Display apparatus and method of manufacturing the same

1. A display apparatus comprising:

a plurality of pixels, each pixel defining a pixel area and a non-pixel area surrounding the pixel area, wherein the non-pixel area comprises:

a first non-pixel area extending in a first direction and disposed between adjacent pixel areas in a second direction crossing the first direction; and

a second non-pixel area disposed between adjacent pixel areas in the first direction,

each pixel comprising:

a substrate comprising a black matrix disposed in the second non-pixel area;

a first electrode disposed on the substrate in the pixel area;

a second electrode extending in the first direction to be disposed in the pixel area and the second non-pixel area, and being spaced apart upward from the substrate by a predetermined distance in the pixel area, such that a tunnel-shaped cavity is defined between the second electrode and the substrate;

an image display layer disposed in the tunnel-shaped cavity and driven by an electric field formed between the first electrode and the second electrode;

a roof layer disposed on the second electrode; and

a sealing layer having a black color, and being disposed in the first non-pixel area to seal the tunnel-shaped cavity,

wherein the black matrix and the sealing layer are formed with different materials from one another.

2. The display apparatus of claim 1 , wherein the second electrode is disposed adjacent to the substrate in the second non-pixel area, is not disposed adjacent to the substrate in the pixel area, and is spaced apart upward from the substrate in the pixel areas to define the tunnel-shaped cavity.

3. The display apparatus of claim 1 , wherein the substrate further comprises:

a base substrate;

a color filter disposed on the base substrate in the pixel area; and

an organic insulating layer disposed on the color filter and the black matrix.

4. The display apparatus of claim 3 , wherein the sealing layer is disposed on the base substrate in the first non-pixel area and has a same height as the roof layer.

5. The display apparatus of claim 3 , wherein the black matrix comprises a photoresist resin and at least one of a chromium-containing metal material having a black color or a carbon-containing organic material having a black color.

6. The display apparatus of claim 1 , wherein the sealing layer comprises at least one of an acryl resin, an ultra-violet curing agent, a photo initiator, a coupling agent, or carbon-containing particles having a black color.

7. The display apparatus of claim 1 , wherein the roof layer is configured to planarize an upper portion of the second electrode.

8. The display apparatus of claim 1 , wherein the substrate further comprises a thin film transistor connected to the first electrode and the thin film transistor is disposed in the first non-pixel area.

9. The display apparatus of claim 1 , wherein the image display layer comprises a liquid crystal layer.

10. A method of manufacturing the display apparatus of claim 1 , comprising:

forming the plurality of pixels, wherein forming the plurality of pixels comprises:

preparing the substrate including the pixel area and the non-pixel area disposed between the pixel areas;

forming the first electrode on the substrate in the pixel area;

forming a sacrificial layer on the substrate, the sacrificial layer extending in the second direction crossing the first direction and being overlapped with the pixel areas arranged in the second direction;

forming the second electrode on the substrate, the second electrode extending in the first direction and covering the sacrificial layer in the pixel area;

forming the roof layer on the second electrode;

wet-etching the sacrificial layer to form the tunnel-shaped cavity between the second electrode and the substrate in the pixel area;

forming a liquid crystal layer in the tunnel-shaped cavity; and

forming the sealing layer extending in the first direction and being disposed in the non-pixel area between the pixel areas in the second direction to seal the tunnel-shaped cavity, the sealing layer having the black color.

11. The method of claim 10 , wherein the non-pixel area comprises:

a first non-pixel area disposed between the pixel areas in the second direction and extending in the first direction; and

a second non-pixel area disposed between the pixel areas in the first direction.

12. The method of claim 11 , wherein preparing the substrate comprises:

preparing a base substrate;

forming a color filter and a black matrix on the base substrate in the pixel area and the second non-pixel area;

forming an organic insulating layer on the base substrate to cover the color filter and the black matrix; and

removing the organic insulating layer in the first non-pixel area, and wherein the sealing layer is disposed on the base substrate in the first non-pixel area.

13. The method of claim 12 , wherein the black matrix comprises a photoresist resin and at least one of a chromium-containing metal material having a black color or a carbon-containing organic material having a black color.

14. The method of claim 12 , wherein forming the sealing layer comprises:

providing a sealant on the base substrate in the first non-pixel area; and

curing the sealant using an ultraviolet ray to form the sealing layer, wherein the sealant is provided to the first non-pixel area using at least one of an inkjet printing or nozzle printing process.

15. The method of claim 14 , wherein the sealant is formed to a height of the roof layer.

16. The method of claim 14 , wherein the sealing layer comprises at least one of an acryl resin, an ultra-violet curing agent, a photo initiator, a coupling agent, or carbon-containing particles having a black color.

17. The method of claim 12 , wherein preparing the substrate further comprises forming a thin film transistor on the base substrate to be connected to the first electrode, wherein the thin film transistor is formed in the first non-pixel area.

18. The method of claim 11 , wherein forming the liquid crystal layer comprises:

providing a liquid crystal in fluid state to the first non-pixel area such that the liquid crystal flows into the tunnel-shaped cavity by a capillary phenomenon; and

removing the liquid crystal that remains in the first non-pixel area, wherein the liquid crystal layer is formed by the liquid crystal provided in the tunnel-shaped cavity.

19. The method of claim 10 , wherein the roof layer is configured to planarize an upper portion of the second electrode.