Patent Publication Number: US-2023157083-A1

Title: Display device and manufacturing method thereof

Description:
CROSS-REFERENCE TO RELATED APPLICATION 
     This application claims priority to and the benefit of Korean Patent Application No. 10-2021-0157478 filed in the Korean Intellectual Property Office on Nov. 16, 2021, the entire content of which is incorporated herein by reference. 
     BACKGROUND 
     (a) Technical Field 
     The present disclosure relates to a display device and a manufacturing method thereof. 
     (b) Description of the Related Art 
     A display device includes a display area that can display an image, wherein a plurality of pixels are positioned in the display area. Each pixel includes a display element such as a light emitting diode and a pixel circuit including a plurality of transistors and at least one capacitor for driving the display element. 
     The display area includes a pixel area, which is a unit that is connected to each pixel circuit and can emit light. The display area includes a plurality of pixel areas emitting light of different colors. 
     The light emitting diode may include two electrodes and an emission layer positioned between the two electrodes. The emission layer may be formed using a mask having an opening corresponding to each pixel area. 
     The display element of the display device may be protected from penetration of impurities such as external moisture and oxygen by being sealed by an encapsulation layer. The encapsulation layer includes at least one organic layer. The organic layer may be formed using an Inkjet process. 
     The above information disclosed in this Background section is only for enhancement of understanding of the background of the disclosure, and therefore it may contain information that does not form the prior art that is already known to a person of ordinary skill in the art. 
     SUMMARY 
     A display device including an organic layer that is evenly formed throughout a substrate by improving spreadability of a dropped ink layer in an inkjet process can be easily formed, and can increase strength against external pressure. 
     A display device according to an embodiment includes: a substrate; an insulation layer that is positioned on the substrate and includes a plurality of openings; a plurality of emission layers that are positioned in the openings; and a plurality of spacers that are positioned on the insulation layer, wherein an area where the plurality of emission layers are positioned defines a plurality of light emitting regions on a plane, at least one of the spacers has a shape of a circle, a regular polygon having five or more sides, or a regular polygon with at least one rounded corner and five or more sides, a planar area of at least one of the spacers is larger than a planar area of a smallest light emitting region among the plurality of light emitting regions, and a number of the plurality of the spacers positioned in a predetermined region is at least 30% of a number of the plurality of the light emitting regions arranged in the predetermined region. 
     A width of the plurality of spacers in a first direction may be 50% or more of a distance between two light emitting regions that are neighboring in the first direction. 
     A width of the plurality of spacers in a second direction that is perpendicular to the first direction may be 50% or more of the distance between two light emitting regions that are neighbored in the second direction. 
     The plurality of spacers may be disposed at a preset interval in at least one of the first direction and the second direction. 
     One spacer may be positioned between two light emitting regions that neighbor each other in one direction. 
     The spacer includes a plurality of sub-spacers that are spaced apart from each other. 
     A planar shape of the sub-spacer may include one of a circle, a regular polygon having five or more sides, and a regular polygon with at least one rounded corner and five or more sides. 
     The plurality of light emitting regions may be arranged in a first direction and a second direction, and one spacer may be positioned for no more than two of the plurality of light emitting regions arranged in the first direction, and one spacer may be positioned for no more than two of the plurality of light emitting regions arranged in the second direction. 
     The insulation layer and the spacer may include a same material. 
     The insulation layer and the spacer may include different materials. 
     The display device may further include: a pixel electrode that is positioned between the substrate and the insulation layer; and a common electrode that is positioned on the emission layer, wherein the pixel electrode, the emission layer, and the common electrode may form a light emitting diode. 
     The display device may further include an organic layer that is positioned on the light emitting diode and coated on an entire surface of the substrate. 
     A display device according to an embodiment includes: a substrate; an insulation layer that is positioned on the substrate and includes a plurality of openings; a plurality of emission layers that are positioned in the opening; and a plurality of spacers that are positioned on the insulation layer, wherein an area where the plurality of emission layers are positioned defines a plurality of light emitting regions on a plane, at least one of the spacers has a shape of a circle, a regular polygon having five or more sides, or a regular polygon with at least one rounded corner and five or more sides, and a number of the plurality of the spacers positioned in a predetermined region is at least 30% of a number of the plurality of the light emitting regions arranged in the predetermined region. 
     A width of the plurality of spacers in a first direction may be 50% or more of a distance between two light emitting regions that are neighboring in the first direction. 
     A width of the plurality of spacers in a second direction that is perpendicular to the first direction may be 50% or more of a distance between two light emitting regions that are neighbored in the second direction. 
     The plurality of spacers may be disposed at a preset interval in at least one of the first direction and the second direction. 
     The spacer may include a plurality of sub-spacers that are spaced apart from each other. 
     A planar shape of the sub-spacer may include one of a circle, a regular polygon having five or more sides, and a regular polygon with at least one rounded corner and five or more sides. 
     The plurality of light emitting regions may be arranged in a first direction and a second direction, one spacer may be positioned for no more than two of the plurality of light emitting regions arranged in the first direction, and one spacer may be positioned for no more than two of the plurality of light emitting regions arranged in the second direction. 
     A manufacturing method of a display device according to an embodiment includes: forming a thin film transistor on a substrate; forming a plurality of pixel electrodes on the thin film transistor; forming an insulation layer including an organic material on the plurality of pixel electrodes and a plurality of spacers positioned on the insulation layer; disposing a mask including a plurality of openings on the plurality of spacers; and forming a plurality of emission layers in an opening of the insulation layer through the plurality of openings of the mask, wherein a shape of the spacer may be one of a circule, a regular polygon having five or more sides, or a regular polygon with at least one rounded corner and five or more sides,. A planar area of the spacer may be larger than a planar area of a smallest light emitting region among the plurality of light emitting regions, and a number of the plurality of the spacers positioned in a predetermined region is at least 30% of a number of the plurality of the light emitting regions arranged in the predetermined region. 
     According to the embodiments, it is possible to form an organic layer evenly onhroughout the substrate by improving the spreadability of the ink layer dropped in the Inkjet process for forming the organic layer of the display device, and the strength against external pressure can be increased. 
    
    
     
       BRIEF DESCRIPTION OF THE DRAWINGS 
         FIG.  1    is a cross-sectional view of a display device according to an embodiment, 
         FIG.  2    is a cross-sectional view of a process of a manufacturing method of the display device according to the embodiment, 
         FIG.  3   ,  FIG.  4   ,  FIG.  5    and  FIG.  6    are top plan views of a display area of a display device according to an embodiment, 
         FIGS.  7 A,  7 B,  7 C,  7 D,  7 E,  8 A,  8 B,  8 C,  8 D,  8 E,  9 A,  9 B,  10 A, and  10 B  respectively illustrate examples of planar shapes of a spacer included in a display device according to an embodiment, 
         FIG.  11    is a top plan view of a display area of a display device according to an embodiment, 
         FIG.  12    is a top plan view of a display area of a display device according to a comparative example, 
         FIG.  13    and  FIG.  14    show movement of ink dropped at the periphery of a spacer according to the comparative example, 
         FIG.  15    is a figure showing spreadability of the dropped ink in a manufacturing process of the display device according to the comparative example, 
         FIG.  16    and  FIG.  17    show movement of ink dropped at the periphery of the spacer according to the embodiment, 
         FIG.  18    shows the spreadability of the ink dropped in a manufacturing process of the display device according to the embodiment, 
         FIG.  19    is a cross-sectional view of a display device according to an embodiment. 
     
    
    
     DETAILED DESCRIPTION OF THE EMBODIMENTS 
     Hereinafter, embodiments of the present invention will be described more fully with reference to the accompanying drawings, in which embodiments of the invention are shown. The inventive concept may be implemented in several different forms and is not limited to the embodiments described herein. 
     In order to clearly describe the disclosed concept, parts that are irrelevant to the description have been omitted, and like reference numerals designate like elements throughout the specification. 
     In the drawings, size and thickness of each element are arbitrarily illustrated for convenience of description, and the inventive concept is not necessarily limited to as illustrated in the drawings. In the drawings, the thickness of layers, films, panels, regions, etc., are exaggerated for clarity. In addition, in the drawings, for better understanding and ease of description, the thicknesses of some layers and regions are exaggerated. 
     It will be understood that when an element such as a layer, film, region, or substrate is referred to as being “on” another element, it can be directly on the other element or intervening elements may also be present. In contrast, when an element is referred to as being “directly on” another element, there are no intervening elements present. Further, throughout the specification, the word “on” a target element will be understood to mean positioned above or below the target element, and will not necessarily be understood to mean “at an upper side” indicating a direction that is opposite of the direction of gravity. 
     In addition, unless explicitly described to the contrary, the word “comprise”, and variations such as “comprises” or “comprising”, will be understood to imply the inclusion of stated elements but not the exclusion of any other elements. 
     Further, throughout the specification, the phrase “on a plane” means viewing a target portion from the top, and the phrase “on a cross-section” means viewing a cross-section formed by vertically cutting a target portion from the side. 
     Referring to  FIG.  1    to  FIG.  10   , a display device according to an embodiment will be described. 
       FIG.  1    is a cross-sectional view of a display device according to an embodiment. 
     Referring to  FIG.  1   , a display device according to an embodiment includes a display area where an image can be displayed, and the display area includes a plurality of pixels PX 1 , PX 2 , and PX 3  which are units for displaying an image. 
     The display device may include a plurality of pixels PX 1 , PX 2 , and PX 3  positioned on a substrate  110 . The substrate  110  may include an insulating material such as glass or plastic, and may have flexibility. 
     A first conductive layer including a conductive pattern  111  and a plurality of signal lines and voltage lines may be positioned on the substrate  110 . The first conductive layer may include a conductive metal or a semiconductor material having a conductive characteristic that is equivalent to that of the conductive metal. 
     A buffer layer  120 , which is an insulation layer, may be positioned on the first conductive layer, and a plurality of active patterns  134  may be positioned on the buffer layer  120 . The active pattern  134  may include a semiconductor material such as an oxide semiconductor such as amorphous silicon, polysilicon, or IGZO. 
     A first insulation layer  140  may be positioned on the active pattern  134 , and a second conductive layer including a gate electrode  154  may be positioned on the first insulation layer  140 . The active pattern  134  and the gate electrode  154  may form a thin film transistor together. 
     At least one of the first conductive layer and the second conductive layer may include at least one of metals such as copper (Cu), aluminum (Al), magnesium (Mg), silver (Ag), gold (Au), platinum (Pt), palladium (Pd), nickel (Ni), neodymium (Nd), iridium (Ir), molybdenum (Mo), tungsten (W), titanium (Ti), chromium (Cr), tantalum (Ta), or alloys thereof. 
     A second insulation layer  160  may be positioned on the second conductive layer, and a third insulation layer  180  may be positioned on the second insulation layer  160 . 
     At least one of the buffer layer  120 , the second insulation layer  160 , and the third insulation layer  180  contains an inorganic insulating material such as a silicon nitride (SiN x ), a silicon oxide (SiO x ), and a silicon oxynitride (SiO x N y ), and/or organic insulating material. 
     The second insulation layer  160  may be omitted in some embodiments. 
     A third conductive layer including a plurality of pixel electrodes  191  may be positioned on the third insulation layer  180 . The pixel electrode  191  may be electrically connected with a conductive area of the active pattern  134  through an opening  89  of the first insulation layer  140 , the second insulation layer  160 , and the third insulation layer  180 . 
     The third conductive layer may contain either a semi-transparent conducting material or a reflective conducting material. 
     A fourth insulation layer  350  may be positioned on the third conductive layer. The fourth insulation layer  350  includes openings  355  that are respectively positioned on pixel electrodes  191  of the pixels PX 1 , PX 2 , and PX 3 . 
     The fourth insulation layer  350  may include an organic insulating material such as a photoresist, a polyacryl-based resin, a polyimide-based resin, an acryl-based resin, or a silicone compound. 
     An emission layer  370  is positioned on each pixel electrode  191 . The emission layer  370  may include a portion positioned inside the opening  355  of the fourth insulation layer  350 . 
     The emission layer  370  may include an organic light emitting material or an inorganic light emitting material. 
     The emission layers  370  positioned on the different pixels PX 1 , PX 2 , and PX 3  may contain a light emitting material capable of emitting light of different colors, or may contain a light emitting material emitting a first color light, which may be blue light. 
     A plurality of spacers  360  are positioned on the fourth insulation layer  350 . The spacer  360  may include the same material as the fourth insulation layer  350 , but alternatively may include other organic materials. The fourth insulation layer  350  and the spacer  360  form two portions with different thicknesses through one photo process using an optical mask including at least two portions with different light transmittance, and a relatively thin fourth insulation layer  350  portion because there is no spacer  360  thereon, and a portion of the spacer  360  having a relatively thick thickness by overlapping the fourth insulation layer  350  and the spacer  360  may be formed, and the fourth insulation layer  350  and the spacer  360  may be sequentially formed through different photo processes. 
     The spacer  360  is not positioned inside the opening  355  of the fourth insulation layer  350 . That is, the spacer  360  does not overlap the opening  355  in the xy plane. 
     A detailed feature of the spacer  360  according to one embodiment will be described in more detail later. 
       FIG.  2    is a cross-sectional view of a process of a manufacturing method of the display device according to the embodiment. 
     Referring to  FIG.  2    together with  FIG.  1   , in a manufacturing method of the display device according to the embodiment, when the above-described constituent elements disposed on the substrate  110 , that is, the thin film transistor, the plurality of pixel electrodes  191 , the fourth insulation layer  350 , and the spacer  360  are sequentially stacked and then the emission layer  370  of each of the pixels PX 1 , P 2 , and PX 3  is formed, a plurality of openings  520  corresponding to the opening  355  of the fourth insulation layer  350  and a mask  500  including a blocking portion  510  may be used. The mask  500  may include, for example, a fine metal mask that includes the blocking portion  510  containing a metal. Through the opening  520  of the mask  500 , a material of the emission layer  370  can be laminated into the opening  355 . 
     In the process of forming the emission layer  370 , the spacer  360  may serve to support the mask  500 . 
     When the user uses the display device after the display device is completed, the spacer  360  may function to resist the pressure when the user applies external pressure to the display device. Therefore, when using the display device, it is possible to prevent damage to elements such as the emission layer  370  and the thin film transistor disposed below the emission layer  370 , thereby increasing the strength of the display device against external pressure. 
     A common electrode  270  is positioned on the emission layer  370  and the spacer  360 . The common electrode  270  may be continuously formed over the plurality of pixels PX 1 , PX 2 , and PX 3 . The common electrode  270  may include a conductive transparent material. 
     Each pixel electrode  191 , the emission layer  370 , and the common electrode  270  together form a light emitting diode, and one of the pixel electrode  191  and the common electrode  270  becomes a cathode and the other becomes an anode. 
     A region in which the opening  355  of the fourth insulation layer  350  is positioned may define light emitting regions P 1 , P 2 , and P 3  of the respective pixels PX 1 , PX 2 , and PX 3 . 
       FIG.  3   ,  FIG.  4   ,  FIG.  5   , and  FIG.  6    are top plan views of a display area of a display device according to an embodiment. 
       FIG.  3    to  FIG.  6    illustrate alignments of a plurality of light emitting regions P 1 , P 2 , and P 3  on a xy plane, as an example. A plurality of light emitting regions P 1 , P 2 , and P 3  according to an embodiment may include a first light emitting region P 1  of a first pixel PX 1 , a second light emitting region P 2  of a second pixel PX 2 , and a third light emitting region P 3  of a third pixel PX 3 . The first light emitting region P 1 , the second light emitting region P 2 , and the third light emitting region P 3  may emit light of different colors. For example, the first light emitting region P 1  may emit red, the second light emitting region P 2  may emit green, and the third light emitting region P 3  may emit blue, but are not limited thereto. In the present description, unless otherwise described, embodiments in which the first light emitting region P 1  emits red light, the second light emitting region P 2  emits green light, and the third light emitting region P 3  emits blue light will be mainly described. 
     According to an embodiment, the first light emitting region P 1  and the third light emitting region P 3  may be alternately arranged in an x direction and a y direction, the first light emitting region P 1  and the second light emitting region P 2  may be alternately arranged in one diagonal direction that is oblique to the x direction and the y direction, and the second light emitting region P 2  and the third light emitting region P 3  may be alternately arranged in another oblique direction. However, the arrangement of the plurality of light emitting regions including the first light emitting region P 1 , the second light emitting region P 2 , and the third light emitting region P 3  is not limited thereto. 
     At least two of the first light emitting region P 1 , the second light emitting region P 2 , and the third light emitting region P 3  may be different from each other in size on the xy plane. Referring to  FIG.  3    to  FIG.  6   , the area on the xy plane of the second light emitting region P 2  may be the smallest, and the area on the xy plane of the third light emitting region P 3  may be the largest, but are not limited thereto. 
     An encapsulation layer  380  including a plurality of insulation layers  381 ,  382 , and  383  may be positioned on the common electrode  270 . The insulation layer  381  and the insulation layer  382  may include an inorganic insulating material, and the insulation layer  382  positioned between the insulation layer  381  and the insulation layer  382  may include an organic insulating material. 
     When the insulation layer  382  is formed in the manufacturing method of the display device according to the embodiment, it may be formed using an inkjet process, which entails dropping or depositing ink for an organic insulating material on the surface of the substrate  110  in several places and spreading the liquid ink. 
     A filling layer  390  including a filler may be positioned on the encapsulation layer  380 . A cover layer  400  including an insulating material, and a plurality of color conversion layers  430   a  and  430   b  and a transmission layer  430   c,  may be positioned on the filling layer  390 . 
     The transmission layer  430   c  may transmit incident light. That is, the transmission layer  430   c  may transmit a first color light that may be blue light. The transmission layer  430   c  may include a polymer material that transmits the first color light. A region in which the transmission layer  430   c  is positioned may correspond to a light emitting region emitting blue, and the transmission layer  430   c  may pass an incident first color light as it is without including a separate semiconductor nanocrystal. 
     The color conversion layers  430   a  and  430   b  may include different semiconductor nanocrystals. For example, the first color light incident on the color conversion layer  430   a  may be converted into a second color light and emitted by a semiconductor nanocrystal included in the color conversion layer  430   b.  The first color light incident on the color conversion layer  430   b  may be converted into a third color light and emitted by the semiconductor nanocrystal included in the color conversion layer  430   b.    
     The semiconductor nanocrystal may include at least one of a phosphor and a quantum dot material that converts the incident first color light into the second color light or the third color light. 
     An insulation layer  440  may be positioned on the plurality of color conversion layers  430   a  and  430   b  and the transmission layer  430   c,  and a plurality of color filters  450   a ,  450   b,  and  450   c  and a light blocking member  460  may be positioned on the insulation layer  440 . 
     The color filter  450   a  may represent the second color light, the color filter  450   b  may represent the third color light, and the color filter  450   c  may represent the first color light. 
     The substrate  210  may be positioned on the plurality of color filters  450   a,    450   b , and  450   c  and the light blocking member  460 . 
     According to another embodiment of the present invention, instead of including a plurality of color conversion layers  430   a  and  430   b  and a transmission layer  430   c,  the emission layer  370  may include quantum dots. 
     Referring to  FIGS.  7 A,  7 B,  7 C,  7 D,  7 E,  8 A,  8 B,  8 C,  8 D,  8 E,  9 A,  9 B,  10 A, and  10 B  together with  FIG.  3    to  FIG.  6   , the spacer  360  according to the embodiment will be described in detail. 
       FIGS.  7 A,  7 B,  7 C,  7 D,  7 E  (collectively “ FIG.  7   ”),  FIGS.  8 A,  8 B,  8 C,  8 D,  8 E  (collectively “ FIG.  8   ”),  FIGS.  9 A,  9 B  (collectively “ FIG.  9   ”), and  FIGS.  10 A and  10 B  (collectively “ FIG.  10   ”) illustrate examples of planar shapes of a spacer included in a display device according to an embodiment. 
     The shape of the spacer  360  on the xy plane according to one embodiment is one of a circule, a regular polygon having five or more sides, or a regular polygon with at least one rounded corner and five or more sides. This will be described in detail hereinafter. 
     Referring to  FIG.  7   , the xy plane shape of the spacer  360  according to one embodiment may be a regular polygon having five or more sides.  FIG.  7    shows an example in which the shape of the spacer  360  in the xy plane is a regular pentagon, a regular hexagon, a regular heptagon, a regular octagon, or a regular decagon. Although it is not shown, the shape of the spacer  360  may include a regular nonagon. 
     Referring to  FIG.  8   , the shape of the spacer  360  in the xy plane according to one embodiment may be a regular polygon that has five or more sides, with at least one corner rounded. 
     Although  FIG.  8    illustrates a shape in which all corners included in each of a regular pentagon, a regular hexagon, a regular heptagon, a regular octagon, or a regular decagon are rounded, these are just examples and fewer than all corners may be rounded. 
     Referring to  FIG.  9   , the shape of spacer  360  in the xy plane according to an embodiment may be circular. It may be understood that a circle is a polygon having an infinite number of sides. 
       FIG.  9    also illustrates an embodiment of the spacer  360  in which quadrants (quarter circles) are positioned at each of the four corners of a square, as viewed in the xy plane. 
     Referring to  FIG.  10   , the shape of the spacer  360  in the xy plane according to an embodiment may have a shape in which a quadrant forms at least two of four corners of an approximately square or rectangular shape, and the other corners have a rounded shape rather than being a quadrant. 
     As shown in the right side in  FIG.  10   , the shape of the spacer  360  in the xy plane according to an embodiment may be a cross in which all corners are rounded. 
     Referring back to  FIG.  3    to  FIG.  6   , when being viewed on the xy plane, an area of each spacer  360  is larger than an area of a light emitting region having the smallest area among the first light emitting region P 1 , the second light emitting region P 2 , and the third light emitting region P 3 , for example, the second light emitting region P 2 . 
     The number of the spacers  360  in the predetermined region of the xy plane may be 30% or more of the total number of the combined number of light emitting regions P 1 , P 2 , and P 3  in the predetermined region. For example, when 100 light emitting regions P 1 , P 2 , and P 3  are arranged in a predetermined region, 30 or more spacers  360  may be arranged in the same predetermined region. 
     The spacer  360  according to the embodiment may satisfy the conditions of 1) having a flat shape such as a circle, 2) having an area larger than the smallest light emitting region, and 3) being present in a number that is 30% or more of the combined the number of light emitting regions P 1 , P 2 , and P 3 . When these three conditions are met, the ink layer flows and spreads out better on the surface it is on, and capillary force helps to form a continuous, even layer to achieve improved lamination of the upper organic layer using the inkjet coating process. 
     The plurality of spacers  360  are disposed at a preset interval in the x direction and/or the y direction. 
     A width of each spacer  360  in the x direction or y direction (diameter, or the widest distance within the shape) may be at least 50% of a distance between two adjacent light emitting regions P 1 , P 2 , and P 3  in the x direction or y direction. The “distance between two adjacent light emitting regions” is intended to mean the distance between two closest edges of the adjacent light emitting regions. Specifically, the widths (diameter when the spacer is a circle, the widest distance within the shape in other cases) of the respective spacers  360  in the x and y directions may be 50% or more of a distance between two second light emitting regions P 2  neighboring in the x direction or y direction. In particular, the width of each spacer  360  in the x direction or y direction (diameter when the spacer is a circle) may be 50% or more of a distance between two neighboring regions of the smallest size (e.g., the second light emitting region P 2  in the examples shown in  FIG.  3    through  FIG.  6   ) among a plurality of light emitting regions P 1 , P 2 , and P 3  when the two smallest light emitting regions neighbor each other in the x direction or y direction. 
     With the spacers  360  being arranged and sized to fulfill the conditions described above, the spreadability of the ink layer can be improved by increasing the ink flow continuity and capillary force when an organic layer on the upper portion of the spacer  360  is laminated by the inkjet coating process. 
       FIG.  3    to  FIG.  6    illustrate examples of the arrangement of the spacers  360  that satisfy all the above-stated conditions. For simplicity, the arrangements of light emitting regions P 1 , P 2 , and P 3  will be described in terms of rows that extend in the x-direction and the columns that extend in the y-direction. 
     According to an embodiment (e.g., embodiments of  FIG.  5    and  FIG.  6   ), when a plurality of light emitting regions P 1 , P 2 , and P 3  are arranged in the x direction and y direction, one spacer  360  may be positioned in every one or two of a plurality of light emitting regions P 1 , P 2 , and P 3  arranged in the x direction, and one spacer  360  may be positioned in every one or two of a plurality of light emitting regions P 1 , P 2 , and P 3  arranged in the y direction. The spacers  360  are spaced close enough to cause capillary force therebetween, and thus the spreadability of the ink layer can be improved by using the increased ink flow continuity and capillary force when an organic layer on the upper portion of the spacer  360  is laminated by the inkjet coating process. 
       FIG.  3    illustrates an embodiment in which one spacer  360  for every two second light emitting regions P 2  in the x direction is positioned in a row that has the second light emitting region P 2  arranged in the x direction, one spacer  360  for every two first or third light emitting regions P 1  and P 3  in the y direction in a column that has first or third light emitting regions P 1  and P 3  arranged in the y direction. In this embodiment, no spacer  360  is positioned between second light emitting regions P 2  arranged in the y direction or in rows that do not have the second light emitting region P 2 . 
       FIG.  4    illustrates an embodiment in which a spacer  360  is positioned between two neighboring light emitting regions in the y-direction. More specifically, a spacer  360  is positioned between a first light emitting region P 1  and a third light emitting region P 3  neighboring each other in the y direction. In the x direction, a spacer  360  is positioned between second light emitting regions P 2  neighboring in the x direction, but no spacer  360  is positioned between a first light emitting region P 1  and a third light emitting region P 3  neighboring in the x direction and second light emitting regions P 2  neighboring in the y direction. In the particular embodiment, this results in the spacers  360  being in every other row extending in the x direction. Compared to the embodiment shown in  FIG.  3   , the embodiment of  FIG.  4    has about twice as many spacers  360  in a given area. 
     Embodiments shown in  FIG.  5    and  FIG.  6    are similar to the embodiment shown in  FIG.  4   , except that a spacer  360  may be additionally positioned between a first light emitting region P 1  and a third light emitting region P 3  neighboring in the x direction or second light emitting regions P 2  neighboring in the y direction. 
     In the embodiment shown in  FIG.  5   , one spacer  360  may be positioned after every two light emitting regions in the x direction, in this case the first or third light emitting regions P 1  or P 3  arranged in the x direction. The spacer  360  is positioned every light emitting region in alternating rows, which may be rows that have the second light emitting regions P 2 . In the y direction, one spacer  360  may be positioned every two second light emitting regions P 2  in the columns that have the second light emitting regions P 2 . In the columns that have the first and third light emitting regions P 1  and P 3 , the spacer  360  is positioned after every light emitting region. 
     In the embodiment shown in  FIG.  6   , a spacer  360  may be positioned between every neighboring light emitting region in every row and every column. More specifically, a spacer is positioned between the first light emitting region P 1  and the third light emitting region P 3  neighboring in the x direction and the y direction, and a spacer  360  may be positioned between all of the second light emitting regions P 2  neighboring in the x direction and the y direction. In the embodiment shown in  FIG.  6   , the spacer  360  may be positioned between the light emitting regions P 1 , P 2 , and P 3  neighboring in all of the x direction, the y direction, and the diagonal direction. 
     Referring to  FIG.  11    together with the above-described drawings, a display device according to an embodiment will be described. 
       FIG.  11    is a top plan view of a display area of a display device according to an embodiment. 
     Referring to  FIG.  11   , a display device according to an embodiment is almost the same as the display device according to the embodiments of  FIGS.  3 ,  4 ,  5 , and  6   , except that “one” spacer  360  may include two or more sub-spacers  360   a  and  360   b  spaced apart from each other.  FIG.  11    shows an example in which the arrangement of light emitting regions P 1 , P 2 , P 3  and spacers  360  are similar to that of  FIG.  3   , except that each spacer  360  includes two spaced sub-spacers  360   a  and  360   b.  the exact number of sub-spacers  360   a  and  360   b  is not limited to two per spacer  360  (e.g., there may be more than two sub-spacers that make up a spacer  360 ). 
     The arrangement shape and direction of a plurality of sub-spacers  360   a  and  360   b  included in one spacer  360  may be varied. When one spacer  360  includes two sub-spacers  360   a  and  360   b,  as shown in  FIG.  11   , the two sub-spacers  360   a  and  360   b  may be arranged in a diagonal direction that is oblique to the x direction and the y direction. When one spacer  360  includes three or more sub-spacers  360   a  and  360   b,  three or more sub-spacers  360   a  and  360   b  may be arranged at the edges of an imaginary regular polygon. 
     The shape of each of the sub-spacers  360   a  and  360   b  in the xy plane may be the same as the shape of each spacer  360  described above in  FIG.  7    to  FIG.  10   . That is, each of the sub-spacers  360   a  and  360   b  on the xy plane may include one of a circular shape, a pentagonal or more regular polygon, or a regular polygon having at least one rounded corner of a pentagonal or more regular polygon. 
     Next, referring to  FIG.  12    to  FIG.  18    together with the above-described drawings, the effect of the display device according to the embodiment will be described in comparison with a display device according to a comparative example. 
       FIG.  12    is a top plan view of a display area of a display device according to a comparative example,  FIG.  13    and  FIG.  14    show movement of ink dropped at the periphery of a spacer according to the comparative example, and  FIG.  15    is a figure showing spreadability of the dropped ink in a manufacturing process of the display device according to the comparative example. 
       FIG.  12    to  FIG.  15    depict display devices according to the conventional or comparative examples, not display devices according to the embodiments of the disclosure. More specifically, the display devices of  FIGS.  12 ,  13 ,  14 , and  15    may include a spacer  360   c  that does not satisfy the planar shape, the area condition, the width range in the x direction or the y direction, and the equal spacing condition in the x direction or the y direction of the spacer  360  described with reference to  FIG.  1    to  FIG.  11   . 
     A spacer  360   c  included in the display device according to the conventional or comparative example shown in  FIG.  12    has a rectangular shape with sharp corners and is longer in the x direction or the y direction, and is not arranged at equal intervals in the x direction or the y direction. 
     A spacer  360   c  included in the display device according to the conventional or comparative example shown in  FIG.  13    to  FIG.  15    has a square shape with sharp corners, and is not arranged at equal intervals in the x direction or the y direction. 
     When a manufacturing method of a display device according to a conventional or comparative example includes forming an organic layer positioned on a substrate where a spacer  360   c  is formed using an inkjet process, the continuity of the flow of a dropped or spotted ink layer is cut off around the spacer  360   c,  making it difficult to spread evenly. 
     Referring to  FIG.  13    and  FIG.  14   , an ink layer  82  is formed and spread by dropping ink on a plurality of impact positions on the upper portion as indicated, near where the spacer  360   c  is formed. Some of the ink spreads as shown by the arrow ARS between adjacent spacers  360   c.  The ink that flows toward the spacer  360   c  may be diverted as shown by the arrow ARW. 
       FIG.  14   , confirms that the ink layer  82  does not spread too far from the impact position and in fact, stagnates soon after reaching the spacer  360   c,  as shown by the arrow ARW. This stagnation is because the ink layer  82  is blocked by the sharp corners of the spacer  360   c.    
       FIG.  15    shows that when the spread of the ink layer  82  is disturbed, the ink layer  82  on the upper portion of the substrate does not spread evenly, and as shown by the arrow in  FIG.  14   , there are many regions that are not covered with ink. When spacers  360   c  deviate from the above-dscribed conditions of spacer  360  according to the present embodiment, the capillary action between a spacer  360   c  and an adjacent spacer  360   c  is not activated and thus the spreadability of the ink layer  82  is weak. 
       FIG.  16    and  FIG.  17    show movement of ink dropped at the periphery of the spacer according to the embodiment, and  FIG.  18    shows the spreadability of the ink dropped in a manufacturing process of the display device according to the embodiment. 
     In the manufacturing method of the display device including the spacer  360  according to the present embodiment, the organic layer positioned on the substrate  110  on which the spacer  360  is formed, for example, the insulation layer  382  of the encapsulation layer  380 , can be formed using an inkjet process. Compared with the conventional or comparative example described above, the continuity of the flow of ink dropped around the spacer  360  according to the present embodiment continues, and thus it can easily form an insulation layer  382  evenly throughout the substrate  110  where the ink layer spreads evenly throughout the substrate  110 . 
     Referring to  FIG.  16    and  FIG.  17   , the ink layer  82  is formed by dropping ink on a plurality of impact positions on the portion of the substrate near the spacer  360 . and the ink flows toward an adjacent spacer  360 , may spread out while passing through the spacer  360  as shown by the arrow ARS by the capillary force between the spacers  360  that are not spaced too far apart, according to the condition of the present embodiment. Due to the shape of the spacer  360  in the form of a circle or regular polygon, the tension on the spacer  360  of the ink layer  82  passing around the spacer  360  acts to continuously flow around the spacer  360  are as indicated by the arrows ARS. 
     Referring to  FIG.  17   , due to the shape of spacer  360 , the ink layer  82  can easily climb the spacer  360  and spread as indicated by the arrow ARS. The ink layer  82  spreads around the spacer  360   c  to form a continuous layer. 
       FIG.  18    shows that, due to the improved spreadability of the ink layer  82 , the ink layer  82  on the upper portion of the substrate spreads evenly, and most regions are covered with the ink layer  82  except for some regions on top of the spacer  360 . 
       FIG.  19    is a cross-sectional view of a display device according to an embodiment. 
     Referring to  FIG.  19   , a display device according to an embodiment is almost the same as the display device according to the above-described embodiment, except that a fourth insulation layer  350  and a spacer  360  positioned on the fourth insulation layer  350  are formed of the same material through one photo process. As previously described, an organic insulation material layer having photosensitivity is formed on a substrate  110  where a pixel electrode  191  is formed, and then two portions with different thicknesses may be formed through a photo process using a photomask that includes at least two portions with different light transmittance. Accordingly, a relatively thin portion of the thin fourth insulation layer  350  can be formed since there is no spacer  360  on an upper portion, and a relatively thick portion of the spacer  360  may be formed since the fourth insulation layer  350  and the spacer  360  overlap. 
     While this invention has been described in connection with what is presently considered to be practical embodiments, it is to be understood that the invention is not limited to the disclosed embodiments. On the contrary, it is intended to cover various modifications and equivalent arrangements included within the spirit and scope of the appended claims.