Patent Description:
Recently, display apparatuses have been used for various purposes. Also, display apparatuses are widely used because they have become thin and lightweight. In particular, flat-panel display apparatuses have recently been extensively researched and manufactured. Because display apparatuses may be formed in the shape of a flat panel, the shapes of display apparatuses may be designed in various ways. Also, an increasing number of functions may be incorporated into, or associated with, the display apparatuses.

<CIT> discloses an EL element comprising a transparent electrode, a luminous layer, the first insulation layer, the second insulation layer and a rear electrode. Either one of the insulation layers, or one of the luminous layer, the rear electrode and two luminous layers when used is formed to have the specified shape.

<CIT> discloses a process of manufacturing the light-emitting panel for an indicator dial, by dividing first and second cathode layers to be deposited on one surface side of a transparent substrate by an inverted taper partition wall, formed in a drive shaft area so that they are divided inside and outside the inverted tapered partition wall, the first and second cathode layers deposited outside the inverted tapered partition wall and contributing to the light emission of an EL element and first and second cathode layers, deposited inside the inverted taper partition wall and not contributing to the light emission of the EL element are formed.

<CIT> discloses an input device that includes a first flexible base material, a second flexible base material, and a sensor circuit that can sense an object such as a finger that is close to or in contact with a surface of the second flexible base material. The sensor circuit includes a transistor portion including a first transistor and a light-emitting element including a second transistor.

<CIT> discloses a method for fabricating a light-emitting device using flexible glass which is capable of withstanding a process temperature higher than or equal to <NUM>.

<CIT> discloses an OLED device having an anode layer, insulating layer, spacer layer, active hole injection layer, active hole transport layer, active electron transport layer and cathode layer that are laminated on a substrate. The spacer layer and cathode layer have respective exclusion areas that are located plumb with the protuberance of a cover. A hole is formed in the protuberance, penetrates through the substrate, and having diameter that is smaller than the geometrical dimensions of the protuberance.

<CIT> discloses a display unit including a plurality of panels joined to each other into one display screen, wherein each of the panels is formed by using organic EL devices.

<CIT> discloses that the thickness of an electron injecting metal layer is set as thin as several nm, and a second transparent conductive layer is laminated on the electron injecting metal layer.

One or more embodiments include display apparatuses having reduced occurrence of cracking and reduced propagation of cracks, and also include methods of manufacturing the same.

Additional aspects will be set forth in part in the description that follows and, in part, will be apparent from the description, or may be learned by practice of the presented embodiments.

According to an aspect of the invention, there is provided a method of manufacturing a display apparatus as set out in claim <NUM>. Optional features are set out in claims <NUM> to <NUM>.

According to an aspect of the invention, there is provided a display apparatus as set out in claim <NUM>. Optional features are set out in claims <NUM> to <NUM>.

These and/or other aspects will become apparent and more readily appreciated from the following description of the embodiments, taken in conjunction with the accompanying drawings, in which:.

Referring to <FIG>, the display apparatus <NUM> includes a display region/display area DA and a non-display region/non-display area NA. The display apparatus <NUM> may include various devices, and may include, for example, an organic light-emitting device (OLED) or a liquid crystal display (LCD) device. Hereinafter, for convenience of description, it is assumed that the display apparatus <NUM> includes an OLED.

The display region DA includes a hole H, and includes a pixel array <NUM> including pixels P around the hole H. Each pixel P of the pixel array <NUM> includes a circuit unit, and an OLED connected electrically to the circuit unit, and provides an image by using the light emitted from the OLED.

The non-display region NA may surround the display region DA, and may include a driving unit, such as a data driving unit and a scan driving unit, for transferring a signal to each pixel P of the display region DA.

Although <FIG> illustrates that the hole H is at a centre portion surrounded by pixels and is also at an edge portion(s) of the display region DA of the display apparatus <NUM>, the inventive concept is not limited thereto. The hole H may be located at any position in the display region DA while having pixels P around it. For example, the hole H may also be located at an outermost portion/an outer edge of the display region DA, as illustrated in <FIG>.

Although <FIG> illustrates that the hole H has a circular shape, a semicircular shape, or a triangular shape, the inventive concept is not limited thereto. The hole H (and the display region DA) may have various shapes, such as an elliptical shape and a tetragonal shape.

Hereinafter, a method of manufacturing a display apparatus according to an embodiment will be described in detail with reference to <FIG>.

First, <FIG> illustrates a substrate <NUM> located in the display region DA. A display unit <NUM> including/defining at least one opening portion OP is formed in the display region DA of the substrate <NUM>.

A buffer layer <NUM> may be first formed over the substrate <NUM>, and then the display unit <NUM> may be formed over the buffer layer <NUM>. Although <FIG> illustrates that the display unit <NUM> is formed over the buffer layer <NUM>, the inventive concept is not limited thereto, and the display unit <NUM> may be formed directly over the substrate <NUM> in an alternative embodiment.

The substrate <NUM> may include various materials. The substrate <NUM> may be formed of a transparent glass material having SiO2 as a main component. However, the substrate <NUM> is not limited thereto, and may also be formed of a transparent plastic material. The plastic material may be an organic material selected from the group consisting of polyethersulphone (PES), polyacrylate (PAR), polyetherimide (PEI), polyethylene naphthalate (PEN), polyethylene terephthalate (PET), polyphenylene sulfide (PPS), polyallylate, polyimide, polycarbonate (PC), cellulose triacetate (TAC), and/or cellulose acetate propionate (CAP), which are insulating organic materials.

Also, the substrate <NUM> may be formed of a flexible material to be two-dimensionally extended. As an alternative embodiment, the substrate <NUM> may be formed of a material having a Poisson's ratio of <NUM> or more. The Poisson's ratio refers to the ratio of a contraction strain, which is in a direction that is opposite to a direction of a stretching force, to an extension strain in a direction corresponding to the direction of the stretching force. When the substrate <NUM> is formed of a material having a Poisson's ratio of <NUM> or more (e.g., when the substrate <NUM> has an easily extensible property), the flexibility of the substrate <NUM> may be improved. Also, because the substrate <NUM> includes a flexible region, the shape of the display apparatus <NUM> may be easily modified in a bending region.

The buffer layer <NUM> may function as a barrier layer and/or a blocking layer for reducing or preventing the diffusion of impurity ions into the display unit <NUM>, reducing or preventing the infiltration of external air or moisture therethrough, and/or planarizing a surface of the substrate <NUM>. For example, the buffer layer <NUM> may include inorganic materials, such as silicon oxide, silicon nitride, silicon oxynitride, aluminum oxide, aluminum nitride, titanium oxide, and/or titanium nitride, and/or may include organic materials, such as polyimide, polyester, and/or acryl, and may be formed of any stack thereof.

Hereinafter, the display unit <NUM> formed over the substrate <NUM> will be described in detail with reference to <FIG>.

A thin film transistor TFT may be formed over the substrate <NUM>. The thin film transistor TFT may include a semiconductor layer A, a gate electrode G, a source electrode S, and a drain electrode D. Although <FIG> illustrates a top gate type TFT sequentially including a semiconductor layer A, a gate electrode G, and a source electrode S and a drain electrode D, the inventive concept is not limited thereto and various types of TFTs, such as bottom gate type TFTs, may also be used herein.

The semiconductor layer A may be formed by using an organic semiconductor or an inorganic semiconductor, such as silicon. Also, the semiconductor layer A includes a source region, a drain region, and a channel region therebetween. For example, when the semiconductor layer A is formed by using amorphous silicon, the semiconductor layer A, which includes a source region, a drain region, and a channel region therebetween, may be formed by forming an amorphous silicon layer over the substrate <NUM>, crystallizing the amorphous silicon layer to form a polycrystalline silicon layer, patterning the polycrystalline silicon layer, and then doping a drain region and a source region of an edge thereof.

After the forming of the semiconductor layer A, a gate insulating film <NUM> may be formed over the semiconductor layer A over the substrate <NUM>. The gate insulating film <NUM> may include a single layer or multiple layers formed of an inorganic material, such as silicon oxide and/or silicon nitride. The gate insulating film <NUM> insulates the semiconductor layer A from the gate electrode G.

The gate electrode G may be formed above the gate insulating film <NUM>. The gate electrode G is connected to a gate line for applying an on/off signal of the thin film transistor TFT. The gate electrode G may include at least one metal selected from molybdenum (Mo), aluminum (Al), platinum (Pt), palladium (Pd), silver (Ag), magnesium (Mg), gold (Au), nickel (Ni), neodymium (Nd), iridium (Ir), chromium (Cr), lithium (Li), calcium (Ca), titanium (Ti), tungsten (W), and/or copper (Cu). However, the gate electrode G is not limited thereto, and may be formed of various materials in consideration of design conditions.

After the forming of the gate electrode G, an interlayer insulating film <NUM> may be formed over the substrate <NUM> to insulate the gate electrode G from the source electrode S and the drain electrode D. The interlayer insulating film <NUM> may be formed of an inorganic material. For example, the interlayer insulating film <NUM> may be formed of metal oxide and/or metal nitride, and the inorganic material may include silicon oxide (SiO2), silicon nitride (SiNx), silicon oxynitride (SiON), aluminum oxide (Al2O3), titanium oxide (TiO2), tantalum oxide (Ta2O5), hafnium oxide (HfO2), and/or zirconium oxide (ZrO2). The interlayer insulating film <NUM> may include a single layer or multiple layers formed of an inorganic material, such as silicon oxide (SiOx) and/or silicon nitride (SiNx). In some embodiments, the interlayer insulating film <NUM> may include a dual structure of SiOx/SiNy and/or SiNx/SiOy.

The source electrode S and the drain electrode D are formed over the interlayer insulating film <NUM>. In an embodiment, the interlayer insulating film <NUM> and the gate insulating film <NUM> are formed to expose the source region and the drain region of the semiconductor layer A, and the source electrode S and the drain electrode D are formed to respectively contact the exposed source region and the exposed drain region of the semiconductor layer A. The source electrode S and the drain electrode D may include a single layer or multiple layers formed of at least one of aluminum (Al), platinum (Pt), palladium (Pd), silver (Ag), magnesium (Mg), gold (Au), nickel (Ni), neodymium (Nd), iridium (Ir), chromium (Cr), lithium (Li), calcium (Ca), molybdenum (Mo), titanium (Ti), tungsten (W), and/or copper (Cu).

The thin film transistor TFT is electrically connected to the OLED to apply a signal for driving the OLED to the OLED. The thin film transistor TFT may be covered and protected by a planarization film <NUM>. The planarization film <NUM> may include an inorganic insulating film and/or an organic insulating film. For example, the inorganic insulating film may include SiO2, SiNx, SiON, Al2O3, TiO2, Ta2O5, HfO2, ZrO2, BST, and/or PZT, and the organic insulating film may include a general-purpose polymer (PMMA, PS), a polymer derivative having a phenol-based group, an acryl-based polymer, an imide-based polymer, an aryl ether-based polymer, an amide-based polymer, a fluorine-based polymer, a p-xylene-based polymer, a vinyl alcohol-based polymer, and/or any blend thereof. Also, the planarization film <NUM> may be formed of a composite stack of an inorganic insulating film and an organic insulating film.

The OLED may be provided over the planarization film <NUM>. The OLED may include a first electrode <NUM>, an intermediate layer <NUM> including an organic emission layer, and a second electrode <NUM>. Holes and electrons injected from the first electrode <NUM> and the second electrode <NUM> of the OLED may be combined in the organic emission layer of the intermediate layer <NUM> to generate light.

The first electrode <NUM> is formed over the planarization film <NUM>, and is electrically connected to the drain electrode D through a contact hole formed in/defined by the planarization film <NUM>. However, the inventive concept is not limited to a case where the first electrode <NUM> is electrically connected to the drain electrode D, and the first electrode <NUM> may also be electrically connected to the source electrode S to receive an application of a signal for driving the OLED in other embodiments.

The first electrode <NUM> may be a reflective electrode, and may include a reflective film formed of Ag, Mg, Al, Pt, Pd, Au, Ni, Nd, Ir, Cr, and/or any compound thereof, and may also include a transparent or semitransparent electrode layer formed over the reflective film. The transparent or semitransparent electrode layer may include at least one selected from the group consisting of indium tin oxide (ITO), indium zinc oxide (IZO), zinc oxide (ZnO), indium oxide (In2O3), indium gallium oxide (IGO), and/or aluminum zinc oxide (AZO).

The intermediate layer <NUM> may include the organic emission layer. As an alternative example, the intermediate layer <NUM> may further include at least one of a hole injection layer (HIL), a hole transport layer (HTL), an electron transport layer (ETL), and an electron injection layer (EIL). However, the present embodiment is not limited thereto, and the intermediate layer <NUM> may include an organic emission layer and may further include other various functional layers.

The second electrode <NUM> is formed over the intermediate layer <NUM>. The second electrode <NUM> may generate an electric field with the first electrode <NUM> to enable the intermediate layer <NUM> to emit light. The first electrode <NUM> may be patterned in each pixel, and the second electrode <NUM> may be formed to apply a common voltage to all pixels.

The second electrode <NUM>, which is arranged to face the first electrode <NUM>, may be a transparent or semitransparent electrode, and may be formed of a thin metal film having a low work function and including Li, Ca, LiF/Ca, LiF/Al, Al, Ag, Mg, and/or any compound thereof. Also, over the thin metal film, an auxiliary electrode layer or a bus electrode may be formed of a transparent electrode formation material such as ITO, IZO, ZnO, and/or In2O3. Accordingly, the second electrode <NUM> may transmit the light emitted from the organic emission layer included in the intermediate layer <NUM>. For example, the light emitted from the organic emission layer may be emitted to the second electrode <NUM> directly, or may be emitted by being reflected by the first electrode <NUM> including a reflective electrode.

However, the display unit <NUM> of the present embodiment is not limited to a top/front emission type, but may also be a bottom/rear emission type in which the light emitted from the organic emission layer is emitted to the substrate <NUM>. In this case, the first electrode <NUM> may include a transparent or semitransparent electrode, and the second electrode <NUM> may include a reflective electrode. Also, the display unit <NUM> of the present embodiment may be a dual-side emission type that emits the light in both directions corresponding to the top side and the bottom side.

As an alternative embodiment, the first electrode <NUM> may be patterned, for example, in each pixel. The display unit <NUM> may further include a pixel definition film/pixel defining film <NUM> formed over the first electrode <NUM> (e.g., over edges of the first electrode <NUM>). The pixel definition film <NUM> may include/define an opening 270a that exposes the first electrode <NUM>. The intermediate layer <NUM> may be electrically connected to the first electrode <NUM> by being formed corresponding to (e.g., in) the opening 270a. For example, by a spin coating process, the pixel definition film <NUM> may be formed of at least one organic insulating material selected from the group consisting of polyimide, polyamide, acrylic resin, benzocyclobutene, and/or phenolic resin.

Referring to <FIG>, a thin film encapsulation layer <NUM> sealing the display unit <NUM> is formed over the display unit <NUM>. The thin film encapsulation layer <NUM> may be formed to completely seal the display unit <NUM> to protect the display unit <NUM> from the external moisture or oxygen. As illustrated in <FIG>, the thin film encapsulation layer <NUM> may be formed to cover all of the display unit <NUM>, including the opening portion OP, so that it may be stacked and formed over the substrate <NUM> while also being in the opening portion OP.

The thin film encapsulation layer <NUM> may have a structure in which a plurality of thin film layers are stacked (i.e. a structure in which an inorganic film <NUM> and an organic film <NUM> are alternately stacked).

The thin film encapsulation layer <NUM> may be formed by sequentially stacking a first inorganic film 310a, an organic film <NUM>, and a second inorganic film 310b as illustrated in <FIG>. The number of thin film layers is not limited thereto, and a plurality of thin film layers may be alternately stacked and formed.

The inorganic film <NUM> may firmly block the infiltration of oxygen or moisture, and the organic film <NUM> may absorb a stress on the inorganic film <NUM> to give flexibility thereto. The inorganic film <NUM> may be a single film or may be a film stack including metal oxide and/or metal nitride. As an alternative embodiment, the inorganic film(s) may include any one of SiNx, Al2O3, SiO2, TiO2, and/or SiON.

The organic film <NUM> may be formed of a polymer and may be, for example, a single film or a film stack formed of any one of polyethylene terephthalate, polyimide, polycarbonate, epoxy, polyethylene, and/or polyacrylate. For example, the organic film <NUM> may be formed of polyacrylate. In an embodiment, the organic film <NUM> may include a polymerized monomer composition including a diacrylate-based monomer and a triacrylate-based monomer. The monomer composition may further include a monoacrylate-based monomer. Also, the monomer composition may further include a photoinitiator such as trimethyl benzoyl diphenyl phosphine oxide (TPO), but the inventive concept is not limited thereto.

The first inorganic film 310a and the second inorganic film 310b may have a larger area than the organic film <NUM>. For example, the organic film <NUM> may be completely sealed by the first inorganic film 310a and the second inorganic film 310b. The first inorganic film 310a and the second inorganic film 310b may contact each other at an edge of the organic film <NUM> in the opening portion OP as illustrated in <FIG>. For example, the first inorganic film 310a and the second inorganic film 310b may contact each other at an edge of, or at edges of, the organic film <NUM> to surround the organic film <NUM>.

Next, referring to <FIG>, a touch electrode <NUM> is formed over the thin film encapsulation layer <NUM>, and a touch insulating film <NUM> is formed to cover the touch electrode <NUM>. The touch electrode <NUM> may be formed of a material that is electrically conductive without obstructing light transmission. For example, the touch electrode <NUM> may include metal oxide, such as indium tin oxide, indium zinc oxide, copper oxide, tin oxide, zinc oxide, and/or titanium oxide. Alternatively, the touch electrode <NUM> may include a nanowire, a photosensitive nanowire film, a carbon nanotube (CNT), a graphene, and/or a conductive polymer. Alternatively, the touch electrode <NUM> may include various metals. For example, the touch electrode <NUM> may include at least one metal among chromium (Cr), nickel (Ni), copper (Cu), aluminum (Al), silver (Ag), molybdenum (Mo), gold (Au), titanium (Ti), and/or any alloy thereof, such as Ti/Al/Ti.

The touch insulating film <NUM> is formed over the thin film encapsulation layer <NUM> to cover the touch electrode <NUM>. The touch insulating film <NUM> is also formed over the thin film encapsulation layer <NUM> in the opening portion OP, as illustrated in <FIG>. The thin film encapsulation layer <NUM> and the touch insulating film <NUM> are sequentially stacked and formed in the opening portion OP formed in the display unit <NUM>. Because the first inorganic film 310a and the second inorganic film 310b of the thin film encapsulation layer <NUM> contact each other at an edge of the organic film <NUM> in the opening portion OP, the first inorganic film 310a, the second inorganic film 310b, and the touch insulating film <NUM> may be sequentially stacked in a region in the opening portion OP.

The touch insulating film <NUM> may be an inorganic film formed of an inorganic material, or may be an organic film formed of an organic material. As an alternative embodiment, the touch insulating film <NUM> may be a single film, or may be a film stack including metal oxide and/or metal nitride. For example, the touch insulating film <NUM> may include any one of SiNx, Al2O3, SiO2, and/or TiO2.

As another alternative embodiment, the touch insulating film <NUM> may be formed of a polymer, and may be, for example, a single film or a film stack formed of any one of polyethylene terephthalate, polyimide, polycarbonate, epoxy, polyethylene, and/or polyacrylate. For example, the touch insulating film <NUM> may be formed of polyacrylate. In an embodiment, the touch insulating film <NUM> may include a polymerized monomer composition including a diacrylate-based monomer and/or a triacrylate-based monomer.

Next, referring to <FIG>, a touch contact hole(s) TCH may be formed by removing portions of the touch insulating film <NUM> to expose at least a portion of the touch electrode <NUM>.

In the display apparatus manufacturing method according to the present embodiment, at least a portion of the touch insulating film <NUM> and the thin film encapsulation layer <NUM> formed in the opening portion OP are removed during the forming of the touch contact hole TCH. For example, as illustrated in <FIG>, a portion of the touch insulating film <NUM> and the thin film encapsulation layer <NUM> located in the opening portion OP are removed to expose the substrate <NUM> during the process of forming the touch contact hole TCH.

Additionally, at least one inorganic film <NUM> of the thin film encapsulation layer <NUM> is removed from the opening portion OP. Further, the first inorganic film 310a, the second inorganic film 310b, and the touch insulating film <NUM> stacked sequentially in the opening portion OP may be removed during the forming of the touch contact hole TCH.

When the touch insulating film <NUM> is formed of an inorganic material, the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP may be removed simultaneously (e.g., nearly simultaneously, or concurrently) while removing the touch insulating film <NUM> to form the touch contact hole TCH.

The thin film encapsulation layer <NUM> may include the first inorganic film 310a, the organic film <NUM>, and the second inorganic film 310b, and the first inorganic film 310a and the second inorganic film 310b contact each other at an edge of the organic film <NUM> in the opening portion OP. Therefore, when the touch insulating film <NUM> is formed of an inorganic material, the inorganic film <NUM> and the touch insulating film <NUM> may be concurrently removed (removed in a single process) from the opening portion OP in the forming of the touch contact hole TCH.

According to an embodiment, the inorganic film <NUM> of the thin film encapsulation layer <NUM> and the touch insulating film <NUM> formed of an inorganic material may be concurrently removed by, for example, a dry etching process. Dry etching may effectively suppress vertical erosion that may otherwise occur with wet etching. Therefore, dry etching is suitable for fine pattern etching, and an etching process may be performed by a gas system, for example, by plasma without using a chemical solution. However, the process of removing the touch insulating film <NUM> and the inorganic film <NUM> of the thin film encapsulation layer <NUM> is not limited thereto, and the forming of the touch contact hole TCH and the removing of the touch insulating film <NUM> and the inorganic film <NUM> in the opening portion OP may be performed by any process for removing a film formed of an inorganic material.

In the display apparatus manufacturing method according to the present embodiment, at least a portion of the touch insulating film <NUM> and the inorganic film <NUM> stacked in the opening portion OP may be removed concurrently while performing the process of forming the touch contact hole TCH.

As another alternative embodiment, the touch insulating film <NUM> may be formed of an organic material. In this case, to form the touch contact hole TCH, the touch insulating film <NUM> may be removed by a photolithography process, and the inorganic film <NUM> may be removed by a dry etching process. For example, a photolithography process may be performed to remove a portion of the touch insulating film <NUM> over the touch electrode <NUM> and to remove a portion of the touch insulating film <NUM> in the opening portion OP, and a dry etching process may be performed to remove the inorganic film <NUM> in the opening portion OP. However, this process is merely an example, and the process of removing the touch insulating film <NUM> and the inorganic film <NUM> of the thin film encapsulation layer <NUM> is not limited thereto.

Next, referring to <FIG>, a touch line <NUM> may be formed over the touch insulating film <NUM>. The touch line <NUM> may contact the touch electrode <NUM> through the touch contact hole TCH. The touch line <NUM> may include any line that is physically or electrically connected to the touch electrode <NUM>. The touch line <NUM> may be formed of a low-resistance metal material, such as molybdenum (Mo), silver (Ag), titanium (Ti), copper (Cu), aluminum (Al), and/or Mo/Al/Mo.

Next, referring to <FIG>, a hole H is formed by removing at least a portion of the substrate <NUM> that is exposed by removing a portion of the touch insulating film <NUM> and a portion of the thin film encapsulation layer <NUM> formed in the opening portion OP. That is, the display apparatus <NUM> having the hole H formed in the substrate <NUM> in the display region DA is manufactured. The hole H may be formed by physically removing at least a portion of the substrate <NUM>. The method of forming the hole H is not limited thereto, and the hole H may be formed by various methods.

Because the hole H is formed by removing at least a portion of the substrate <NUM> exposed by removing a portion of the touch insulating film <NUM> and a portion of the thin film encapsulation layer <NUM> formed in the opening portion OP, the hole H may have a smaller width than the opening portion OP. The hole H has a smaller width than the width of the portion of touch insulating film <NUM> and the portion of the thin film encapsulation layer <NUM> removed in the opening portion OP.

A crack may occur when a portion of the substrate <NUM> is physically removed. Further, a crack may occur and propagate when an inorganic film is located over a portion where the substrate <NUM> is cut. In this case, the propagated crack may affect the display unit <NUM> to degrade the reliability of a display apparatus.

However, in the case of the display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, because the touch insulating film <NUM> and the inorganic film <NUM> in the opening portion OP are concurrently removed in advance of the process of forming the touch contact hole TCH, and because the hole H is formed by cutting a portion of the substrate <NUM> that is exposed by removing portions of the touch insulating film <NUM> and the inorganic film <NUM>, the risk that a crack will occur and propagate in the inorganic film is reduced or eliminated. Thus, the display apparatus <NUM> having the display unit <NUM> over the substrate <NUM> including the hole H may be manufactured without crack occurrence.

<FIG> are sequential cross-sectional views illustrating a method of manufacturing a display apparatus according to another embodiment. In <FIG>, reference numerals alike to those in <FIG> will denote like elements. Thus, redundant descriptions thereof will be omitted hereafter for conciseness.

Referring to <FIG>, the display apparatus manufacturing method according to the present embodiment prepares a substrate <NUM>, forms a display unit <NUM> defining an opening portion OP over the substrate <NUM> of a display region DA , and forms a thin film encapsulation layer <NUM> for sealing the display unit <NUM>.

The thin film encapsulation layer <NUM> includes at least one inorganic film <NUM> and at least one organic film <NUM>. A first inorganic film 310a, an organic film <NUM>, and a second inorganic film 310b may be alternately stacked and formed therein. The thin film encapsulation layer <NUM> is also formed in the opening portion OP to completely protect the display unit <NUM> from the external moisture or oxygen. Further, the inorganic film <NUM> may have a larger area than the organic film <NUM>. In this case, when the inorganic film <NUM> includes the first inorganic film 310a and the second inorganic film 310b, it may surround the organic film <NUM>.

Next, referring to <FIG>, a touch electrode <NUM> is formed over the thin film encapsulation layer <NUM>, and a touch insulating film <NUM> is formed over the thin film encapsulation layer <NUM> to cover the touch electrode <NUM>.

The touch insulating film <NUM> may be an organic film formed of an organic material, or may be an inorganic film formed of an inorganic material. The touch insulating film <NUM> is formed over the substrate <NUM>, and is stacked and formed in the opening portion OP. The thin film encapsulation layer <NUM> and the touch insulating film <NUM> are sequentially stacked and formed over the substrate <NUM> in the opening portion OP. In another embodiment, the touch insulating film <NUM> and the inorganic film <NUM> of the thin film encapsulation layer <NUM> may contact each other at an edge of the organic film <NUM> of the thin film encapsulation layer <NUM> in the opening portion OP.

Next, the touch insulating film <NUM> is partially removed to expose at least a portion of the touch electrode <NUM>. The touch insulating film <NUM> located over the touch electrode <NUM> is partially removed to form a touch contact hole TCH.

The touch insulating film <NUM> and the thin film encapsulation layer <NUM> formed in the opening portion OP are partially removed during the forming of the touch contact hole TCH.

As an alternative embodiment, the inorganic film <NUM> and the touch insulating film <NUM> may be sequentially stacked and formed to contact each other at an edge of the organic film <NUM> in the opening portion OP, and the touch insulating film <NUM> and the inorganic film <NUM> in the opening portion OP may be partially removed during the forming of the touch contact hole TCH.

When the touch insulating film <NUM> is an inorganic film formed of an inorganic material, a portion of the touch insulating film <NUM> and the inorganic film <NUM> in the opening portion OP may be removed concurrently with the removal of a portion of the touch insulating film <NUM> to form the touch contact hole TCH.

The inorganic film <NUM> and the touch insulating film <NUM> may be removed, for example, by a dry etching process.

The touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP may be partially removed to form a barrier B. The barrier B may include a first layer formed of the thin film encapsulation layer <NUM> (e.g., the inorganic film <NUM>), and a second layer formed of the touch insulating film <NUM>.

As an alternative embodiment, the first inorganic film 310a and the second inorganic film 310b may be stacked to form the thin film encapsulation layer <NUM> in the opening portion OP, and in this case, the first layer of the barrier B may include the first inorganic film 310a and the second inorganic film 310b.

At least one valley V exposing a surface of the substrate <NUM> may be formed by partially removing the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the barrier B during the forming of the barrier B.

As illustrated in <FIG>, two valleys V may be formed in the barrier B. Accordingly, two portions exposing the substrate <NUM> may be formed in the barrier B, and thus, the barrier B may be formed to be split into three pillars.

The display apparatus manufacturing method according to the present embodiment may reduce or prevent the propagation of a crack by partially removing the touch insulating film <NUM> and the thin film encapsulation layer <NUM> formed of an inorganic material to expose the substrate <NUM>.

Also, time and cost may be saved because the barrier B and the valley V may be formed in the opening portion OP concurrently with the forming of the touch contact hole TCH without an additional process.

Next, referring to <FIG>, a touch line <NUM> may be formed in/over the touch contact hole TCH. The touch line <NUM> may contact the touch electrode <NUM> through the touch contact hole TCH, and the touch line <NUM> may include any line that is physically or electrically connected to the touch electrode <NUM>.

Next, referring to <FIG>, a hole H is formed by removing at least a portion of the substrate <NUM> that is exposed by removing a portion of the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP.

In a display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, the hole H is formed in the substrate <NUM> in the display region DA, and the barrier B formed of the thin film encapsulation layer <NUM> and the touch insulating film <NUM> may be arranged at or around an edge of the hole H.

The hole H is formed by physically removing at least a portion of the substrate <NUM>. The hole H may have a smaller width than the opening portion OP.

When the hole H is physically formed in the substrate <NUM>, a crack may occur due to an impact thereof. In this case, the crack may propagate through the inorganic film arranged over the substrate <NUM>, to affect the reliability of a display apparatus.

However, in the case of the display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, because the inorganic films arranged at a portion for formation of the hole H are removed in advance before the forming of the hole H in the substrate <NUM>, the occurrence and propagation of a crack may be reduced or prevented. Also, the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP may be concurrently removed in the process of forming the touch contact hole(s) TCH.

Also, because the barrier B is formed by partially removing the touch insulating film <NUM> and the thin film encapsulation layer <NUM> that are arranged at an edge of the portion for formation of the hole H before the forming of the hole H, even if a crack occurs, the propagation of the crack may be reduced or prevented.

<FIG> are sequential cross-sectional views illustrating a method of manufacturing a display apparatus according to another embodiment. Herein, for conciseness, differences from the display apparatus manufacturing method illustrated in <FIG> will be mainly described, and like reference numerals will denote like elements, and thus redundant descriptions thereof will be omitted.

First, referring to <FIG>, a display unit <NUM> including an opening portion OP, a thin film encapsulation layer <NUM>, a touch electrode <NUM>, and a touch insulating film <NUM> are sequentially formed over a substrate <NUM>.

Thereafter, when a touch contact hole(s) TCH is formed, the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP may be partially removed to form a barrier B. As an alternative embodiment, a valley V partially exposing the substrate <NUM> may be additionally formed in the barrier B.

Thereafter, a touch line <NUM> may be formed in/over the touch contact hole(s) TCH. The touch line <NUM> may contact the touch electrode(s) <NUM> through the touch contact hole(s) TCH.

Next, referring to <FIG>, a passivation layer <NUM> may be formed to cover the barrier B.

In an embodiment, the passivation layer <NUM> may be formed of an organic material. The passivation layer <NUM> may be formed of a polymer and may be, for example, a single film or a film stack formed of any one of polyethylene terephthalate, polyimide, polycarbonate, epoxy, polyethylene, and polyacrylate. For example, the organic films may be formed of polyacrylate. In an embodiment, the organic films may include a polymerized monomer composition including a diacrylate-based monomer and a triacrylate-based monomer.

As an alternative embodiment, the passivation layer <NUM> may be formed by, for example, an organic process or a printing (ink-jet) process.

The passivation layer <NUM> may be formed in the opening portion OP to cover the barrier B. For example, as illustrated in <FIG>, the passivation layer <NUM> may be formed over the substrate <NUM> at the formation position of the barrier B in the opening portion OP.

The passivation layer <NUM> may be formed in a region where the touch insulating film <NUM> and the thin film encapsulation layer <NUM> are partially removed, to cover the barrier B.

As an alternative embodiment, when a valley V partially exposing the substrate <NUM> is formed in the barrier B, the passivation layer <NUM> may be formed also in the valley V (e.g., to touch the substrate <NUM>).

Because an organic film may absorb a stress on an inorganic film to give flexibility thereto, the occurrence of a crack may be reduced or prevented when the passivation layer <NUM> formed of an organic material is formed in the valley V and over the barrier B to cover the barrier B formed of an inorganic material.

In a display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, the hole H is formed in the substrate <NUM> in the display region DA, and the barrier B formed of the thin film encapsulation layer <NUM> and the touch insulating film <NUM> may be arranged at or around an edge of the hole H. Also, the passivation layer <NUM> may be formed in the opening portion OP to cover the barrier B.

The hole H is formed by physically removing at least a portion of the substrate <NUM>.

As an alternative embodiment, the hole H may have a smaller width than the opening portion OP.

In the case of the display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, because the inorganic films arranged at a portion for formation of the hole H are removed in advance before the forming of the hole H in the substrate <NUM>, the occurrence and propagation of a crack may be reduced or prevented. Also, time and cost may be saved because the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP may be concurrently removed in the process of the forming the touch contact hole(s) TCH.

Also, because the barrier B is formed by partially removing the touch insulating film <NUM> and the thin film encapsulation layer <NUM> arranged at/around an edge of the portion to be removed for formation of the hole H before the forming of the hole H, even when a crack occurs, the propagation of the crack may be reduced or prevented.

In addition, because the passivation layer <NUM> covering the barrier B may be formed, and because the passivation layer <NUM> may be formed of an organic film absorbing a stress to give flexibility, the occurrence of a crack may be efficiently reduced or prevented.

<FIG> are sequential cross-sectional views illustrating a method of manufacturing a display apparatus according to another embodiment. In <FIG>, like reference numerals as those in <FIG> will denote like elements. Thus, herein, redundant descriptions thereof will be omitted for conciseness.

First, referring to <FIG>, a display unit <NUM> including an opening portion OP is formed over a substrate <NUM>, and a thin film encapsulation layer <NUM> is formed to seal the display unit <NUM>.

Next, an upper dam <NUM> may be formed over the thin film encapsulation layer <NUM>.

As an alternative embodiment, the upper dam <NUM> may be formed at a position corresponding to an edge of the opening portion OP. For example, the upper dam <NUM> may be formed to surround the opening portion OP.

The number of upper dams <NUM> is not limited, and the upper dam <NUM> may be formed to have a certain height to function as a dam as described later.

<FIG> illustrates that the upper dam <NUM> is formed at a position corresponding to an edge of the opening portion OP (e.g., to be at least partially within the opening portion OP). However, the formation position of the upper dam <NUM> is not limited thereto, and the upper dam <NUM> may be formed at any position over the thin film encapsulation layer <NUM> as long as it functions as a dam.

Next, referring to <FIG>, a buffer layer <NUM> may be formed over the thin film encapsulation layer <NUM>. In this case, the upper dam <NUM> may reduce or prevent the buffer layer <NUM> from spreading or leaking to the opening portion OP.

As described above, the display unit <NUM> may include a light-emitting device, such as an organic light-emitting device (OLED), and the light-emitting device may include an electrode.

As an alternative embodiment, as described above, the display unit <NUM> may include an OLED (see <FIG>), and the OLED (see <FIG>) may include a first electrode <NUM> (see <FIG>) and a second electrode <NUM> (see <FIG>). In this case, a parasitic capacitance may occur between the touch electrode <NUM> (see <FIG>) over the display unit <NUM> and the first and second electrodes <NUM> and <NUM> (see <FIG>) included in the display unit <NUM>. When a parasitic capacitance occurs between the touch electrode <NUM> (see <FIG>) over the display unit <NUM> and the first and second electrodes <NUM> and <NUM> (see <FIG>) included in the display unit <NUM>, the sensing sensitivity thereof may be degraded.

As in the following, a parasitic capacitance Cp generated between two layers is inversely proportional to a distance "d" between the two layers. To reduce the parasitic capacitance Cp generated between the display unit <NUM> and the touch electrode <NUM> (see <FIG>), a certain distance is required between the display unit <NUM> and the touch electrode <NUM> (see <FIG>).

Thus, as an alternative embodiment, the buffer layer <NUM> may be additionally formed over the thin film encapsulation layer <NUM> to maintain a certain distance between the display unit <NUM> and the touch electrode <NUM> (see <FIG>).

In this case, the buffer layer <NUM> may be an organic film, as a film having a certain thickness should be formed to maintain the distance therebetween.

The buffer layer <NUM> may be formed to have an organic single-layer structure or a multiple-layer structure, and may be formed by various deposition processes. In some embodiments, the buffer layer <NUM> may be formed of at least one of polyacrylates resin, epoxy resin, phenolic resin, polyamides resin, polyimides rein, unsaturated polyesters resin, poly phenylenethers resin, poly phenylenesulfides resin, and/or benzocyclobutene (BCB).

When the buffer layer <NUM> is formed of an organic material, because a film may be easily formed to have a certain thickness, the distance between the display unit <NUM> and the touch electrode <NUM> (see <FIG>) may be maintained.

Also, when the buffer layer <NUM> is formed of an organic material, because the buffer layer <NUM> has fluidity, it may spread or flow to the opening portion OP or to the edge of the substrate <NUM>. However, as described above, the display apparatus manufacturing method according to the present embodiment may reduce or prevent the spreading of the buffer layer <NUM> by forming the upper dam <NUM> over the thin film encapsulation layer <NUM>.

Next, referring to <FIG>, a touch electrode <NUM> may be formed over the buffer layer <NUM>. As described above, because the buffer layer <NUM> maintains the distance between the display unit <NUM> and the touch electrode <NUM>, the occurrence of a touch sensing failure may be reduced or prevented.

Next, referring to <FIG>, a touch insulating film <NUM> is formed to cover the touch electrode(s) <NUM>.

Thereafter, to expose at least a portion of the touch electrode <NUM>, at least a portion of the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP are removed together with a process of removing a portion(s) the touch insulating film <NUM> to form a touch contact hole(s) TCH.

When the touch insulating film <NUM> is an inorganic film formed of an inorganic material, a portion of the substrate <NUM> may be exposed by removing the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP concurrently with the forming of the touch contact hole(s) TCH, for example, by a dry etching process.

Next, referring to <FIG>, a touch line(s) <NUM> may be formed over the touch insulating film <NUM>. The touch line(s) <NUM> may contact the touch electrode <NUM> through the touch contact hole(s) TCH.

Next, referring to <FIG>, a hole H is formed by removing at least a portion of the substrate <NUM> exposed by the removal of a portion of the touch insulating film <NUM> and a portion of the thin film encapsulation layer <NUM> in the opening portion OP.

In a display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, the hole H is formed in the substrate <NUM> in the opening portion OP in the display region DA.

The hole H is formed by physically removing at least a portion of the substrate <NUM>. In an embodiment, the hole H may have a smaller width than the opening portion OP. Also, the hole H has a smaller width than a width of the touch insulating film <NUM> and the thin film encapsulation layer <NUM> removed in the opening portion OP.

In the case of the display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, because the inorganic films arranged at a portion for formation of the hole H are removed prior to forming of the hole H in the substrate <NUM>, the occurrence and propagation of a crack may be reduced or prevented. Also, time and cost may be saved because the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP may be concurrently removed in the process of the forming the touch contact hole TCH.

Also, because the upper dam <NUM> and the buffer layer <NUM> are formed to increase the distance between the touch electrode <NUM> and the display unit <NUM>, the occurrence of a touch sensing failure may be reduced or prevented.

First, referring to <FIG>, a display unit <NUM> including an opening portion OP and a lower dam <NUM> may be formed over a substrate <NUM>.

As an alternative embodiment, the lower dam <NUM> may be formed at an edge portion of the opening portion OP.

Although <FIG> illustrates the embodiment of forming two lower dams <NUM> at each edge portion of the opening portion OP, the number of lower dams <NUM> is not limited thereto. Also, the shape of the lower dam <NUM> is not limited, and the lower dam <NUM> may be formed to have any shape as long as it has a suitable height.

As an alternative embodiment, the lower dam <NUM> may be formed to surround an area of a hole H (see <FIG>) to be formed later in the substrate <NUM>.

As an alternative embodiment, the lower dam <NUM> may include at least two lower dams <NUM> that are formed at positions spaced apart from each other by a suitable distance. For example, as illustrated in <FIG>, two lower dams <NUM> may be formed in parallel at an edge of the opening portion OP to be spaced apart from each other by a certain distance.

Next, a thin film encapsulation layer <NUM> may be formed to cover the lower dam <NUM> and the display unit <NUM>. A concave portion C may be formed in thin film encapsulation layer <NUM> at a portion covering the lower dam <NUM>. For example, as illustrated in <FIG>, when the thin film encapsulation layer <NUM> is formed to cover two lower dams <NUM>, the thin film encapsulation layer <NUM> may be formed to be concavely curved between the two lower dams <NUM> spaced apart from each other by a certain distance. Thus, the thin film encapsulation layer <NUM> may include the concave portion C formed at a position between the two lower dams <NUM>.

Next, referring to <FIG>, an upper dam <NUM> may be formed over the thin film encapsulation layer <NUM>.

As described above, because the concave portion C is formed in the thin film encapsulation layer <NUM>, the upper dam <NUM> may be easily formed. For example, as an alternative embodiment, two lower dams <NUM> spaced apart from each other may be formed, a concave portion C may be formed at a corresponding position between the two lower dams in the thin film encapsulation layer <NUM> covering the lower dam <NUM>, and an upper dam <NUM> may be formed over the concave portion C. Because the concave portion C is formed to be curved concavely between the two lower dams <NUM>, the upper dam <NUM> may be easily formed at a position of the concave portion C.

Next, referring to <FIG>, a buffer layer <NUM> may be formed over the thin film encapsulation layer <NUM>, and the buffer layer <NUM> may not flow into the opening portion OP due to the upper dam <NUM>.

Next, referring to <FIG>, a touch electrode <NUM> may be formed over the buffer layer <NUM>. Because the distance between the touch electrode <NUM> and the display unit <NUM> is increased by the buffer layer <NUM>, a touch sensing failure (e.g., electrical noise) may be eliminated.

Next, referring to <FIG>, a touch insulating film <NUM> is formed to cover the touch electrode <NUM>, and a touch contact hole(s) TCH is formed in the touch insulating film <NUM>. For example, the touch contact hole(s) TCH may be formed by removing portions of the touch insulating film <NUM> to expose at least a portion of the touch electrode(s) <NUM>.

In this case, at least a portion of the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP are together removed to expose at least a portion of the substrate <NUM>.

As an alternative embodiment, the thin film encapsulation layer <NUM> in the opening portion OP may be an inorganic film <NUM>.

Next, referring to <FIG>, a touch line(s) <NUM> may be formed in/over the touch contact hole(s) TCH. The touch line(s) <NUM> may contact the touch electrode(s) <NUM> through the touch contact hole(s) TCH.

Next, referring to <FIG>, a hole H is formed by removing at least a portion of the substrate <NUM> that is exposed by removing a portion of the touch insulating film <NUM> and a portion of the thin film encapsulation layer <NUM> in the opening portion OP.

In a display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, the hole H may be formed in the substrate <NUM> in the opening portion OP in the display region DA.

] The hole H is formed by physically removing at least a portion of the substrate <NUM>. The hole H may have a smaller width than the opening portion OP. The hole has a smaller width than the portions of the touch insulating film <NUM> and the thin film encapsulation layer <NUM> removed from the opening portion OP.

In the case of the display apparatus <NUM> manufactured by the display apparatus manufacturing method according to the present embodiment, because the inorganic films, which are arranged at a portion for formation of the hole H, are removed in advance before the forming of the hole H in the substrate <NUM>, the occurrence and propagation of a crack may be reduced or prevented. Also, time and cost may be saved because the touch insulating film <NUM> and the thin film encapsulation layer <NUM> in the opening portion OP may be concurrently removed during the process of the forming the touch contact hole TCH.

Also, the upper dam <NUM> may be easily formed because the lower dam <NUM> is formed over the substrate <NUM> and the concave portion C is formed to be downwardly concaved and curved by the lower dam <NUM> in the thin film encapsulation layer <NUM> covering the lower dam <NUM>.

As described above, according to one or more of the above embodiments, it may be possible to reduce or prevent a crack from propagating or occurring in the inorganic film in the case of forming the hole in the substrate in the display region.

Also, because the inorganic film of a portion where the hole will be formed in the progress of a touch process is removed in advance, the hole may be formed in the substrate without cracking, and while reducing the number of processes.

While the embodiments of the inventive concept have been illustrated and described above with reference to the figures, those of ordinary skill in the art will understand that the inventive concept is not limited to the above embodiments, and that various changes and modifications in form and details may be made therein without departing from the scope of the invention as defined by the appended claims.

Claim 1:
A method of manufacturing a display apparatus (<NUM>), the method comprising:
providing a substrate (<NUM>);
forming a display unit (<NUM>) having an opening portion (OP) in a display region (DA) over the substrate (<NUM>);
forming a thin film encapsulation layer (<NUM>) to seal the display unit (<NUM>), the thin film encapsulation layer (<NUM>) comprising an organic film (<NUM>) and an inorganic film (<NUM>);
forming a touch electrode (<NUM>) over the thin film encapsulation layer (<NUM>);
forming a touch insulating film (<NUM>) covering the touch electrode (<NUM>) such that the thin film encapsulation layer (<NUM>) and the touch insulating film (<NUM>) are sequentially stacked and formed over the substrate (<NUM>) in the opening portion (OP);
forming a touch contact hole (TCH) by removing a portion of the touch insulating film (<NUM>) to expose a portion of the touch electrode (<NUM>); and
during the forming of the touch contact hole (TCH), removing a portion of the touch insulating film (<NUM>) and a portion of the inorganic film (<NUM>) formed in the opening portion (OP) to expose a portion of the substrate (<NUM>),
further comprising forming a hole (H) in the substrate (<NUM>) by removing a portion of the exposed portion of the substrate (<NUM>),
wherein a width of the hole (H) is less than a width of the removed portions of the inorganic film (<NUM>) and the touch insulating film (<NUM>) in the opening portion (OP),
wherein the inorganic film (<NUM>) has a larger area than the organic film (<NUM>), and,
wherein the touch insulating film (<NUM>) and the inorganic film (<NUM>) contact each other at an edge of the organic film (<NUM>) in the opening portion (OP), wherein removing the portion of the touch insulating film (<NUM>) and the portion of the inorganic film (<NUM>) comprises removing a portion of the touch insulating film (<NUM>) and the inorganic film (<NUM>) contacting each other at the edge of the organic film (<NUM>) in the opening portion (OP) during the forming of the touch contact hole (TCH).