Method of manufacturing display device and display device manufactured according to the same
A method of manufacturing a display device includes forming a color filter layer (CFL), and forming a light control layer (LCL) on the CFL. Forming the LCL includes: forming, on the CFL, preliminary partition parts (PPPs) spaced apart from each other; forming a preliminary light control part (PLCP) by providing a quantum dot (QD) solution between the PPPs, the QD solution including a QD and a base resin; forming a light control part (LCP) by volatilizing the base resin from the PLCP; and forming partition parts by reducing a thickness of the PPPs. A ratio between a first weight ratio (WR) of the QD in the PLCP and a second WR of the QD in the LCP is about 1:1.1 to about 1:3.0. The first WR is a WR of the QD in the entire PLCP, and the second WR is a WR of the QD in the entire LCP.
1. A method for manufacturing a display device, the method comprising:
forming a color filter layer; and
forming a light control layer on the color filter layer,
wherein forming the light control layer comprises:
forming, on the color filter layer, preliminary partition parts spaced apart from each other;
forming a preliminary light control part by providing a quantum dot solution between the preliminary partition parts, the quantum dot solution comprising a quantum dot and a base resin;
forming a light control part by volatilizing the base resin from the preliminary light control part; and
forming partition parts by reducing a thickness of each of the preliminary partition parts,
wherein a ratio between a first weight ratio of the quantum dot in the preliminary light control part and a second weight ratio of the quantum dot in the light control part is about 1:1.1 to about 1:3.0, and
wherein the first weight ratio is a weight ratio of the quantum dot in the entire preliminary light control part, and the second weight ratio is a weight ratio of the quantum dot in the entire light control part.
2. The method of claim 1 , wherein:
forming the light control part comprises providing heat to the preliminary light control part; and
providing the heat to the preliminary light control part comprises:
providing heat in a range from about 20° C. to about 100° C. through a single process; or
providing first heat in a range from about 20° C. to about 150° C. and providing second heat in a range from about 100° C. to about 200° C.
3. The method of claim 2 , wherein forming the light control part further comprises a vacuum drying process after provision of the heat.
4. The method of claim 1 , wherein forming the partition parts comprises reducing a thickness of each of the preliminary partition parts to a thickness of about 10% to about 90% of an initial thickness of each of the preliminary partition parts.
5. The method of claim 1 , wherein forming the partition parts comprises removing, by an etching process or a polishing process, one surface of the preliminary partition parts that is spaced apart from the color filter layer.
6. The method of claim 1 , wherein:
each of the preliminary partition parts comprises:
a first partition part disposed on the color filter layer; and
a second partition part disposed on the first partition part; and
forming the partition parts comprises removing the second partition part of each of the preliminary partition parts by an etching process or a polishing process.
7. The method of claim 1 , wherein:
forming the light control layer further comprises forming a first capping layer by a deposition process before forming the preliminary light control part; and
the first capping layer is disposed between the color filter layer and the preliminary light control part.
8. The method of claim 1 , wherein forming the preliminary partition parts comprises:
forming first partition parts on the color filter layer;
forming a first capping layer on the first partition parts; and
forming second partition parts on the first partition parts, respectively, with the first capping layer disposed therebetween.
9. The method of claim 1 , further comprising:
forming, after forming the light control part, a second capping layer by a deposition process,
wherein the second capping layer covers one surface of the light control part that is spaced apart from the color filter layer.
10. The method of claim 1 , further comprising:
forming, after forming the light control part, a sub-capping layer by providing a polymer solution,
wherein the sub-capping layer covers one surface of the light control part that is spaced apart from the color filter layer.
11. The method of claim 10 , wherein:
the polymer solution comprises a first dispersant comprising at least one of an acidic substituent and a basic substituent;
the quantum dot solution comprises a second dispersant comprising at least one of an acidic substituent and a basic substituent; and
the first dispersant has a same chemical property as the second dispersant.
12. The method of claim 11 , wherein the polymer solution further comprises a scatterer.
13. The method of claim 1 , wherein the base resin comprises at least one of hexamethylene diacrylate, tetraethylene glycol diacrylate, dipropylene glycol diacrylate, and tripropylene glycol diacrylate.
14. The method of claim 13 , wherein the base resin further comprises at least one of propylene glycol methyl ether acetate (PGMEA), dimethyl acetamide (DMA), gamma-butyrolactone (GBL), cyclohexyl acetate (CHA), and dipropylene glycol monomethyl ether acetate (DPMA).
15. The method of claim 1 , wherein each of the preliminary partition parts has a thickness in a range from about 2 μm to about 20 μm.
16. The method of claim 1 , wherein the quantum dot solution has viscosity in a range from about 2 cP to about 40 cP at room temperature and surface energy in a range from about 1 dyne/cm to about 40 dyne/cm.
17. The method of claim 1 , wherein the quantum dot solution has a vapor pressure in a range from about 10 −6 mmHg to about 1 mmHg and a boiling point in a range from about 25° C. to about 250° C.