Display device, method of manufacturing the same, and composition for use in manufacturing the same

Abstract

A display device includes an insulating substrate, barriers surrounding predetermined regions on the insulating substrate, wherein ink composition is supplied in the predetermined regions, the ink composition including a first solvent which remains in a solid state in a temperature range between 10° C. and 30° C., a second solvent which remains in a liquid state in a temperature range between 10° C. and 30° C., and an organic material, and an organic layer formed in the predetermined regions by volatilizing the first solvent and the second solvent. Thus, the present invention provides a display device with an organic layer of regular quality.

1 . A display device comprising: 
 an insulating substrate;    barriers surrounding predetermined regions on the insulating substrate, wherein an ink composition is supplied in the predetermined regions, the ink composition comprising a first solvent which remains in a solid state in a temperature range between 10° C. and 30° C., a second solvent which remains in a liquid state in a temperature range between 10° C. and 30° C., and an organic material; and    an organic layer formed in the predetermined regions by volatilizing the first solvent and the second solvent.    
     
     
         2 . The display device according to  claim 1 , wherein the second solvent is volatilized before the first solvent is volatilized, and 
 wherein the first solvent is volatilized after the first solvent changes into a solid state.    
     
     
         3 . The display device according to  claim 1 , further comprising thin film transistors formed on the insulating substrate, and pixel electrodes connected to the thin film transistors and at least partially surrounded by the barriers, 
 wherein the organic layer is formed on the pixel electrodes.    
     
     
         4 . The display device according to  claim 1 , further comprising a source electrode and a drain electrode, which are isolated from each other on the insulating substrate, with a channel region interposed between the source electrode and the drain electrode, 
 wherein the barriers are formed to expose at least portions of the source electrode and the drain electrode, and the organic layer is formed on the channel region.    
     
     
         5 . The display device according to  claim 4 , wherein the organic layer is a semiconductor layer.  
     
     
         6 . The display device according to  claim 1 , wherein the organic layer comprises at least one of a hole injection layer and an organic light emitting layer.  
     
     
         7 . The display device according to  claim 1 , wherein the organic layer comprises a color filter layer.  
     
     
         8 . The display device according to  claim 1 , wherein the organic layer has a substantially uniform thickness within each of the predetermined regions, with a variance of less than about 1 nm.  
     
     
         9 . A display device comprising: 
 an insulating substrate;    barriers surrounding predetermined regions on the insulating substrate, wherein a powder composition is supplied in the predetermined regions, the powder composition comprising a solvent which remains in a solid state in a temperature range between 10° C. and 30° C., and an organic material; and    an organic layer formed in the predetermined regions by removing the solvent.    
     
     
         10 . The display device according to  claim 9 , wherein the solvent is removable using a vacuum after heating and liquefying the solvent.  
     
     
         11 . The display device according to  claim 9 , wherein the organic layer is one of a semiconductor layer, a hole injection layer, an organic light emitting layer, and a color filter layer.  
     
     
         12 . The display device according to  claim 9 , wherein the organic layer has a substantially uniform thickness within each of the predetermined regions, with a variance of less than about 1 nm.  
     
     
         13 . A method of manufacturing a display device, the method comprising: 
 making an ink composition comprising a mixture of a first solvent which remains in a solid state in a temperature range between 10° C. and 30° C., a second solvent which remains in a liquid state in a temperature range between 10° C. and 30° C., and an organic material;    volatilizing the second solvent in the ink composition; and    forming an organic layer by volatilizing the first solvent in the ink composition in which the second solvent is volatilized.    
     
     
         14 . The method according to  claim 13 , wherein volatilizing the first solvent comprises liquefying the first solvent by heating the ink composition which is in a solid state.  
     
     
         15 . The method according to  claim 13 , further comprising forming pixel electrodes on an insulating substrate, 
 wherein the organic layer is formed on the pixel electrodes.    
     
     
         16 . The method according to  claim 15 , further comprising at least partially surrounding the pixel electrodes by barriers.  
     
     
         17 . The method according to  claim 13 , wherein volatilizing the first solvent includes volatilizing the first solvent in a vacuum state.  
     
     
         18 . A method of manufacturing a display device, the method comprising: 
 providing a powder composition comprising a first solvent which remains in a solid state in a temperature range between 10° C. and 30° C., and an organic material; and    forming an organic layer by removing the first solvent from the powder composition.    
     
     
         19 . The method according to  claim 18 , wherein providing the powder composition comprises: 
 making an ink composition comprising a mixture of the first solvent, a second solvent which remains in a liquid state in a temperature range between 10° C. and 30° C., and the organic material; and    removing the second solvent from the ink composition.    
     
     
         20 . The method according to  claim 19 , wherein, prior to removing the second solvent from the ink composition, the ink composition is coated on a substrate and heated to remove the second solvent and form a solid film, the method further comprising powdering the solid film into particles to form the powder composition.  
     
     
         21 . The method according to  claim 18 , wherein removing the first solvent comprises: 
 liquefying the first solvent by heating the powder composition; and    removing the first solvent using a vacuum.    
     
     
         22 . The method according to  claim 18 , further comprising: 
 forming barriers surrounding predetermined regions on an insulating substrate; and    placing the powder composition in the predetermined regions surrounded by the barriers.    
     
     
         23 . The method according to  claim 22 , wherein placing the powder composition in the predetermined regions comprises using a shadow mask having openings formed corresponding to at least some of the predetermined regions.  
     
     
         24 . An ink composition for use in manufacturing a display device, the ink composition comprising: 
 a first solvent which remains in a solid state in a temperature range between 10° C. and 30° C.;    a second solvent which remains in a liquid state in a temperature range between 10° C. and 30° C.; and    an organic material.    
     
     
         25 . The ink composition according to  claim 24 , wherein a melting point of the first solvent ranges from 30° C. to 200° C.  
     
     
         26 . The ink composition according to  claim 24 , wherein a boiling point of the first solvent ranges from 200° C. to 500° C.  
     
     
         27 . The ink composition according to  claim 24 , wherein a boiling point of the second solvent ranges from 100° C. to 200° C.  
     
     
         28 . The ink composition according to  claim 24 , wherein the first solvent ranges from 10 to 150 parts by weight with respect to 100 parts by weight of the second solvent.  
     
     
         29 . The ink composition according to  claim 24 , wherein the first solvent ranges from 20 to 40 parts by weight with respect to 100 parts by weight of the second solvent.  
     
     
         30 . The ink composition according to  claim 24 , wherein the first solvent comprises at least one of bibenzyl, 2,5-dibromo-p-xylene, 3,5-dibromo-toluene, 2-chloro-5-methylphenol, 4-chloro-2-methylphenol, 3-chloro-3-methylphenol, 5-chloro-2-methylphenol, 1-phenylpyrrole, 4H-pyran-4-one, 2,4,6-trichloropyrimidine, 2,3,4-trimethyl-1,3-pentanediol, dicafluorobiphenyl, 1,4-di-tert-butylbenzene, 2,6-di-tert-butyl-4-ethylphenol, 2,6-di-tert-butyl-ethylphenol, 2,6-di-tert-butylphenol, 2,4-di-tert-butylphenol, 2,5-dichloroaniline, and 3,5-dichlorocatechol.  
     
     
         31 . The ink composition according to  claim 24 , wherein the second solvent comprises at least one of tetrahydrofuran, chloroform, N,N-dimethylformamide, 4-methylheptane, 1,4-dioxane, 1-propanol, cyclohexanone, decane, propylene carbonate, nonane, 4-methyl anisole, toluene, tetralin, diphenylether, 1,3-dichorobezene, 2-pyrrolidone, aniline, benzene, benzonitrile, bromobenzene, chlorobenzene, cyclohexylbenzene, ethylbenzene, mesitylene, metylbenzonate, nitrobenzene, pyridine, and quinoline.  
     
     
         32 . The ink composition according to  claim 24 , wherein the organic material comprises at least one of a hole injection material and an organic light emitting material.  
     
     
         33 . The ink composition according to  claim 24 , wherein the organic material comprises at least one of derivatives comprising substituents of tetracene or pentacene; oligothiopene connected with 4, 5, 6, 7, or 8 carbons through positions 2 and 5 of thiopene ring; perylenetetracarboxlic dianhidride or its imide derivatives; naphthalenetetracarboxlic dianhydride or its imide derivatives; metallized pthalocyanine or its halogen derivatives; perylene or coroene or its derivatives having its substituents; co-oligomer or co-polymer of thienylene and vinylene; thiophene; thienylene or coroene, or its derivatives comprising its substituents; and derivatives comprising at least one hydrocarbon chain having 1 to 30 carbons connected to aromatic or heteroaromatic ring of the materials.  
     
     
         34 . A powder composition for use in manufacturing a display device, the powder composition comprising: 
 a solvent which remains in a solid state in a temperature range between 10° C. and 30° C.; and    an organic material.    
     
     
         35 . The powder composition according to  claim 34 , wherein a melting point of the solvent ranges from 30° C. to 200° C.