U.S. patent application number 12/752489 was filed with the patent office on 2010-07-29 for display apparatus and fabricating method thereof.
This patent application is currently assigned to SAMSUNG ELECTRONICS CO., LTD.. Invention is credited to Young-ho KANG, Joo-hyeon LEE.
Application Number | 20100188388 12/752489 |
Document ID | / |
Family ID | 38367497 |
Filed Date | 2010-07-29 |
United States Patent
Application |
20100188388 |
Kind Code |
A1 |
LEE; Joo-hyeon ; et
al. |
July 29, 2010 |
DISPLAY APPARATUS AND FABRICATING METHOD THEREOF
Abstract
A method of fabricating a display apparatus includes depositing
a first layer on a substrate while a mask is disposed at a first
distance from the substrate, and forming a second layer on the
substrate while the mask is disposed at a second distance larger
than the first distance from the substrate after forming the first
layer. Thus, the present invention provides a method of fabricating
a display apparatus, in which a single mask is used in forming an
electron injection layer and a common electrode.
Inventors: |
LEE; Joo-hyeon; (Yongin-si,
KR) ; KANG; Young-ho; (Incheon, KR) |
Correspondence
Address: |
CANTOR COLBURN, LLP
20 Church Street, 22nd Floor
Hartford
CT
06103
US
|
Assignee: |
SAMSUNG ELECTRONICS CO.,
LTD.
Suwon-si
KR
|
Family ID: |
38367497 |
Appl. No.: |
12/752489 |
Filed: |
April 1, 2010 |
Related U.S. Patent Documents
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Application
Number |
Filing Date |
Patent Number |
|
|
11674446 |
Feb 13, 2007 |
7718476 |
|
|
12752489 |
|
|
|
|
Current U.S.
Class: |
345/211 ;
345/76 |
Current CPC
Class: |
H01L 51/0011 20130101;
H01L 27/1288 20130101; H01L 27/3276 20130101; H01L 51/56
20130101 |
Class at
Publication: |
345/211 ;
345/76 |
International
Class: |
G09G 3/30 20060101
G09G003/30; G09G 5/00 20060101 G09G005/00 |
Foreign Application Data
Date |
Code |
Application Number |
Feb 14, 2006 |
KR |
10-2006-0014237 |
Claims
1. A display apparatus comprising: an insulating substrate; a thin
film transistor formed on the insulating substrate and a pixel
electrode connected to the thin film transistor; an organic layer
formed on the pixel electrode and including a light emitting layer;
a first layer formed in a first region and having an outer profile
with a first inclination; and a second layer formed in the first
region and in a second region surrounding the first region and
having an outer profile with a second inclination smaller than the
first inclination.
2. The display apparatus according to claim 1, wherein the first
layer comprises an electron injecting layer, and the second layer
comprises a common electrode.
3. The display apparatus according to claim 1, wherein the second
region is provided with a common voltage applying part, and the
second layer is electrically connected to the common voltage
applying part.
4. The display apparatus according to claim 3, further comprising a
passivation layer that is formed in the first region, in the second
region, and in a third region surrounding the second region and has
an outer profile with a third inclination smaller than the first
inclination.
5. The display apparatus according to claim 3, wherein the second
region comprises a driving voltage bar to apply a driving voltage,
and the organic layer is at least partially disposed on the driving
voltage bar.
6. The display apparatus according to claim 3, wherein the first
region is of a rectangular shape, and the second region comprises a
first sub-region running parallel with a short side of the first
region and a second sub-region running parallel with a long side of
the first region, and the first sub-region is wider than the second
sub-region.
7. The display apparatus according to claim 6, wherein the common
voltage applying part is provided in the first sub-region and the
second sub-region, and the common voltage applying part in the
first sub-region is larger than the common voltage applying part in
the second sub-region.
Description
CROSS REFERENCE TO RELATED APPLICATIONS
[0001] This application is a divisional of U.S. application Ser.
No. 11/674,446, filed on Feb. 13, 2007, which claims priority to
Korean Patent Application No. 2006-0014237, filed on Feb. 14, 2006,
and all the benefits accruing therefrom under 35 U.S.C. .sctn.119,
the contents of which in its entirety are herein incorporated by
reference.
BACKGROUND OF THE INVENTION
[0002] 1. Field of the Invention
[0003] The present invention relates to a display apparatus and a
fabricating method thereof. More particularly, the present
invention relates to a display apparatus formed as a result of a
simplified fabricating method, and the fabricating method
thereof.
[0004] 2. Description of the Related Art
[0005] An organic light emitting diode ("OLED") has recently
attracted attention as a flat panel display because it is driven
with a low voltage, is thin and lightweight, has a wide view angle,
has a relatively short response time, etc.
[0006] The OLED includes an insulating substrate, a thin film
transistor, a pixel electrode, an organic layer, an electron
injection layer, and a common electrode, all of which are stacked
on the insulating substrate. Here, the electron injection layer and
the common electrode are deposited on an entire surface of the
organic layer through masks.
[0007] However, the masks, separately needed in forming the
electron injection layer and the common electrode, complicate a
fabricating process.
BRIEF SUMMARY OF THE INVENTION
[0008] Accordingly, it is an aspect of the present invention to
provide a method of fabricating a display apparatus, in which a
single mask is used in forming an electron injection layer and a
common electrode.
[0009] Another aspect of the present invention is to provide a
display apparatus, in which a single mask is used in forming an
electron injection layer and a common electrode.
[0010] Additional aspects and/or advantages of the present
invention will be set forth in part in the description which
follows and, in part, will be obvious from the description, or may
be learned by practice of the present invention.
[0011] The foregoing and/or other aspects of the present invention
include a method of fabricating a display apparatus, the method
including depositing a first layer on a substrate while a mask is
disposed at a first distance from the substrate, and forming a
second layer on the substrate while the mask is disposed at a
second distance larger than the first distance from the substrate
after forming the first layer.
[0012] The first layer may include an electron injecting layer, and
the second layer may include a common electrode.
[0013] The first layer may be formed in a first region, and the
second layer may be formed in the first region and in a second
region surrounding the first region.
[0014] The method may further include forming an encapsulation
passivation film on the second layer while the mask is disposed at
a third distance larger than the second distance from the
substrate.
[0015] The first region may correspond to a display region.
[0016] The first layer and the second layer may be formed by a heat
evaporation process. The substrate may be formed with an organic
layer thereon, and the first layer and the second layer may be
formed in a state where the organic layer of the substrate is
disposed to face downward. Alternatively, The first layer and the
second layer may be formed in a state where the substrate is
disposed in a standing direction.
[0017] The substrate may be provided by forming a thin film
transistor ("TFT") on an insulating substrate, forming a pixel
electrode connected to the TFT, and forming an organic layer on the
pixel electrode. The organic layer may include material of low
molecular weight, and the first layer may include lithium (Li) and
fluorine (F). Alternatively, the organic layer may include polymer,
and the first layer may include calcium (Ca) and barium (Ba). The
second layer may include aluminum (Al) and may have a thickness
between 4,000 .ANG. and 8,000 .ANG..
[0018] The foregoing and/or other aspects of the present invention
can also be achieved by providing a display apparatus including an
insulating substrate, a TFT formed on the insulating substrate and
a pixel electrode connected to the TFT, an organic layer formed on
the pixel electrode and including a light emitting layer, a first
layer formed in a first region and having an outer profile with a
first inclination, and a second layer formed in the first region
and in a second region surrounding the first region and having an
outer profile with a second inclination smaller than the first
inclination.
[0019] The first layer may include an electron injecting layer, and
the second layer may include a common electrode.
[0020] The second region may be provided with a common voltage
applying part, and the second layer may be electrically connected
to the common voltage applying part. A passivation layer may be
formed in the first region, in the second region, and in a third
region surrounding the second region and may have an outer profile
with a third inclination smaller than the first inclination. The
second region may include a driving voltage bar to apply a driving
voltage, and the organic layer may be at least partially disposed
on the driving voltage bar.
[0021] The first region may be of a rectangular shape, and the
second region may include a first sub-region running parallel with
a short side of the first region and a second sub-region running
parallel with a long side of the first region, in which the first
sub-region is wider than the second sub-region. The common voltage
applying part may be provided in the first sub-region and the
second sub-region, and the common voltage applying part in the
first sub-region may be larger than the common voltage applying
part in the second sub-region.
BRIEF DESCRIPTION OF THE DRAWINGS
[0022] The above and/or other aspects and advantages of the present
invention will become apparent and more readily appreciated from
the following description of the embodiments, taken in conjunction
with the accompanying drawings of which:
[0023] FIG. 1 is an equivalent circuit diagram of an exemplary
display apparatus according to a first exemplary embodiment of the
present invention;
[0024] FIGS. 2A and 3 are layout diagrams of the exemplary display
apparatus according to the first exemplary embodiment of the
present invention, and FIG. 2B is an enlarged view of portion B in
FIG. 2A;
[0025] FIG. 4 illustrates regions of the exemplary display
apparatus according to the first exemplary embodiment of the
present invention;
[0026] FIG. 5 is a sectional view taken along line V-V of FIG.
2A;
[0027] FIG. 6 is a sectional view taken along line VI-VI of FIG.
2B;
[0028] FIG. 7 is a schematic sectional view of the exemplary
display apparatus including an exemplary encapsulation plate
according to the first exemplary embodiment of the present
invention;
[0029] FIGS. 8A through 8C illustrate an exemplary fabricating
method of the exemplary display apparatus according to the first
exemplary embodiment of the present invention;
[0030] FIG. 9 is a schematic sectional view of an exemplary display
apparatus according to a second exemplary embodiment of the present
invention;
[0031] FIG. 10 illustrates an exemplary fabricating method of the
exemplary display apparatus according to the second exemplary
embodiment of the present invention;
[0032] FIG. 11A is a layout diagram of an exemplary display
apparatus according to a third exemplary embodiment of the present
invention, and FIG. 11B is an enlarged view of portion C of FIG.
11A;
[0033] FIG. 12 is a sectional view taken along line XII-XII of FIG.
11B;
[0034] FIG. 13 is a sectional view of an exemplary display
apparatus according to a fourth exemplary embodiment of the present
invention;
[0035] FIG. 14 is a sectional view of an exemplary display
apparatus according to a fifth exemplary embodiment of the present
invention;
[0036] FIG. 15 illustrates an exemplary fabricating method of the
exemplary display apparatus according to the fifth exemplary
embodiment of the present invention; and
[0037] FIG. 16 is a layout diagram of an exemplary display
apparatus according to a sixth exemplary embodiment of the present
invention.
DETAILED DESCRIPTION OF THE INVENTION
[0038] Hereinafter, embodiments of the present invention will be
described with reference to accompanying drawings, wherein like
numerals refer to like elements and repetitive descriptions will be
avoided as necessary. This invention may, however, be embodied in
many 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 invention to those skilled in
the art.
[0039] Further, a term of "on" means that a new layer (i.e., film)
may be interposed or not interposed between two layers (i.e.,
films), and a term of "directly on" means that two layers (i.e.
films) are in contact with each other. As used herein, the term
"and/or" includes any and all combinations of one or more of the
associated listed items.
[0040] It will be understood that, although the terms first,
second, third etc. may be used herein to describe various elements,
components, regions, layers and/or sections, these elements,
components, regions, layers and/or sections should not be limited
by these terms. These terms are only used to distinguish one
element, component, region, layer or section from another element,
component, region, layer or section. Thus, a first element,
component, region, layer or section discussed below could be termed
a second element, component, region, layer or section without
departing from the teachings of the present invention.
[0041] The terminology used herein is for the purpose of describing
particular embodiments only and is not intended to be limiting of
the invention. As used herein, the singular forms "a", "an" and
"the" are intended to include the plural forms as well, unless the
context clearly indicates otherwise. It will be further understood
that the terms "comprises" and/or "comprising," or "includes"
and/or "including" when used in this specification, specify the
presence of stated features, regions, integers, steps, operations,
elements, and/or components, but do not preclude the presence or
addition of one or more other features, regions, integers, steps,
operations, elements, components, and/or groups thereof.
[0042] Spatially relative terms, such as "beneath", "below",
"lower", "above", "upper" and the like, may be used herein for ease
of description to describe one element or feature's relationship to
another element(s) or feature(s) as illustrated in the figures. It
will be understood that the spatially relative terms are intended
to encompass different orientations of the device in use or
operation in addition to the orientation depicted in the figures.
For example, if the device in the figures is turned over, elements
described as "below" or "beneath" other elements or features would
then be oriented "above" the other elements or features. Thus, the
exemplary term "below" can encompass both an orientation of above
and below. The device may be otherwise oriented (rotated 90 degrees
or at other orientations) and the spatially relative descriptors
used herein interpreted accordingly.
[0043] Unless otherwise defined, all terms (including technical and
scientific terms) used herein have the same meaning as commonly
understood by one of ordinary skill in the art to which this
invention belongs. It will be further understood that terms, such
as those defined in commonly used dictionaries, should be
interpreted as having a meaning that is consistent with their
meaning in the context of the relevant art and the present
disclosure, and will not be interpreted in an idealized or overly
formal sense unless expressly so defined herein.
[0044] Embodiments of the present invention are described herein
with reference to cross section illustrations that are schematic
illustrations of idealized embodiments of the present invention. As
such, variations from the shapes of the illustrations as a result,
for example, of manufacturing techniques and/or tolerances, are to
be expected. Thus, embodiments of the present invention should not
be construed as limited to the particular shapes of regions
illustrated herein but are to include deviations in shapes that
result, for example, from manufacturing. For example, a region
illustrated or described as flat may, typically, have rough and/or
nonlinear features. Moreover, sharp angles that are illustrated may
be rounded. Thus, the regions illustrated in the figures are
schematic in nature and their shapes are not intended to illustrate
the precise shape of a region and are not intended to limit the
scope of the present invention.
[0045] FIG. 1 is an equivalent circuit diagram of an exemplary
display apparatus according to a first exemplary embodiment of the
present invention.
[0046] A pixel is provided with a plurality of signal lines. The
signal lines include a gate line to transmit a scan signal,
otherwise known as a gate signal, a data line to transmit a data
signal, and a driving voltage line to transmit a driving voltage.
Here, the data line and the driving voltage line are adjacent to
and parallel with each other. On the other hand, the gate line is
extended perpendicularly to the data line and the driving voltage
line.
[0047] Each pixel includes an organic light emitting device LD, a
switching thin film transistor ("TFT") Tsw, a driving TFT Tdr, and
a capacitor C.
[0048] The driving TFT Tdr has a control terminal, such as a gate
electrode, connected to the switching TFT Tsw, an input terminal,
such as a source electrode, connected to the driving voltage line,
and an output terminal, such as a drain electrode, connected to the
organic light emitting device LD.
[0049] The organic light emitting device LD has an anode connected
to the output terminal of the driving TFT Tdr, and a cathode
connected to a common voltage Vcom. The organic light emitting
device LD emits light with brightness varying according to the
intensity of a current outputted from the driving TFT Tdr, thereby
displaying an image. Here, the intensity of the current outputted
from the driving TFT Tdr varies according to voltages applied
between the control terminal and the output terminal of the driving
TFT Tdr.
[0050] The switching TFT Tsw has a control terminal, such as a gate
electrode, connected to the gate line, an input terminal, such as a
source electrode, connected to the data line, and an output
terminal, such as a drain electrode, connected to the control
terminal of the driving TFT Tdr. The switching TFT Tsw transmits
the data signal from the data line to the driving TFT Tdr in
response to the scan signal applied to the gate line.
[0051] The capacitor C is connected between the control terminal
and the input terminal of the driving TFT Tdr. The capacitor C
stores and maintains the data signal to be inputted to the control
terminal of the driving TFT Tdr.
[0052] Below, the display apparatus according to the first
exemplary embodiment will be described in more detail with
reference to FIGS. 2A through 6. FIG. 2A illustrates the display
apparatus except for a data driver 400, a gate driver 500, a
driving voltage medium 611, and a common voltage medium 622, which
are shown in FIG. 3. FIGS. 5 and 6 illustrate only the driving TFT
Tdr.
[0053] A first insulating substrate 110 includes a rectangular
display region, and a non-display region surrounding the display
region, as shown in FIG. 4.
[0054] First, the non-display region will be described below.
[0055] In the non-display region, a first non-display region
adjacent to a top side of the display region is provided with a
data pad 144, as shown in FIGS. 2A and 2B, connected to the data
driver 400, shown in FIG. 3. Further, the data pad 144 is connected
with the data line 141 extended toward the display region.
[0056] The data pad 144 is plurally provided and the data pads 144
are spaced apart from each other at predetermined intervals.
Further, a driving voltage pad 125, also shown in FIG. 2A, is
provided between the data pads 144. The driving voltage pad 125
receives a driving voltage from the data driver 400 through the
driving voltage medium 611, shown in FIG. 3.
[0057] Each driving voltage pad 125 is connected to a driving
voltage bar 126 arranged in parallel with the gate line 121. Also,
the driving voltage bar 126 is connected with the driving voltage
line 145 extended in parallel with the data line 141.
[0058] As shown in FIG. 6, the driving voltage bar 126 and the
driving voltage line 145 are formed in different layers of the
display apparatus. Further, the driving voltage bar 126 and the
driving voltage line 145 are connected with each other by a driving
bridge 163 made of a transparent conductive material. To be
connected by the driving bridge 163, contact holes 155 and 156 are
formed through a passivation film 151 exposing the driving voltage
bar 126 and the driving voltage line 145, respectively. On the
driving bridge 163 are formed a partition wall 171 and a common
electrode 190.
[0059] In the non-display region, a second non-display region,
identified in FIG. 4, adjacent to a left side of the display region
is provided with a gate pad 124, shown in FIG. 2A, connected to the
gate driver 500, shown in FIG. 3. Further, the gate pad 124 is
connected with the gate line 121 extended toward the display
region.
[0060] The gate pad 124 is plurally provided and the gate pads 124
are spaced apart from each other at predetermined intervals.
Further, a common voltage applying part 123, also shown in FIG. 2A,
is provided between the gate pads 124. The common voltage applying
part 123 receives a common voltage from the gate driver 500 through
the common voltage medium 622, shown in FIG. 3.
[0061] The common voltage applying part 123 has a first end exposed
through a contact hole 154 as shown in FIG. 5, and the exposed part
is covered with a contact member 162. The contact member 162 is
connected with the common voltage medium 622, so that the common
voltage applying part 123 receives the common voltage.
[0062] Further, the common voltage applying part 123 has a second
end facing the display region and exposed through a contact hole
153, and the exposed part is connected to the common electrode 190.
As shown in FIG. 4, the common electrode 190 is formed in the
display region (i.e., the first region) and the second region
surrounding the display region. Thus, the second region having the
common electrode 190 overlaps portions of the first, second, third,
and fourth non-display regions.
[0063] In the non-display region of one exemplary embodiment, third
and fourth non-display regions each placed adjacent to bottom and
right sides of the display region include no separate
component.
[0064] Meanwhile, the data driver 400 includes a flexible printed
circuit film 401, a data driving chip 402, and a data circuit board
403. The gate driver 500 includes a flexible printed circuit film
501, a gate driving chip 502, and a gate circuit board 503.
[0065] Next, the display region will be described as follows.
[0066] The gate line 121 and the gate electrode 122, shown in FIG.
5, are formed on the first insulating substrate 110 made of an
insulating material such as glass, quartz, plastic or the like. The
gate line 121 and the gate electrode 122 are formed in the same
metal layer as the common voltage applying part 123, the gate pad
124, the driving voltage pad 125, and the driving voltage bar 126
of the non-display region. Here, the gate line 121 is connected
with the gate pad 124.
[0067] A gate insulating film 131 including silicon nitride
(SiN.sub.X) or the like is formed on the gate line 121 and the gate
electrode 122 and on exposed portions of the first insulating
substrate 110.
[0068] A semiconductor layer 132 that is made of amorphous silicon
("a-Si"), microcrystalline silicon, or crystalline silicon and an
ohmic contact layer 133 that is made of n+a-Si hydride highly doped
with an n-type dopant are formed in sequence on the gate insulating
film 131 corresponding to the gate electrode 122. Here, the ohmic
contact layer 133 is separated into two parts with reference to the
gate electrode 122, thus exposing a channel portion of the
semiconductor layer 132.
[0069] The data line 141, a source electrode 142, and a drain
electrode 143 are formed on the ohmic contact layer 133 and the
gate insulating film 131. Further, the source electrode 142 and the
drain electrode 143 are separated with reference to the gate
electrode 122. Also, the data line 141, the source electrode 142,
and the drain electrode 143 are formed in the same metal layer as
the data pad 144 of the non-display region and the driving voltage
line 145.
[0070] A passivation film 151 is formed on the source electrode
142, the drain electrode 143, an upper part of the semiconductor
layer 132 exposed between the source and drain electrodes 142 and
143, and on other exposed portions of the gate insulating film 131.
The passivation film 151 may include silicon nitride (SiN.sub.X).
In addition to the contact holes 153 and 154, the passivation film
151 is further partially removed to form a contact hole 152
exposing the drain electrode 143.
[0071] A pixel electrode 161 is formed on the passivation film 151.
The pixel electrode 161 supplies a hole to an organic layer 180.
The pixel electrode 161 includes a transparent conductive material
such as indium tin oxide ("ITO"), indium zinc oxide ("IZO"), etc.,
and is connected to the drain electrode 143 through the contact
hole 152. Here, the pixel electrode 161 is formed in the same
transparent conductive layer as the driving bridge 163 and the
contact member 162 of the non-display region.
[0072] A partition wall 171 is formed on the pixel electrode 161
and the passivation film 151 and surrounds the pixel electrode 161.
The partition wall 171 divides adjacent pixel electrodes 161 from
each other and defines pixel regions. Further, the partition wall
171 prevents the source and drain electrodes 142 and 143 of the
driving TFT Tdr from being short-circuited with the common
electrode 190. The partition wall 171 may include a photosensitive
material such as an acrylic resin, a polyimide resin, etc., which
has heat resistance and solvent resistance, and an inorganic
material such as SiO.sub.2 and TiO.sub.2. Further, the partition
wall 171 may have a double structure of an organic layer and an
inorganic layer.
[0073] An organic layer 180 is formed on the pixel electrode 161
that is not covered with the partition wall 171. The organic layer
180 is substantially formed in a region corresponding to the
display region.
[0074] The organic layer 180 may include a hole injecting layer
181, a hole transfer layer 182, a light emitting layer 183, and an
electron transfer layer 184. In one exemplary embodiment, the
organic layer 180 is formed by a dry process, such as a heat
evaporation process.
[0075] In the organic layer 180, the hole injecting layer 181, the
hole transfer layer 182, and the electron transfer layer 184 are
each formed in common on all of the pixel electrodes 161 and the
partition wall 171. The light emitting layer 183 includes a
plurality of light emitting sub-layers different in light color.
Alternatively, in the case where the light emitting layer 183 emits
white light, the light emitting layer 183 can be also formed in
common on all of the pixel electrodes 161. In the case where the
light emitting layer 183 emits white color, a color filter may be
formed between the first insulating substrate 110 and each pixel
electrode 161. Here, the light emitting layer 183 emitting the
white light can be formed by stacking three light emitting
materials that emit light of red, green and blue, respectively.
[0076] For the hole injecting layer 181 and the hole transfer layer
182, it is preferable but not necessary to use amine derivatives
having strong fluorescence, for instance, triphenyldiamine
derivatives, styrylamine derivatives, and amine derivatives having
an aromatic fused ring.
[0077] For the electron transfer layer 184, it is preferable but
not necessary to use quinoline derivatives, in particular, aluminum
tris(8-hydroxyquinoline), Alq3. It is also preferable but not
necessary to use phenyl anthracene derivatives and tetraarylethene
derivatives.
[0078] On the organic layer 180 is formed an electron injecting
layer 185. The electron injecting layer 185 includes barium (Ba) or
calcium (Ca) and may be formed by the heat evaporation process.
Here, the electron injecting layer 185 is not formed on the common
voltage applying part 123 that is formed on the second region
within the non-display region.
[0079] On the electron injecting layer 185 is formed the common
electrode 190. The common electrode 190 supplies electrons to the
light emitting layer 183. The common electrode 190 contains
aluminum (Al) and may also be formed by the heat evaporation
process. Preferably, the common electrode 190 has a thickness of
about 4,000 .ANG. through 8,000 .ANG.. Here, the common electrode
190 is formed throughout the first region, thus encompassing the
display region, and the second region, within the non-display
region, surrounding the first region. In the meantime, with
reference to FIGS. 2A and 4, the width (W2) of the second region
corresponding to the opposing second and fourth non-display regions
is wider than the width (W1) of the second region corresponding to
the opposing first and third non-display regions.
[0080] The common electrode 190 is connected to the common voltage
applying part 123 within the second region via contact hole 153 as
shown in FIG. 5.
[0081] The hole transferred from the pixel electrode 161 and the
electron transferred from the common electrode 190 are combined
into an exciton, and light is emitted.
[0082] In the foregoing display apparatus, the organic layer 180
deteriorates by moisture and oxygen. Thus, the display apparatus
may further include an encapsulation plate.
[0083] FIG. 7 is a schematic sectional view of the exemplary
display apparatus including an encapsulation plate according to the
first exemplary embodiment of the present invention.
[0084] A display portion is formed on the insulating substrate 110,
and the electron injecting layer 185 is formed on the display
portion. Here, the display portion indicates a portion between the
insulating substrate 110 and the electron injecting layer 185. On
the electron injecting layer 185 is formed the common electrode
190. As described above, the common electrode 190 is formed in a
region larger than the electron injecting layer 185.
[0085] Here, each of the electron injecting layer 185 and the
common electrode 190 has a gently inclined outer profile because
they are formed by diffusion, which will be further described
below.
[0086] On the common electrode 190 is formed a sealant 300, and an
encapsulation plate 200 is attached to the insulating substrate 110
through the sealant 300. The encapsulation plate 200 and the
sealant 300 protect the organic layer 180 from moisture and oxygen.
Here, the encapsulation plate 200 may be made of, by example only,
glass or stainless steel, and the sealant 300 may be made of
thermosetting resin or ultraviolet ("UV") hardening resin.
[0087] The electron injecting layer 185 made of barium or calcium
is likely to be oxidized if it comes in contact with the sealant
300. However, according to the exemplary embodiment, the electron
injecting layer 185 is covered with the common electrode 190,
thereby preventing the electron injecting layer 185 from being in
direct-contact with the sealant 300.
[0088] Below, an exemplary method of fabricating the exemplary
display apparatus according to the first exemplary embodiment of
the present invention will be described.
[0089] FIGS. 8A through 8C illustrate an exemplary fabricating
method of the exemplary display apparatus according to the first
exemplary embodiment of the present invention.
[0090] FIG. 8A illustrates the electron injecting layer 185 formed
on a deposition-objective substrate 2 having the display portion
including the organic layer 180 formed on the first insulating
substrate 110.
[0091] The deposition-objective substrate 2 may be disposed so that
the organic layer 180 faces downward. Further, the
deposition-objective substrate 2 rotates on its own axis in a
horizontal plane. Then, a mask 10 is disposed to be spaced apart
from the deposition-objective substrate 2 at a first distance "d1,"
thereby determining a region for the electron injecting layer 185.
Here, the mask 10 rotates along with the deposition-objective
substrate 2.
[0092] The mask 10 is shaped like a window frame as shown in FIG.
8B, and has a rectangular opening 11 corresponding to the display
region.
[0093] Under the deposition-objective substrate 2 is provided an
electron injection material source 20. Thus, the electron injection
material source 20 supplies vapor of an electron injection material
to the deposition-objective substrate 2.
[0094] In an exemplary embodiment, the electron injection material
source 20 is not aligned with the center of the
deposition-objective substrate 2 but leans to the right or is
otherwise positioned off-center with respect to the display portion
of the deposition-objective substrate 2. In this state, the
deposition-objective substrate 2 rotates on its own axis, with the
mask 10, and the electron injection material is uniformly deposited
on the deposition-objective substrate 2. In this portion of the
method, the mask 10 may also be covered with the electron injection
material that forms the electron injecting layer 185.
[0095] Then, as shown in FIG. 8C, the mask 10 is disposed to be
spaced apart at a second distance "d2" from the
deposition-objective substrate 2 formed with the electron injecting
layer 185, and then the common electrode 190 is formed. To adjust
the distance between the deposition-objective substrate 2 and the
mask 10, the mask 10 and the deposition-objective substrate 2 are
relatively moved not in a horizontal direction but in a vertical
direction. Here, the second distance d2 for the common electrode
190 is a little larger than the first distance d1.
[0096] In this portion of the method, a common electrode material
source 30 is disposed under the deposition-objective substrate 2.
Thus, the common electrode material source 30 supplies vapor of a
common electrode material to the deposition-objective substrate 2
that was previously covered with the electron injecting layer 185.
In this portion of the method, the mask 10 may further be covered
with the common electrode material that forms the common electrode
layer 190.
[0097] In one exemplary embodiment of the method, the common
electrode material source 30 is not aligned with the center of the
deposition-objective substrate 2 but leans to the right or is
otherwise positioned off-center with respect to the display portion
of the deposition-objective substrate 2. In this state, the
deposition-objective substrate 2 rotates on its own axis with the
mask 10.
[0098] During the deposition process, diffusion arises through the
space between the mask 10 and the deposition-objective substrate 2,
so that the electron injecting layer 185 and the common electrode
190 are formed in a region larger than the opening 11 of the mask
10.
[0099] However, the space between the mask 10 and the
deposition-objective substrate 2 for forming the common electrode
190 is larger than that for forming the electron injecting layer
185, since the mask 10 is spaced further from the
deposition-objective substrate 2 during formation of the common
electrode 190 than during formation of the electron injecting layer
185. Therefore, the common electrode 190 is formed in the region
larger than that for the electron injecting layer 185. Meanwhile,
each outer profile of the electron injecting layer 185 and the
common electrode 190 is gently inclined because they are formed by
diffusion.
[0100] Disposition between the non-display region and the common
electrode material source 30 is as follows.
[0101] The minimum angle .theta. between the common electrode
material source 30 and the deposition-objective substrate 2 in the
second non-display region is smaller than that in the first
non-display region because the display region is shaped like a
rectangle instead of a square, and the second non-display region
can be more distant from the common electrode material source 30
than the first non-display region. Thus, the vapor of the common
electrode material in the second non-display region is more deeply
diffused than that in the first non-display region. Therefore, the
width of the common electrode 190 in the second non-display region
is larger than that in the first non-display region. In other
words, W2>W1 as shown in FIG. 2A.
[0102] Likewise, the width of the common electrode 190 in the
fourth non-display region is larger than the third non-display
region.
[0103] In this embodiment, the single mask 10 is used for forming
the electron injecting layer 185 and the common electrode 190,
which have different deposition regions. Therefore, both the
electron injecting layer 185 and the common electrode 190 are
formed without difficulty of using multiple masks, and changing and
moving such masks between chambers.
[0104] FIG. 9 is a schematic sectional view of an exemplary display
apparatus according to a second exemplary embodiment of the present
invention.
[0105] According to the second exemplary embodiment, an outer
profile of an electron injecting layer 185 is steeply inclined
because it is not formed by diffusion as in the prior embodiment,
but an outer profile of a common electrode 190 is gently inclined
because it is formed by diffusion. Further, in this exemplary
embodiment, the electron injecting layer 185 is formed only in the
display region, so that the first region is equal with the display
region. In the following exemplary embodiments, the first region
will be equal to the display region.
[0106] Below, an exemplary method of fabricating the exemplary
display apparatus according to the second exemplary embodiment of
the present invention will be described with reference to FIG.
10.
[0107] FIG. 10 illustrates that the electron injecting layer 185 is
formed on the deposition-objective substrate 2 having the organic
layer 180, as in the prior embodiment.
[0108] However, in this exemplary embodiment, the
deposition-objective substrate 2 is disposed in a standing
direction and rotates on its own axis. A mask 10 is closely
attached to the deposition-objective substrate 2, thereby
determining a forming region of the electron injecting layer 185.
Here, the mask 10 rotates along with the deposition-objective
substrate 2.
[0109] An electron injection material source 20 is provided in
front of the deposition-objective substrate 2, so that the electron
injection material source 20 supplies vapor of an electron
injection material to the deposition-objective substrate 2. To
obtain uniform deposition, the deposition-objective substrate 2
moves upward and downward or forward and backward. As the mask 10
is attached to the deposition-objective substrate 2, the electron
injection material may be further formed on the mask 10.
[0110] In this embodiment, because the mask 10 is closely attached
to the deposition objective substrate 2, the vapor of the electron
injection material is not diffused between the mask 10 and the
deposition-objective substrate 2. Therefore, the electron injection
layer 185 has a periphery limited by the opening 11 of the mask 10
and thus has a steeply inclined outer profile.
[0111] Then, the common electrode 190 is formed in the state where
the mask 10 is spaced apart from the deposition-objective substrate
2. Thus, vapor of a common electrode material is diffused between
the mask 10 and the deposition substrate 2, so that the common
electrode 190 has a gently inclined outer profile, such as
previously shown in FIG. 8C.
[0112] Below, an exemplary display apparatus according to a third
exemplary embodiment of the present invention will be described
with reference to FIGS. 11A, 11B, and 12.
[0113] FIG. 11A is a layout diagram of an exemplary display
apparatus according to a third exemplary embodiment of the present
invention, FIG. 11B is an enlarged view of portion C in FIG. 11A,
and FIG. 12 is a sectional view taken along line XII-XII of FIG.
11B.
[0114] In the exemplary display apparatus according to the third
exemplary embodiment of the present invention, an organic layer 180
is partially extended to the outside of a display region. In other
words, common layers of the organic layer 180, such as a hole
injecting layer 181, a hole transfer layer 182, an electron
transfer layer 184 or the like with the exception of a light
emitting layer 183, are extended to a region A, i.e., to the top of
the display region within a portion of the first non-display
region.
[0115] As shown in FIG. 12, the common layers 181, 182, and 184 are
expanded to the region A and are disposed between a driving bridge
163 and a common electrode 190. Between the driving bridge 163 and
the common electrode 190 are provided the common layers 181, 182,
and 184 along with a partition wall 171. Thus, short-circuit
between the driving bridge 163 and the common electrode 190 is
prevented.
[0116] The common layers 181, 182, and 184 are deposited through a
mask having an opening with no separate pattern. Therefore, the
opening of the mask may simply be changed in order to extend the
common layers 181, 182, and 184 to the region A.
[0117] On the other hand, the light emitting layer 183 is formed
through a shadow mask having a patterned opening corresponding to
each of the pixel electrodes 161. Alternatively, the light emitting
layer 183 may also extended to the region A by changing the shadow
mask.
[0118] FIG. 13 is a sectional view of an exemplary display
apparatus according to a fourth exemplary embodiment of the present
invention, corresponding to the sectional view taken along line V-V
of FIG. 2A.
[0119] According to the fourth exemplary embodiment of the present
invention, an organic layer 180 includes a hole injecting layer 181
and a light emitting layer 183. The organic layer 180 includes a
polymer, and may be formed by an inkjet method. Here, the hole
injecting layer 181 and the light emitting layer 183 are not formed
on a partition wall 171 but formed only on the pixel electrode 161
within the openings defined by the partition wall 171.
[0120] The hole injecting layer 181 may include a hole injection
material such as poly(3,4-ethylenedioxy thiophene)("PEDOT") and
polystyrene sulfonic acid ("PSS"). The light emitting layer 183 may
include polyfluorene derivatives, (poly) paraphenylenevinylene
derivatives, polyphenylene derivatives, polyvinyl cabazole,
polythiophene derivatives, or such polymer materials doped with
pherylene pigment, rhodamine pigment, rubrene, pherylene,
9,10-diphenylantracen, tetraphenylbutadienem, nile-red, coumarin 6,
quinacridone, etc.
[0121] The electron injecting layer 185 is formed on the whole
organic layer 180 and may include lithium (Li) and fluorine (F).
The common electrode layer 190 may cover the entire electron
injection layer 185 and expand partially into the non-display
region, as in the prior exemplary embodiments.
[0122] Below, an exemplary display apparatus according to a fifth
exemplary embodiment of the present invention will be described
with reference to FIGS. 14 and 15. FIG. 14 is a sectional view of
an exemplary display apparatus according to a fifth exemplary
embodiment of the present invention, and FIG. 15 illustrates an
exemplary fabricating method of the exemplary display apparatus
according to the fifth exemplary embodiment of the present
invention.
[0123] As shown in FIG. 14, the exemplary display apparatus
according to the fifth exemplary embodiment of the present
invention further includes an encapsulation passivation film 195
formed on the common electrode 190. The encapsulation passivation
film 195 further protects an organic layer 180 from moisture and
oxygen. Further, the encapsulation passivation film 195 is formed
in a region larger than that of the common electrode 190, and may
have a relatively gentle outer profile as illustrated.
[0124] As shown in FIG. 15, the encapsulation passivation film 195
may be formed by spacing a mask 10 apart from a
deposition-objective substrate 2 by a third distance d3, and
supplying vapor of an encapsulation passivation material from an
encapsulation passivation material source 40. The encapsulation
passivation material may also cover the mask 10 as shown.
[0125] The third distance d3 for the encapsulation passivation film
195 is larger than the distance d2 in which the mask 10 was spaced
apart from the deposition-objective substrate 2 for formation of
the common electrode 190. Thus, the encapsulation passivation film
195 is formed in a region larger than that of the common electrode
190. Further, the vapor of the encapsulation passivation material
is diffused between the mask 10 and the deposition-objective
substrate 2, so that the encapsulation passivation film 195 has a
gentle outer profile.
[0126] According to the fifth exemplary embodiment, the electron
injecting layer 185, the common electrode 190, and the
encapsulation passivation film 195 can be formed using the single
mask 10.
[0127] FIG. 16 is a layout diagram of an exemplary display
apparatus according to a sixth exemplary embodiment of the present
invention.
[0128] A common voltage applying part 123 is placed adjacent to
left and bottom sides of a display region having the electron
injecting layer 185, and a common electrode 190 in the left side of
the display region is larger than that that in the bottom side.
Thus, the common voltage applying part 123 in the left side of the
display region is larger than that in the bottom side.
[0129] According to the sixth exemplary embodiment of the present
invention, the size of the common voltage applying part 123 can be
adjusted by considering a deposition region of the common electrode
190, thereby increasing contact between the common electrode 190
and the common voltage applying part 123.
[0130] As described above, the present invention provides a method
of fabricating a display apparatus, in which a single mask is used
in forming an electron injection layer and a common electrode.
[0131] Further, the present invention provides a display apparatus,
in which a single mask is used in forming an electron injection
layer and a common electrode.
[0132] Although a few exemplary embodiments of the present
invention have been shown and described, it will be appreciated by
those skilled in the art that changes may be made in these
embodiments without departing from the principles and spirit of the
invention, the scope of which is defined in the appended claims and
their equivalents.
* * * * *