Display device and method of manufacturing same

Abstract

The invention relates to a display device and a method of manufacturing the same. The display device includes: a display panel layer; a light transmission layer disposed on the display panel layer, in which a plurality of trenches are defined in the light transmission layer to be recessed in a first direction toward the display panel layer; and a light blocking material filling the plurality of trenches. A profile in a cross-section of each of the plurality of grooves includes a first parallel section, a connecting section, and a second parallel section sequentially defined along the first direction. A first width of the profile on the cross-section in the first parallel section in a second direction perpendicular to the first direction is less than a second width of the profile on the cross-section in the second parallel section in the second direction.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and all benefits derived from Korean Patent Application No. 10-2023-0157610, filed on November 14, 2023, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] Embodiments of the present disclosure generally relate to a display device and a method of manufacturing the display device. Background Art

[0004] The display device generally includes a display panel layer. The display panel layer may include at least one light emitting element, and the light emitted from the light emitting element may be emitted toward the front surface of the display device. The display device may display an image by combining the light emitted from the light emitting elements. Summary of the invention

[0005] Recently, the demand for vehicles including display devices that provide various images, such as real-time traffic information, has increased. However, light emitted from the display device included in the vehicle may obstruct the driver's field of view while being reflected from the windshield of the vehicle.

[0006] The embodiment provides a display device and a method of manufacturing the display device, in which a viewing angle of an image displayed in the display device is controlled so that display quality can be improved while preventing emission of unintended light.

[0007] According to an embodiment of the present disclosure, a display device includes: a display panel layer; a light transmission layer, which is arranged on the display panel layer, wherein a plurality of grooves are defined in the light transmission layer to be recessed in a first direction toward the display panel layer; and a light blocking material, which fills the plurality of grooves, wherein a profile on a cross section of each of the plurality of grooves includes a first parallel segment, a connecting segment, and a second parallel segment sequentially defined along the first direction, and a first width of the profile on the cross section in the first parallel segment in a second direction perpendicular to the first direction is smaller than a second width of the profile on the cross section in the second parallel segment in the second direction.

[0008] In an embodiment, a width of the profile on the cross section in the connecting section in the second direction may gradually increase from the first width to the second width along the first direction.

[0009] In an embodiment, the profile on the cross section of each of the plurality of grooves may further include an upper section as a section between the upper surface of the light transmission layer and the first parallel sections. The width of the profile on the cross section in the upper section in the second direction may gradually increase along the first direction and then gradually decrease.

[0010] In an embodiment, a maximum width of the profile on the cross section in the upper section in the second direction may be smaller than the second width.

[0011] In an embodiment, the profile on the cross section of each of the plurality of grooves may further include a lower section as a section between the second parallel section and the lower surface of the light transmission layer. In such an embodiment, the width of the profile on the cross section in the lower section in the second direction may gradually decrease along the first direction.

[0012] In an embodiment, the second width may be equal to or less than 1.3 times the first width.

[0013] In an embodiment, the sum of the length of the profile on the cross section in the first parallel segment in the first direction and the length of the profile on the cross section in the second parallel segment in the first direction may be equal to or greater than 60% of the total length of the profile on the cross section of each of the multiple grooves in the first direction.

[0014] In an embodiment, the light transmitting layer may be a single layer including an organic insulating material.

[0015] In an embodiment, the display panel layer may include an inorganic insulating layer in direct contact with a lower surface of the light transmission layer.

[0016] In an embodiment, each of the plurality of trenches may expose at least a portion of an upper surface of the inorganic insulating layer.

[0017] According to another embodiment of the present disclosure, a method for manufacturing a display device includes: forming a preliminary light transmission layer on a display panel layer; forming a mask layer on the preliminary light transmission layer, the mask layer defining an opening that exposes a portion of an upper surface of the preliminary light transmission layer; forming a light transmission layer by dry etching the preliminary light transmission layer using the mask layer, the light transmission layer defining a plurality of grooves recessed in a first direction toward the display panel layer; and filling the plurality of grooves with a light blocking material, wherein the mask layer includes a first layer and a second layer disposed on the first layer, and a side surface of the second layer is further recessed in a second direction perpendicular to the first direction compared to a side surface of the first layer.

[0018] In an embodiment, the second layer may have a shape tapered in a direction opposite to the first direction in cross section.

[0019] In an embodiment, the mask layer may further include a third layer disposed on the second layer. In such an embodiment, the side surface of the second layer may be further recessed in the second direction than the side surface of the third layer to define a first undercut.

[0020] In an embodiment, the mask layer may further include a fourth layer disposed on the third layer and a fifth layer disposed on the fourth layer. In such an embodiment, a side surface of the fourth layer may be further recessed in the second direction than each of the side surfaces of the third layer and the side surfaces of the fifth layer to define a second undercut.

[0021] In an embodiment, forming the mask layer may include: sequentially forming the first layer and the second layer on the preliminary light transmitting layer; performing a first etching process to form the opening by removing portions of the first layer and the second layer; and performing a second etching process to selectively etch the second layer.

[0022] In an embodiment, the first etching process may be a dry etching process, and the second etching process may be a wet etching process.

[0023] In an embodiment, an etching selectivity of the second layer with respect to an etchant used in the second etching process may be higher than an etching selectivity of the first layer with respect to the etchant.

[0024] In an embodiment, a thickness of the second layer in the first direction may be greater than a thickness of the first layer in the first direction.

[0025] In an embodiment, the method may further include removing the mask layer.

[0026] In an embodiment, the profile on the cross section of each of the plurality of grooves may include a first parallel section, a connecting section, and a second parallel section sequentially defined along the first direction. In such an embodiment, a first width of the profile on the cross section in the first parallel section in a second direction perpendicular to the first direction may be smaller than a second width of the profile on the cross section in the second parallel section in the second direction. BRIEF DESCRIPTION OF THE DRAWINGS

[0027] The above and other features of the present invention will become more apparent by describing embodiments of the present invention in more detail with reference to the accompanying drawings, in which:

[0028] Figure 1 is a view showing a display device according to an embodiment of the present disclosure;

[0029] Figure 2 is a cross-sectional view taken along the line II' shown in 1;

[0030] Figure 3 It is shown Figure 2 An enlarged view of area A shown in;

[0031] Figure 4 yes Figure 2 An image of region A shown in ;

[0032] Figure 5 It shows the manufacturing Figures 1 to 4 A flowchart of an embodiment of a method of displaying a device as shown in ;

[0033] Figures 6 to 9 It is shown Figure 5 A cross-sectional view of a method for manufacturing a display device shown in ;

[0034] Fig.10 and Fig.11 is a cross-sectional view illustrating a method of manufacturing a display device according to another embodiment of the present disclosure; and

[0035] Fig.12 and Fig.13 is a cross-sectional view illustrating a method of manufacturing a display device according to still another embodiment of the present disclosure. DETAILED DESCRIPTION

[0036] The present invention will now be described more fully hereinafter with reference to the accompanying drawings, in which various embodiments are shown. However, the present invention may be implemented in many different forms and should not be construed as being limited to the embodiments set forth herein. Rather, these embodiments are provided so that this disclosure will be exhaustive and complete and will fully convey the scope of the invention to those skilled in the art.

[0037] Throughout the specification, when an element is referred to as being “connected” or “coupled” to another element, the element may be directly connected or coupled to the other element, or may be indirectly connected or coupled to the other element with one or more intervening elements interposed therebetween.

[0038] It will be understood that when an element is referred to as being "on" another element, the element can be directly on the other element or intervening elements may be present between the element and the other element. In contrast, when an element is referred to as being "directly on" another element, there are no intervening elements.

[0039] The terms used in this article are only for the purpose of describing specific embodiments, and are not intended to be limiting. As used in this article, unless the context clearly indicates otherwise, "one", "one (kind / person)", "described (the)" and "at least one (kind / person)" do not represent the limitation of quantity, but are intended to include both singular and plural. Therefore, the reference to "one (kind / person)" element in the claim followed by the reference to "described" element includes one element and multiple elements. For example, unless the context clearly indicates otherwise, "one element" has the same meaning as "at least one element". "At least one (kind / person)" will not be interpreted as limiting "one" or "one (kind / person)". "Or" means "and / or". As used in this article, the term "and / or" includes any combination and all combinations of one or more of the relevant listed items. It will also be understood that the terms “include” and / or “comprises” or “has” and / or “contains” when used in this specification, indicate 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.

[0040] It will be understood that for the purposes of this disclosure, "at least one of X, Y, and Z" may be interpreted as only X, only Y, only Z, or any combination of two or more items X, Y, and Z (e.g., XYZ, XY, YZ, XZ). Similarly, for the purposes of this disclosure, "at least one selected from the group consisting of X, Y, and Z" may be interpreted as only X, only Y, only Z, or any combination of two or more items X, Y, and Z (e.g., XYZ, XY, YZ, XZ).

[0041] It will be understood that although the terms "first", "second", etc. may be used herein to describe various elements, these elements should not be limited by these terms. These terms are only used to distinguish one element from another element. Therefore, without departing from the teachings of the present disclosure, the "first" element discussed below may also be referred to as the "second" element.

[0042] For ease of description, spatially relative terms such as "below" and "above" may be used herein to describe the relationship of one element to another element as shown in the accompanying drawings. It will be understood that, in addition to the orientations described herein and depicted in the accompanying drawings, spatially relative terms and the configurations (configurations) shown are also intended to include different orientations of the device in use or operation. For example, if the device in the accompanying drawings is flipped, an element described as "below" or "below" other elements or features will subsequently be oriented to be "above" other elements or features. Therefore, the exemplary term "above..." can be included in both above and below orientations. The device can be oriented otherwise (e.g., rotated 90 degrees or at other orientations), and the spatially relative descriptors used in this article are interpreted accordingly.

[0043] In the accompanying drawings, dimensions may be exaggerated for clarity of illustration. It will be understood that when an element is referred to as being "between" two elements, the element may be the only element between the two elements, or one or more intervening elements may also be present. The same reference numerals always represent the same elements.

[0044] In addition, embodiments of the present disclosure are described herein with reference to schematic diagrams of idealized embodiments (and intermediate structures) of the present disclosure such that variations from the shapes as illustrated due to, for example, manufacturing techniques and / or tolerances are anticipated. Thus, embodiments of the present disclosure should not be limited to the particular shapes of regions illustrated herein, but rather include deviations in shapes resulting from, for example, manufacturing techniques. The regions illustrated in the drawings are schematic in nature, and the shapes of the regions illustrated in the drawings do not represent the actual shape of a region of a device and do not limit the scope of the present disclosure.

[0045] As used herein, "about" or "approximately" includes the stated value and means within an acceptable range of deviation of the particular value as determined by one of ordinary skill in the art, taking into account the measurement in question and the errors associated with the measurement of a particular quantity (i.e., the limitations of the measurement system). For example, "about" can mean within one or more standard deviations, or within ±30%, ±20%, ±10%, or ±5% of the stated value.

[0046] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those of ordinary skill in the art to which the present disclosure belongs. It will also be understood that, unless expressly defined as such herein, terms (such as those defined in general dictionaries) should be interpreted as having a meaning 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.

[0047] Embodiments are described herein with reference to cross-sectional views as schematic diagrams of idealized embodiments. As such, variations in the shapes of the diagrams due to, for example, manufacturing techniques and / or tolerances are expected. Therefore, the embodiments described herein should not be interpreted as being limited to the specific shapes of the zones as shown herein, but rather include shape deviations due to, for example, manufacturing. For example, a zone shown or described as flat may typically have rough and / or nonlinear features. In addition, the sharp corners shown may be rounded. Therefore, the zones shown in the drawings are schematic in nature, and their shapes are not intended to illustrate the precise shapes of the zones, and are not intended to limit the scope of the current claims.

[0048] Figure 1 is a view showing a display device according to an embodiment of the present disclosure.

[0049] Reference Figure 1 , the display device DD according to an embodiment of the present disclosure may include a display area DA for displaying an image and a peripheral area PA adjacent to at least one side of the display area DA. The display area DA may be a region in which an image is displayed by combining light emitted from the display device DD, and the peripheral area PA may be a region in which a driving circuit for driving the display device DD, etc. is disposed. Hereinafter, for the convenience of description, it is considered that the display area DA is on a plane defined by the second direction DR2 and the third direction DR3 intersecting each other, and is substantially parallel to a plane perpendicular to the first direction DR1.

[0050] In an embodiment, the display device DD may be a display device for a vehicle. In such an embodiment, for example, an image representing real-time traffic information may be displayed in the display area DA of the display device DD.

[0051] The display device DD may include a light blocking pattern to prevent an image displayed in the display area DA from being reflected from the windshield WS of the vehicle and obstructing the driver's field of vision. The light blocking pattern may include an extension pattern LP arranged along the second direction DR2 and including a light blocking material LBM. Each of the extension patterns LP may extend along the third direction DR3 and have a predetermined thickness in the first direction DR1. Therefore, light emitted from the display device DD in a direction facing (or toward) the windshield WS may be blocked by the extension pattern LP.

[0052] Alternatively, light emitted from the display device DD in a direction facing the driver and the passenger may not be blocked by the extended pattern LP. That is, the driver and the passenger may normally view an image displayed based on a combination of light emitted from the display device DD.

[0053] It is desirable that the width of each of the extended patterns LP in the second direction DR2 is small enough not to be seen by the driver and the passenger. When the width of each of the extended patterns LP in the second direction DR2 is relatively large, the extended pattern LP may be seen by the driver and the passenger, or the light emitted from the display device DD may be excessively blocked. Therefore, the display quality of the image displayed in the display area DA of the display device DD may be deteriorated.

[0054] Figure 2 It is along Figure 1 A cross-sectional view taken along line II' shown in FIG.

[0055] Reference Figure 2 , also refer to Figure 1 , the display device DD may include a display panel layer PNL, a light transmitting layer LTL, a light blocking material LBM, and a window WD.

[0056] The display panel layer PNL may emit light, and an image may be displayed on the display area ( Figure 1 In the display area DA shown in .

[0057] In an embodiment, the display panel layer PNL may include a substrate SUB, a pixel circuit layer CIR, a light emitting element layer EML, and a functional layer TSL.

[0058] The substrate SUB may be glass or plastic, and may be flexible or rigid.

[0059] The pixel circuit layer CIR may be disposed on the substrate SUB. The pixel circuit layer CIR may include at least one transistor constituting a pixel circuit.

[0060] The light emitting element layer EML may be disposed on the pixel circuit layer CIR. The light emitting element layer EML may have various structures capable of emitting light based on an electrical signal received from the pixel circuit layer CIR. In an embodiment, for example, a layer included in various types of display devices known in the art (such as an organic light emitting display device, a micro light emitting diode (LED) display device, an inorganic light emitting display device, and a liquid crystal display device) may be used as the light emitting element layer EML without limitation.

[0061] Hereinafter, a light emitting element layer EML according to an embodiment in which the display device DD is an organic light emitting display device will be described. However, the light emitting element layer EML of an embodiment of the present disclosure is not limited to the light emitting element layer EML described herein.

[0062] In an embodiment, the light emitting element layer EML may include a pixel electrode PXE, a pixel defining layer PDL, a light emitting layer EL, a common electrode layer CE, and an encapsulation layer EN.

[0063] The pixel electrode PXE may be electrically connected to at least one transistor included in the pixel circuit layer CIR. Therefore, the pixel electrode PXE may receive an electrical signal from the pixel circuit. In an embodiment, the pixel electrode PXE may be designated as an anode electrode.

[0064] The pixel defining layer PDL may be disposed on the pixel circuit layer CIR and the pixel electrode PXE and define a pixel opening exposing at least a portion of the pixel electrode PXE. In embodiments, the pixel defining layer PDL may include an organic insulating material and / or an inorganic insulating material.

[0065] The light emitting layer EL may be disposed on the pixel electrode PXE in the pixel opening. The light emitting layer EL may emit light based on an electrical signal provided from the pixel electrode PXE and the common electrode layer CE. In an embodiment, the light emitting layer EL may include at least an organic light emitting material.

[0066] The common electrode layer CE may cover the pixel defining layer PDL and the light emitting layer EL. In an embodiment, the common electrode layer CE may be designated as a cathode electrode.

[0067] The encapsulation layer EN may cover the common electrode layer CE. The encapsulation layer EN may be used to protect the common electrode layer CE and the like from the penetration of moisture or gas. In an embodiment, the encapsulation layer EN may have a three-layer structure including a first inorganic encapsulation layer, an organic encapsulation layer disposed on the first inorganic encapsulation layer, and a second inorganic encapsulation layer disposed on the organic encapsulation layer.

[0068] The functional layer TSL may be disposed on the light emitting element layer EML. The functional layer TSL may include various types of layers that perform various functions other than image display. In an embodiment, for example, the functional layer TSL may include an input sensing layer that senses a user's touch input. In an embodiment, the functional layer TSL may be omitted.

[0069] The light transmission layer LTL disposed on the display panel layer PNL may be provided with a plurality of grooves (or groove holes) TR recessed in the first direction DR1. Figure 2 As shown in , each of the plurality of trenches TR may be defined to pass through the light transmitting layer LTL along the first direction DR1.

[0070] In an embodiment, the light transmitting layer LTL may include an organic insulating material having a relatively high light transmittance. The light transmitting layer LTL may be a single layer including the organic insulating material.

[0071] In an embodiment, the bottom surface of the light transmission layer LTL may be in direct contact with the display panel layer PNL. Figure 2As shown in , the bottom surface of the light transmission layer LTL may be in direct contact with the functional layer TSL. The uppermost layer in direct contact with the bottom surface of the light transmission layer LTL among various layers constituting the functional layer TSL may be an inorganic insulating layer including an inorganic insulating material.

[0072] In another embodiment, when the functional layer TSL is omitted, the bottom surface of the light transmission layer LTL may be in direct contact with the encapsulation layer EN. The uppermost layer in direct contact with the bottom surface of the light transmission layer LTL among the various layers constituting the encapsulation layer EN may be an inorganic insulating layer including an inorganic insulating material.

[0073] In embodiments, each of the plurality of trenches TR may expose at least a portion of an upper surface of the inorganic insulating layer in direct contact with a bottom surface of the light transmitting layer LTL.

[0074] The light blocking material LBM may be provided to fill the plurality of trenches TR. The light blocking material LBM may include a material having a relatively high light absorption rate. Therefore, the light blocking material LBM may block a portion of light emitted from the display panel layer PNL.

[0075] The window WD may be disposed on the light transmitting layer LTL and the light blocking material LBM. The window WD may include a material having relatively high hardness while having relatively high light transmittance. In an embodiment, for example, the window WD may include glass or plastic or the like.

[0076] Return to reference Figure 1 and Figure 2 , the extension pattern LP may be defined by a light blocking material LBM filling a plurality of trenches TR defined in the light transmitting layer LTL.

[0077] In the embodiment, it is desirable to sufficiently ensure the thickness of each of the extension patterns LP in the first direction DR1 to effectively block light emitted from the display device DD in a direction facing the windshield WS.

[0078] In an embodiment of the present disclosure, each of the plurality of grooves TR may have the above-mentioned sufficient length in the first direction DR1 to prevent the emission of undesired light. Therefore, among the light emitted from the light emitting element layer EML, the light emitted through the second path P2 facing the windshield WS may be blocked by the light blocking material LBM filling the plurality of grooves TR. In such an embodiment, the light emitted through the first path P1 not facing the windshield WS may not be blocked by the light blocking material LBM and may be seen by the user of the display device DD.

[0079] In an embodiment, some of the light emitted from the display device DD in a direction not facing the windshield WS may be blocked by the light blocking material LBM filled in the plurality of grooves TR. In an embodiment, for example, light traveling through a third path P3 parallel to the first direction DR1 may be absorbed into the bottom surface of the light blocking material LBM. When light that does not cause obstruction to the user's field of view (e.g., reflection from the windshield WS) is absorbed into the light blocking material LBM, the display quality of the image displayed in the display device DD may be deteriorated.

[0080] In an embodiment, it may be desirable that the width of each of the plurality of trenches TR in the second direction DR2 is sufficiently small to prevent degradation of the display quality of the display device DD.

[0081] In such an embodiment, the width of each of the plurality of trenches TR in the second direction DR2 may be relatively small. In such an embodiment, the width of each of the plurality of trenches TR of the present disclosure in the second direction DR2 may be substantially constant. That is, each of the plurality of trenches TR may substantially not include any recessed portion recessed in the second direction DR2 or in a direction opposite to the second direction DR2.

[0082] Therefore, the light traveling through the fourth path P4 adjacent to the plurality of trenches TR and parallel to the third path P3 may not be blocked by the light blocking material LBM filled in the plurality of trenches TR. Therefore, since the light traveling through the fourth path P4 may normally contribute to the image display in the display area DA, the display quality of the display device DD may be further improved.

[0083] In the following, reference will be made to Figure 3 and Figure 4 The plurality of trenches TR in the embodiment of the present disclosure is described in more detail.

[0084] Figure 3 It is shown Figure 2 Magnified view of area A shown in FIG. Figure 4 yes Figure 2 Image of area A shown in .

[0085] Reference Figure 3 , a profile on a cross section of each of the plurality of trenches TR may include a first parallel section PS1 , a connecting section CS, and a second parallel section PS2 sequentially defined along the first direction DR1 .

[0086] The width of the profile on the cross section in the first parallel section PS1 in the second direction DR2 may be substantially constant. “The width is substantially constant” may mean that the difference between the maximum value and the minimum value of the width of the profile on the cross section in the first parallel section PS1 in the second direction DR2 is about 5% or less (e.g., about 3% or less) of the maximum value.

[0087] Similarly, the width of the profile on the cross section in the second parallel section PS2 in the second direction DR2 may be substantially constant. That is, the difference between the maximum and minimum values ​​of the width of the profile on the cross section in the second parallel section PS2 in the second direction DR2 may be about 5% or less (e.g., about 3% or less) of the maximum value.

[0088] The width of the profile on the cross section in the first parallel section PS1 in the second direction DR2 may be the first width W1. That is, the width of the profile on the cross section in the first parallel section PS1 in the second direction DR2 may be the first width W1 on average.

[0089] The width of the profile on the cross section in the second parallel section PS2 in the second direction DR2 may be the second width W2. That is, the width of the profile on the cross section in the second parallel section PS2 in the second direction DR2 may be the second width W2 on average. The second width W2 may be greater than the first width W1. In an embodiment, for example, the second width W2 may be greater than the first width W1 and be equal to or less than about 1.3 times the first width W1.

[0090] In an embodiment, the width of the profile on the cross section in the connecting section CS in the second direction DR2 may gradually increase from the first width W1 to the second width W2 along the first direction DR1 (e.g., toward the first direction DR1). That is, in the first parallel section PS1, the connecting section CS, and the second parallel section PS2, the width of the profile on the cross section in the second direction DR2 may be substantially equal to or less than the second width W2.

[0091] In an embodiment, the profile on the cross section may further include an upper section US as a section between the upper surface LTL_U of the light transmission layer LTL and the first parallel section PS1, and the width of the profile on the cross section in the upper section US in the second direction DR2 may gradually increase along the first direction DR1 and then gradually decrease. In an embodiment, for example, the width of the profile on the cross section in the upper section US in the second direction DR2 may gradually increase from the first width W1 and then gradually decrease, thereby becoming the first width W1 again.

[0092] The profile presented in the above-mentioned upper section US can be designated as a bowing profile, and the upper section US is designated as a bowing section. The maximum width of the profile on the cross section in the upper section US in the second direction DR2 can be smaller than the second width W2. That is, in the upper section US, the first parallel section PS1, the connecting section CS, and the second parallel section PS2, the width of the profile on the cross section can be substantially equal to or smaller than the second width W2. Therefore, light (for example, through the windshield WS) that does not cause obstruction to the user's field of vision (for example, reflection from the windshield WS) can be reduced. Figure 2 Light travelling along the fourth path P4 shown in FIG. 4 ) may be substantially not blocked by the light blocking material LBM in the upper segment US.

[0093] In another embodiment, the upper section US may be omitted. That is, the arcuate profile may not be substantially present in the profile on the cross section. The profile on the cross section may include only the first parallel section PS1 between the upper surface LTL_U of the light transmission layer LTL and the connection section CS.

[0094] In an embodiment, the profile on the cross section may further include a lower section LS between the second parallel section PS2 and the lower surface LTL_L of the light transmission layer LTL, and the width of the profile on the cross section in the lower section LS in the second direction DR2 may gradually decrease along the first direction DR1. In an embodiment, for example, the width of the profile on the cross section in the lower section LS in the second direction DR2 may gradually decrease from the second width W2. That is, in the first parallel section PS1, the connecting section CS, the second parallel section PS2, and the lower section LS, the width of the profile on the cross section in the second direction DR2 may be substantially equal to or less than the second width W2.

[0095] In an embodiment, the sum of the length L1 of the first parallel section PS1 in the first direction DR1 and the length L2 of the second parallel section PS2 in the first direction DR1 may be equal to or greater than about 60% of the total length LT of the profile on the cross section in the first direction DR1. That is, each of the length L3 of the connecting section CS in the first direction DR1, the length L4 of the upper section US in the first direction DR1, and the length L5 of the lower section LS in the first direction DR1 may be relatively small.

[0096] In an embodiment, as described above, the width of the profile on the cross section of each of the plurality of trenches TR in the second direction DR2 may be equal to or less than the second width W2. Therefore, the width of the light blocking material LBM filling each of the plurality of trenches TR in the second direction DR2 may also be equal to or less than the second width W2.

[0097] Reference Figure 4 , also refer to Figure 3In an embodiment, the width of the profile on the cross section in the first parallel segment PS1 in the second direction DR2 may be approximately 3.05 micrometers (μm), the width of the profile on the cross section in the second parallel segment PS2 in the second direction DR2 may be approximately 3.66 μm, and the total length of the profile on the cross section in the first direction DR1 may be approximately 37 μm.

[0098] However, Figure 4 The cross-sectional profile shown in is only an example, and the cross-sectional profile of the present disclosure may have other than limited Figure 4 The various contour shapes shown in the image are as long as the contour on the cross section of the present disclosure meets the above reference Figure 3 Describing features is sufficient.

[0099] Figure 5 It shows the manufacturing Figures 1 to 4 A flow chart of an embodiment of a method of a display device is shown in FIG.

[0100] Reference Figure 5 According to an embodiment of the method for manufacturing a display device, a preliminary light transmission layer can be formed on the display panel layer (S10), a mask layer defining (or provided with) an opening for exposing a portion of the upper surface of the preliminary light transmission layer can be formed on the preliminary light transmission layer (S20), a light transmission layer defining (or provided with) a plurality of grooves recessed in a first direction facing the display panel layer can be formed by dry etching the preliminary light transmission layer using the mask layer (S30), and the plurality of grooves can be filled with a light blocking material (S40).

[0101] Figures 6 to 9 It is shown Figure 5 A cross-sectional view of a method for manufacturing a display device is shown in FIG. Figures 1 to 4 Description of components that are described are substantially the same or similar components.

[0102] Reference Figure 6 In an embodiment of the method of manufacturing a display device, a preliminary light transmitting layer PRE_LTL may be formed on the display panel layer PNL (S10). In an embodiment, the preliminary light transmitting layer PRE_LTL may be a single layer including an organic insulating material.

[0103] Reference Figure 7 , a mask layer MSKL defining (or provided with) an opening OP exposing a portion of the upper surface of the preliminary light transmitting layer PRE_LTL may be formed on the preliminary light transmitting layer PRE_LTL ( S20 ).

[0104] The mask layer MSKL may include a first layer ML1 and a second layer ML2 disposed on the first layer ML1. The second layer ML2 may have a side surface ML2_S that is recessed compared to the side surface of the first layer ML1, that is, a side surface ML2_S that is further recessed in the second direction DR2 compared to the side surface of the first layer ML1 that defines the opening OP. That is, the side surface ML2_S of the second layer ML2 adjacent to the opening OP may be further away from the center of the opening OP compared to the side surface of the first layer ML1 that defines the opening OP. In other words, the second layer ML2 may completely overlap with the first layer ML1 and have a width narrower than that of the first layer ML1. Therefore, the upper surface of the first layer ML1 that does not overlap with the second layer ML2 may be exposed in the area adjacent to the opening OP.

[0105] In an embodiment, the second layer ML2 may have a forward tapered shape in cross section. Figure 7 As shown in , the second layer ML2 may have a trapezoidal shape in which the length of the lower side is longer than the length of the upper side.

[0106] In an embodiment, the thickness of the second layer ML2 in the first direction DR1 may be greater than the thickness of the first layer ML1 in the first direction DR1 so that a process margin of the second layer ML2 may be secured in the dry etching step S30 to be described later.

[0107] In an embodiment, the mask layer MSKL may be formed by sequentially forming a first layer ML1 and a second layer ML2 on the preliminary light transmitting layer PRE_LTL, and sequentially performing a first etching process to form an opening OP by removing portions of the first layer ML1 and the second layer ML2 and a second etching process to selectively etch the second layer ML2. The first etching process may be a dry etching process, and the second etching process may be a wet etching process.

[0108] In an embodiment, the etching selectivity of the second layer ML2 with respect to the etchant used in the second etching process may be higher than the etching selectivity of the first layer ML1 with respect to the etchant. In an embodiment, for example, the second layer ML2 may include copper or aluminum having a relatively high etching selectivity, and the first layer ML1 may include titanium having a relatively low etching selectivity. Therefore, when the second etching process is performed, the second layer ML2 may be further selectively etched, and the first layer ML1 may not be substantially etched.

[0109] Reference Figure 8 , a light transmitting layer LTL defined with a plurality of grooves recessed in a first direction DR1 facing the display panel layer PNL may be formed by dry-etching the preliminary light transmitting layer PRE_LTL using the mask layer MSKL ( S30 ).

[0110] In dry etching, a portion of the preliminary light-transmitting layer PRE_LTL may be removed by spraying etching particles (e.g., plasma, ions, or etching gas, etc.) in the first direction DR1 and in a direction crossing the first direction DR1. In an embodiment, for example, the first etching particles EG1 traveling in the first direction DR1 may etch the preliminary light-transmitting layer PRE_LTL while traveling into the opening OP, and thus, a profile including the first parallel section PS1, etc., on a cross section of the trench TR may be formed.

[0111] In an embodiment, for the second etching particles EG2 and the third etching particles EG3 that travel toward the side surface ML2_S of the second layer ML2, the second etching particles EG2 may be scattered from the side surface ML2_S of the second layer ML2 to travel in a direction facing the upper surface of the first layer ML1. Then, the second etching particles EG2 may be scattered from the upper surface of the first layer ML1 again. Therefore, the second etching particles EG2 may not travel into the opening OP. That is, the second etching particles EG2 may be blocked by the first layer ML1 of the mask layer MSKL and substantially do not contribute to the etching of the preliminary light transmission layer PRE_LTL.

[0112] In such an embodiment, the third etching particles EG3 may be scattered from the side surface ML2_S of the second layer ML2 to travel into the opening OP. The third etching particles EG3 may particularly contribute to etching in the region adjacent to the opening OP. Therefore, the third etching particles EG3 may form the reference Figure 3 The arcuate profile in the upper section US is described.

[0113] In the embodiment of the present disclosure, when the side surface ML2_S of the second layer ML2 is recessed compared to the side surface of the first layer ML1 in the mask layer MSKL, the mask layer MSKL can perform a function of blocking some second etching particles EG2 having a high possibility of contributing to the formation of the above-mentioned bow-shaped profile among the etching particles EG2 and EG3. Therefore, the excessive formation of the bow-shaped profile can be effectively prevented.

[0114] In an embodiment, some etching particles (such as fourth etching particles EG4) that travel into the opening OP along a direction intersecting the first direction DR1 may be scattered in the first parallel section PS1 of the trench TR. By the scattered etching particles and various other factors caused by the shape of the mask layer MSKL described above, the preliminary light transmission layer PRE_LTL may be relatively more etched in the second parallel section PS2 than in the first parallel section PS1. Therefore, the width of the trench TR in the second parallel section PS2 in the second direction DR2 may be greater than the width of the trench TR in the first parallel section PS1 in the second direction DR2. In addition, a connecting section CS in which the width of the trench TR in the second direction DR2 gradually increases may be formed between the first parallel section PS1 and the second parallel section PS2.

[0115] In the embodiment, when various etching conditions including etching time or kind of etching particles, etc. are appropriately adjusted, a profile in the lower section LS in which the width of the trench TR in the second direction DR2 gradually decreases may be formed.

[0116] In an embodiment, for example, when the etching time is set to be relatively short, a profile in the lower segment LS may be formed. If the etching time is set to be relatively long, when etching particles accumulate in a region adjacent to the uppermost layer of the display panel layer PNL, etching may be excessively performed in the region, so that the width of the trench TR in the second direction DR2 may be excessively or undesirably increased.

[0117] That is, when the etching conditions are appropriately adjusted so that the profile in the lower segment LS is formed, the width of the trench TR in the region adjacent to the uppermost layer of the display panel layer PNL in the second direction DR2 may not be excessively increased.

[0118] Reference Fig. 9 , the plurality of trenches TR may be filled with a light blocking material LBM (S40). Therefore, the light blocking material LBM may have a shape in cross section corresponding to the profile in cross section of each of the plurality of trenches TR. The method of filling the plurality of trenches TR with the light blocking material LBM is not limited, and various methods known in the art may be used.

[0119] In an embodiment, a process of removing the mask layer MSKL may be further performed. In an embodiment, for example, after the plurality of trenches TR are filled with the light blocking material LBM, a component disposed on the upper surface of the light transmission layer LTL may be removed using chemical mechanical polishing (CMP). In another embodiment, for example, the mask layer MSKL may be removed after performing process S30 and before performing process S40.

[0120] Fig.10 and Fig.11is a cross-sectional view illustrating a method of manufacturing a display device according to another embodiment of the present disclosure.

[0121] Reference Fig.10 and Fig.11 , except that process S20' and process S30' are performed instead of referring to Figure 5 Except for the process S20 and the process S30 described above, the method for manufacturing a display device according to another embodiment of the present disclosure may be substantially the same as or similar to the method for manufacturing a display device according to the embodiment of the present disclosure described above. Therefore, any repeated detailed description of the process that is the same as or similar to the above process may be omitted or simplified.

[0122] Reference Fig.10 In an embodiment of the method of manufacturing a display device, a mask layer MSKL′ defining (or provided with) an opening OP exposing a portion of an upper surface of the preliminary light transmitting layer PRE_LTL may be formed on the preliminary light transmitting layer PRE_LTL ( S20 ′).

[0123] The mask layer MSKL' may include a first layer ML1, a second layer ML2 disposed on the first layer ML1, and a third layer ML3 disposed on the second layer ML2. The second layer ML2 may have a side surface ML2_S recessed compared to the side surface of the first layer ML1, and thus, an upper surface of the first layer ML1 that does not overlap with the second layer ML2 may be exposed in a region adjacent to the opening OP. In addition, the second layer ML2 may have a side surface ML2_S recessed compared to the side surface of the third layer ML3, and thus, a first undercut UC1 may be defined.

[0124] In an embodiment, a mask layer MSKL' may be formed by sequentially forming a first layer ML1, a second layer ML2, and a third layer ML3 on the preliminary light transmitting layer PRE_LTL, and sequentially performing a first etching process to form an opening OP by removing portions of the first layer ML1, the second layer ML2, and the third layer ML3 and a second etching process to selectively etch the second layer ML2. The first etching process may be a dry etching process, and the second etching process may be a wet etching process.

[0125] In an embodiment, the etching selectivity of the second layer ML2 with respect to the etchant used in the second etching process may be higher than the etching selectivity of each of the first layer ML1 and the third layer ML3 with respect to the etchant. In an embodiment, for example, the second layer ML2 may include copper or aluminum having a relatively high etching selectivity, and each of the first layer ML1 and the third layer ML3 may include titanium having a relatively low etching selectivity. Therefore, when the second etching process is performed, the second layer ML2 may be further selectively etched, and the first layer ML1 and the third layer ML3 may not be substantially etched.

[0126] Reference Fig.11 , a light transmitting layer LTL defining a plurality of trenches TR recessed in a first direction DR1 facing the display panel layer PNL may be formed by dry-etching the preliminary light transmitting layer PRE_LTL using the mask layer MSKL′ ( S30 ′).

[0127] With reference Figure 8 Unlike the process S30 described above, in the process S30', the third layer ML3 can further perform a mask function on the etching particles. The third layer ML3 can perform a function of further blocking the etching particles (such as the third etching particles EG3) traveling toward the side surface ML2_S of the second layer ML2. Therefore, the change in the width of the trench TR in the arched profile presented in the upper section US in the second direction DR2 can be relatively reduced, or the arched profile can be substantially not presented in the upper section US.

[0128] Fig.12 and Fig.13 is a cross-sectional view illustrating a method of manufacturing a display device according to still another embodiment of the present disclosure.

[0129] Reference Fig.12 and Fig.13 , except that process S20" and process S30" are performed instead of referring to Figure 5 In addition to the process S20 and the process S30 described above, the method for manufacturing a display device according to another embodiment of the present disclosure can be the same as that described above with reference to FIG. Figures 5 to 11 The described methods are substantially the same or similar. Therefore, any repeated detailed description of the processes that are the same or similar to the above processes may be partially omitted below.

[0130] Reference Fig.12 In an embodiment of the method of manufacturing a display device, a mask layer MSKL defining (or provided with) an opening OP exposing a portion of the upper surface of the preliminary light transmitting layer PRE_LTL may be formed on the preliminary light transmitting layer PRE_LTL (S20").

[0131] The mask layer MSKL″ may include a first layer ML1, a second layer ML2 disposed on the first layer ML1, a third layer ML3 disposed on the second layer ML2, a fourth layer ML4 disposed on the third layer ML3, and a fifth layer ML5 disposed on the fourth layer ML4.

[0132] The second layer ML2 may have a side surface ML2_S recessed compared to the side surface of the first layer ML1, and thus, the upper surface of the first layer ML1 not overlapping with the second layer ML2 may be exposed in a region adjacent to the opening OP. In addition, the second layer ML2 may have a side surface ML2_S recessed compared to the side surface of the third layer ML3, and thus, a first undercut UC1 may be defined.

[0133] The fourth layer ML4 may have a side surface ML4_S that is recessed compared to the side surface of the third layer ML3, and therefore, the upper surface of the third layer ML3 that does not overlap with the third layer ML3 may be exposed in the area adjacent to the opening OP. In addition, the fourth layer ML4 may have a side surface ML4_S that is recessed compared to the side surface of the fifth layer ML5, and therefore, a second undercut UC2 may be defined.

[0134] In an embodiment, a mask layer MSKL" may be formed by sequentially forming a first layer ML1, a second layer ML2, a third layer ML3, a fourth layer ML4, and a fifth layer ML5 on a preliminary light transmitting layer PRE_LTL, and sequentially performing a first etching process to form an opening OP by removing portions of the first layer ML1, the second layer ML2, the third layer ML3, the fourth layer ML4, and the fifth layer ML5, and a second etching process to selectively etch the second layer ML2 and the fourth layer ML4. The first etching process may be a dry etching process, and the second etching process may be a wet etching process.

[0135] In an embodiment, the etching selectivity of each of the second layer ML2 and the fourth layer ML4 with respect to the etchant used in the second etching process may be higher than the etching selectivity of each of the first layer ML1, the third layer ML3, and the fifth layer ML5 with respect to the etchant. In an embodiment, for example, each of the second layer ML2 and the fourth layer ML4 may include copper or aluminum having a relatively high etching selectivity, and each of the first layer ML1, the third layer ML3, and the fifth layer ML5 may include titanium having a relatively low etching selectivity. Therefore, when the second etching process is performed, the second layer ML2 and the fourth layer ML4 may be further etched selectively, and the first layer ML1, the third layer ML3, and the fifth layer ML5 may not be substantially etched.

[0136] Reference Fig.13 , a light transmitting layer LTL defining a plurality of trenches TR recessed in a first direction DR1 facing the display panel layer PNL may be formed by dry-etching the preliminary light transmitting layer PRE_LTL using the mask layer MSKL″ ( S30 ″).

[0137] With reference Figure 8 Process S30 described and reference Fig.11Unlike the process S30' described above, in the process S30", the fourth layer ML4 and the fifth layer ML5 can perform a mask function for the etching particles. The fourth layer ML4 can perform the same function as described by reference. Figure 8 The second layer ML2 described above performs substantially the same or similar functions, and the fifth layer ML5 may perform functions similar to those described above. Fig.11 The third layer ML3 described performs substantially the same or similar functions.

[0138] According to an embodiment of a display device and a method of manufacturing the display device, a viewing angle of an image displayed in the display device is controlled, so that display quality can be improved while preventing emission of unintended or unwanted light.

[0139] The present invention should not be construed as being 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 concept of the present invention to those skilled in the art.

[0140] While the invention has been particularly shown and described with reference to embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made therein without departing from the spirit or scope of the invention as defined by the appended claims.

Claims

1. A display device, wherein: The display device comprises: Display panel layer; a light transmission layer disposed on the display panel layer, wherein a plurality of grooves are defined in the light transmission layer to be recessed in a first direction toward the display panel layer; and a light blocking material filling the plurality of trenches, wherein a profile of each of the plurality of grooves on a cross section includes a first parallel section, a connecting section, and a second parallel section sequentially defined along the first direction, and A first width of the profile on the cross section in the first parallel section in a second direction perpendicular to the first direction is smaller than a second width of the profile on the cross section in the second parallel section in the second direction.

2. The display device according to claim 1, wherein: A width of the profile on the cross section in the connecting section in the second direction gradually increases from the first width to the second width along the first direction.

3. The display device according to claim 1, wherein: The profile on the cross section of each of the plurality of grooves also includes an upper section that is a section between an upper surface of the light transmitting layer and the first parallel sections, and Wherein, a width of the profile on the cross section in the upper section in the second direction gradually increases along the first direction and then gradually decreases.

4. The display device according to claim 3, wherein: The maximum width of the profile on the cross section in the upper section in the second direction is smaller than the second width.

5. The display device according to claim 1, wherein: The profile on the cross section of each of the plurality of grooves also includes a lower section that is a section between the second parallel section and a lower surface of the light transmitting layer, and Wherein, the width of the profile on the cross section in the lower section in the second direction gradually decreases along the first direction.

6. The display device according to claim 1, wherein: The second width is equal to or less than 1.3 times the first width.

7. The display device according to claim 1, wherein: The sum of the length of the profile on the cross section in the first parallel section and the length of the profile on the cross section in the second parallel section in the first direction is equal to or greater than 60% of the total length of the profile on the cross section of each of the plurality of grooves in the first direction.

8. A method for manufacturing a display device, wherein: The method comprises: forming a preliminary light transmission layer on the display panel layer; forming a mask layer on the preliminary light-transmitting layer, the mask layer defining an opening exposing a portion of an upper surface of the preliminary light-transmitting layer; forming a light transmission layer by dry-etching the preliminary light transmission layer using the mask layer, the light transmission layer defining a plurality of grooves recessed in a first direction toward the display panel layer; and filling the plurality of trenches with a light blocking material, The mask layer includes a first layer and a second layer disposed on the first layer, and Wherein, the side surface of the second layer is further recessed in a second direction perpendicular to the first direction compared with the side surface of the first layer.

9. The method according to claim 8, wherein: The second layer has a cross-sectional shape tapering toward a direction opposite to the first direction.

10. The method according to claim 8, wherein: The mask layer further includes a third layer disposed on the second layer, and The side surface of the second layer is further recessed in the second direction compared to the side surface of the third layer to define a first undercut.

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