Display device and method of manufacturing the same

Abstract

A display device and a method for manufacturing the display device are provided, wherein the display device comprises: a polymer matrix layer comprising a first surface and a second surface facing away from the first surface; and a display panel comprising a third surface facing the second surface and a fourth surface facing away from the third surface, wherein the polymer matrix layer comprises: a first outer surface adjacent to the first surface; a second outer surface adjacent to the second surface and spaced outwardly from the first outer surface; and a cutting surface arranged between the first outer surface and the second outer surface.

Description

[0001] This application claims priority from Korean Patent Application No. 10-2019-0032163, filed on Mar. 21, 2019, the contents of which are hereby incorporated by reference in their entirety. Technical Field

[0002] The present invention relates to a display device and a method for manufacturing the same, and more particularly, to a display device manufactured by laser cutting and a method for manufacturing the same. Background Art

[0003] With the development of multimedia, the importance of display devices has increased. Therefore, various types of display devices such as organic light emitting displays ("OLED") and liquid crystal displays ("LCD") have been widely used. Such display devices can be used in various mobile electronic appliances such as smart phones, smart watches, and tablet personal computers ("PCs").

[0004] Recently, foldable display devices have attracted considerable attention. Foldable display devices can be used for smart phones and tablet PCs to achieve good portability and a wide screen. Summary of the invention

[0005] In a foldable display device, a folding operation of the display device applies stress to each layer constituting the display device. When an adhesive layer used to attach a stacked structure is exposed to such stress, the adhesive layer may cause defective film separation.

[0006] Embodiments of the invention are directed to a display device manufactured by irradiating lasers having different energies, thereby minimizing a carbonized area formed on a polymer base layer.

[0007] Embodiments of the invention are directed to a method of manufacturing a display device in which defects due to foreign substances that may be generated during a laser cutting process are minimized and a processing time is minimized.

[0008] According to a disclosed embodiment, a display device includes: a polymer matrix layer, including a first surface and a second surface facing away from the first surface; and a display panel, including a third surface facing the second surface and a fourth surface facing away from the third surface, wherein the polymer matrix layer includes: a first outer surface, adjacent to the first surface; a second outer surface, adjacent to the second surface and spaced outwardly from the first outer surface; and a cutting surface, arranged between the first outer surface and the second outer surface.

[0009] In an exemplary embodiment, the third outer side surface, which is an outer side surface of the display panel, may be aligned with a surface extending from the second outer side surface.

[0010] In exemplary embodiments, the height of the second outer side surface may range from about 20% to about 40% of the thickness of the polymer base layer, and the width of the cutting surface may range from about 40% to about 75% of the height of the second outer side surface.

[0011] In an exemplary embodiment, a height of the second outer side surface may be in a range of about 40 micrometers (μm) to about 50 μm, and a width of the cut surface may be in a range of about 20 μm to about 30 μm.

[0012] In certain example embodiments, the polymer matrix layer may include polyimide.

[0013] In an exemplary embodiment, the display device may include a linear portion and a curved portion, and at least one of the linear portions may include: a first sub-linear portion; a second sub-linear portion spaced apart from the first sub-linear portion in one direction; and a sub-curved portion connecting the first sub-linear portion with the second sub-linear portion.

[0014] According to a disclosed embodiment, a method for manufacturing a display device includes the following steps: preparing a first stack, the first stack including a display panel and a polymer base layer disposed on the display panel; irradiating a surface of the polymer base layer with a first laser to form a hole portion in which a portion of the one surface is recessed; and irradiating the hole portion with a second laser different from the first laser to form a second stack by cutting a portion of the polymer base layer and a portion of the display panel.

[0015] In an exemplary embodiment, the hole portion may include a first cutting line perpendicular to the one surface of the polymer base layer and a first cutting surface parallel to the one surface of the polymer base layer, and the second laser may be applied to the first cutting surface.

[0016] In an exemplary embodiment, energy density of the first laser may be in a range of about 20% to about 30% of energy density of the second laser.

[0017] In an exemplary embodiment, the width of the first cutting surface may be in a range of about 2 times to about 2.5 times the width of the first laser. BRIEF DESCRIPTION OF THE DRAWINGS

[0018] The above-mentioned features and / or other features of the invention will become more apparent by describing in detail exemplary embodiments of the invention with reference to the accompanying drawings, in which:

[0019] Figure 1 is a perspective view of a display device according to an embodiment;

[0020] Figure 2 The folded state is shown Figure 1 A perspective view of a display device;

[0021] Figure 3 is a cross-sectional view of a display device in an unfolded state according to an embodiment;

[0022] Figure 4 is a cross-sectional view of a display device in a folded state according to an embodiment;

[0023] Figure 5 is a cross-sectional view of a display panel according to an embodiment;

[0024] Figure 6 is an exploded perspective view of a display device according to an embodiment;

[0025] Figure 7 is a plan view of a second stacked body according to an embodiment;

[0026] Figure 8 is a plan view showing one surface of a first stacked body according to the embodiment;

[0027] Fig. 9 is a plan view showing another surface of the first stacked body according to the embodiment;

[0028] Fig.10 is along Fig. 9 A cross-sectional view taken along line Q1-Q1';

[0029] Fig.11 for Fig. 9 An enlarged view of part A in FIG.

[0030] Fig.12 is along Fig. 9 A cross-sectional view taken along line Q2-Q2';

[0031] Fig.13 yes Fig. 9 An enlarged view of part B in FIG.

[0032] Fig.14 is a flowchart showing a method of manufacturing a display device according to an embodiment;

[0033] Figures 15 to 18 is a schematic diagram showing a process of manufacturing a display device according to an embodiment;

[0034] Fig.19 is a plan view showing a first stacked body of a display device according to an alternative embodiment; and

[0035] Figure 20 to Figure 23 is a partial cross-sectional view showing a first stacked body of a display device according to another alternative embodiment. DETAILED DESCRIPTION

[0036] The invention will now be described more fully hereinafter with reference to the accompanying drawings, in which preferred embodiments of the invention are shown. However, the invention may be implemented in different forms and should not be construed as being limited to the embodiments set forth herein. On the contrary, 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. The same reference numerals represent the same elements throughout.

[0037] It will also be understood that when a layer is referred to as being “on” another layer or substrate, it can be directly on the other layer or substrate, or intervening layers may also be present. Throughout the specification, the same reference numerals refer to the same components.

[0038] 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. For example, the first element discussed below may be referred to as the second element without departing from the teachings of the invention. Similarly, the second element may also be referred to as the first element.

[0039] The terms used herein are only used for the purpose of describing specific embodiments and are not intended to be limiting. As used herein, the singular forms "one", "one (person / kind)" and "the (said)" are intended to include plural forms including "at least one (person / kind)", unless the content clearly indicates otherwise. "Or" means "and / or". "At least one (person / kind) of A and B" means "A and / or B". As used herein, 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 when the term "includes" or "comprising" is used in this specification, the term describes the presence of the stated features, regions, wholes, steps, operations, elements and / or components, but does not exclude the presence or addition of one or more other features, regions, wholes, steps, operations, elements, components and / or their groups.

[0040] In this specification, "on", "above", "top", "upper side" or "upper surface" refers to the Z-axis direction, and "below", "below", "bottom", "lower side" or "lower surface" refers to the direction opposite to the Z-axis direction. In addition, "left", "right", "upper" and "lower" refer to directions when the drawings are viewed from a plane. For example, "left" refers to the direction opposite to the X-axis direction, "right" refers to the X-axis direction, "upper" refers to the Y-axis direction, and "lower" refers to the direction opposite to the Y-axis direction.

[0041] As used herein, "about" or "approximately" is inclusive of the stated value and means: within an acceptable range of deviation for the particular value as determined by one of ordinary skill in the art, taking into account the referenced measurements and errors associated with the measurement of the particular quantity (i.e., limitations of the measurement system).

[0042] 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 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 in the present disclosure, and will not be interpreted in an idealized or overly formal sense, unless explicitly defined as such herein.

[0043] Exemplary 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, such as those caused by manufacturing techniques and / or tolerances, are anticipated. Therefore, the embodiments described herein should not be construed as being limited to the specific shapes of the regions shown here, but will include deviations in shapes, such as those caused by manufacturing. For example, a region shown or described as being flat may typically have rough and / or nonlinear features. In addition, the sharp corners shown may be rounded. Therefore, the regions shown in the figures are schematic in nature, and their shapes are not intended to illustrate the precise shapes of the regions and are not intended to limit the scope of the claims.

[0044] Hereinafter, embodiments of the invention will be described in detail with reference to the accompanying drawings.

[0045] Figure 1 is a perspective view of a display device according to an embodiment, Figure 2 The folded state is shown Figure 1 A perspective view of a display device.

[0046] Reference Figure 1 and Figure 2, an embodiment of the display device 10 displays a screen or an image through a display area DA, and various devices including the display area DA may be included in the embodiment of the display device 10. Embodiments of the display device 10 may include, but are not limited to, mobile phones, tablet personal computers ("PCs"), personal digital assistants ("PDAs"), portable multimedia players ("PMPs"), televisions, game consoles, watch-type electronic devices, head-mounted displays, monitors of PCs, notebook computers, car navigation systems, car dashboards, digital cameras, video cameras, external billboards, electric signal boards, various medical devices, various detection devices, various household appliances including the display area DA such as refrigerators and washing machines, and Internet of Things ("IoT") devices. Embodiments of the display device 10 to be described later may include, but are not limited to, for example, foldable smart phones, tablet PCs, and notebooks.

[0047] In an embodiment, the display device 10 may have a generally rectangular shape in plan view. In an embodiment, for example, when viewed from a plan view, the display device 10 may have a rectangular shape in which the corners are right angles or a rectangular shape in which the corners are rounded. The display device 10 may include four sides or edges. The display device 10 may include a long side and a short side.

[0048] The display device 10 may include one surface and a back surface facing away from the one surface. At least one of the one surface and the back surface of the display device 10 may be a display surface. In an embodiment, the display surface may be limited to the one surface of the display device 10, and the image may not be displayed toward the back surface of the display device 10. Hereinafter, for the convenience of description, such an embodiment of the invention will be mainly described in detail, but the invention is not limited thereto. Alternatively, the display device may be, for example, a dual-surface display device in which image display is performed on the one surface and the opposite surface.

[0049] The display device 10 may be divided into a display area DA for displaying an image and a non-display area NDA provided around the display area DA according to whether an image is displayed on the one surface.

[0050] The display area DA may include a plurality of pixels. A pixel is a basic unit for displaying an image. A pixel may include, but is not limited to, a red pixel, a green pixel, and a blue pixel. A pixel may also include a white pixel. A plurality of pixels may be alternately arranged on a plane. In one embodiment, for example, the pixels may be arranged substantially in a matrix form, but the invention is not limited thereto.

[0051] The non-display area NDA may be arranged around the display area DA. The non-display area NDA may surround the display area DA. In an embodiment, the display area DA may be in a rectangular shape, and the non-display area NDA may be arranged around four sides of the display area DA, but the invention is not limited thereto. The non-display area NDA is provided with a black matrix form or is defined by a black matrix form to prevent light emitted from adjacent pixels from leaking.

[0052] The display device 10 may be a foldable device. As used herein, as a device that can be folded, the term "foldable device" refers to a device that can be in both a folded state and an unfolded state and a device that is only in a folded state. Folding generally includes a situation where it is folded at an angle of about 180°, but the invention is not limited thereto. It is understood that the display device 10 is folded even when the folding angle is greater than 180° or less than 180° (for example, when the folding angle is greater than 90° and less than 180° or greater than 120° and less than 180°). Here, it is understood that when the display device 10 is bent from the unfolded state, the display device 10 is also folded even though the display device 10 is not completely folded. In one embodiment, for example, even when the display device 10 is bent at an angle of 90° or less, as long as the maximum folding angle is 90° or more, the state may also be described as a folded state to distinguish such a state from the unfolded state. The radius of curvature when folded may be about 5 millimeters (mm) or less, for example, about 1 mm to about 2 mm or about 1.5 mm, but is not limited thereto.

[0053] The display device 10 can be folded according to an imaginary folding line FDA (or folding axis). The folding line FDA may be a straight line extending in one direction on a plane. In an embodiment, as shown in the accompanying drawings, the folding line FDA extends parallel to the short side of the display device 10, but the invention is not limited thereto. Alternatively, the folding line FDA may extend parallel to the long side of the display device 10, or may be inclined relative to the short side and the long side of the display device 10.

[0054] In an embodiment, the folding line FDA of the display device 10 may be fixed at a specific position. The number of the folding lines FDA fixed at a specific position may be one or more. In an optional embodiment, the position of the folding line FDA is not specified in the display device 10, but can be freely set in various regions.

[0055] The display device 10 may be divided into a first expansion area NFA1 and a second expansion area NFA2 according to a folding line FDA. The first expansion area NFA1 may be positioned at one side of the folding line FDA, and the second expansion area NFA2 may be positioned at the other side of the folding line FDA. In an embodiment where the folding line FDA is fixed at a specific position, the first expansion area NFA1 and the second expansion area NFA2 may be designated as areas where no folding occurs. In an embodiment, the designated first expansion area NFA1 and the second expansion area NFA2 may have the same width as each other, but the invention is not limited thereto. In an embodiment where the folding line FDA is not designated, the first expansion area NFA1 and the second expansion area NFA2 may be changed according to the position of the set folding line FDA.

[0056] In an embodiment, the display area DA of the display device 10 may be provided throughout both the first expansion area NFA1 and the second expansion area NFA2, or may be limited to both the first expansion area NFA1 and the second expansion area NFA2. In such an embodiment, the display area DA may be positioned at a folding line FDA corresponding to a boundary between the first expansion area NFA1 and the second expansion area NFA2. In such an embodiment, the display area DA of the display device 10 may be provided continuously without regard to the boundary between the first expansion area NFA1 and the second expansion area NFA2. However, the invention is not limited thereto. Optionally, the display area DA may be provided in the first expansion area NFA1, but the display area DA may not be provided in the second expansion area NFA2. In an embodiment, the display area DA is provided in the first expansion area NFA1 and the second expansion area NFA2, but the non-display area NDA may not be provided along the folding line FDA.

[0057] The display device 10 can be in an inward-folding manner ( Figure 2 The display device 10 may be folded in an inner folding manner (as shown in FIG. 1 ), and may also be folded in an outer folding manner in which the display surface is folded in an outward-facing manner. The display device 10 may be folded in only one of the inner folding manner and the outer folding manner, or may be folded in both the inner folding manner and the outer folding manner. In an embodiment in which the display device 10 is folded in both the inner folding manner and the outer folding manner, the inner folding and the outer folding may be performed according to the same folding line FDA, or the display device 10 may include a plurality of folding lines FDA that perform folding in different manners, such as a folding line only for the inner folding and a folding line only for the outer folding.

[0058] In an embodiment, the display panel, the layers stacked on the display panel, and the substrate have flexible properties, so that the display device 10 can be folded by folding all the corresponding components. In an optional embodiment, at least a portion of the display panel or some of the components stacked on the display panel may have a separate shape about the folding line FDA. In such an embodiment, the separate components positioned in the unfolded area may not have flexible properties.

[0059] Figure 3 is a cross-sectional view of a display device in an unfolded state according to an embodiment, Figure 4 is a cross-sectional view of a display device in a folded state according to an embodiment.

[0060] Reference Figure 3 and Figure 4 , an embodiment of the display device 10 may include a display panel 100, a polarization member 200, a cover window 300, a polymer base layer 400, and a heat radiation member 500. The display device 10 includes a bonding member BP, and the bonding member BP can attach the corresponding members to each other. Here, the front of the display panel 100 means the direction along which the display panel 100 displays an image, and the back (or rear) of the display panel 100 means the direction opposite to the front of the display panel 100. One surface of the display panel 100 may be located at the front, and the back-to-back surface of the display panel 100 may be located at the back.

[0061] The display panel 100 is a panel for displaying an image, and the display panel 100 may include a self-luminous display panel such as an organic light-emitting display panel ("OLED"), an inorganic light-emitting display panel, a quantum dot light-emitting display panel ("QED"), a micro-light-emitting diode ("LED") display panel, a nano-LED display panel, a plasma display panel ("PDP"), a field emission display panel ("FED"), and a cathode ray tube display panel ("CRT"), and at least one of a light-receiving display panel such as a liquid crystal display panel ("LCD") and an electrophoretic display panel ("EPD"). Hereinafter, for the convenience of description, an embodiment in which the display panel 100 is an organic light-emitting display panel will be described in detail, and the organic light-emitting display panel applied to the embodiment will be referred to as the display panel 100 for short, unless otherwise specifically described. However, the embodiment of the display panel 100 is not limited to the organic light-emitting display panel, and other display panels listed above or known in the art may be used as the display panel 100 without departing from the teachings herein.

[0062] The display panel 100 may further include a touch member. The touch member may be provided as a separate panel or film and attached to the display panel 100, or may be provided in the display panel 100 in the form of a touch layer. In the drawings, for convenience of description, an embodiment in which the touch member is provided in and included in the display panel 100 is shown, but the invention is not limited thereto.

[0063] Figure 5 is a cross-sectional view of a display panel according to an embodiment.

[0064] Reference Figure 5 , an embodiment of the display panel 100 may include: a substrate SUB; a circuit driving layer DRL located on the substrate SUB; a light emitting layer EML located on the circuit driving layer DRL; an encapsulation layer ENL located on the light emitting layer EML; and a touch layer TSL located on the encapsulation layer ENL.

[0065] In an embodiment, the substrate SUB may be a flexible substrate including a flexible polymer material such as polyimide ("PI"). In such an embodiment, the display panel 100 may be twisted, bent, folded, or curled. In an embodiment, the substrate may have a multilayer structure including a plurality of sub-substrates stacked on each other in a thickness direction with a barrier layer therebetween. In such an embodiment, each of the sub-substrates may be a flexible substrate.

[0066] The circuit driving layer DRL may be disposed on the substrate SUB. The circuit driving layer DRL may include a circuit for driving the light emitting layer EML of the pixel. The circuit driving layer DRL may include a plurality of thin film transistors.

[0067] The light emitting layer EML may be disposed on the circuit driving layer DRL. The light emitting layer EML may include an organic light emitting layer. The light emitting layer EML may emit light having various brightnesses corresponding to a driving signal transmitted from the circuit driving layer DRL.

[0068] The encapsulation layer ENL may be disposed on the light emitting layer EML. The encapsulation layer ENL may include an inorganic film or a stacked film of an inorganic film and an organic film.

[0069] The touch layer TSL may be disposed on the encapsulation layer ENL. The touch layer TSL is a layer for sensing a touch input and may perform a function of a touch member. The touch layer TSL may include a plurality of sensing regions and a plurality of sensing electrodes.

[0070] Reference Figure 3 and Figure 4The polarization member 200 and the cover window 300 may be disposed at the side of the one surface of the display panel 100 (ie, the front of the display panel 100). The polarization member 200 and the cover window 300 may be sequentially stacked on the one surface of the display panel 100, and an adhesive member BP may be disposed between the polarization member 200 and the cover window 300.

[0071] The polarization member 200 polarizes the light transmitted therethrough. The polarization member 200 may be used to reduce reflection of external light. In an embodiment, the polarization member 200 may be a polarizing film. The polarizing film may include a polarizing layer and a protective substrate sandwiching the polarizing layer therebetween. The polarizing layer may include a polyvinyl alcohol film. The polarizing layer may extend in one direction. The extending direction of the polarizing layer may be an absorption axis, and the direction perpendicular to the extending direction may be a transmission axis. The protective substrates may be respectively disposed on the opposite surfaces of the polarizing layer. The protective substrates may include a cellulose resin such as triacetyl cellulose or a polyester resin, or may be made of a cellulose resin such as triacetyl cellulose or a polyester resin, but the material of the protective substrate is not limited thereto.

[0072] The cover window 300 may be disposed in front of the polarization member 200. The cover window 300 serves to protect the display panel 100. The cover window 300 may include a transparent material. In one embodiment, for example, the cover window 300 may include glass or plastic.

[0073] In embodiments where the cover window 300 includes glass, the glass may be ultra-thin glass ("UTG") or thin-film glass. In embodiments where the glass is ultra-thin glass (UTG) or thin-film glass, the cover window 300 may be twisted, bent, folded, or curled due to its flexible properties. The thickness of the glass may be in the range of about 10 micrometers (μm) to about 300 μm, for example, in the range of about 30 μm to about 80 μm or about 50 μm. The glass of the cover window 300 may be soda-lime glass, alkali-aluminosilicate glass, borosilicate glass, or lithium-aluminosilicate glass. The glass of the cover window 300 may include chemically strengthened or thermally strengthened glass to have high strength. Chemical strengthening of the glass may be performed by an ion exchange treatment process in an alkali salt. The ion exchange treatment process may be performed twice or more.

[0074] In an optional embodiment where the cover window 300 includes a plastic material, the cover window 300 may have a highly flexible property. In an embodiment, the plastic material of the cover window 300 may include, but is not limited to, PI, polyacrylate, polymethyl methacrylate ("PMMA"), polycarbonate ("PC"), polyethylene naphthalate ("PEN"), polyvinylidene chloride, polyvinylidene fluoride ("PVDF"), polystyrene, ethylene vinyl alcohol copolymer, polyether sulfone ("PES"), polyetherimide ("PEI"), polyphenylene sulfide ("PPS"), polyallylate, triacetyl cellulose ("TAC"), cellulose acetate propionate ("CAP"), or a combination thereof.

[0075] The cover window protection layer 310 may be disposed in front of the cover window 300. The cover window protection layer 310 may be used as at least one of anti-scattering, shock absorption, anti-stamping, anti-fingerprint, and anti-glare functions for the cover window 300. The cover window protection layer 310 may include a transparent polymer film. The transparent polymer film may include at least one of polyethylene terephthalate ("PET"), PEN, PES, PI, polyacrylate ("PAR"), PC, PMMA, and cyclic olefin copolymer ("COC").

[0076] The adhesive member BP may attach the display panel 100, the polarization member 200, and the cover window 300 to each other. The polymer base layer 400 and the heat radiation member 500, which will be described later, may also be attached to each other by the adhesive member BP. The adhesive member BP close to the one surface of the display panel 100 may include a protective layer bonding member for attaching the cover window protective layer 310, a window bonding member for attaching the cover window 300, and a polarization member bonding member for attaching the polarization member 200. All adhesive members BP disposed close to the one surface of the display panel 100 (i.e., disposed in front of the display panel 100) may be optically transparent.

[0077] The polymer base layer 400 and the heat radiation member 500 may be disposed close to the other surface of the display panel 100 (ie, disposed behind the display panel 100 ).

[0078] The polymer matrix layer 400 may include a polymer film. In one embodiment, for example, the polymer matrix layer 400 may include PI, PET, PC, polyethylene ("PE"), polypropylene ("PP"), polysulfone ("PSF"), PMMA, TAC, or cycloolefin polymer ("COP"). The polymer matrix layer 400 may include a functional layer at its surface. The functional layer may include, for example, a light absorbing layer. The light absorbing layer may include a light absorbing material such as a black pigment or a black dye. The light absorbing layer may be formed on the polymer film by coating or printing a black ink.

[0079] The heat radiation member 500 may be disposed behind the polymer base layer 400. The heat radiation member 500 is used to diffuse heat generated from the display panel 100 or other components of the display device 10. The heat radiation member 500 may include a metal plate. The metal plate may include a metal with high thermal conductivity such as copper or silver. The heat radiation member 500 may be a heat radiation sheet including graphite, carbon nanotubes, etc.

[0080] In an embodiment, Figure 3 and Figure 4 As shown in , the heat radiation member 500 may include portions spaced apart from each other based on the folding line FDA to facilitate folding of the display device 10, but the invention is not limited thereto. In one embodiment, for example, the heat radiation member 500 may include a first heat radiation member 510 and a second heat radiation member 520. The first heat radiation member 510 may be disposed in the first deployment area NFA1, and the second heat radiation member 520 may be disposed in the second deployment area NFA2. The first heat radiation member 510 and the second heat radiation member 520 may be physically separated or physically spaced apart from each other relative to the folding line FDA.

[0081] In an embodiment, as described above, the polymer base layer 400 and the heat radiation member 500 may be attached to each other by an adhesive member BP. In an embodiment, for example, the adhesive member BP close to the back-facing surface of the display panel 100 may include a polymer film bonding member for attaching the polymer base layer 400 and a heat radiation film bonding member for attaching the heat radiation member 500. In an embodiment in which the heat radiation member 500 includes portions separated from each other relative to the folding line FDA, the heat radiation film bonding members of the adhesive member BP may be separated in the same shape. Alternatively, the heat radiation member 500 may be integrally formed as a single unit without being separated for each of the first deployment area NFA1 and the second deployment area NFA2.

[0082] In an embodiment where the display device 10 displays an image only through its front surface, the adhesive member BP disposed at the opposite surface of the display panel 100 (ie, the adhesive member BP disposed at the rear side of the display panel 100 ) may not be optically transparent.

[0083] Each of the above-mentioned adhesive members BP may include an adhesive material. Each of the adhesive members BP may include a pressure-sensitive adhesive layer. The respective adhesive members may have the same composition as each other, or may have different compositions depending on their positions and elements to be attached.

[0084] Some of the adhesive members BP may include an optically transparent adhesive layer or an optically transparent resin. In one embodiment, for example, the adhesive member BP for attaching the cover window 300 to the display panel 100 may include an optically transparent adhesive layer or an optically transparent resin. However, the invention is not limited thereto.

[0085] Each of the plurality of bonding members BP may have a thickness of about 300 μm or less. In an embodiment, all bonding members BP may have a thickness of about 200 μm or less, for example, a thickness of about 100 μm or less. The lower limit of the thickness of the bonding member BP is not particularly limited, but may be about 10 μm or more or about 50 μm or more to exhibit minimum adhesive force.

[0086] Each of the bonding members BP may be formed or defined by a single bonding layer, may be formed or defined by a plurality of laminated bonding layers, or may include bonding layers on the opposing surfaces of the substrate as a double-sided tape.

[0087] In an embodiment, the bonding member BP may include a silicone adhesive. The silicone adhesive may include a siloxane resin. In such an embodiment, the silicone adhesive may include a silica gel containing a polyorganosiloxane compound. The silica gel may include a cross-linkable functional group such as a vinyl group. The silicone adhesive may also include an MQ resin having a three-dimensional molecular structure including a monofunctional siloxane unit and a tetrafunctional siloxane unit. The silicone adhesive may also include an additive including at least one of a borane compound and a borate (or borate ester) compound.

[0088] In an optional embodiment, the bonding member BP may include an acrylic adhesive. The acrylic adhesive may include an acrylic polymer. The acrylic polymer is obtained by polymerizing an acrylic monomer, and the acrylic monomer may be a primary material. In such an embodiment, the acrylic monomer may include, for example, ethyl acrylate, n-butyl acrylate, tert-butyl acrylate, isobutyl acrylate, n-hexyl acrylate, 2-ethylhexyl acrylate, n-octyl acrylate, isooctyl acrylate, n-nonyl acrylate, isononyl acrylate, n-decyl acrylate, isodecyl acrylate, n-dodecyl acrylate, n-tridecyl acrylate, n-tetradecyl acrylate, 2-(2-ethoxyethoxy)ethyl acrylate, 2-hydroxyethyl acrylate, 2-hydroxypropyl acrylate, 3-hydroxypropyl acrylate, 2-hydroxybutyl acrylate, 4-hydroxybutyl acrylate, 6-hydroxyhexyl acrylate, 8-hydroxyoctyl acrylate, 10-hydroxydecyl acrylate, 12-hydroxydodecyl acrylate, and at least one of acrylate-[4-(hydroxymethyl)cyclohexyl]methyl. In addition to the acrylic polymer, the acrylic adhesive may also include an azo-based initiator such as 2,2'-azobisisobutyronitrile, a filler such as silicon oxide or zirconium oxide, a crosslinking agent, and an antistatic agent such as polyethylene dioxythiophene: polystyrene sulfonate ("PEDOT:PSS"). In an embodiment, the acrylic adhesive may be prepared by the following steps: 120 to 250 parts by weight of an acrylic monomer is mixed with a solvent, and the mixed solution is stirred and heated; 0.1 to 1 parts by weight of an azo-based initiator, 0.5 to 1 parts by weight of a filler, 1.5 to 2.5 parts by weight of a crosslinking agent, and 0.5 to 1 parts by weight of an antistatic agent are added to the solution; and the resulting solution is stirred and heated.

[0089] In another optional embodiment, the bonding member BP may include a crystalline polymer and a rubber-like polymer. In such an embodiment, the crystalline polymer may include, for example, at least one of polypropylene, syndiotactic polystyrene, polyamide, polycaprolactone, polycarbonate-diol, PET, polyphenylene sulfide, polybutylene terephthalate ("PBT"), PAR, poly (DPAA), PEI, polyacetal, and polyoxymethylene ("POM").

[0090] In such an embodiment, the rubber-based polymer may include, for example, at least one of polybutadiene, polyisoprene, polychloroprene, polyisobutylene, cellulose acetate, polyvinyl acetate, and copolymers thereof. The weight ratio of the crystalline polymer to the rubber-based polymer may be about 1:0.3 to about 1:1.5. In such an embodiment, the bonding member BP may also include a urethane polymer, an ester polymer, and / or a (meth)acrylate polymer, and may also include a coupling agent such as a silane coupling agent, a titanate coupling agent, or a chromium coupling agent, an adhesion improver such as a rosin resin, a rosin ester resin, a terpene phenol resin, or a terpene resin, a yellowing inhibitor, or an antioxidant.

[0091] The constituent materials and components of the bonding member BP are not limited to the above-mentioned materials and components, and other components or ingredients of bonding materials known in the art may be applied.

[0092] In an embodiment, the display device 10 may be manufactured by forming a first stack body 11 including a display panel 100, a polymer base layer 400, a polarization member 200, and a cover window 300 and attaching a heat radiation member 500 to one surface of the first stack body 11. Fig.15 As shown in , the first stacked body 11 may be formed by the following steps: first forming the second stacked body 15 having an area larger than that of the display device 10; and then partially removing the second stacked body 15 to have the shape of the display device 10. According to an embodiment, the display device 10 may include the first stacked body 11 formed by cutting a portion of the second stacked body 15 with a laser.

[0093] Figure 6 is an exploded perspective view of a display device according to an embodiment. Figure 7 is a plan view of a second stacked body according to the embodiment.

[0094] Reference Figure 6 and Figure 7 , an embodiment of the display device 10 may include a first stack 11 and a heat radiation member 500 disposed under the first stack 11. The first stack 11 may include a display panel 100, a polarization member 200, a cover window 300, a polymer base layer 400, and a plurality of adhesive members BP for attaching these components to each other. The display device 10 may be manufactured by forming the first stack 11 and then placing the heat radiation member 500 on the lower surface of the first stack 11.

[0095] In an embodiment, Figure 7As shown in , the first laminate 11 may include a first circuit board 710 connected to a bonding area BA of the display panel 100 and a second circuit board 720 connected to the first circuit board 710. Unlike the polarization member 200 and the cover window 300, one side of each of the display panel 100 and the polymer matrix layer 400 may partially protrude, and the display panel 100 and the polymer matrix layer 400 may be connected to the first circuit board 710 in a bonding area BA defined on one surface of the display panel 100. The first laminate 11 may include a bonding area BA protruding at least partially from one side of the first laminate 11 on which the first circuit board 710 is disposed. One side of the display panel 100 and the polymer matrix layer 400 of the first laminate 11 protrudes from the polarization member 200 and the cover window 300, and the bonding area BA may be defined in the protruding area. As will be described in detail later, such a configuration of the display panel 100 and the polymer matrix layer 400 may be formed in a process of forming the first laminate 11 by cutting a portion of the second laminate 15.

[0096] The first circuit board 710 can be attached to a pad (or "pad" or "solder pad") provided on one side edge portion of the display panel 100 using an anisotropic conductive film. Therefore, the lead of the first circuit board 710 can be electrically connected to the pad. The first circuit board 710 can be a flexible printed circuit board, a printed circuit board, or a flexible film such as a chip on a film. The first circuit board 710 can be bent toward the lower portion of the display panel 100. In such an embodiment, one side of the first circuit board 710 can be attached to one side edge portion of the display panel 100, and the other side of the first circuit board 710 can be provided under the display panel 100 to be connected to a system board in which a host system is installed.

[0097] The second circuit board 720 may include a circuit pad area attached to one side portion of the first circuit board 710. A plurality of circuit pads may be provided in the circuit pad area of ​​the second circuit board 720 and connected to leads provided on the first circuit board 710.

[0098] In an embodiment, Figure 6 As shown in FIG. 1 , the first circuit board 710 may be bent in a direction opposite to the third direction (Z-axis direction) (i.e., in a downward direction of the first laminate 11). The other sides of the first circuit board 710 and the second circuit board 720 may be positioned below the heat radiation member 500 of the display device 10. The lower surface of the heat radiation member 500 may be attached to the second circuit board 720 by a separate adhesive member, but the invention is not limited thereto.

[0099] Can be cut Figure 7The first stack 11 including the first circuit board 710 and the second circuit board 720 connected to the bonding area BA of the display panel 100 is formed by using the portion of the second stack 15 shown in FIG. The second stack 15 may include the display panel 100, the polarization member 200, the cover window 300, and the polymer matrix layer 400, all of which are manufactured to have an area larger than that of the display device 10. In an embodiment, similar to the display device 10, the second stack 15 may include a display area DA, a non-display area NDA, a folding line FDA, and a first unfolding area NFA1 and a second unfolding area NFA2, and may include a removal area RVA positioned outside the non-display area NDA. As will be described later, in the process of manufacturing the display device 10, the removal area RVA of the second stack 15 may be separated or removed along a cutting line LCL formed along the non-display area NDA to form the first stack 11. In an embodiment, the first stack 11 may be formed by separating the removal area RVA from the second stack 15 by a cutting process using a laser. The second stacked body 15 is irradiated with laser along the cutting line LCL at the lower surface of the second stacked body 15 , and the first stacked body 11 manufactured by irradiating laser along the cutting line LCL may have the cutting line LCL whose upper and lower surfaces are different from each other.

[0100] Figure 8 is a plan view showing one surface of a first stacked body according to the embodiment, Fig. 9 is a plan view showing the other surface of the first stacked body according to the embodiment.

[0101] Figure 8 is a plan view showing one surface (ie, the front surface) of the first stacked body 11, Fig. 9 1 is a plan view showing the other surface of the first stacked body 11 (ie, the rear surface thereof).

[0102] Reference Figure 8 and Fig. 9 , an embodiment of the first stack 11 may include a cutting line LCL formed along the outer side surface of the non-display area NDA. The cutting line LCL may include a first cutting line LCL1 and a second cutting line LCL2 protruding from the first cutting line LCL1 toward the outside of the first stack 11. The first cutting line LCL1 and the second cutting line LCL2 may be cutting lines of the periphery of the first stack 11 when the first stack 11 is viewed in a plan view, and may constitute the outer side surface of the first stack 11. In such an embodiment, the first cutting line LCL1 may be the first outer side surface of the first stack 11, and the second cutting line LCL2 may be the second outer side surface of the first stack 11. Hereinafter, for the convenience of description, the outer side surface of the first stack 11 will be referred to as the first cutting line LCL1 and the second cutting line LCL2.

[0103] According to an embodiment, one surface of the first stack 11 may include the second cutting line LCL2, and the other surface (or the opposite surface) of the first stack 11 may include the first cutting line LCL1 and the second cutting line LCL2. The one surface and the other surface of the first stack 11 may form the second cutting line LCL2 located on the same line in a plan view, and the other surface of the first stack 11 may further include the first cutting line LCL1 spaced apart from the second cutting line LCL2 inwardly.

[0104] As a surface facing the front of the display panel 100, one surface of the first stacked body 11 (at Figure 8 The first stacked body 11 may include a display area DA, a non-display area NDA, a folding line FDA, and a first and second unfolding areas NFA1 and NFA2. One surface of the first stacked body 11 may include a second cutting line LCL2, and the second cutting line LCL2 may correspond to the outer side surface of the non-display area NDA. Although not shown, the second cutting line LCL2 extends to correspond to portions of the cover window 300, the polarization member 200, the display panel 100, and the polymer base layer 400.

[0105] As the surface at the rear of the display panel 100, the other surface ( Fig. 9 ) may include a lower surface of the polymer base layer 400. In such an embodiment, the other surface of the first stack 11 may include a second cutting line LCL2 and a first cutting line LCL1 spaced inwardly from the second cutting line LCL2. The first cutting line LCL1 may have a shape substantially the same as that of the second cutting line LCL2, and may be spaced apart from the second cutting line LCL2 by a predetermined width. The first cutting line LCL1 extends to a portion of the polymer base layer 400. In such an embodiment of the first stack 11, the polymer base layer 400 may include the first cutting line LCL1 and the second cutting line LCL2, and the cover window 300, the polarization member 200, and the display panel 100 may include only the second cutting line LCL2.

[0106] In an embodiment, as described above, one surface of the first stack 11 may include a folding line FDA defined therein to be folded, and thus the display device 10 may be a foldable display device. In an embodiment, for example, the polymer base layer 400 may include a colored polyimide, and thus the display device 10 may have high durability even when the display device 10 is folded and unfolded multiple times. In an embodiment, the first stack 11 may be formed by irradiating the lower surface of the second stack 15 (i.e., the upper surface of the polymer base layer 400) with a laser and removing a portion of the second stack 15. In such an embodiment, when the polymer base layer 400 including the colored polyimide is irradiated with a laser, a portion of the polymer base layer 400 may be carbonized, and thus a portion of the first stack 11 may be contaminated or foreign matter may be generated. In the method of manufacturing the display device 10 according to the embodiment, the second stack 15 can be cut using lasers having different energy densities, so even when the polymer base layer 400 includes colored polyimide, contamination of the first stack 11 and generation of foreign matter due to laser irradiation can be effectively prevented. Therefore, the embodiment of the display device 10 according to the embodiment may include a first cutting line LCL1 formed by a first laser and a second cutting line LCL2 formed by a second laser, which will be described in detail later.

[0107] Fig.10 is along Fig. 9 A cross-sectional view taken along line Q1-Q1', Fig.11 for Fig. 9 Magnified view of part A in FIG.

[0108] Fig.10 is a cross-sectional view passing through a first cutting line LCL1 and a second cutting line LCL2 at one side of the first stacked body 11, Fig.11 is an enlarged view showing the above-mentioned one side. Fig.10 Only the display panel 100, the polarization member 200, the cover window 300, the cover window protection layer 310 and the polymer matrix layer 400 of the first stack 11 are shown. Fig.10 The bonding member BP is omitted.

[0109] In the embodiments, reference Fig.10 and Fig.11 , the display device 10 may include a polymer matrix layer 400 including first and second cutting lines LCL1 and LCL2. In such an embodiment, the display device 10 includes a first stacked body 11, and the polymer matrix layer 400 of the first stacked body 11 has the first and second cutting lines LCL1 and LCL2.

[0110] The first cutting line LCL1 may form or define a first outer side surface of the first stack 11 adjacent to the upper surface of the polymer base layer 400 (i.e., the surface opposite to the rear surface of the display panel 100) in the drawings. The first cutting line LCL1 may be formed in a direction substantially perpendicular to the lower surface of the polymer base layer 400, and may extend to terminate spaced apart from the lower surface of the polymer base layer 400. In an embodiment, the first cutting line LCL1 may be formed by removing only a portion of the polymer base layer 400.

[0111] The second cutting line LCL2 may form a second outer side surface of the first stack 11 adjacent to the lower surface of the polymer base layer 400 (i.e., the other surface facing the display panel 100). The second cutting line LCL2 may be spaced apart from the end of the first cutting line LCL1 of the polymer base layer 400 and extend to the cover window protective layer 310 of the first stack 11. In such an embodiment, the second cutting line LCL2 may be an area of ​​the polymer base layer 400 in which the first cutting line LCL1 is not formed, and may be an area in which the display panel 100, the polarization member 200, the cover window 300, and the cover window protective layer 310 extend in a stacking direction thereof when the display panel 100, the polarization member 200, the cover window 300, and the cover window protective layer 310 are cut. In such an embodiment, the second cutting line LCL2 may be defined by the outermost surface of the first stack 11 substantially including a member such as the display panel 100.

[0112] In an exemplary embodiment, the polymer matrix layer 400 may include a cutting surface LCA disposed between the first cutting line LCL1 and the second cutting line LCL2. The cutting surface LCA may form a surface substantially parallel to the upper surface of the polymer matrix layer 400. The cutting surface LCA may be a region where the upper portion of a portion of the polymer matrix layer 400 is removed in the process of forming the first cutting line LCL1 and some particles formed by laser irradiation remain. In an embodiment, the cutting surface LCA may be a region where a portion of the polymer matrix layer 400 is carbonized in the process of forming the first cutting line LCL1. As will be described later, in the process of forming the first cutting line LCL1, irradiation is performed with a laser having a lower energy density compared to the process of forming the second cutting line LCL2. The cutting surface LCA may be formed only between the first cutting line LCL1 and the second cutting line LCL2 using a laser having a low energy density, thereby minimizing the formation of particles or contamination of the first stack 11 by the process of forming the second cutting line LCL2.

[0113] Fig.10The cutting surface LCA may be formed in the laser process of forming the first cutting line LCL1, and may be a portion remaining after removing a portion of the cutting surface LCA in the laser process of forming the second cutting line LCL2. Therefore, the cutting surface LCA may be disposed in a region where one end of the first cutting line LCL1 is spaced apart from one end of the second cutting line LCL2. However, the present invention is not limited thereto, and at least a portion of the cutting surface LCA may overlap with the first cutting line LCL1, or a plurality of cutting surfaces LCA may be provided.

[0114] In an embodiment, the height DL1 of the first cutting line LCL1 of the polymer base layer 400 (or the length in the thickness direction of the polymer base layer 400) may be greater than the height DL2 of the second cutting line LCL2 of the polymer base layer 400. In an embodiment, the height DL2 of the second cutting line LCL2 of the polymer base layer 400 may be minimized as much as possible in practice, thereby minimizing the range in which the laser with high energy density is applied to the polymer base layer 400 in the process of forming the second cutting line LCL2. In an embodiment, the height DL2 of the second cutting line LCL2 may be in the range of about 20% to about 40% of the overall thickness (DL1+DL2) of the polymer base layer 400. In an embodiment, for example, the height DL2 of the second cutting line LCL2 may be in the range of about 40 μm to about 50 μm, but is not limited thereto.

[0115] In an embodiment, the first cutting line LCL1 may be spaced apart from the second cutting line LCL2 by a width WL of the cutting surface LCA to prevent contamination or foreign matter that may appear in the polymer base layer 400 in the process of forming the second cutting line LCL2. In an embodiment, the laser applied in the process of forming the first cutting line LCL1 may be applied to the polymer base layer 400 with a predetermined width to form the cutting surface LCA. In an embodiment, the width WL of the cutting surface LCA may be in a range of about 40% to about 75% of the height DL2 of the second cutting line LCL2. In an embodiment, for example, the width WL of the cutting surface LCA may be in a range of about 20 μm to about 30 μm, but is not limited thereto.

[0116] In an embodiment, the first stack 11 may include a bonding area BA to which the first circuit board 710 is attached, and the bonding area BA may be defined in a region where the display panel 100 and the polymer base layer 400 protrude from the polarization member 200 and the cover window 300 .

[0117] Fig.12 is along Fig. 9 A cross-sectional view taken along line Q2-Q2', Fig.13 yes Fig. 9 Magnified view of part B in FIG.

[0118] Fig.12 It is a cross-sectional view passing through one side including the bonding area BA of the first stacked body 11 . Fig.13 1 is an enlarged view showing the sub-bending portion CP in a region adjacent to the bonding area BA of the first stacked body 11 .

[0119] Reference Fig. 9 and Fig.12 , the first laminate 11 may have a structure in which the display panel 100 and the polymer base layer 400 protrude from the polarization member 200, and the first circuit board 710 may be attached to the display panel 100 in the protruding area. In an embodiment, as described above, the first circuit board 710 may be attached to the second circuit board 720. The first circuit board 710 and the second circuit board 720 may transmit a predetermined electrical signal to the display panel 100 coupled in the coupling area BA.

[0120] In an embodiment, the display device 10 including the first stacked body 11 may include at least one linear portion and at least one curved portion. Fig. 9 As shown in , when viewed from a plan view, the upper side, left side, and right side of the first stack 11 may have linear portions extending in one direction, and the corner portions where the linear portions meet each other may include curved portions rounded with a predetermined curvature. However, at the lower side of the first stack 11 (located at the side of the bonding area BA where the first stack 11 is located), at least a portion of the linear portions facing away from the upper side of the first stack 11 may protrude with a certain curvature. In an embodiment, the first stack 11 may include a sub-curved portion CP defined by a portion of the one side of the first stack 11 protruding with a certain curvature at at least one side of the first stack 11. The one side may include a first sub-linear portion, a second sub-linear portion spaced apart from the first sub-linear portion, and a sub-curved portion CP connecting the first sub-linear portion with the second sub-linear portion.

[0121] Reference Fig.13, a sub-bend portion CP whose portion protrudes with a certain curvature may be located at one side of the first laminate 11 adjacent to the bonding area BA, that is, at the lower side of the first laminate 11. The sub-bend portion CP may connect a first sub-linear portion (not shown) extending in one direction in the bonding area BA attached to the first circuit board 710 with a second sub-linear portion (not shown) connected to the right side of the first laminate 11 through a bent portion. An extension line of the first sub-linear portion may be spaced apart from an extension line of the second sub-linear portion. The sub-bend portion CP may connect the first sub-linear portion with the second sub-linear portion in an area where the first sub-linear portion is spaced apart from the second sub-linear portion. The shape of the first laminate 11 may be formed by cutting the lower side of the second laminate 15 while moving along the shape of the sub-bend portion CP in a process of cutting a portion of the second laminate 15. However, the invention is not limited thereto.

[0122] In the process of manufacturing the display device 10, the structure of the first stack 11 described above may be formed by irradiating the other surface of the second stack 15 with lasers different from each other to remove a portion of the second stack 15. In an embodiment, the first cutting line LCL1 of the first stack 11 may be formed by irradiating the polymer base layer 400 with a first laser, and the second cutting line LCL2 of the first stack 11 may be formed by irradiating the polymer base layer 400 and the display panel 100 with a second laser different from the first laser. These features will be described in more detail later.

[0123] Fig.14 is a flowchart illustrating a method of manufacturing a display device according to an embodiment.

[0124] Reference Fig.14 , an embodiment of the method for manufacturing the display device 10 may include the following steps: preparing a second stacked body 15 including a display panel 100 and a polymer base layer 400 disposed on the display panel 100 (S100); irradiating one surface of the polymer base layer 400 with a first laser to form a hole portion HP in which a portion of the one surface is recessed ( Fig.16 and irradiating the hole portion HP with a second laser different from the first laser to form a first stacked body 11 in which the polymer base layer 400 and the display panel 100 are at least partially cut (S300).

[0125] In an embodiment, the display device 10 may include a first stack 11, and the first stack 11 may be prepared by irradiating a second stack 15 having a larger plane area than the first stack 11 with a laser to cut a portion of the second stack 15. In such an embodiment, a process of preparing the first stack 11 by irradiating the second stack 15 with a laser may be performed by irradiating the second stack 15 with a first laser and a second laser having different energy densities from each other. A first cutting line LCL1 may be formed by irradiating the second stack 15 with the first laser, and a second cutting line LCL2 may be formed by irradiating the second stack 15 with the second laser, so that a portion of the second stack 15 may be removed, thereby forming the first stack 11.

[0126] Figures 15 to 18 is a schematic diagram illustrating a process of manufacturing a display device according to an embodiment.

[0127] First, refer to Fig.15 and Fig.16 , prepare a second laminate 15 including a polymer base layer 400 and a display panel 100 (S100), and apply a first laser to one surface of the polymer base layer 400 (i.e., an upper surface of the polymer base layer 400 in the same direction as the rear surface of the display panel 100) (S200). Although not shown, similar to the above-mentioned first laminate 11, the second laminate 15 may include a polarization member 200, a cover window 300, a cover window protective layer 310, and an adhesive member BP disposed therebetween. However, the invention is not limited thereto.

[0128] In an embodiment, the first laser may be applied along a shape substantially the same as the shape of the region of the first stack 11. In such an embodiment, the first laser may be applied in such a manner that at least one linear portion and at least one curved portion are formed in the first stack 11 of the display device 10. The first cutting line LCL1 may be formed along a line irradiated with the first laser, and the second cutting line LCL2 may be formed along a line irradiated with the second laser. An area of ​​the second stack 15 positioned outside the second cutting line LCL2 may be a removal area RVA to be cut off by the second cutting line LCL2.

[0129] According to an embodiment, in the process of irradiating with the first laser, a hole portion HP may be formed in a portion of one surface of the polymer base layer 400. Fig.16As shown in , a portion of the polymer base layer 400 irradiated with the first laser may be removed to form a hole portion HP. The hole portion HP may include a sub-cut surface LCA' substantially parallel to the upper surface of the polymer base layer 400 and at least one first cutting line LCL1 perpendicular to the upper surface of the polymer base layer 400. In such an embodiment, a lower surface of the hole portion HP formed by irradiating with the first laser may be the sub-cut surface LCA', and a side surface of the hole portion HP may be the first cutting line LCL1.

[0130] The height DL1 of the hole portion HP is substantially equal to the height DL1 of the first cutting line LCL1 described above. However, the width WL' of the hole portion HP may be greater than Fig.10 The width WL of the cutting surface LCA (at Fig.10 The sub-cut surface LCA′ may be formed by irradiating the first laser and then cutting a portion of the sub-cut surface LCA′ of the hole portion HP by irradiating the second laser. Fig.10 In such an embodiment, as Fig.16 The sub-cut surface LCA′ of the lower surface of the hole portion HP may have a width greater than a width of the cut surface LCA of the first stack body 11 .

[0131] The structure of the hole portion HP may be formed by applying a first laser having a predetermined width PW while moving the first laser in one direction by an offset pitch OSW. In such an embodiment, in the first laser irradiation process, the first laser is also applied to the region spaced apart by the offset pitch OSW to form the hole portion HP, and the width WL' of the lower surface of the hole portion HP may be greater than the width PW of the first laser. In one embodiment, for example, the width WL' of the lower surface of the hole portion HP may be in the range of about 2 times to about 2.5 times the width PW of the first laser. In such an embodiment, the width WL' of the lower surface of the hole portion HP is formed to be greater than the width PW of the first laser, so that the formation of foreign matter caused by the second laser applied in a subsequent process may be minimized.

[0132] In an embodiment, the first laser may be applied in such a manner that the lower surface of the hole portion HP forms a surface parallel to the upper surface of the polymer base layer 400. When the first laser is applied while moving the first laser at the offset spacing OSW, the lower surface of the hole portion HP may form a flat surface by irradiating with a predetermined energy for a predetermined time. However, the invention is not limited thereto.

[0133] In an embodiment, the first laser may have an energy density lower than that of a second laser to be described later. In an embodiment where the polymer base layer 400 as a colored polymer base layer includes polyimide, foreign matter may be formed on the polymer base layer 400 by irradiation with laser, or the display panel 100 may be contaminated by irradiation with laser. In an embodiment, a method for manufacturing the display device 10 may include a process of applying a first laser and a second laser having energy densities different from each other to effectively prevent the above phenomenon. In one embodiment, for example, the energy density of the first laser may have a range of about 20% to about 30% of the energy density of the second laser. However, the invention is not limited thereto.

[0134] In an embodiment, as described above, the height DL2 of the second cutting line LCL2 may be smaller than the height DL1 of the first cutting line LCL1, and the second laser having a relatively large energy density may cut only a portion of the polymer base layer 400. Therefore, in such an embodiment, the area of ​​the polymer base layer 400 on which foreign matter is formed by the second laser may be minimized.

[0135] Next, refer to Fig.17 and Fig.18 , a second laser irradiation step ( S300 ) is performed in which the hole portion HP is irradiated with a second laser to form the first stacked body 11 by cutting a portion of the polymer base layer 400 and a portion of the display panel 100 .

[0136] The second laser may be applied while being spaced apart from the line irradiated with the first laser. The second laser may be applied to the hole portion HP to form a second cutting line LCL2 spaced apart from the first cutting line LCL1. The second laser may be applied to a portion of the lower surface LCA' of the hole portion HP, and the second laser may be applied to the polarization member 200, the cover window 300, and the cover window protective layer 310 in addition to the polymer base layer 400 and the display panel 100. As the second laser is applied, the removal area RVA of the second stack 15 is cut and removed, and the second cutting line LCL2 may extend from the polymer base layer 400 to the cover window 300 or the cover window protective layer 310.

[0137] In the embodiment, as described above, the second laser has an energy density greater than that of the first laser. Since the height DL1 of the hole portion HP formed on the upper surface of the polymer base layer 400 is greater than the height DL2 of the region cut by the second laser (i.e., the second cutting line LCL2), even when the polymer base layer 400 includes colored polyimide, the region where foreign matter is formed by the second laser can be minimized.

[0138] In an embodiment, the second laser may have a laser width PW that is the same as the laser width PW of the first laser. In the first laser irradiation process (S200), since the first laser is applied at an offset pitch OSW, the width WL' of the sub-cut surface LCA' of the hole portion HP is wider than the width PW of the first laser. In the second laser irradiation process (S300), when the second laser is applied to the sub-cut surface LCA', the second laser may be applied at a point spaced apart from the first cutting line LCL1, and contamination of the display panel 100 may be effectively prevented even when the second laser having a large energy density is applied. When a portion of the sub-cut surface LCA' is cut by the second laser, a cutting surface LCA of the first stack 11 may be formed.

[0139] The first stacked body 11 in which the removal area RVA of the second stacked body 15 is removed may be formed by performing the second laser irradiation process (S300). In the embodiment, as described above, the first stacked body 11 may include the first cutting line LCL1, the second cutting line LCL2, and the cutting surface LCA. According to an embodiment of the method of manufacturing the display device 10, the display device 10 including the first cutting line LCL1 and the second cutting line LCL2 spaced apart from each other on the outer surface may be manufactured by applying the first laser and the second laser having different energy densities from each other. The display device 10 manufactured by the above method is different from the above referenced method. Figures 1 to 13 The display devices 10 described are substantially the same and any repeated detailed description thereof will be omitted.

[0140] Hereinafter, alternative embodiments of the display device 10 will be described in detail.

[0141] Fig.19 is a plan view showing a first stacked body of a display device according to an alternative embodiment.

[0142] Reference Fig.19 , the display device 10 may include a first stacked body 11_1 including a polymer matrix layer 400_1, and the polymer matrix layer 400_1 includes or is made of a transparent polymer material. In addition to the first stacked body 11_1 including the polymer matrix layer 400_1, Fig.19 The first stacked body 11_1 is similar to the above-mentioned Fig. 9 The first stacked body 11_1 described above is substantially the same. In such an embodiment, the first stacked body 11_1 may include a first circuit board 710_1 connected to the bonding area BA_1 and a second circuit board 720_1 connected to the first circuit board 710_1. In the following, for convenience of description, the description of Fig.19 The first stacked body 11_1 is similar to the above reference Fig. 9 Any repeated description of the same or identical elements of the described first stack 11 is detailed.

[0143] In the embodiment of the first stacked body 11_1, as Fig.19 As shown in , the polymer matrix layer 400_1 may include a transparent polymer material such as PET. In such an embodiment, a partially carbonized area of ​​the polymer matrix layer 400_1 may not be formed on the cutting surface LCA_1 formed in the first laser irradiation process (S200) of forming the first cutting line LCL1_1. Therefore, the first stack 11_1 includes the first cutting line LCL1_1, the second cutting line LCL2_1, and the cutting surface LCA_1 disposed between the first cutting line LCL1_1 and the second cutting line LCL2_1, and there may be no carbonized material, foreign matter, dirt, etc. formed on the cutting surface LCA_1.

[0144] In an embodiment, the first cutting line LCL1_1 of the first stack 11_1 may not be formed perpendicular to the upper surface of the polymer base layer 400_1. In an embodiment, a portion of the first cutting line LCL1_1 may have a curved shape or an inclined shape. Optionally, the first cutting line LCL1_1 includes at least one sub-cutting line and may further include a cutting surface disposed between the sub-cutting lines.

[0145] Figure 20 to Figure 23 is a partial cross-sectional view showing a first stacked body of a display device according to another alternative embodiment.

[0146] First, refer to Fig. 20 In the embodiment of the first stacked body 11_2 of the display device 10, at least a portion of the first cutting line LCL1_2 may be recessed inward. In addition to the first cutting line LCL1_2 being partially recessed to form a plurality of sub-cutting lines LCL1a_2 and LCL1b_2, Fig. 20 The first stacked body 11_2 is similar to the above-mentioned Fig.10 The first stacked body 11 described above is the same as the first stacked body 11 described above. Fig. 20 The first stacked body 11_2 is similar to the above reference Fig.10 Any repeated description of the same or identical elements of the described first stack 11 is detailed.

[0147] The first cutting line LCL1_2 may include a first sub-cutting line LCL1a_2 and a second sub-cutting line LCL1b_2. The cutting surface LCA_2 may include a first cutting surface LCA1_2 formed between the second cutting line LCL2_2 and the first sub-cutting line LCL1a_2 and a second cutting surface LCA2_2 formed between the first sub-cutting line LCL1a_2 and the second sub-cutting line LCL1b_2.

[0148] In the first laser irradiation process (S200) of forming the first cutting line LCL1_2, the upper surface of the polymer base layer 400_2 may have a hole portion HP ( Fig.16 ), the hole portion HP has a width PW ( Fig.16 The first laser can be used to generate a predetermined offset spacing OSW ( Fig.16 ) illuminates the hole portion HP, so the width WL' ( Fig.16 ) may be wider than the width PW of the first laser. Here, the first laser may be applied in such a manner that the hole portion HP has different depths before and after the first laser moves at a predetermined offset pitch OSW. In one embodiment, for example, the first laser may be applied at a height DL1a_2 of the first cutting line LCL1_2 during initial irradiation, and may be applied at a height DL1b_2 of the second sub-cutting line LCL1b_2 after the first laser moves at a predetermined offset pitch OSW. In such an embodiment, when the first laser is applied to areas spaced apart by an offset pitch OSW, the first laser may be applied at different times or energies.

[0149] Therefore, if Fig. 20 As shown in , in the first stack 11_2, a portion of the first cutting line LCL1_2 is recessed inwardly, and the first stack 11_2 may include a first sub-cutting line LCL1a_2 and a second sub-cutting line LCL1b_2. In such an embodiment, a height DL1a_2 of the first cutting line LCL1_2 of the polymer base layer 400_2 may be greater than a height DL2_2 of the second cutting line LCL2_2 of the polymer base layer 400_2. In an embodiment, when forming the first sub-cutting line LCL1a_2 and the second sub-cutting line LCL1b_2, the first laser may be applied in such a manner that each of the first sub-cutting line LCL1a_2 and the second sub-cutting line LCL1b_2 has a surface parallel to the upper surface of the polymer base layer 400_2.

[0150] In an embodiment, when the first laser is applied in the first laser irradiation process (S200) while being moved by the offset spacing OSW, the first cutting line LCL1_2 may not be formed to be perpendicular to the upper surface of the polymer base layer 400_2. In an alternative embodiment, the first cutting line LCL1_2 may be formed in such a manner that at least a portion thereof is bent, or may have a shape inclined from the cutting surface LCA_2.

[0151] Reference Fig.21In an optional embodiment of the first stacked body 11_3 of the display device 10, the first stacked body 11_3 may have a shape in which at least a portion of the first cutting line LCL1_3 is bent, and the cutting surface LCA_3 includes a first cutting surface LCA1_3 disposed between the first cutting line LCL1_3 and the second cutting line LCL2_3 and a second cutting surface LCA2_3 overlapping the first cutting line LCL1_3. In addition to the first cutting line LCL1_3 being partially bent and the first stacked body 11_3 also including the second cutting surface LCA2_3 overlapping the first cutting line LCL1_3, Fig.21 The first stacked body 11_3 is similar to the above Fig.10 The first stacked body 11 described above is substantially the same. In the following, for the convenience of description, the description of Fig.21 The first stacked body 11_3 is similar to the above Fig.10 Any repeated description of the same or identical elements of the described first stack 11 is detailed.

[0152] In the embodiment of the first stack 11_3, as Fig.21 As shown in FIG. 1 , the first cutting line LCL1_3 may have a bent shape. In the first laser irradiation process ( S200 ) of forming the first cutting line LCL1_3 , the first cutting line LCL1_3 may have a bent shape. Fig.16 As shown in FIG. 1 ) vibrates and applies a first laser. Fig. 20 As described above, when the first laser is applied at the offset spacing OSW, the first laser may be applied at different times or energies. Fig.21 In such an embodiment of the first stacked body 11_3, as the first laser is continuously applied at the offset pitch OSW, the first cutting lines LCL1_3 may have a curved shape.

[0153] The cutting surface LCA_3 may include a first cutting surface LCA1_3 and a second cutting surface LCA2_3, and the second cutting surface LCA2_3 may overlap with the first cutting line LCL1_3. The first laser may be applied while moving the first laser at an offset spacing OSW, and the second cutting surface LCA2_3 in which a portion of the polymer base layer 400_3 is carbonized may also be formed on the first cutting line LCL1_3. In such an embodiment, when forming the second cutting surface LCA2_3, the first laser may be applied while continuously moving the first laser in a manner that the second cutting surface LCA2_3 is not parallel to the upper surface of the polymer base layer 400_3. However, the invention is not limited thereto.

[0154] Reference Fig. 22In another optional embodiment of the first stacked body 11_4 of the display device 10, the first stacked body 11_4 may have a shape in which the first cutting line LCL1_4 is inclined toward the upper surface of the polymer base layer 400_4 based on the cutting surface LCA_4 disposed between the first cutting line LCL1_4 and the second cutting line LCL2_4. In addition to the first cutting line LCL1_4 having an inclined shape, Fig. 22 The first stacked body 11_4 is similar to the above reference Fig.10 The first stacked body 11 described above is the same as the first stacked body 11 described above. Fig. 22 The first stacked body 11_4 and Fig.10 Any repeated detailed description of the same or identical elements of the first stack 11 is omitted.

[0155] In the embodiment of the first stack 11_4, as Fig. 22 As shown in FIG. , when the first laser is applied and the first laser is moved by an offset distance OSW ( Fig.16 ), the first cutting line LCL1_4 may have an inclined shape as time or energy linearly decreases. Therefore, the first cutting line LCL1_4 may be inclined from one end contacting the cutting surface LCA_4 toward the other end contacting the upper surface of the polymer base layer 400_4.

[0156] Reference Fig.23 In another optional embodiment of the first stacked body 11_5 of the display device 10, the first cutting line LCL1_5 may be formed so that one end thereof contacts one end of the second cutting line LCL2_5, and the cutting surface LCA_5 may be disposed to overlap with the first cutting line LCL1_5. In addition to the cutting surface LCA_5 being disposed to overlap with the first cutting line LCL1_5, Fig.23 The first stacked body 11_5 is similar to the above reference Fig. 22 In the following, for the convenience of description, the description of the first stacked body 11_4 will be omitted or simplified. Fig.23 The first stacked body 11_5 and Fig. 22 Any repeated detailed description of the same or identical elements of the first stack 11_4 is omitted.

[0157] Fig.23 The first stacked body 11_5 may be formed in such a manner that the first cutting line LCL1_5 and the second cutting line LCL2_5 contact each other. Fig.16When the first laser is applied (as shown in FIG. 1 ), the structure of the first stack 11_5 can be formed by continuously moving the first laser without forming a cutting surface LCA_5 parallel to the upper surface of the polymer base layer 400_5. In such an embodiment, a partially carbonized area of ​​the polymer base layer 400_5 can be formed to overlap with the first cutting line LCL1_5. However, the invention is not limited thereto.

[0158] In an embodiment of the method for manufacturing a display device according to the invention, a predetermined area is cut by laser irradiation, for example, a first laser and a second laser having different energy densities are applied to manufacture a display device. In such an embodiment, a first cutting line is formed in an area to which the first laser is applied, and a second cutting line is formed in an area to which the second laser is applied, so that the area of ​​the polymer base layer irradiated with the second laser having a high energy density can be sufficiently minimized.

[0159] In an embodiment of the invention, the display device includes a first cutting line or a first outer side surface and a second cutting line or a second outer side surface protruding outward from the first cutting line. In such an embodiment, the cutting surface is arranged between the first cutting line and the second cutting line, and there may be a partially carbonized area of ​​the polymer matrix layer in the cutting surface. In the display device manufactured by the embodiment of such a manufacturing method, the carbonized area that may be formed in the polymer matrix layer can be minimized, so that the defect rate caused by foreign matter during the process of manufacturing the display device can be fully minimized and the manufacturing time can be shortened.

[0160] The 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 invention to those skilled in the art.

[0161] While the invention has been particularly shown and described with reference to exemplary embodiments thereof, it will be understood by those skilled in the art that various changes in form and details may be made without departing from the spirit or scope of the invention as defined by the claims.

Claims

1. A display device, comprising: a polymer matrix layer comprising a first surface and a second surface opposite to the first surface; as well as The display panel includes a third surface facing the second surface and a fourth surface facing away from the third surface. The polymer matrix layer includes: a first outer surface adjacent to the first surface; a second outer surface adjacent to the second surface and spaced outwardly from the first outer surface and being the outermost surface of the polymer matrix layer; and a cutting surface disposed between the first outer surface and the second outer surface. wherein a third outer surface as the outer surface of the display panel is aligned with a surface extending from the second outer surface, The first outer surface is formed by irradiating a first laser, the second outer surface and the third outer surface are formed by irradiating a second laser, and the first laser has an energy density lower than that of the second laser.

2. The display device according to claim 1, wherein: The height of the second outer side surface is in the range of 20% to 40% of the thickness of the polymer matrix layer, and The width of the cutting surface is in the range of 40% to 75% of the height of the second outer side surface.

3. The display device according to claim 2, wherein: The height of the second outer side surface is in the range of 40 μm to 50 μm, and The width of the cut surface is in the range of 20 μm to 30 μm.

4. The display device according to claim 1, wherein: The polymer matrix layer includes polyimide.

5. The display device according to claim 1, wherein: The display device includes a linear portion and a curved portion, and At least one of the linear portions includes: a first sub-linear portion; a second sub-linear portion spaced apart from the first sub-linear portion in one direction; and a sub-bending portion connecting the first sub-linear portion and the second sub-linear portion.

6. A method for manufacturing a display device, the method comprising the following steps: preparing a first stacked body, the first stacked body comprising a display panel and a polymer base layer disposed on the display panel; irradiating the outer surface of the polymer base layer with a first laser to form a hole portion in which a portion of the outer surface is recessed; and irradiating the hole portion with a second laser different from the first laser to form a second stacked body by cutting a portion of the polymer base layer and a portion of the display panel, in, In the second stack, an outer side surface of the remaining portion of the display panel is aligned with an outermost side surface of the remaining portion of the polymer base layer, The first laser has an energy density lower than that of the second laser.

7. The method according to claim 6, wherein: The hole portion includes a first cutting line perpendicular to the one surface of the polymer base layer and a first cutting surface parallel to the one surface of the polymer base layer, and The second laser is applied to the first cutting surface.

8. The method according to claim 6, wherein: The energy density of the first laser light is in a range of 20% to 30% of the energy density of the second laser light.

9. The method according to claim 7, wherein: The width of the first cutting surface is in a range of 2 to 2.5 times the width of the first laser.

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