Apparatus for manufacturing curved panel of display device and protective film for display device

Abstract

The present disclosure relates to an apparatus for manufacturing a curved panel of a display device and a protective film for the display device. An apparatus for manufacturing a curved panel of a display device includes: a lower mold having a first member for placing a target panel on the first member; an upper mold arranged adjacent to the lower mold and including a second member, the second member including a first surface for pressing a portion of the target panel and a second surface having a first slope relative to the first surface; and side molds arranged at opposite sides of the lower mold, each side mold having a third member, the third member having a third surface complementary to the second surface of the second member. The first slope is less than about 90 degrees.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of Korean Patent Application No. 10-2019-0047751, filed on Apr. 24, 2019, which is hereby incorporated by reference for all purposes as if fully set forth herein. Technical Field

[0003] Exemplary implementations of the present disclosure generally relate to display devices, and more particularly, to a protective film for a display device, a method for manufacturing a display device having the protective film, and a manufacturing device for a curved panel such as a protective film, which can prevent the protective film from being separated from the display device and improve its reliability. Background Art

[0004] In recent years, various electronic devices to which display devices such as liquid crystal displays (LCDs) or organic light emitting diodes (OLEDs) are applied, such as mobile phones, navigation units, digital cameras, e-books, portable game units, or various terminals, are being used with increasing frequency.

[0005] Furthermore, electronic devices having displays with curved surfaces have been developed and are also being used with increasing frequency.

[0006] The above information disclosed in this Background section is only for understanding the background of the inventive concept and therefore it may contain information that does not constitute prior art. Summary of the invention

[0007] The applicant has recognized that, with the increasing development of electronic devices having displays with curved surfaces, there is an increasing need to ensure durability and reliability of each component of a display device having a curved surface, such as a curved panel (eg, a protective film).

[0008] A curved panel of a display device constructed according to the principles and exemplary implementations of the present disclosure, such as a protective film, can be attached to a display panel without separation. For example, according to one of the multiple exemplary embodiments, the protective film is manufactured by a device that bends the outer portion of the protective film before coupling the protective film to the display panel to reduce the risk of separation later.

[0009] A method of manufacturing a display device according to the principles and exemplary implementations of the present disclosure can prevent a protective film disposed under a display panel from being separated therefrom and improve the reliability of the display device.

[0010] Additional features of the inventive concepts will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the inventive concepts.

[0011] According to one aspect of the present disclosure, an apparatus for manufacturing a curved panel of a display device includes: a lower mold having a first member for placing a target panel on the first member; an upper mold disposed adjacent to the lower mold and including a second member, the second member having a first surface and a second surface, the first surface being used to press a portion of the target panel, and the second surface having a first slope relative to the first surface; and side molds disposed at opposite sides of the lower mold, each of the side molds having a third member having a third surface complementary to the second surface of the second member. The first slope is less than about 90 degrees.

[0012] The first member may include a stand having a receiving portion substantially parallel to a plane defined by a first direction and a second direction intersecting the first direction. The side mold may include: a pair of first side molds spaced apart from each other in the first direction and disposed at opposite sides of the lower mold to press the target panel in the first direction; and a pair of second side molds spaced apart from each other in the second direction and disposed at both sides of the lower mold to press the target panel in the second direction.

[0013] The upper mold may be spaced apart from the lower mold in a third direction intersecting the first direction and the second direction. The upper mold may be configured to press the target panel in the third direction.

[0014] The second member may include an upper pressing member having a cross-sectional shape having an area in a plan view that increases as a distance from the lower mold in the third direction decreases.

[0015] The second member may include a first pressing portion extending in the first direction, a second pressing portion extending in the second direction, and a third pressing portion disposed between the first pressing portion and the second pressing portion and having an arc shape.

[0016] The lower mold may further include an outer curvature forming portion configured to overlap the third pressing portion in a plane defined by the first direction and the second direction. The outer curvature forming portion may have a shape complementary to the arc shape of the third pressing portion.

[0017] The third member may include: an upper surface supporting the outer portion of the target panel; and a side surface for pressing the target panel and having a second slope relative to the upper surface. The second slope may be less than about 90 degrees.

[0018] The first slope and the second slope may be substantially the same.

[0019] The upper mold may further include a first portion to move the second member up and down, and the side mold may further include a second portion to move the side pressing member left and right.

[0020] The lower mold may further include one or more biasing members disposed below the first member, the one or more biasing members being compressed when the second member is pressed against the target panel.

[0021] The upper mold may further include an upper plate supporting the second member, and an upper heating heater connected to the upper plate and applying heat to the upper plate.

[0022] The side mold may further include a side plate supporting the third member, and a side heating heater connected to the side plate and applying heat to the side plate.

[0023] According to another aspect of the present disclosure, an apparatus for manufacturing a curved panel includes: a first mold, including a first member, the first member having a first surface substantially parallel to a plane defined by a first direction and a second direction intersecting the first direction; a second mold, spaced apart from the first mold in a third direction intersecting both the first and second directions, and including a second member, the second member having a second surface and a third surface, the second surface being substantially parallel to the first surface, and the third surface having a slope less than about 90 degrees relative to the second surface; and a third mold, spaced apart from the first mold in the first direction and the second direction, and including a third member, the third member having a fourth surface complementary to the third surface.

[0024] According to another aspect of the present disclosure, a method for manufacturing a display device includes the steps of: coupling a display panel to a first portion of a window member; and, coupling a protective film to a lower portion of the display panel. The step of coupling the protective film includes the steps of: bending two edges of the protective film at a bending angle of about 90 degrees or more; arranging the bent protective film at a lower portion of the display panel; and coupling the protective film to the display panel.

[0025] The step of bending the two edges of the protective film may include: placing the protective film on a support; pressing the upper portion of the protective film to bend the two edges to a first angle; and pressing the side portion bent to the first angle to bend the two edges to a second angle. The second angle is smaller than the first angle.

[0026] An elastic member may be disposed below the support. The step of pressing the upper portion of the protective film may include compressing the elastic member.

[0027] The step of pressing the upper portion of the protective film may further include the step of indirectly applying heat to the upper portion of the protective film.

[0028] The step of pressing the side of the protective film may further include the step of applying heat to the side of the protective film.

[0029] The step of pressing the side of the protective film may be performed by horizontally moving the one or more side pressing members or by rotating the one or more side pressing members.

[0030] The step of bending both edges of the protective film may further include the steps of: providing a release film under the protective film before placing the protective film on the support; and removing the release film before coupling the protective film to the display panel.

[0031] The method may further include the step of bending the window member and the outer portion of the display panel at a third angle greater than the second angle at which the protection film is bent, before the step of coupling the protection film to the lower portion of the display panel.

[0032] According to another aspect of the present disclosure, a protective film for a display device includes: a substantially flat portion disposed substantially parallel to a plane defined by a first direction and a second direction intersecting the first direction; and a curved portion disposed at one side of the substantially flat portion. The curved portion includes a first curved portion extending in the first direction and a second curved portion extending in the second direction. An angle between the first curved portion and the substantially flat portion and an angle between the second curved portion and the substantially flat portion are both less than about 90 degrees.

[0033] The curved portion may further include a third curved portion disposed between the first curved portion and the second curved portion.

[0034] The third bent portion may have an arc shape.

[0035] A plurality of slits may be provided between the first curved portion and the third curved portion and between the second curved portion and the third curved portion.

[0036] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the disclosure as claimed. BRIEF DESCRIPTION OF THE DRAWINGS

[0037] The accompanying drawings, which are included to provide a further understanding of the disclosure and are incorporated in and constitute a part of this specification, illustrate exemplary embodiments of the disclosure and together with the description serve to explain the inventive concept.

[0038] Figure 1A is a cross-sectional view of an exemplary embodiment of a curved panel manufacturing apparatus constructed according to the principles of the present disclosure, taken in a first direction.

[0039] Figure 1B is intercepted in a second direction orthogonal to the first direction Figure 1A Cross-sectional view of a curved panel manufacturing facility.

[0040] Figure 2A yes Figure 1A A combined perspective view of an exemplary embodiment of an upper mold of a curved panel manufacturing apparatus.

[0041] Figure 2B yes Figure 1A An exploded perspective view of an exemplary embodiment of an upper mold of a curved panel manufacturing apparatus.

[0042] Figure 2C yes Figure 1A A front view of an exemplary embodiment of an upper mold of a curved panel manufacturing apparatus.

[0043] Figure 2D yes Figure 1A A side view of an exemplary embodiment of an upper mold of a curved panel manufacturing apparatus.

[0044] Figure 3A yes Figure 1A A combined perspective view of an exemplary embodiment of a lower mold of a curved panel manufacturing apparatus.

[0045] Figure 3B yes Figure 1A An exploded perspective view of an exemplary embodiment of a lower mold of a curved panel manufacturing apparatus.

[0046] Figure 3C yes Figure 1A A top view of an exemplary embodiment of a lower mold of a curved panel manufacturing apparatus.

[0047] Figure 4A yes Figure 1A A perspective view of an exemplary embodiment of a side mold of a curved panel manufacturing apparatus.

[0048] Figure 4B yes Figure 1A A front view of an exemplary embodiment of a side mold of a curved panel manufacturing apparatus.

[0049] Figure 4C yes Figure 1A A side view of an exemplary embodiment of a side mold of a curved panel manufacturing apparatus.

[0050] Figure 4D yes Figure 1A A front view of an exemplary embodiment of a side mold of a curved panel manufacturing apparatus.

[0051] Figure 5 yes Figure 1A A top view of an exemplary embodiment of some components of a curved panel manufacturing apparatus.

[0052] Fig. 6Ais a cross-sectional view of another exemplary embodiment of a curved panel manufacturing apparatus constructed according to the principles of the present disclosure in a first orientation.

[0053] Figure 6B is intercepted in a second direction orthogonal to the first direction Fig. 6A Cross-sectional view of a curved panel manufacturing facility.

[0054] Fig. 7A is a perspective view of an exemplary embodiment of a curved panel constructed according to the principles of the present disclosure in a substantially flat planar state.

[0055] Figure 7B It is in a bent state Fig. 7A Perspective view of the curved panel.

[0056] Figure 7C yes Figure 7B Front view of the curved panel.

[0057] Fig.7D yes Figure 7B Side view of the curved panel.

[0058] Fig. 7E is a perspective view of another exemplary embodiment of a curved panel constructed according to the principles of the present disclosure in a substantially flat planar state.

[0059] Fig. 8A , Figure 8B , Figure 8C , Fig.8D , Fig. 8E , Figure 8F , Figure 8G , Figure 8H and Fig.8I are cross-sectional views sequentially illustrating an exemplary method of manufacturing a display device according to the principles of the present disclosure.

[0060] Fig.9A , Fig. 9B and Fig. 9C is a cross-sectional view sequentially showing some steps of another exemplary method of manufacturing a display device according to the principles of the present disclosure.

[0061] Fig.10 is a cross-sectional view showing steps of yet another exemplary method of manufacturing a display device according to the principles of the present disclosure. DETAILED DESCRIPTION

[0062] In the following description, for the purpose of illustration, many specific details are set forth in order to provide a thorough understanding of various exemplary embodiments or implementations of the present disclosure. "Embodiment" and "implementation / implementation method" as used herein are interchangeable terms that are non-limiting examples of devices or methods using one or more inventive concepts disclosed herein. However, it is apparent that various exemplary embodiments may be implemented without these specific details or using one or more equivalent arrangements. In other examples, known structures and devices are shown in the form of block diagrams in order to avoid unnecessary obscurity of various exemplary embodiments. In addition, various exemplary embodiments may be different, but need not be exclusive. For example, without departing from the inventive concept, the specific shape, configuration and features of the exemplary embodiment may be used or implemented in another exemplary embodiment.

[0063] Unless otherwise specified, the exemplary embodiments shown are understood to be exemplary features that provide different details of some ways in which the inventive concept can be implemented in practice. Therefore, unless otherwise specified, the features, components, modules, layers, films, panels, regions and / or aspects of the various embodiments (hereinafter individually or collectively referred to as "elements") can be further combined, separated, interchanged and / or rearranged without departing from the inventive concept.

[0064] It is generally provided that the boundaries between adjacent elements are clarified using cross hatching and / or shading in the drawings. Thus, the presence or absence of cross hatching or shading does not convey or indicate any preference or requirement for a particular material, material property, size, ratio, commonality between the elements shown, and / or any other features, attributes, characteristics, etc. of the elements, unless otherwise specified. In addition, in the drawings, the size and relative size of the elements may be magnified for the purpose of clarity and / or description. When the exemplary embodiment can be implemented differently, a specific processing sequence can be performed differently from the described sequence. For example, two consecutively described processes can be performed substantially simultaneously or in an order opposite to the described sequence. In addition, the same reference numerals represent the same elements.

[0065] When an element such as a layer is referred to as being "on" another element or layer, "connected to" or "coupled to" another element or layer, it may be directly on, directly connected to or directly coupled to other elements or layers, or there may be intermediate elements or layers. However, when an element or layer is referred to as being "directly on" another element or layer, "directly connected to" or "directly coupled to" another element or layer, there are no intermediate elements or layers. For this reason, the term "connection" may refer to a physical connection, an electrical connection and / or a fluid connection with or without intermediate elements. In addition, the D1 axis, the D2 axis and the D3 axis are not limited to the three axes of a rectangular coordinate system such as the x, y, and z axes, and may be interpreted in a broader sense. For example, the D1 axis, the D2 axis and the D3 axis may be perpendicular to each other, or may represent different directions that are not perpendicular to each other. For the purpose of this disclosure, "at least one of X, Y, Z" and "at least one selected from the group consisting of X, Y, Z" may be interpreted as only X, only Y, only Z, or any combination of two or more of X, Y, Z, such as, for example, XYZ, XYY, YZ, and ZZ. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0066] Although the terms "first", "second", etc. may be used herein to describe various types of elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another element. Therefore, without departing from the teachings of the present disclosure, the first element discussed below may be referred to as the second element.

[0067] Spatially relative terms such as "below," "beneath," "under," "lower," "above," "upper," "above," "higher," "side" (e.g., as in "sidewall"), etc. may be used herein for descriptive purposes, and thus, to describe the relationship of one element to another element shown in the drawings. Spatially relative terms are intended to encompass different orientations of the device in use, operation, and / or manufacture in addition to the orientations depicted in the drawings. For example, if the device in the figure is turned over, an element described as being "below" or "beneath" other elements or features would subsequently be oriented "above" the other elements or features. Thus, the exemplary term "below" may encompass both above and below orientations. Further, the device may be oriented in other ways (e.g., rotated 90 degrees or in other orientations), and thus, the spatially relative descriptions used herein are interpreted accordingly.

[0068] The terms used here are for the purpose of describing specific embodiments and are not restrictive. As used herein, the singular forms "a", "an", "the" are also intended to include plural forms unless the context clearly states otherwise. In addition, the terms "comprises", "comprising", "includes", and / or "including" when used in this specification represent the presence of the features, integers, steps, operations, elements, components and / or groups thereof, but do not exclude the presence or increase of one or more other features, integers, steps, operations, elements, components and / or groups thereof. It should also be noted that as used herein, the terms "substantially", "approximately" and other similar terms are used as approximate terms rather than terms of degree, and thus, are used to explain the inherent deviations of measured values, calculated values ​​and / or provided values ​​that one of ordinary technicians in the art will recognize.

[0069] Various exemplary embodiments are described herein with reference to cross-sectional illustrations and / or exploded illustrations as schematic illustrations of idealized exemplary embodiments and / or intermediate structures. Thus, variations in the shapes of the illustrations due to, for example, manufacturing techniques and / or margins can be expected. Therefore, the exemplary embodiments disclosed herein should not be construed as limited to the specific illustrated shapes of the regions, but rather include shape deviations due to, for example, manufacturing. In this manner, the regions shown in the drawings may be schematic in nature and the shapes of these regions may not reflect the actual shapes of the regions of the device, and thus, are not necessarily restrictive.

[0070] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure is a part. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and should not be interpreted in an idealized or overly formal sense unless explicitly so defined herein.

[0071] Figure 1A is a cross-sectional view of an exemplary embodiment of a curved panel manufacturing apparatus 10 constructed according to the principles of the present invention, taken in a first direction DR1. Figure 1B It is intercepted in the second direction DR2 which is orthogonal to the first direction DR1. Figure 1A sectional view of a curved panel manufacturing apparatus 10 . Figure 1A A cross section substantially parallel to a plane defined by the first direction DR1 and the third direction DR3 in the curved panel manufacturing apparatus 10 is shown. Figure 1BA cross section substantially parallel to a plane defined by the second direction DR2 and the third direction DR3 in the curved panel manufacturing apparatus 10 is shown, the cross section being orthogonal to the first direction DR1.

[0072] In reference Figure 1A and Figure 1B In describing the curved panel manufacturing apparatus 10, the vertical direction of the curved panel manufacturing apparatus 10 is indicated by the third direction DR3. However, the directions indicated by the first direction DR1, the second direction DR2, and the third direction DR3 are relative to each other, and thus the directions indicated by the first direction DR1, the second direction DR2, and the third direction DR3 may be changed to other directions. In the following description, the expression "when viewed in a plan view" refers to the case of viewing in the third direction DR3. In addition, the term "thickness direction" refers to the third direction DR3.

[0073] refer to Figure 1A and Figure 1B The curved panel manufacturing apparatus 10 includes an upper mold 100 , a lower mold 200 , and a side mold 300 .

[0074] The upper mold 100 includes an upper pressing member 101, an upper plate 102, and a first moving unit (eg, a part of a motor) 103. The upper mold 100 is disposed adjacent to the lower mold 200. In the present embodiment, the upper mold 100 is disposed above the lower mold 200.

[0075] The upper pressing member 101 is connected to the upper plate 102 to perform a function of pressing a target panel placed on the curved panel manufacturing apparatus 10 to form the target panel into a desired shape. In an exemplary embodiment, the target panel is a Fig. 8A The target panel may be any panel, film or other component of a display device having a curved, bent or arcuate shape. The upper pressing member 101 is configured to correspond to the upper portion of the stand 201 of the lower mold 200. The upper pressing member 101 may include various materials without limitation, as long as the material is suitable for thermoforming the target panel using heat transferred from the upper plate 102. For example, the upper pressing member 101 may include a porous material such as silicon carbide. As another example, the upper pressing member 101 may include a metal material.

[0076] The upper plate 102 is connected to the upper pressing member 101 and transfers heat from a heater (described later) to the upper pressing member 101. In addition, the upper plate 102 performs a function of fixing the positional relationship of corresponding components (such as the upper pressing member 101) included in the upper mold 100. The upper plate 102 includes a metal material having high thermal conductivity to transfer heat applied thereto to the upper pressing member 101.

[0077] The first moving unit 103 is connected to the upper plate 102 to move the upper mold 100 in the up-down direction. In detail, the first moving unit 103 moves the upper plate 102 connected thereto upward and downward along the third direction DR3 to allow the upper pressing member 101 connected to the upper plate 102 to move up and down. Therefore, the upper pressing member 101 presses downward the target panel placed on the stage 201 of the lower mold 200, which is disposed below the upper pressing member 101.

[0078] The lower mold 200 includes a stage 201, an elastic member 202, and a body unit 203. The lower mold 200 is disposed below the upper mold 100. The lower mold 200 is spaced apart from the upper mold 100 in the third direction DR3.

[0079] The stage 201 supports a target panel placed thereon. The stage 201 provides a flat surface 201-US substantially parallel to the first direction DR1 and the second direction DR2 (refer to Figure 3B ) to allow the target panel to be arranged on the flat surface 201-US substantially parallel to the first direction DR1 and the second direction DR2. The flat surface 201-US defined at the top of the stage 201 may be a receiving portion on which the target panel is arranged. When the upper pressing member 101 moves downward and presses the target panel, the stage 201 moves downward.

[0080] The elastic member 202 is disposed below the stage 201 and provides a predetermined elastic force in the upward direction of the stage 201. When the upper pressing member 101 applies downward pressure to the target panel placed on the stage 201, the elastic member 202 is compressed. The elastic member 202 may be implemented in various ways as long as the elastic member 202 provides an elastic force in the upward direction of the stage 201. For example, the elastic member 202 may be one of a plurality of springs, but is not limited thereto.

[0081] The main body unit 203 accommodates the stage 201 and the elastic member 202 therein, and fixes the stage 201 so that the stage 201 moves up and down without being misaligned while being pressed by the upper pressing member 101. The main body unit 203 further includes an outer curved forming portion (213, reference numeral 214) that forms a curved shape on the outside of the target panel. Figure 3A and Figure 3B ).

[0082] The side mold 300 is disposed at both sides of the lower mold 200. The side mold 300 includes a pair of first side molds 310 and 320 and a pair of second side molds 330 and 340, the pair of first side molds 310 and 320 being spaced apart from each other in the first direction DR1 and Figure 1AThe pair of second side molds 330 and 340 extend in the second direction DR2 shown in FIG. Figure 1B The pair of first side molds 310 and 320 are spaced apart from each other in the first direction DR1 and are disposed at a first set of opposite sides of the lower mold 200. The pair of second side molds 330 and 340 are spaced apart from each other in the second direction DR2 and are disposed at a second set of opposite sides of the lower mold 200.

[0083] The pair of first side molds 310 and 320 and the pair of second side molds 330 and 340 include respective side pressing members 311, 321, 331 and 341, respective side plates 312, 322, 332 and 342, and respective second moving units 313, 323, 333 and 343. The side pressing members 311, 321, 331 and 341 are connected to the side plates 312, 322, 332 and 342 and perform secondary pressing on the placed target panel. In detail, the side pressing members 311, 321, 331 and 341 perform secondary pressing on the target panel that is bent by the primary pressing by the upper pressing member 101. The side pressing members 311 and 321 of the pair of first side molds 310 and 320 press the target panel in the first direction DR1 , and the side pressing members 331 and 341 of the pair of second side molds 330 and 340 press the target panel in the second direction DR2 .

[0084] The side pressing members 311, 321, 331 and 341 are connected to the side plates 312, 322, 332 and 342, respectively, and the side plates 312, 322, 332 and 342 are Figure 4A The heat of the side heating heaters 314, 324, 334 and 344 shown in the figure is transferred to the side pressing members 311, 321, 331 and 341. The side plates 312, 322, 332 and 342 fix the positional relationship between the components (such as the side pressing members 311, 321, 331 and 341) included in the side mold 300. The side plates 312, 322, 332 and 342 include a metal material with high thermal conductivity to transfer the heat applied thereto to the side pressing members 311, 321, 331 and 341.

[0085] The second moving units 313, 323, 333, and 343 are connected to the side plates 312, 322, 332, and 342 and move the side mold 300 in the first direction DR1 and the second direction DR2. In detail, the second moving units 313, 323, 333, and 343 move the side plates 312, 322, 332, and 342 connected thereto left and right along the first direction DR1 and the second direction DR2 to allow the side pressing members 311, 321, 331, and 341 connected to the side plates 312, 322, 332, and 342 to move left and right. Therefore, the side pressing members 311, 321, 331, and 341 press the target panel placed on the stage 201 of the lower mold 200, which is disposed between the pair of first side molds 310 and 320 and between the pair of second side molds 330 and 340, toward the center of the curved panel manufacturing apparatus 10.

[0086] Figure 1A and Figure 1B A representative example of the upper mold 100 that moves downward along the third direction DR3 and initially presses the target panel by the operation of the first moving unit 103 is shown, but it should not be limited to or thereby. That is, a moving unit such as the first moving unit 103 may be included in the lower mold 200 and the side mold 300. In this case, the operation of initially pressing the target panel can be performed by moving the lower mold 200 and the side mold 300 upward along the third direction DR3 by the first moving unit 103 connected to the lower mold 200 and the side mold 300.

[0087] Hereinafter, each component included in the curved panel manufacturing apparatus 10 according to the exemplary embodiment will be described in detail with reference to the respective drawings.

[0088] Figure 2A yes Figure 1A FIG. 1 is a combined perspective view of an exemplary embodiment of an upper mold 100 of a curved panel manufacturing apparatus. Figure 2B yes Figure 1A 1 is an exploded perspective view of an exemplary embodiment of an upper mold 100 of a curved panel manufacturing apparatus. Figure 2C yes Figure 1A 1 is a front view of an exemplary embodiment of an upper mold 100 of a curved panel manufacturing apparatus. Figure 2D yes Figure 1A 1 is a side view of an exemplary embodiment of an upper mold 100 of a curved panel manufacturing apparatus.

[0089] refer to FIG. 2A to FIG. 2D , the upper mold 100 according to an exemplary embodiment may include an upper pressing member 101 , an upper plate 102 , a first moving unit 103 , an upper heating heater 104 , and an upper temperature sensor 105 .

[0090] The upper pressing member 101 is connected to the upper plate 102 and has a shape in which an area on a plane defined by the first direction DR1 and the second direction DR2 increases as the upper pressing member 101 is closer to the lower mold 200 along the third direction DR3. The upper pressing member 101 may have a trapezoidal cross section. The upper pressing member 101 may have an inverted tapered shape.

[0091] The upper pressing member 101 may include a first pressing portion 101-1, a second pressing portion 101-2, and a third pressing portion 101-3. The first pressing portion 101-1 may extend in the first direction DR1 and may press both ends of the target panel spaced apart from each other in the second direction DR2. The second pressing portion 101-2 may extend in the second direction DR2 and may press both ends of the target panel spaced apart from each other in the first direction DR1. The third pressing portion 101-3 may be defined between the first pressing portion 101-1 and the second pressing portion 101-2 and may have an arc shape. The third pressing portion 101-3 may press a portion of the target panel corresponding to a vertex and may bend the portion into an arc shape.

[0092] The upper pressing member 101 includes a lower surface 101-US and side surfaces 101-LS1, 101-LS2. The lower surface 101-US of the upper pressing member 101 may be a surface that substantially presses the upper portion of the target panel. The side surfaces 101-LS1, 101-LS2 of the upper pressing member 101 may have a first slope relative to the lower surface 101-US of the upper pressing member 101. The side surfaces 101-LS1, 101-LS2 of the upper pressing member 101 may have a first slope that is inclined at a first angle θ1 relative to the lower surface 101-US of the upper pressing member 101. The first angle θ1 may be an acute angle. That is, the first angle θ1 may be less than about 90 degrees.

[0093] The upper plate 102 may be connected to the upper pressing member 101 , the first moving unit 103 , the upper heating heater 104 , and the upper temperature sensor 105 included in the upper mold 100 to determine the positional relationship therebetween.

[0094] The first moving unit 103 may be disposed on the upper plate 102 and may move the upper mold 100 up and down along the third direction DR3. The first moving unit 103 may move the upper mold 100 up and down along the third direction DR3 using a pneumatic cylinder or a hydraulic cylinder or other means known in the art. As another example, the first moving unit 103 may move the upper mold 100 up and down along the third direction DR3 using a mechanical cylinder.

[0095] The upper heating heater 104 may be connected to the upper plate 102 and may apply heat to the upper plate 102 so that the upper pressing member 101 thermoforms the target panel using the heat applied thereto. When the upper heating heater 104 applies heat to the upper plate 102, the heat may be adjusted to a temperature suitable for thermoforming the target panel by the upper temperature sensor 105 connected to the upper plate 102.

[0096] The upper mold 100 may further include guide pins for aligning with the lower mold 200 when pressing the target panel.

[0097] exist FIG. 2A to FIG. 2D In the embodiment of the present invention, the components included in the upper mold 100 have separate components, however, they should not be limited thereto or thereby. That is, some of the components included in the upper mold 100 may have a single integral form. For example, the upper pressing member 101 may have a shape provided integrally with the upper plate 102.

[0098] Figure 3A yes Figure 1A FIG. 1 is a combined perspective view of an exemplary embodiment of a lower mold 200 of a curved panel manufacturing apparatus 10 . Figure 3B yes Figure 1A FIG. 2 is an exploded perspective view of an exemplary embodiment of a lower mold 200 of a curved panel manufacturing apparatus 10 . Figure 3C yes Figure 1A FIG. 1 is a top view of an exemplary embodiment of a lower mold 200 of a curved panel manufacturing apparatus 10 .

[0099] refer to FIG. 3A to FIG. 3C The lower mold 200 may include a stand 201 , an elastic member 202 , and a main body unit 203 .

[0100] The stage 201 is disposed at the center of the main body unit 203. Figure 3A and Figure 3B In the embodiment, the stage 201 is shown as a rectangular parallelepiped shape, however, the shape of the stage 201 should not be limited thereto or thereby. That is, the stage 201 may have various shapes, each of which provides a surface such as a plane on which a target panel may be placed. The stage 201 may have a rectangular shape on a plane defined by the first direction DR1 and the second direction DR2. The stage 201 may have a first length d1 in the first direction DR1 and a second length d2 in the second direction DR2.

[0101] The elastic member (biasing member) 202 is disposed below the stage 201 and provides elastic force to the stage 201 in the upward direction along the third direction DR3. The elastic member 202 may be one or more springs. Figure 3BIn the embodiment, as a representative example, the lower mold 200 includes nine elastic members 202, however, the number of the elastic members 202 should not be limited to nine. The number, shape, and arrangement relationship of the elastic members 202 can be appropriately selected according to the type of the elastic members 202 and the magnitude of the pressure applied to the stage 201.

[0102] The main body unit 203 may include an outer curvature forming portion 213 and a fixing portion 223. The outer curvature forming portion 213 is configured to overlap with the third pressing portion 101-3 of the above-mentioned upper mold 100 in a plane defined by the first direction DR1 and the second direction DR2. The outer curvature forming portion 213 is disposed at a vertex on the plane of the main body unit 203 and includes an inner surface 213-LS having an arc or curved shape. The inner surface 213-LS of the outer curvature forming portion 213 may have a shape corresponding to / complementary to the shape of the third pressing portion 101-3 of the above-mentioned upper mold 100. Figure 3A and Figure 3B In the embodiment, the outer curvature forming portion 213 and the fixing portion 223 may have a single integral form, however, the outer curvature forming portion 213 and the fixing portion 223 may be separate components having independent shapes.

[0103] The stand 201 and the elastic member 202 are placed on the fixing portion 223, and the fixing portion 223 keeps the stand 201 from moving up and down along the third direction DR3 without being misaligned when the stand 201 is pressed by the upper pressing member 101. A predetermined internal space is defined at the center of the fixing portion 223, and the stand 201 and the elastic member 202 are placed in the predetermined internal space.

[0104] The lower mold 200 may further include a guide sleeve for aligning with the upper mold when the target panel is pressed by the upper mold 100 .

[0105] Figure 4A yes Figure 1A 1 is a perspective view of an exemplary embodiment of a side mold 300 of a curved panel manufacturing apparatus 10. Figure 4B yes Figure 1A FIG. 1 is a front view of an exemplary embodiment of a side mold 300 of the curved panel manufacturing apparatus 10 . Figure 4C yes Figure 1A FIG. 1 is a side view of an exemplary embodiment of a side mold 300 of the curved panel manufacturing apparatus 10 . Figure 4D yes Figure 1A A front view of an exemplary embodiment of a side mold of a curved panel manufacturing apparatus.

[0106] refer to FIG. 4A to FIG. 4CThe side mold 300 includes a pair of first side molds 310 and 320, which are spaced apart from each other in the first direction DR1 and extend in the second direction DR2, and a pair of second side molds 330 and 340, which are spaced apart from each other in the second direction DR2 and extend in the first direction DR1. The pair of first side molds 310 and 320 are spaced apart from each other in the first direction DR1. The pair of second side molds 330 and 340 are spaced apart from each other in the second direction DR2.

[0107] The pair of first side molds 310 and 320 and the pair of second side molds 330 and 340 include respective side pressing members 311, 321, 331 and 341, respective side plates 312, 322, 332 and 342, respective second movable units 313, 323, 333 and 343, respective side heating heaters 314, 324, 334 and 344, and respective side temperature sensors 315, 325, 335 and 345.

[0108] The side pressing members 311, 321, 331, and 341 may be connected to one ends of the side plates 312, 322, 332, and 342, respectively, and may have a cross-sectional shape that decreases in a direction away from the side plates 312, 322, 332, and 342. The cross-sectional shape of the side pressing members 311 and 321 of the first side molds 310 and 320 decreases in a first direction DR1 in a direction away from the side plates 312 and 322. The cross-sectional shape of the side pressing members 331 and 341 of the second side molds 330 and 340 decreases in a second direction DR2 in a direction away from the side plates 332 and 342.

[0109] The side pressing members 311, 321, 331 and 341 may include upper surfaces 311-US, 321-US, 331-US and 341-US, respectively, and may include side surfaces 311-LS, 321-LS, 331-LS and 341-LS, respectively. When the target panel is placed on the stage 201, the upper surfaces 311-US, 321-US, 331-US and 341-US of the side pressing members 311, 321, 331 and 341 may support the outside of the target panel. The side surfaces 311-LS, 321-LS, 331-LS and 341-LS of the side pressing members 311, 321, 331 and 341 may be surfaces that substantially press the target panel as the side mold 300 moves.

[0110] The side surfaces 311-LS, 321-LS, 331-LS, and 341-LS of the side pressing members 311, 321, 331, and 341 may be inclined at a second slope relative to the upper surfaces 311-US, 321-US, 331-US, and 341-US. The side surfaces 311-LS, 321-LS, 331-LS, and 341-LS of the side pressing members 311, 321, 331, and 341 may have a second slope that is inclined at a second angle θ2 relative to the upper surfaces 311-US, 321-US, 331-US, and 341-US. The second angle θ2 may be an acute angle. That is, the second angle θ2 may be less than about 90 degrees.

[0111] The second slope may be substantially the same as the first slope of the upper pressing member 101. That is, the second angle θ2 may be substantially the same as the first angle θ1 (reference angle θ2) between the side surfaces 101-LS1, 101-LS2 and the lower surface 101-US of the upper pressing member 101. Figure 2C ). The side pressing members 311, 321, 331, and 341 may have a shape corresponding to / complementary to the upper pressing member 101. The side surfaces 311-LS, 321-LS, 331-LS, and 341-LS of the side pressing members 311, 321, 331, and 341 may be substantially parallel to the side surfaces 101-LS1, 101-LS2 of the upper pressing member 101.

[0112] The side plates 312, 322, 332, and 342 may perform a function of fixing the positional relationship between components included in the side mold 300, such as the side pressing members 311, 321, 331, and 341, the second moving units 313, 323, 333, and 343, the side heating heaters 314, 324, 334, and 344, and the side temperature sensors 315, 325, 335, and 345. FIG. 4A to FIG. 4C , the side pressing members 311, 321, 331, and 341 may be provided integrally with the side plates 312, 322, 332, and 342, however, the side pressing members 311, 321, 331, and 341 may be formed separately from the side plates 312, 322, 332, and 342 to have independent shapes.

[0113] The second moving units 313, 323, 333 and 343 may be disposed outside the side plates 312, 322, 332 and 342 and may move the side mold 300 left and right along the first direction DR1 or the second direction DR2. The second moving units 313, 323, 333 and 343 may move the side mold 300 left and right along the first direction DR1 or the second direction DR2 using a pneumatic cylinder or a hydraulic cylinder or other known means. As another example, the second moving units 313, 323, 333 and 343 may move the side mold 300 left and right along the first direction DR1 or the second direction DR2 using a mechanical cylinder.

[0114] The side heating heaters 314, 324, 334, and 344 may be connected to the side plates 312, 322, 332, and 342 and may apply heat to the side plates 312, 322, 332, and 342 so that the side pressing members 311, 321, 331, and 341 thermoform the target panel using the heat applied thereto. When the side heating heaters 314, 324, 334, and 344 apply heat to the side plates 312, 322, 332, and 342, the side temperature sensors 315, 325, 335, and 345 connected to the side plates 312, 322, 332, and 342 may adjust the temperature to be suitable for thermoforming the target panel.

[0115] refer to Figure 4D , the side molds 310-1 and 320-1 may further include auxiliary pressing members 316 and 326. The auxiliary pressing members 316 and 326 may be disposed below the side pressing members 311-1 and 321-1 and may be connected to the side panels 312 and 322. Since the side molds 310-1 and 320-1 include the auxiliary pressing members 316 and 326, when the side molds 310-1 and 320-1 move in the first direction DR1 and press the target panel, the target panel may be prevented from sagging downward. In addition, when the target panel is pressed, the upper mold and the side molds 310-1 and 320-1 may engage with each other due to the shapes of the auxiliary pressing members 316 and 326.

[0116] Figure 5 yes Figure 1A 1 is a top view of an exemplary embodiment of some components of a curved panel manufacturing apparatus 10. Figure 5 Schematically shows Figure 1A The lower mold 200 and the side molds 310 , 320 , 330 , and 340 of the curved panel manufacturing apparatus 10 .

[0117] refer to Figure 5, the side molds 310, 320, 330, and 340 of the curved panel manufacturing apparatus 10 may be disposed to correspond to the edge of the lower mold 200. The first side molds 310 and 320 may be disposed to have the lower mold 200 interposed therebetween to be spaced apart from each other in the first direction DR1, and the first side molds 310 and 320 may extend in the second direction DR2. The second side molds 330 and 340 may be disposed to have the lower mold 200 interposed therebetween to be spaced apart from each other in the second direction DR2, and the second side molds 330 and 340 may extend in the first direction DR1.

[0118] The longitudinal lengths of the side molds 310, 320, 330, and 340 may respectively correspond to the edge lengths of the stage 201 of the lower mold 200. The first side molds 310 and 320 may extend in the second direction DR2 by the same length as the second length d2, which is the edge length of the stage 201 in the second direction DR2. The second side molds 330 and 340 may extend in the first direction DR1 by the same length as the first length d1, which is the edge length of the stage 201 in the first direction DR1.

[0119] Fig. 6A is a cross-sectional view of another exemplary embodiment of a curved panel manufacturing apparatus 10 - 2 constructed according to the principles of the present disclosure in a first direction DR1 . Figure 6B It is intercepted in the second direction DR2 which is orthogonal to the first direction DR1. Fig. 6A 10-2 is a cross-sectional view of a curved panel manufacturing apparatus 10-2. In the following, the curved panel manufacturing apparatus 10-2 and Figure 1A and Figure 1B Various features of the curved panel manufacturing apparatus 10 are shown.

[0120] refer to Fig. 6A and Figure 6B The curved panel manufacturing equipment 10-2 includes a first mold 200-2, a second mold 100-2 and a third mold 300-2. Figure 1A and Figure 1B The description of the lower mold 200 described in the above is applied to each component of the first mold 200-2. Figure 1A and Figure 1B The description of the upper mold 100 described in the above is applied to each component of the second mold 100-2. Figure 1A and Figure 1B The description of the side mold 300 described in is applied to each component of the third mold 300 - 2 .

[0121] Fig. 6A and Figure 6BThe curved panel manufacturing equipment 10-2 shown may have such a structure: Figure 1A and Figure 1B In the curved panel manufacturing apparatus 10 shown in FIG. 1 , the upper mold 100 and the lower mold 200 are inverted with each other. That is, the first mold 200-2 is disposed above the second mold 100-2 in the third direction DR3. The third mold 300-2 may be disposed on both sides of the first mold 200-2 in the first direction DR1 and the second direction DR2.

[0122] and Figure 1A and Figure 1B On the contrary, according to Fig. 6A and Figure 6B The curved panel manufacturing device 10-2 shown, because the second mold 100-2 is arranged on the lower side in the third direction DR3, the target panel can be placed on the second mold 100-2, and then the bending process can be performed. The target panel can be placed on the first pressing member 101-2 of the second mold 100-2, the second mold 100-2 can be moved upward due to the operation of the first moving unit 103-2, and thus the target panel can be initially pressed between the stand 201-2 of the first mold 200-2 and the first pressing member 101-2. Subsequently, the target panel that has been initially pressed is secondarily pressed by the second pressing members 311-2, 321-2, 331-2 and 341-2 included in the third mold 300-2.

[0123] exist Fig. 6A and Figure 6B In the embodiment, the second mold 100-2 is moved upward along the third direction DR3 due to the operation of the first moving unit 103-2 to initially press the target panel, however, it should not be limited to or thereby. That is, the moving unit that moves the mold in the third direction DR3 may be included in the first mold 200-2 and the third mold 300-2. In this case, the operation of initially pressing the target panel may be performed by moving the first mold 200-2 and the third mold 300-2 along the third direction DR3 by the moving unit connected to the first mold 200-2 and the third mold 300-2.

[0124] Hereinafter, a curved panel according to exemplary embodiments will be described with reference to the accompanying drawings.

[0125] Fig. 7A is a perspective view of an exemplary embodiment of a curved panel 1000 constructed in accordance with the principles of the present disclosure in a substantially flat planar state. Figure 7B It is in a bent state Fig. 7A A perspective view of a curved panel 1000 is shown. Figure 7C yes Figure 7BFront view of the curved panel 1000. Fig.7D yes Figure 7B A side view of the curved panel 1000 is shown. Fig. 7A A planar state of the bent panel 1000 before the bent panel 1000 is bent is shown. FIG. 7B to FIG. 7D The curved panel 1000 is shown in a curved state. Fig. 7E is a perspective view of an exemplary embodiment of a curved panel 1000 - 1 constructed according to the principles of the present disclosure in a substantially flat planar state.

[0126] refer to FIG. 7A to FIG. 7D The curved panel 1000 may be any member to be applied to a display device such as a protective film. In an exemplary embodiment, the curved panel 1000 may be a protective film disposed on one surface (eg, bottom surface) of a display panel of a display device and protecting the display panel.

[0127] The curved panel 1000 includes a flat portion 1100 and curved portions 1210 , 1220 , and 1300 . The flat portion 1100 is disposed at the center of the curved panel 1000 , and the curved portions 1210 , 1220 , and 1300 are disposed around the edge of the flat portion 1100 .

[0128] The flat portion 1100 is substantially parallel to a plane defined by the first direction DR1 and the second direction DR2. In an exemplary embodiment, the flat portion 1100 has a substantially rectangular shape with a curved vertex, however, it should not be limited thereto or thereby. That is, the flat portion 1100 may have various shapes according to the shape of a display device to which the curved panel 1000 is applied.

[0129] The curved portions 1210, 1220, and 1300 may include a first curved portion 1210, a second curved portion 1220, and a third curved portion 1300. The first curved portion 1210 may extend in the second direction DR2 and may be disposed to be spaced apart from each other in the first direction DR1, with the flat portion 1100 interposed therebetween. The second curved portion 1220 may extend in the first direction DR1 and may be disposed to be spaced apart from each other in the second direction DR2, with the flat portion 1100 interposed therebetween. The third curved portion 1300 may be disposed between the first curved portion 1210 and the second curved portion 1220 and may be disposed at the vertex of the flat portion 1100. In the curved state of the curved panel 1000, the height of the third curved portion 1300 in the third direction DR3 may be less than the heights of the first curved portion 1210 and the second curved portion 1220 in the third direction DR3.

[0130] In the bent state of the curved panel 1000, the first curved portion 1210 and the second curved portion 1220 may be bent upward. The first curved portion 1210 and the second curved portion 1220 may be bent in an upward direction of the curved panel 1000 along the third direction DR3. In the curved panel 1000, the first curved portion 1210 and the second curved portion 1220 may be bent at a bending angle of about 90 degrees or more. For example, Figure 7C As shown in FIG. 1 , the bending angles of the first bending portion 1210 and the second bending portion 1220 may be “180-θ4” degrees. Figure 7C As shown in FIG. 1 , the fourth angle θ4 between the flat portion 1100 and the first curved portion 1210 and between the flat portion 1100 and the second curved portion 1220 may be less than about 90 degrees. The curved panel 1000 may be bent by the curved panel manufacturing apparatus 10 described above, and the fourth angle θ4 between the flat portion 1100 and the first curved portion 1210 and between the flat portion 1100 and the second curved portion 1220 may be substantially the same as the first angle θ1 between the side surfaces 101-LS1, 101-LS2 and the lower surface 101-US of the upper pressing member 101 of the curved panel manufacturing apparatus 10 (refer to FIG. 1 ). Figure 2C ).

[0131] In the bent state of the bent panel 1000, the third bent portion 1300 may have a curved or arc shape. The third bent portion 1300 may be disposed between the first bent portion 1210 and the second bent portion 1220 to have an arc shape. The bent panel 1000 may be bent by the above-mentioned bent panel manufacturing apparatus 10, and the bent shape of the third bent portion 1300 may correspond to the arc shape of the third pressing portion 101-3 of the upper pressing member 101 (refer to Figure 2B ) and the arc shape of the outer curved forming portion 213 of the lower mold 200 of the curved panel manufacturing equipment 10.

[0132] A plurality of slits SL1 and SL3 may be defined between the first curved portion 1210 and the third curved portion 1300 and between the second curved portion 1220 and the third curved portion 1300. The third curved portion 1300 may include a first sub-curved portion 1310 and a second sub-curved portion 1320, and a plurality of slits SL2 may be defined between the first sub-curved portion 1310 and the second sub-curved portion 1320. Since the slits SL1, SL2, and SL3 are defined between the first curved portion 1210 and the third curved portion 1300, between the second curved portion 1220 and the third curved portion 1300, and between the first sub-curved portion 1310 and the second sub-curved portion 1320, the first curved portion 1210, the second curved portion 1220, and the third curved portion 1300 may be bent without overlapping each other when the curved panel 1000 is bent. In particular, the vertex portion of the curved panel 1000 may be effectively bent.

[0133] refer to Fig. 7E , no slit is defined in the curved panel 1000-1, and a third curved portion 1300-1 having a single overall shape may be provided between the first curved portion 1210 and the second curved portion 1220. Although no slit is defined in the curved panel 1000-1, when the third curved portion 1300-1 of the curved panel 1000-1 is pressed by the third pressing portion 101-3 (refer to Figure 2B When the outer curved forming portion 213 of the lower mold 200 is pressed, the material of the curved panel 1000-1 may be stretched and the third curved portion 1300-1 may have an arc shape.

[0134] Hereinafter, an exemplary method of manufacturing a display device will be described with reference to the accompanying drawings.

[0135] An exemplary manufacturing method of a display device includes coupling a display panel to a first portion (e.g., a lower portion) of a window member and coupling a protective film to a first portion (e.g., a lower portion) of the display panel. The step of coupling the protective film includes the steps of: bending both ends of the protective film; placing the bent protective film on the lower portion of the display panel; and coupling the display panel to the protective film.

[0136] FIG. 8A to FIG. 8I are cross-sectional views sequentially illustrating exemplary embodiments of an exemplary method of manufacturing a display device according to principles of the present disclosure. FIG. 8A to FIG. 8F The steps of bending the protective film of the method for manufacturing the display device are sequentially shown. Figure 8G Schematically showing the process of bending the protective film in the manufacturing method of the display device Figure 3C The cross section corresponding to the line II'. Figure 8H and Fig.8I A step of disposing a curved protection film on a lower portion of a display panel in a method of manufacturing a display device is shown.

[0137] FIG. 8A to FIG. 8C The steps of bending the protective film when viewed in a cross section corresponding to a plane defined by the first direction DR1 and the third direction DR3 are sequentially shown. FIG. 8D to FIG. 8F The steps of bending the protective film when viewed in a cross section corresponding to a plane defined by the second direction DR2 and the third direction DR3 are sequentially shown. FIG. 8A to FIG. 8F The steps of bending the protective film will be described.

[0138] refer to Fig. 8A and Fig.8D , the manufacturing method of the display device includes the step of placing the target panel 1000 on the stage 201. In the manufacturing method of the display device, the target panel 1000 may be a protective film applied to the display device. In an exemplary embodiment, the target panel 1000 may be a protective film that is placed on a first surface (e.g., bottom surface) of a display panel of the display device to protect the display panel. When the target panel 1000 is placed on the stage 201, the outside of the target panel 1000 may be placed on some of the side molds 310, 320, 330, and 340.

[0139] refer to Fig. 8A , Figure 8B , Fig.8D and Fig. 8E , the manufacturing method of the display device includes the step of pressing the upper portion of the target panel 1000 using the upper pressing member 101. The upper pressing member 101 may be moved downward by the operation of the first moving unit 103 and may press the upper portion of the target panel 1000. As the upper pressing member 101 presses the upper portion of the target panel 1000, the elastic member 202 disposed under the stage 201 may be compressed, and the stage 201 may move downward.

[0140] In the step of pressing the upper portion of the target panel 1000 using the upper pressing member 101, the outer portion of the target panel 1000 may be bent at a bending angle of "180-θ3" degrees to form a target panel 1000-P1 having a third angle θ3. The outer portion of the target panel 1000 may be primarily bent by the upper pressing member 101 so that the angle between the bent portion and the flat portion becomes the third angle θ3. The third angle θ3 may be greater than the first angle θ1 of the corner of the upper pressing member 101. In the step of pressing the upper portion of the target panel 1000 using the upper pressing member 101, the upper heating heater 104 may provide heat to the upper plate 102 connected to the upper pressing member 101, and the target panel 1000-P1 may be thermoformed by the heat provided to the upper pressing member 101.

[0141] refer to Figure 8B , Figure 8C , Fig. 8E and Figure 8F The manufacturing method of the display device includes the step of pressing a curved portion of the target panel 1000-P1 that has been primarily bent using the side pressing members 311, 321, 331, and 341. The side pressing members 311, 321, 331, and 341 are moved to the stage 201 by the second moving units 313, 323, 333, and 343 and press the curved side surface of the target panel 1000-P1 that has been primarily bent.

[0142] In the step of pressing the bent portion of the target panel 1000-P1 that has been primarily bent using the side pressing members 311, 321, 331, and 341, the outer portion of the target panel 1000-P1 may be bent at a bending angle of "θ3-θ4" degrees to form a target panel 1000-P2 having a fourth angle θ4. The outer portion of the target panel 1000 may be primarily bent by the upper pressing member 101 and may be secondarily bent by the side pressing members 311, 321, 331, and 341, and thus the angle between the bent portion and the flat portion may become the fourth angle θ4 (refer to Figure 7C and Fig.7D ). The fourth angle θ4 may be smaller than the third angle θ3 obtained after the primary bending. The fourth angle θ4 may be substantially the same as the first angle θ1 of the corner of the upper pressing member 101. The fourth angle θ4 may be smaller than about 90 degrees. In the step of pressing the side of the target panel 1000-P1 using the side pressing members 311, 321, 331, and 341, the side heating heaters 314, 324, 334, and 344 may provide heat to the side plates 312, 322, 332, and 342 connected to the side pressing members 311, 321, 331, and 341, and the target panel 1000-P2 may be thermoformed by the heat transferred to the side pressing members 311, 321, 331, and 341.

[0143] refer to Figure 8G In the exemplary manufacturing method of the display device, the vertex portion of the target panel 1000 can be bent by the upper pressing member 101 and the outer bending forming portion 213 of the lower mold 200. In detail, the third pressing portion 101-3 (refer to Figure 2B ) and the outer curvature forming portion 213 (reference Figure 3B) may have arc shapes corresponding to each other. In the vertex portion of the target panel 1000, the third bending portion 1300 of the target panel 1000 disposed between the third pressing portion 101-3 and the outer bending forming portion 213 may be bent to have an arc shape by the shapes of the third pressing portion 101-3 and the outer bending forming portion 213 meshing with each other.

[0144] refer to Figure 8H and Fig.8I , the target panel bent by the bent panel manufacturing apparatus may be coupled to the window member 2000 and the display panel 3000. The target panel may be a protective film 1000-P3 protecting the display panel 3000. Figure 8H , the protective film 1000-P3 can be bent at a bending angle of about 90 degrees or more by a curved panel manufacturing device, and the fourth angle θ4 formed between the flat portion and the curved portion of the protective film 1000-P3 may be less than about 90 degrees. The outside of the window member 2000 and the outside of the display panel 3000 may be bent at a relatively smaller bending angle than the protective film 1000-P3. In an exemplary embodiment, the window member 2000 and the display panel 3000 may be bent at a bending angle of about 90 degrees. The fifth angle θ5 between the curved portion and the flat portion of each of the window member 2000 and the display panel 3000 may be about 90 degrees. The fifth angle θ5 between the curved portion and the flat portion of each of the window member 2000 and the display panel 3000 may be greater than the fourth angle θ4. The protective film 1000-P3 bent to the fourth angle θ4 may be disposed under the display panel 3000 and may be attached to the display panel 3000 by being pressed using a roller. Reference Fig.8I , in the display device DS to which the protective film 1000 is attached, the protective film 1000 - P3 may be stretched into the protective film 1000 to allow a final bending angle of the protective film 1000 to correspond to final bending angles of the window member 2000 and the display panel 3000 .

[0145] In an exemplary manufacturing method of a display device, before the protective film is coupled to the lower portion of the display panel, the protective film is bent by a curved panel manufacturing device, and the bent protective film is coupled to the lower portion of the display panel. In more detail, the display panel and the window member are bent at a predetermined bending angle, the protective film is bent at a greater bending angle than the bending angles of the display panel and the window member, and then the protective film is coupled to the lower portion of the display panel.

[0146] In the case where the protective film is coupled to the display panel and the window member without being bent, the display panel and the protective film may be separated from each other due to the repulsive force of the material of the protective film, and the reliability of the protective film is reduced. According to an exemplary manufacturing method of a display device, since the protective film is pre-bent before being coupled to the lower portion of the display panel, even if the protective film is coupled to a display panel having a curvature, the protective film can be prevented from being separated from the display panel, and thus the reliability of the display device can be improved. In particular, since the protective film is coupled to the display panel and the window member after being bent at a greater bending angle than the bending angle of the display panel and the window member, the separation of the protective film due to the repulsive force of its material can be minimized.

[0147] Fig.9A , Fig. 9B and Fig. 9C are cross-sectional views sequentially illustrating some steps of another exemplary method of manufacturing a display device according to the principles of the present disclosure. 9A to 9C The process of bending the protective film in the method of manufacturing the display device is shown. 9A to 9C In the same reference numerals, FIG. 1A to FIG. 8I , and thus detailed description of the same elements will be omitted. Fig.9A The protective film 1001 and the cover film 4000 shown in FIG. 1 are initially bent to form a Fig. 9B The protective film 1001-P1 and the cover film 4000-P1 shown in FIG. 4 are then bent twice to form a Fig. 9C The protective film 1001-P2 and the covering film 4000-P2 are shown in FIG.

[0148] refer to 9A to 9C The method for manufacturing a display device may include the step of placing a cover film (eg, a release film) 4000 under the protective film 1001 before placing the protective film 1001 on the stage 201. 9A to 9C In the embodiment, the cover film 4000 is only disposed under the protective film 1001 , however, it should not be limited thereto or thereby. The cover film 4000 may also be disposed on the protective film 1001 .

[0149] The cover film 4000 can prevent the protective film 1001 from being damaged in the operation of bending the protective film 1001, and can prevent the protective film 1001 from being attached to the curved panel manufacturing equipment due to the adhesive force of the protective film 1001. Since the cover film 4000 is disposed below the protective film 1001 and / or on the protective film 1001, the upper pressing member 101 and the side pressing members 311 and 321 can press the cover film 4000 to bend the protective film 1001 without directly pressing the protective film 1001. After the protective film 1001 is bent using the curved panel manufacturing equipment and before the protective film 1001 is coupled to the lower portion of the display panel, the cover film 4000 can be removed.

[0150] Fig.10 is a cross-sectional view showing steps of yet another exemplary method of manufacturing a display device according to the principles of the present disclosure. Fig.10 The step of pressing the protective film by the side molds 310 and 320 to bend the protective film in the manufacturing method of the display device is shown. Fig.10 In the same reference numerals, Figures 1A to 9C , and thus detailed description of the same elements will be omitted to avoid repetition.

[0151] refer to Fig.10 , in the step of pressing the side of the target panel 1000-P1 using the side pressing members 311 and 321 of the manufacturing method of the display device, the side molds 310 and 320 do not move left and right along the first direction DR1 but rotate around the rotation axes 317 and 327 to press the side of the target panel 1000-P1. That is, when the side molds 310 and 320 can rotate around the rotation axes 317 and 327, the side pressing members 311 and 321 can secondarily press the side of the target panel 1000-P1 that has been initially bent. In this case, since the upper surfaces of the side pressing members 311 and 321 do not support the target panel 1000-P1 before the secondary pressing operation, the curved panel manufacturing apparatus may further include a support member 500 for supporting the outside of the target panel 1000-P1.

[0152] Although certain exemplary embodiments and implementations have been described herein, other embodiments and modifications will be apparent from this description. Therefore, the inventive concept is not limited to such embodiments, but rather to the broader scope of the disclosure and to various obvious modifications and equivalent arrangements apparent to those of ordinary skill in the art.

Claims

1. An apparatus for manufacturing a curved panel of a display device, wherein: The device comprises: A lower mold having a first member for placing a target panel on the first member; an upper mold disposed adjacent to the lower mold and comprising a second member having a first surface and a second surface, the first surface being used to press a portion of the target panel as the upper mold moves, and the second surface having a first slope relative to the first surface; and side molds disposed at opposite sides of the lower mold, and each side mold having a third member having a third surface complementary to the second surface of the second member, wherein the first slope is less than 90 degrees; Wherein, the third component comprises: an upper surface supporting an exterior of the target panel; and A side surface having a second slope relative to the upper surface, wherein the second slope is less than 90 degrees, and the first slope and the second slope are the same; As the third member of the side mold moves to the second member, the side surface as the third surface presses the target panel together with the second surface, so that the target panel is formed into the curved panel whose angle between the curved portion and the flat portion is less than 90 degrees.

2. The device according to claim 1, wherein: The first member includes a stand having a receiving portion parallel to a plane defined by a first direction and a second direction intersecting the first direction, and The side mold comprises: a pair of first side molds spaced apart from each other in the first direction and disposed at the opposite sides of the lower mold to press the target panel in the first direction; and A pair of second side molds are spaced apart from each other in the second direction and are disposed at both sides of the lower mold to press the target panel in the second direction.

3. The device according to claim 2, wherein: The upper mold is spaced apart from the lower mold in a third direction intersecting the first direction and the second direction, and the upper mold is configured to press the target panel in the third direction.

4. The device according to claim 3, wherein: The second member includes an upper pressing member having a cross-sectional shape having an area in a plan view that increases as a distance from the lower mold in the third direction decreases.

5. The device according to claim 2, wherein: The second component comprises: a first pressing portion extending in the first direction; a second pressing portion extending in the second direction; and The third pressing portion is disposed between the first pressing portion and the second pressing portion and has an arc shape.

6. The device according to claim 5, wherein: The lower mold further includes an outer curvature forming portion configured to overlap with the third pressing portion in the plane defined by the first direction and the second direction, and the outer curvature forming portion has a shape complementary to the arc shape of the third pressing portion.

7. The device according to claim 1, wherein: The upper mold further includes a first portion for moving the second member up and down, and the side mold further includes a second portion for moving the side pressing member left and right.

8. The device according to claim 1, wherein: The lower mold further includes one or more biasing members disposed below the first member, the one or more biasing members being compressed when the second member is pressed against the target panel.

9. The device according to claim 1, wherein: The upper mold further comprises: an upper plate supporting the second member; and An upper heating heater is connected to the upper plate to apply heat to the upper plate.

10. The device according to claim 1, wherein: The side mold further comprises: a side plate supporting the third member; and A side heating heater is connected to the side plate to apply heat to the side plate.

11. An apparatus for manufacturing a curved panel, wherein: The device comprises: A first mold including a first member having a first surface parallel to a plane defined by a first direction and a second direction intersecting the first direction; a second mold spaced apart from the first mold in a third direction intersecting both the first direction and the second direction, and comprising a second member having a second surface and a third surface, the second surface being parallel to the first surface, and the third surface having a first slope less than 90 degrees with respect to the second surface; and a third mold spaced apart from the first mold in the first direction and the second direction and comprising a third member having a fourth surface complementary to the third surface; Wherein, the third component comprises: an upper surface supporting an exterior of the target panel; and A side surface having a second slope relative to the upper surface, wherein the second slope is less than 90 degrees, and the first slope and the second slope are the same; As the third member of the third mold moves to the second member, the side surface as the fourth surface presses the target panel together with the third surface to form the target panel into the curved panel whose angle between the curved portion and the flat portion is less than 90 degrees.

12. A method for manufacturing a display device, wherein: The method comprises the steps of: coupling a display panel to the first portion of the window member; as well as A protective film is coupled to the lower portion of the display panel, wherein the step of coupling the protective film further comprises the steps of: By using the apparatus for manufacturing a curved panel of a display device according to any one of claims 1 to 10 or the apparatus for manufacturing a curved panel according to claim 11, the two edges of the protective film are bent at a bending angle of 90 degrees or more to form the curved protective film as the curved panel; disposing the curved protection film on the lower portion of the display panel; and The protection film is coupled to the display panel.

13. The method according to claim 12, wherein: The step of bending the two edges of the protective film further comprises the steps of: placing the protective film on a support; pressing an upper portion of the protective film to bend the two edges into a first angle; and The side portion bent at the first angle is pressed to bend the two edges at a second angle smaller than the first angle.

14. The method according to claim 13, wherein: An elastic member is disposed below the support, and wherein the step of pressing the upper portion of the protection film includes compressing the elastic member.

15. The method according to claim 13, wherein: The step of pressing the upper portion of the protection film further includes the step of indirectly applying heat to the upper portion of the protection film.

16. The method according to claim 13, wherein: The step of pressing the side of the protection film further includes the step of indirectly applying heat to the side of the protection film.

17. The method according to claim 13, wherein: The step of pressing the side of the protection film is performed by horizontally moving one or more side pressing members or by rotating the one or more side pressing members.

18. The method according to claim 13, wherein: The step of bending the two edges of the protective film further comprises the steps of: Before placing the protective film on the support, disposing a release film under the protective film; and Before coupling the protection film to the display panel, the release film is removed.

19. The method according to claim 13, wherein: The method further includes, before the step of coupling the protection film to the lower portion of the display panel, bending the window member and the outer portion of the display panel at a third angle greater than the second angle at which the protection film is bent.

20. A protective film for a display device, the protective film being manufactured using the apparatus for manufacturing a curved panel of a display device according to any one of claims 1 to 10 or the apparatus for manufacturing a curved panel according to claim 11, wherein: The protective film as the curved panel includes: a flat portion disposed parallel to a plane defined by a first direction and a second direction intersecting the first direction; and A curved portion is disposed at one side of the flat portion, the curved portion comprising: a first curved portion extending in the first direction; and A second curved portion extends in the second direction, wherein an angle between the first curved portion and the flat portion and an angle between the second curved portion and the flat portion are both less than 90 degrees.

21. The protective film according to claim 20, wherein: The curved portion further includes a third curved portion disposed between the first curved portion and the second curved portion.

22. The protective film according to claim 21, wherein The third curved portion has an arc shape.

23. The protective film according to claim 21, wherein A plurality of slits are provided between the first curved portion and the third curved portion and between the second curved portion and the third curved portion.

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