G) may not be disposed below the second dummy pattern D2, the second conductive layer CL2(seeFIG.10G) may be entirely removed.

FIG.10Iillustrates a display panel DP-1completed through the fourth group process. As illustrated inFIG.10I, according to this embodiment, the second conductive material may not remain in the display panel DP-1that has been manufactured.

Also in this embodiment, as the outer side surfaces of the first to third dummy patterns D1, D2, and D3may not be exposed during the process of removing the photoresist layer, it is possible to prevent the first to third dummy patterns D1, D2, and D3from being damaged during the process. Accordingly, the lifting phenomenon of the first to third lower inorganic encapsulation patterns LIL1, LIL2, and LIL3may be prevented, and therefore, it is possible to provide the display panel DP-1including the first to third light-emitting elements ED1, ED2, and ED3with improved process reliability.

In an embodiment, the descriptions given above with reference toFIGS.7A to7Jmay be applied to the first process group, and the descriptions given above with reference toFIGS.10C to101may be applied to the second to fourth process groups. By way of example, the descriptions given above with reference toFIGS.10A and10Bmay be applied to the first process group, and the descriptions given above with reference toFIGS.8A to9Jmay be applied to the second to fourth process groups.

According to the disclosure, since a light-emitting layer may be patterned without a metal mask, the display panel having improved process reliability and capable of readily implementing high resolution may be provided.

According to the disclosure, the lifting phenomenon of an inorganic encapsulation pattern may be prevented by preventing damage to an organic pattern disposed below the inorganic encapsulation pattern. Through this, it is possible to prevent the inflow of foreign matter such as moisture and to provide light-emitting elements with improved process reliability and reduced defects and a display panel including the same.

According to the disclosure, it is possible to provide a method for manufacturing the display panel including light-emitting elements which may readily implement high resolution and have improved process reliability.

Although the above has been described with reference to embodiments, those skilled in the art or those having ordinary knowledge in the art will appreciate the spirit and technical scope of the disclosure and as described in the claims to be described later. It will be understood that the disclosure can be variously modified and changed within the scope of the disclosure. Therefore, the technical scope of the disclosure is not limited to the contents described in the detailed description of the specification, but should also be determined by the claims.