Patent Description:
The present disclosure relates to a display device and a method for manufacturing the same.

Recently, with the advancement of the information age, a display field for processing and displaying large amounts of information has been rapidly developed. In response to this trend, various display devices have been developed and used. Among such display devices, there is a trend that liquid crystal display (LCD) devices and organic light emitting display (OLED) devices having excellent properties of a thin profile, a light weight, and low power consumption have been widely used.

Such a display device includes a display panel comprised of a substrate. In this case, since a glass substrate is generally used to withstand high heat generated during a manufacturing process, there is a limitation in making properties of a thin profile, a light weight, and flexibility. Therefore, a flexible display device manufactured using flexible materials such as plastic, instead of an inflexible glass substrate, so as to maintain the same display property even when being bent like paper has recently emerged as a display device for a new generation and its research and development is actively in progress.

In order to manufacture the flexible display device, after a display element forming process is performed for forming a display element such as a thin film transistor on a large area of the flexible substrate on a basis of unit area, a cutting process for cutting the substrate into cell units is required. A flexible substrate is formed on a base substrate made of glass or quartz material due to a flexible property of the flexible substrate. Afterwards, the flexible substrate is cut on the basis of the cell unit and the flexible substrate is separated from the base substrate, whereby the flexible display device is completed.

However, in the process of cutting the flexible substrate and the base substrate on the basis of the cell unit, defects of a display panel such as excitation of the flexible substrate and side permeability of the flexible substrate may be caused due to a difference in a margin between the process of cutting the flexible substrate and the process of cutting the base substrate.

<CIT> discloses a display device including a first substrate comprising a resin material provided with a plurality of pixels including a display device, and a second substrate provided facing the first substrate and installed with the pixel region. An outer periphery side surface of the first substrate has a taper shape and includes a barrier layer covering an upper layer, lower layer and the outer periphery surface of the first substrate.

Aspects of the invention are set out in the independent claims.

Accordingly, the present disclosure is directed to a display device and a method for manufacturing the same, which substantially obviate one or more problems due to limitations and disadvantages of the related art.

An advantage of the present disclosure is to provide a display device and a method for manufacturing the same, in which excitation and side permeability of a flexible substrate are minimized to prevent defects of a display panel from occurring.

Additional advantages and features of the disclosure will be set forth in part in the description which follows and in part will become apparent to those having ordinary skill in the art upon examination of the following or may be learned from practice of the disclosure. The objectives and other advantages of the disclosure may be realized and attained by the structure particularly pointed out in the written description and claims hereof as well as the appended drawings.

To achieve these objects and other advantages and in accordance with the purpose of the disclosure, as embodied and broadly described herein, a display device according to the present disclosure comprises a first substrate; a buffer layer arranged on the first substrate; a pixel array layer arranged on the buffer layer; and an encapsulation layer covering the pixel array layer, wherein the buffer layer surrounds a front surface and a side of the first substrate, the front surface being a surface of the first substrate that faces the pixel array layer, the display device further comprising a passivation film formed at the side of the first substrate and on a same layer as the first substrate and spaced apart from the first substrate on every side of the first substrate, wherein the buffer layer surrounds a side of the passivation film, and wherein the passivation film has a same height as that of the buffer layer surrounding the side and the front surface of the first substrate.

In another aspect of the present disclosure, a method for manufacturing a display device comprises the steps of (A) preparing a supporting substrate; (B) forming a plurality of first substrates spaced apart from one another on the supporting substrate; (C) forming a passivation film on the supporting substrate, spaced apart from each of the plurality of substrates on every side of each of the plurality of first substrates; (D) forming a buffer layer covering the plurality of first substrates, wherein the buffer layer is formed to surround a front surface and a side of the plurality of first substrates, and wherein the buffer layer is formed to surround the passivation film, and wherein the passivation film has a same height as that of the buffer layer surrounding the side and the front surface of the plurality of first substrates; (E) forming a pixel array layer on an area of the buffer layer that overlap with the plurality of first substrates; (F) forming an encapsulation layer covering the pixel array layer; and (G) forming a plurality of display panels by cutting the supporting substrate and the buffer layer along at least one cutting line defined among the plurality of first substrates.

It is to be understood that both the foregoing general description and the following detailed description of the present disclosure are exemplary and explanatory and are intended to provide further explanation of the disclosure.

Advantages and features of the present disclosure, and implementation methods thereof, will be clarified through the following embodiments described with reference to the accompanying drawings. The present disclosure may, however, be embodied in different forms and should not be construed as limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be thorough and complete, and will fully convey the scope of the present disclosure to those skilled in the art.

A shape, a size, a ratio, an angle, and a number disclosed in the drawings for describing embodiments are merely examples, and thus, the present disclosure is not limited to the illustrated details. In the following description, when the detailed description of the relevant known function or configuration is determined to unnecessarily obscure an important point of the present disclosure, the detailed description will be omitted.

In a case where 'comprise', 'have', and 'include' described in the present specification are used, another part may be added unless 'only~' is used. The terms of a singular form may include plural forms unless referred to the contrary.

In describing a position relationship, for example, when the position relationship is described as 'upon~', 'above~', 'below~', and 'next to~', one or more portions may be arranged between two other portions unless 'just' or 'direct' is used.

In describing a time relationship, for example, when the temporal order is described as 'after~', 'subsequent~', 'next~', and 'before~', a case which is not continuous may be included unless 'just' or 'direct' is used.

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. Therefore, a first element mentioned hereinafter could be termed a second element, without departing from the scope of the present disclosure.

"A first horizontal-axis direction", "a second horizontal-axis direction" and "a vertical-axis direction" should not be construed to entail absolute directions, but rather only relative directions, and may have broader directionality within the range that elements of the present disclosure may functionally enable.

It should be understood that the term "at least one" includes all combinations related with one or more items. For example, "at least one among a first item, a second item and a third item" may include all combinations of two or more items selected from the first, second and third items as well as each item of the first, second and third items.

Features of various embodiments may be partially or completely coupled to or combined with each other, and may be variously inter-operated with each other and driven technically as those skilled in the art can sufficiently understand. The embodiments may be carried out independently from each other, or may be carried out together in co-dependent relationships.

Hereinafter, the preferred embodiments will be described in detail with reference to the accompanying drawings. In adding reference numerals to elements of respective drawings, it is to be understood that the same reference elements may have the same reference numerals if possible even though the same reference elements are shown on different drawings.

<FIG> is a view illustrating a configuration of a display device according to one embodiment.

Referring to <FIG>, the light emitting diode display apparatus according to this embodiment includes a first substrate <NUM>, and a second substrate <NUM>.

The first substrate <NUM> is a thin film transistor array substrate, and may be made of a glass or plastic material.

The first substrate <NUM> according to one example includes a plurality of pixels SP.

Each of the plurality of pixels SP is a minimum unit area where light is actually emitted, and may be defined as a sub pixel. At least three adjacent pixels SP may constitute one unit pixel for color display. For example, one unit pixel may include a red pixel, a green pixel and a blue pixel, which are adjacent to one another, and may further include a white pixel for improvement of luminance.

The second substrate <NUM> is arranged to cover the first substrate <NUM>, and may be defined as an opposing substrate, a color filter array substrate, or an encapsulation substrate. The second substrate <NUM> may be bonded to the first substrate <NUM> by a sealant.

Additionally, the light emitting diode display apparatus according to one example of the present invention further includes a gate driving circuit <NUM>, and a panel driver <NUM>.

The gate driving circuit <NUM> generates a gate pulse in accordance with a gate signal input from the panel driver <NUM> and supplies the generated gate pulse to the gate line. The gate driving circuit <NUM> according to one example is built in the third non-display area of the first substrate <NUM> by the same process as that of the thin film transistor provided in each pixel SP. For example, the gate driving circuit <NUM> may be provided in, but not limited to, the non-display area at a left side and/or right side of the display area. The gate driving circuit <NUM> may be provided in a random non-display area that may supply a gate pulse to the gate line.

Selectively, the gate driving circuit <NUM> may be manufactured in the form of a driving integrated circuit. In this case, the gate driving circuit <NUM> according to one example may be packaged in the third and/or fourth non-display area of the first substrate <NUM> to be connected with the plurality of gate lines one to one. The gate driving circuit <NUM> according to another example may be packaged in a gate flexible circuit film. In this case, the gate flexible circuit film may be attached to a gate pad portion provided in the third and/or fourth non-display area of the first substrate <NUM>, whereby the gate driving circuit <NUM> may be connected to the plurality of gate lines through the gate flexible circuit film and the gate pad portion one to one.

The panel driver <NUM> is connected to the pad portion provided in the first non-display area of the first substrate <NUM> and displays an image corresponding to image data supplied from a display driving system on the display area. The panel driver <NUM> according to one example includes a plurality of data flexible circuit films <NUM>, a plurality of data driving integrated circuits <NUM>, a printed circuit board <NUM>, a timing controller <NUM>, and a power circuit <NUM>.

Each of the plurality of data flexible circuit films <NUM> is attached to the pad portion of the first substrate <NUM> by a film attachment process.

Each of the plurality of data driving integrated circuits <NUM> is individually packaged in each of the plurality of data flexible circuit films <NUM>. The data driving integrated circuit <NUM> receives pixel data and data control signal provided from the timing controller <NUM>, converts the pixel data to an analog type data voltage per pixel in accordance with the data control signal, and supplies the converted data voltage to the corresponding data line.

The printed circuit board <NUM> is connected with the plurality of data flexible circuit films <NUM>. The printed circuit board <NUM> supports the timing controller <NUM> and the power circuit <NUM>, and serves to deliver a signal and a power source between elements of the panel driver <NUM>.

The timing controller <NUM> is packaged in the printed circuit board <NUM>, and receives image data and a timing synchronization signal provided from the display driving system through a user connector provided in the printed circuit board <NUM>. The timing controller <NUM> generates pixel data by aligning the image data to be suitable for a pixel arrangement structure of the display area on the basis of the timing synchronization signal, and provides the generated pixel data to the data driving integrated circuit <NUM>. Also, the timing controller <NUM> controls each driving timing of the plurality of data driving integrated circuits <NUM> and the gate driving circuits <NUM> by generating each of the data control signal and the gate control signal on the basis of the timing synchronization signal.

The power circuit <NUM> is packaged in the printed circuit board <NUM>, generates various voltages required to display an image on the display area by using externally input power source and supplies the generated voltages to the corresponding element.

Additionally, the panel driver <NUM> may further include a control board connected to the printed circuit board <NUM>. In this case, the timing controller <NUM> and the power circuit <NUM> are packaged in the control board without being packaged in the printed circuit board <NUM>. Therefore, the printed circuit board <NUM> serves to deliver a signal and a power source between the plurality of data flexible circuit films <NUM> and the control board.

<FIG> is a cross-sectional view illustrating a display device according to one embodiment.

Referring to <FIG>, the display device according to one embodiment displays an image corresponding to a data signal provided from a driving circuit, and comprises a first substrate <NUM>, a buffer layer <NUM>, a passivation film <NUM>, a pixel array layer <NUM>, an encapsulation layer <NUM>, a second substrate <NUM>, and a light-transmitting film <NUM>.

The first substrate <NUM> is a base substrate, and may include a plastic material. In this case, if the first substrate <NUM> includes a plastic material, the first substrate <NUM> may include an opaque or colored polyimide material. For example, the first substrate <NUM> made of a polyimide material may be a hardened polyimide resin coated with a constant thickness on a front surface of a delamination layer arranged on a supporting substrate which is relatively thick. In this case, the supporting substrate is separated from the first substrate <NUM> by delamination of the delamination layer using a laser delamination process. The supporting substrate may also be referred to as a base substrate herein.

The buffer layer <NUM> is arranged on the first substrate <NUM>. The buffer layer <NUM> according to one embodiment serves to prevent water from being permeated into the buffer layer <NUM> and the pixel array layer <NUM>. The buffer layer <NUM> may be made of an inorganic insulating material, for example, but not limited to, a silicon dioxide (SiO<NUM>), a silicon nitride (SiNx) or a multi-layer of SiO<NUM> and SiNx.

The buffer layer is formed to surround a front surface and a side of the first substrate <NUM>. In this case, the front surface may be an upper surface. In other words, the front surface is a surface of the first substrate <NUM> that is closest to the second substrate 160and/or that is closest to the pixel array layer (<NUM>). Put another way, the front surface of the first substrate <NUM> is the surface of the first substrate <NUM> that faces the second substrate <NUM>. If the buffer layer <NUM> is formed to cover only the front surface of the first substrate <NUM>, permeability to the side of the first substrate <NUM> occurs, which causes a defect of the display panel. However, since the buffer layer <NUM> according to the present invention is formed to surround even the side of the first substrate <NUM>, side permeability of the first substrate <NUM> may be avoided, whereby the defect of the display panel may be prevented from occurring.

As can be appreciated, the first substrate <NUM> is in the form of rectangular cube, also called a rectangular prism. As such, it has six sides, the front and back sides and the sidewalls that extend between the front and back sides. The buffer layer will surround five of these six walls. In a preferred embodiment, the buffer layer is in abutting contact with each of the five sides, which may also be called surfaces of the first substrate <NUM>.

The passivation film <NUM> is formed at the side of the first substrate <NUM>. The passivation film <NUM> according to one embodiment may be made of an inorganic material or metal material. The passivation film <NUM> may be formed to have a same height as that of the buffer layer <NUM> surrounding the side and the front surface of the first substrate <NUM>. The passivation film <NUM> according to one embodiment may prevent side permeability of the first substrate <NUM> from occurring in a similar manner to the buffer layer <NUM>, and may serve as a dam that prevents particles such as dust from being permeated into the first substrate <NUM>.

Since the buffer layer <NUM> together with the passivation film <NUM> according to one embodiment may protect the first substrate <NUM>, a defect ratio of the display panel may be reduced remarkably, and therefore reliability of the display device may be improved.

The pixel array layer <NUM> is arranged on the buffer layer <NUM> and includes a plurality of pixels for displaying an image. The plurality of pixels according to one embodiment may include various kinds of elements such as a thin film transistor, a light emitting diode, a pixel electrode, etc., to provide display by the display device according to the present disclosure. The plurality of pixels are minimum units of area from which a light is emitted and may each comprise a light emitting diode emitting light based on a pixel driving power source provided from a driving power line. The light emitting diode according to one embodiment may be an organic light emitting diode OLED, and light generated from the organic light emitting diode is emitted to the outside to display an image.

The encapsulation layer <NUM> is formed to cover the pixel array layer <NUM> to prevent water permeation to each pixel and protect the light emitting diode vulnerable to external water or oxygen. The encapsulation layer <NUM> according to one embodiment may be formed of an inorganic material or organic material, or may be formed of a deposition structure where an inorganic material and an organic material are deposited alternately.

The second substrate <NUM> is arranged on the encapsulation layer <NUM> to protect the light emitting diode like the encapsulation layer <NUM>. The second substrate <NUM> according to one embodiment may be formed of metal with a reflective material. The second substrate <NUM> may be attached to the encapsulation layer <NUM> using an adhesive layer <NUM> disposed between the second substrate <NUM> and the encapsulation layer <NUM>, which may prevent water permeation into the entire surface of the display panel. The second substrate <NUM> according to one embodiment may be formed to have a larger area than the pixel array layer <NUM> to effectively prevent water permeation into the entire surface of the light emitting diode.

The adhesive layer <NUM> is formed to adhere and fix the encapsulation layer <NUM> and the second substrate <NUM> to each other. The adhesive layer <NUM> may perform adhesion using a hardening method of high energy such as heat, ultraviolet, and laser, or a physical pressure using a pressure-sensitive adhesive (PSA) material.

The light-transmitting film <NUM> is attached to a rear surface of the first substrate <NUM> by using a transparent adhesive material as a medium. In this case, the rear surface corresponds to an opposite direction to the front surface. The light-transmitting film <NUM> according to one embodiment may be made of a flexible film, for example, at least one of a polyethylene terephthalate film, an anti-reflective film, a polarizing film, and a transmittance controllable film. The light-transmitting film <NUM> may be attached to the rear surface of the first substrate <NUM> that is separated from the supporting substrate. The transparent adhesive material may be an optically clear resin (OCR) or an optically clear adhesive (OCA). The light-transmitting film <NUM> according to one embodiment is formed to avoid deterioration of visibility due to reflection by metals inside the display panel, and has advantages in improving visibility and in reducing fatigue of a user.

<FIG> is cross-sectional view illustrating a display device according to another embodiment, wherein the display device shown in <FIG> additionally includes an inorganic layer.

Referring to <FIG>, the display device according to another embodiment of the present disclosure includes an inorganic layer <NUM> formed on the rear surface of the first substrate <NUM>. Hereinafter, description of elements repeated from <FIG> will be omitted, and only properties of the inorganic layer <NUM> will described.

The inorganic layer <NUM> is formed on the rear surface of the first substrate <NUM> and protects the first substrate <NUM> and the light emitting diode from permeation of external particles, impact, water, and oxygen. The inorganic layer <NUM> according to one embodiment may be formed of a single layer or a plurality of layers. For example, the inorganic layer <NUM> may be made of an inorganic insulating material, which enables low temperature deposition, such as a silicon nitride (SiNx), a silicon oxide (SiOx), and an aluminum oxide (AlOx).

The inorganic layer <NUM> according to one embodiment is formed to prevent defects of the display panel caused by the first substrate <NUM> being damaged by external particles, water, etc. after being exposed to the outside when the supporting substrate is separated from the first substrate <NUM> by the delamination during the process of forming the display panel. The inorganic layer <NUM> is not arranged on the rear surface of the first substrate <NUM> separately after the display panel is formed, but arranged during the process of forming the display panel. The inorganic film <NUM> will be described later in more detail.

<FIG> is a cross-sectional view illustrating a display device according to still another embodiment, wherein the display device shown in <FIG> includes a barrier film instead of a light-transmitting film.

Referring to <FIG>, the display device according to this embodiment includes a barrier film <NUM> attached to the rear surface of the first substrate <NUM>. Hereinafter, description of elements repeated from <FIG> will be omitted, and only properties of the barrier film <NUM> will described.

The barrier film <NUM> is attached to the rear surface of the first substrate <NUM> by using a transparent adhesive material as a medium. The barrier film <NUM> according to one embodiment may be a phase difference film or optically isotropic film. If the barrier film has optically isotropic property, light entering the barrier film <NUM> is transmitted without a phase delay. Also, more inorganic films may be arranged on the upper surface of the barrier film. In this case, the inorganic film may include a silicon nitride (SiNx) and a silicon oxide (SiOx). The inorganic film formed on the upper surface of the barrier film <NUM> serves to block permeation of external water or oxygen.

Since the barrier film <NUM> according to one embodiment has properties of being an excellent water barrier and providing impact mitigation, the buffer film <NUM> may prevent the first substrate <NUM> and the light emitting diode from being damaged. The barrier film <NUM> includes a liquid moisture absorbing material, and if external water is permeated into the barrier film <NUM>, water particles are combined with the liquid moisture absorbing material and are kept in an empty space in the barrier film <NUM>, whereby the barrier film <NUM> may have properties of water permeation prevention or water permeation delay.

<FIG> are cross-sectional views illustrating a method for manufacturing a display device according to one embodiment. Therefore, the same reference numerals are given to the same elements, and redundant description of the repeated parts regarding elements and the structure of each element will be omitted.

First of all, as shown in <FIG>, a process of preparing the supporting substrate <NUM> is performed. In this case, the supporting substrate <NUM> serves to securely support a flexible substrate so that a thin flexible substrate is not easily bent or distorted and its shape is fixed during the process of manufacturing the display device. Through such a supporting substrate <NUM>, the flexible substrate may be used easily, and a subsequent process may be performed more precisely and securely. The supporting substrate <NUM> may be made of a transparent inorganic material such as a plate shaped glass or quartz, which has excellent heat-resistance. Although not shown, the supporting substrate <NUM> may have a cutting line defined among a plurality of flexible substrates.

Next, as shown in <FIG>, a plurality of the first substrates <NUM> are formed to be spaced apart from one another on the supporting substrate <NUM>. In this case, the first substrate <NUM> may be a flexible substrate including plastic materials. Since the first substrates <NUM> according to one embodiment are not formed on the supporting substrate <NUM> in a single body but formed to be spaced apart from one another, cutting of the first substrate <NUM> is not required when the display panel is formed through the cutting process. Therefore, the process is more simplified than the related art process that includes two steps of a process of cutting the first substrate <NUM> and a process of cutting the supporting substrate <NUM>, and defects may be prevented from occurring in the cutting process due to a margin difference between the two processes.

Next, as shown in <FIG>, the passivation film <NUM> is formed on the supporting substrate <NUM>. The passivation film <NUM> is formed to be spaced apart on every side of the first substrate <NUM> to protect the sides of the first substrate <NUM>. The passivation film <NUM> may serve as a dam that prevents particles such as dust generated in the cutting process for forming the display panel from being permeated into the first substrate <NUM>.

Next, as shown in <FIG>, the buffer layer <NUM> surrounding the front surface and the sides of the plurality of the first substrates <NUM> and the passivation film <NUM> is formed. The buffer layer <NUM> is formed to surround the side as well as the front surface of a first substrate <NUM>. Therefore, since the side of the first substrate <NUM> is not exposed in the process of cutting the supporting substrate <NUM> and the buffer layer <NUM>, excitation and side permeability of the first substrate <NUM> may be minimized. The buffer layer <NUM> protects the first substrate <NUM> from external damages together with the passivation film <NUM>.

Each substrate <NUM> has six sides, a large area front side, a large area back side and four sides, which are the sidewalls that extend from the front side to the back side. As can be appreciated, only four of the sides can be seen in <FIG>, the other two sides being located behind and in front of the image shown in <FIG>. The buffer layer therefore surrounds the substrate <NUM> on five sides. In one embodiment, the buffer layer <NUM> is in contact with five of the six sides of the substrate <NUM>.

Next, as shown in <FIG>, the pixel array layer <NUM>, the encapsulation layer <NUM>, the adhesive layer <NUM>, and the second substrate <NUM> are sequentially formed on the buffer layer <NUM>. Each of the pixel array layer <NUM>, the encapsulation layer <NUM>, the adhesive layer <NUM>, and the second substrate <NUM> may be formed on an area overlapped with each of the plurality of first substrates <NUM>. Therefore, each of the pixel array layer <NUM>, the encapsulation layer <NUM>, the adhesive layer <NUM>, and the second substrate <NUM> is not cut by the cutting process. The second substrate <NUM> according to one embodiment may be attached to the encapsulation layer <NUM> by using an adhesive material. Such an adhesive material may be the adhesive layer <NUM>, and may be made of resin.

Referring to <FIG> again, the supporting substrate <NUM> and the buffer layer <NUM> have cutting lines CL defined among the plurality of the first substrates <NUM>. The cutting lines CL are lines arranged among the plurality of the first substrates <NUM> to designate a plurality of display panels, and a display panel cell cutting process is performed along the cutting lines CL.

Next, as shown in <FIG>, a display panel on a cell basis is formed by cutting the supporting substrate <NUM> and the buffer layer <NUM> along the cutting line(s). As described above, since the display panel according to one embodiment does not permit permeation of water and particles into the first substrate <NUM> in the cutting process, a display panel having no defects may be obtained through the process according to one embodiment.

Next, as shown in <FIG>, the first substrate <NUM> formed on the supporting substrate <NUM> is separated from the supporting substrate <NUM> through a delamination process. Such a delamination process may comprise a laser beam being irradiated onto a silicon film provided on the supporting substrate <NUM>, heat treatment being applied to the silicon film and then the heat-treated silicon film being subjected to dehydrogenation. Through this process, the first substrate <NUM> may be separated from the supporting substrate <NUM>.

Next, as shown in <FIG>, the light-transmitting film <NUM> is attached to the rear surface of the first substrate <NUM> that is separated from the supporting substrate <NUM>. The light-transmitting film <NUM> may be attached to the rear surface of the first substrate <NUM> by a transparent adhesive material. The light-transmitting film <NUM> according to one embodiment is attached to the rear surface of the first substrate that is separated from the supporting substrate <NUM> to avoid deterioration of visibility due to reflection by metals inside the display panel, and has the advantage of protecting the rear surface of the first substrate <NUM> from the outside.

As described above, as the display device is manufactured in accordance with the method for manufacturing the display device according to one embodiment, the conventional cutting process of the first substrate <NUM> may be omitted, whereby the number of entire processes and time for production may be reduced, and defects in the cutting process due to a margin difference between the cutting process of the supporting substrate <NUM> and the cutting process of the first substrate <NUM> may be prevented from occurring. Also, since cracks and damage that may occur in the conventional cutting process of the first substrate <NUM> may be avoided, a display panel with a low defect ratio and an improved yield may be formed.

Also, since the buffer layer covers the front surface and the sides of the plurality of the first substrates <NUM> formed on the supporting substrate <NUM>, the sides of the first substrates <NUM> are not exposed to the outside during the cutting process, whereby excitation and permeability of the first substrate <NUM> may be minimized. Therefore, entire permeability of the display panel is avoided and reliability of the display panel may be improved.

<FIG> are cross-sectional views illustrating a method for manufacturing a display device according to another embodiment. Since the process of additionally forming an inorganic layer is added to the method for manufacturing the display device according to <FIG>, in <FIG> description repeated from the <FIG> will be omitted and the additional process will be described.

Referring to <FIG>, the inorganic layer <NUM> is formed on the supporting substrate <NUM>, and a plurality of first substrates <NUM> is formed on the inorganic layer <NUM>. The inorganic layer <NUM> is formed in a single body unlike the plurality of first substrates <NUM>. This is to allow the inorganic layer <NUM> to have a width greater than the first substrates <NUM> to protect the rear surface of the first substrate <NUM> from the outside even if the supporting substrate <NUM> is separated later through the cutting process and the delamination process.

The inorganic layer <NUM> according to one embodiment serves to protect the first substrate(s) <NUM> by being formed on the supporting substrate <NUM> in advance before the first substrate(s) <NUM> is/are formed in order to prevent the first substrate(s) <NUM> from being damaged by external particles and water when the first substrate(s) <NUM> is/are separated from the supporting substrate <NUM>.

Therefore, the inorganic layer <NUM> is formed on the supporting substrate <NUM>, the plurality of first substrates are formed on the inorganic layer <NUM>, and the buffer layer <NUM>, the pixel array layer <NUM>, the encapsulation layer <NUM>, the adhesive layer <NUM>, and the second substrate <NUM> are sequentially formed on the plurality of first substrates <NUM>.

Referring to <FIG> again, the supporting substrate <NUM>, the inorganic layer <NUM>, and the buffer layer <NUM> are cut based on the cutting lines CL defined among the plurality of first substrates <NUM>. Since the inorganic layer <NUM> is cut along with the supporting substrate <NUM> and the buffer layer <NUM> after being formed in a single body, the inorganic layer <NUM> may have a larger width than the first substrate(s) <NUM> and may later protect the rear surface of the first substrate(s) <NUM> from the outside even when the supporting substrate <NUM> is separated.

Referring to <FIG>, the light-transmitting film <NUM> is attached to the rear surface of the inorganic layer <NUM> from which the supporting substrate <NUM> is separated. The light-transmitting film <NUM> may be attached to the rear surface of the inorganic layer <NUM> by using a transparent adhesive material. The light-transmitting film <NUM> according to one embodiment may avoid deterioration of visibility and have an advantage in protecting the rear surface of the first substrate <NUM> from the outside like the inorganic layer <NUM>.

<FIG> are cross-sectional views illustrating a method for manufacturing a display device according to another embodiment. Since a barrier film, instead of the light-transmitting film described in the method according to <FIG>, is attached in <FIG>, description repeated from <FIG> will be omitted, and the changed process will be described.

Referring to <FIG>, up to the process of separating the supporting substrate <NUM>, the process is the same as that of <FIG>. Therefore, repeated descriptions regarding this will be omitted.

Referring to <FIG>, the barrier film <NUM> is attached to the rear surface of the first substrate <NUM> separated from the supporting substrate <NUM>. The barrier film <NUM> is attached the rear surface of the first substrate <NUM> using a transparent adhesive material. Since the barrier film <NUM> according to one embodiment has properties of being an excellent water barrier and providing impact mitigation, damage to the first substrate <NUM> may be avoided. Also, an additional inorganic film may be arranged on the upper surface of the barrier film. The inorganic film serves to block permeation of external water or oxygen, and may be attached to the rear surface of the first substrate <NUM> using a transparent adhesive material. If the barrier film <NUM> according to one embodiment includes an inorganic film, an effect of preventing water permeation into the first substrate <NUM> may be improved, and reliability of the display panel may be improved.

As described above, the display device according to the present disclosure has the following advantages.

The display device according to the present disclosure has an advantage in preventing defects in the display panel by minimizing excitation and side permeability of the first substrate.

Also, the display device according to the present disclosure has an advantage in improving reliability and reducing costs for production by preventing defects in the display panel from occurring.

Also, the display device according to the present disclosure has an advantage in simplifying a module process and improving yield by omitting the process of cutting the first substrate.

It will be appreciated by persons skilled in the art that that the advantageous effects that can be achieved through the present disclosure are not limited to what has been particularly described hereinabove and other advantages of the present disclosure will be more clearly understood from the aforementioned detailed description.

Claim 1:
A display device comprising:
a first substrate (<NUM>);
a buffer layer (<NUM>) arranged on the first substrate;
a pixel array layer (<NUM>) arranged on the buffer layer; and
an encapsulation layer (<NUM>) covering the pixel array layer,
wherein the buffer layer (<NUM>) surrounds a front surface and a side of the first substrate, the front surface being a surface of the first substrate that faces the pixel array layer,
the display device further comprising a passivation film (<NUM>) formed at the side of the first substrate (<NUM>) and on a same layer as the first substrate (<NUM>), wherein the buffer layer (<NUM>) surrounds a side of the passivation film (<NUM>),
characterized in that the passivation film (<NUM>) is spaced apart from the first substrate (<NUM>) on every side of the first substrate (<NUM>) and has a same height as that of the buffer layer (<NUM>) surrounding the side and the front surface of the first substrate (<NUM>).