Apparatus and method for manufacturing a display device

Abstract

A method and apparatus for manufacturing a display device are provided. The method for manufacturing a display device includes the steps of: placing a panel having a panel flat portion and a panel bent portion on a deformable pad having a core member, and placing a cover window above the panel; and moving a core member provided within the pad from a first position adjacent to the panel flat portion of the panel to a second position adjacent to the panel bent portion of the panel, and pressing the panel to bond the cover window to the panel.

Description

[0001] Cross - reference to related applications

[0002] This application claims the priority and benefit of Korean Patent Application No. 10 - 2019 - 0051409, filed on May 2, 2019, which is incorporated herein by reference in its entirety for all purposes as if fully set forth herein. Technical field

[0003] Exemplary embodiments of the present invention generally relate to a display device, and more particularly, to an apparatus and method for manufacturing a display device capable of uniformly bonding a curved window to a curved display panel. Background art

[0004] Recently, flexible display devices have been developed, which are lightweight, have strong impact resistance, and include a flexible substrate made of a material such as plastic. The flexible display device can be folded or rolled up for transportation and can be used in various fields.

[0005] The flexible display device includes display elements formed on a flexible substrate. Display elements that can be used in the flexible display device may include organic light - emitting display elements, liquid - crystal display elements, etc.

[0006] The display elements generally include thin - film transistors. Accordingly, the flexible substrate undergoes a plurality of thin - film processes. The flexible substrate that has undergone the thin - film processes is encapsulated by an encapsulation layer. The flexible substrate, the thin - film transistors, and the encapsulation layer constitute a display panel of the display device, where the thin - film transistors are formed on the flexible substrate.

[0007] Generally, a cover window for protecting the display panel is attached to the front surface of the display panel. In this case, an adhesive is interposed between the display panel and the cover window, and the display panel and the cover window are bonded to each other.

[0008] Recently, side - view display devices have been developed, which include a main display area for displaying a main image and a sub - display area for displaying a sub - image on a curved side portion. The cover window of the side - view display device has a curved structure having a bent portion extending above the side of the side - view display device.

[0009] The above information disclosed in this background art section is only for understanding the background of the inventive concept, and thus, it may include information that does not constitute the prior art. Summary of the invention

[0010] The applicant has found that the adhesive force required to connect a curved window to a curved display panel may be insufficient for reliable bonding and / or may create excessive pressure that may damage sensitive electronic components of the display.

[0011] An apparatus (e.g., a laminating apparatus) for manufacturing a display device constructed according to an exemplary embodiment of the present invention and a method of manufacturing a display device according to an exemplary embodiment of the present invention can bond a curved window uniformly to a curved display panel.

[0012] Additional features of the inventive concept will be set forth in the following description and will be partially apparent from the description, or may be learned by practice of the inventive concept.

[0013] According to an aspect of the present invention, a method of manufacturing a display device includes the steps of: placing a panel having a panel flat portion and a panel bent portion on a deformable pad having a core member; placing a cover window above the panel; and moving the core member disposed within the pad from a first position adjacent to the panel flat portion of the panel to a second position adjacent to the panel bent portion of the panel, and pressing the panel to bond the cover window to the panel.

[0014] The panel bent portion of the panel may include a panel bending portion adjacent to the panel flat portion of the panel and a panel side portion spaced apart from the panel flat portion of the panel by the panel bending portion interposed therebetween, and the cover window includes a cover flat portion and a cover bent portion, and the cover bent portion may include a cover bending portion adjacent to the cover flat portion and a cover side portion spaced apart from the cover flat portion by the cover bending portion interposed therebetween.

[0015] The step of moving the core member and pressing the panel to bond the cover window to the panel may include the step of raising the pad to bond the panel flat portion to the cover flat portion.

[0016] The method may further include the step of: after raising the pad to bond the panel flat portion to the cover flat portion, bonding the panel bending portion to the cover bending portion by pressing the panel bending portion with the core member.

[0017] The method may further include the step of: after bonding the panel bending portion to the cover bending portion by pressing the panel bending portion with the core member, bonding the panel side portion to the cover side portion by pressing the panel side portion with the core member.

[0018] The step of raising the pad to bond the panel flat portion to the cover flat portion may further include the step of pressing the pad to move the constituent material of the pad toward its periphery.

[0019] The core member can be moved from the first position to the second position by moving the constituent material of the pad toward the periphery.

[0020] The method may further include the step of placing a guide member between the pad and the panel, the guide member extending beyond opposite ends of the pad.

[0021] The method may further include the step of fixing, by a clamping member, a portion of the guiding member extending beyond the end of the pad.

[0022] The method may further include the step of, after fixing, by a clamping member, a portion of the guiding member extending beyond the end of the pad, lowering the clamping member to lower the portion of the guiding member extending beyond the end of the pad.

[0023] The method may further include the step of, after lowering the clamping member to lower the portion of the guiding member extending beyond the end of the pad, moving a roller portion fixed to the clamping member toward the pad.

[0024] When the roller portion fixed to the clamping member moves inwardly toward the pad, a panel bending portion of the panel may be formed.

[0025] The pad may be a shaped pad, and the core member may include a rigid core connection portion and a rigid main core portion, wherein the core connection portion is connected to a support member disposed under the pad, and the main core portion is disposed within the pad and connected to the core connection portion.

[0026] The step of moving the core member and pressing the panel to bond the cover window to the panel may further include the step of moving the main core portion from a first position to a second position using the core connection portion as a rotation axis.

[0027] The core member may further include a sub-core portion extending in a direction crossing the longitudinal direction of the main core portion.

[0028] The step of moving the main core portion from a first position to a second position using the core connection portion as a rotation axis may further include the step of bringing the sub-core portion into contact with the surface of the pad.

[0029] The step of moving the core member and pressing the panel to bond the cover window to the panel may further include the step of moving the core member without contacting any outer surface of the pad.

[0030] According to another aspect of the present invention, an apparatus for manufacturing a display device includes a support member, a motor, a deformable pad, and a core member, wherein the motor is disposed under the support member and is operable to linearly move the support member, the deformable pad is disposed on the support member, and the core member is connected to the support member and disposed within the pad.

[0031] The support member may include a pad support having a main support portion, a first sub-support portion disposed on one side of the main support portion, and a second sub-support portion disposed on the other side of the main support portion, and the main support portion may have a first thickness, the first sub-support portion has a second thickness and the second sub-support portion has a third thickness, and the first thickness is greater than the second thickness or the third thickness.

[0032] The main support portion may include a groove recessed from its surface, and the core member may include a rigid core connection portion engaged with the groove of the main support portion and a rigid main core portion connected to the core connection portion.

[0033] The pad may include a main pad portion, a first sub-pad portion, and a second sub-pad portion, wherein the main pad portion overlaps with the main support portion, the first sub-pad portion overlaps with the first sub-support portion, the second sub-pad portion overlaps with the second sub-support portion, and the first sub-pad portion and the second sub-pad portion have substantially the same thickness.

[0034] The thickness of the main pad portion may be less than the thicknesses of the first sub-pad portion and the second sub-pad portion.

[0035] The main core portion of the core member may be disposed within each of the first sub-pad portion and the second sub-pad portion of the pad.

[0036] The ends of the main core portion may be located within each of the first sub-pad portion and the second sub-pad portion.

[0037] The pad may include silicon (Si), and the main core portion may include a metallic material.

[0038] The core member may further include a rigid sub-core portion connected to the main core portion and extending in a direction crossing the longitudinal axis of the main core portion.

[0039] The sub-core portion may be in contact with the surface of at least one of the first sub-pad portion and the second sub-pad portion.

[0040] One end of the sub-core portion may have a pointed shape or a curved shape.

[0041] One end of the main core portion may have a pointed shape or a curved shape.

[0042] The main core portion has a width that may gradually decrease from the portion connected to the core connection portion to one end of the main core portion.

[0043] The support member may include a main support portion, a first sub-support portion, a second sub-support portion, a third sub-support portion, and a fourth sub-support portion, wherein the first sub-support portion is disposed on one side of the main support portion in a first direction, the second sub-support portion is disposed on the other side of the main support portion in the first direction, the third sub-support portion is disposed on one side of the main support portion in a second direction crossing the first direction, the fourth sub-support portion is disposed on the other side of the main support portion in the second direction, and the main support portion may have a thickness greater than the thickness of each of the first to fourth sub-support portions.

[0044] 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 invention as claimed. BRIEF DESCRIPTION OF THE DRAWINGS

[0045] The drawings (which are included to provide a further understanding of the present invention and are incorporated in and constitute a part of this specification) illustrate exemplary embodiments of the present invention and, together with the specification, are used to explain the inventive concept.

[0046] Figure 1 is a perspective view of an exemplary embodiment of a lamination device constructed in accordance with the principles of the present invention.

[0047] Figure 2 is Figure 1 a cross-sectional view of the lamination device.

[0048] Figure 3 is a flowchart of an exemplary embodiment of a method for manufacturing a display device in accordance with the principles of the present invention.

[0049] Figures 4 to 8 is a cross-sectional view of an exemplary embodiment of a step of a method for manufacturing a display device in accordance with the principles of the present invention.

[0050] Figures 9 to 11 is a cross-sectional view of an exemplary embodiment of a step in which a rigid core is used to attach a curved portion and a side portion of a cover window to a target panel.

[0051] Figure 12 illustrates an exemplary embodiment of the contact pressure between a target panel and a cover window depending on whether a rigid core is included.

[0052] Figure 13A is a perspective view of another exemplary embodiment of a cover window, and Figure 13B is a perspective view of another exemplary embodiment of a target panel.

[0053] Figure 14 is a perspective view of another exemplary embodiment of a lamination device constructed in accordance with the principles of the present invention.

[0054] Figures 15A to 15C is a cross-sectional view showing an exemplary embodiment of a rigid core of the lamination device.

[0055] Figure 16 is a perspective view of yet another exemplary embodiment of a lamination device constructed in accordance with the principles of the present invention.

[0056] Figure 17 is Figure 16 a cross-sectional view of the lamination device.

[0057] Figure 18 is a perspective view of yet another exemplary embodiment of a lamination device constructed in accordance with the principles of the present invention.

[0058] Figure 19A and Figure 19B A cross-sectional view showing another exemplary embodiment of the rigid core of the lamination device. Detailed Description

[0059] In the following description, for purposes of explanation, numerous specific details are set forth in order to provide a thorough understanding of various exemplary embodiments or examples of the present invention. As used herein, "embodiment" and "example" are interchangeable terms that are non-limiting examples of a device or method that employs one or more of the inventive concepts disclosed herein. However, it will be apparent that the various exemplary embodiments may be practiced without these specific details or with one or more equivalent arrangements. In other instances, well-known structures and devices are shown in block diagram form in order to avoid unnecessarily obscuring the various exemplary embodiments. Additionally, the various exemplary embodiments may be different, but not necessarily exclusive. For example, without departing from the inventive concept, the specific shapes, configurations, and characteristics of an exemplary embodiment may be used or implemented in another exemplary embodiment.

[0060] Unless otherwise indicated, the exemplary embodiments shown should be understood to provide exemplary features of different details of some ways in which the inventive concept may be practiced. Thus, unless otherwise indicated, the features, components, modules, layers, films, panels, regions, and / or aspects, etc. (hereinafter individually or collectively referred to as "elements") of each embodiment may be combined, separated, interchanged, and / or rearranged otherwise without departing from the inventive concept.

[0061] The use of hatching and / or shading in the drawings is generally used to clarify the boundaries between adjacent elements. Thus, unless specified, the presence or absence of hatching or shading does not convey or indicate any preference or requirement for a particular material, material property, dimension, scale, commonality between the elements shown, and / or any other characteristic, property, nature, etc. of the elements. Additionally, in the drawings, for clarity and / or descriptive purposes, the sizes and relative sizes of elements may be exaggerated. When the exemplary embodiments are implemented differently, a particular process sequence may be performed differently than the sequence described. For example, two consecutively described processes may be performed substantially simultaneously or in a sequence opposite to that described. Additionally, like reference numerals denote like elements.

[0062] When an element or layer is referred to as being on, connected to, or coupled to another element or layer, it can be directly on, directly connected to, or directly coupled to the other element or layer, or intervening elements or layers may be present. However, when an element or layer is referred to as being directly on, directly connected to, or directly coupled to another element or layer, no intervening elements or layers are present. For this reason, the term "connected" can mean physical connection, electrical connection, and / or fluid connection with or without intervening elements. In addition, the D1 axis, D2 axis, and D3 axis are not limited to the three axes of a rectangular coordinate system, such as the x-axis, y-axis, and z-axis, and can be interpreted in a broader sense. For example, the D1 axis, D2 axis, and D3 axis can be perpendicular to each other, or can represent different directions that are not perpendicular to each other. For the purposes of this disclosure, "at least one of X, Y, and Z" and "at least one selected from the group consisting of X, Y, and Z" can be interpreted as only X, only Y, only Z, or any combination of two or more of X, Y, and 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.

[0063] 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. Thus, a first element discussed below could be termed a second element without departing from the teachings of this disclosure.

[0064] Spatial relative terms, such as "beneath", "below", "under", "lower", "above", "upper", "over", "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 as shown in the figures. In addition to the orientation depicted in the figures, the spatial relative terms are intended to encompass different orientations of the device in use, operation, and / or manufacture. For example, if the device in the figures is flipped, an element described as "below" or "beneath" another element or feature would then be oriented "above" the other element or feature. Thus, the exemplary term "below" can encompass both an orientation above and below. In addition, the device may be otherwise oriented (e.g., rotated 90 degrees or at other orientations), and as such, the spatial relative descriptors used herein should be interpreted accordingly.

[0065] The terms used herein are for the purpose of describing particular embodiments and are not intended to be limiting. As used herein, unless the context clearly dictates otherwise, the singular forms "a", "an" and "the" are intended to include the plural forms as well. Further, when the terms "comprises", "comprising", "includes" and / or "including" are used in this specification, they specify the presence of the stated features, integers, steps, operations, elements, components and / or combinations thereof, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components and / or combinations thereof. It is also noted that, as used herein, the terms "substantially", "about" and other similar terms are used as approximate terms and not as terms of degree, and as such, are used to account for inherent deviations that would be recognized by one of ordinary skill in the art in measured values, calculated values and / or provided values.

[0066] In this document, each exemplary embodiment is described with reference to cross-sectional views and / or exploded views that are schematic diagrams of idealized exemplary embodiments and / or intermediate structures. Thus, variations in the illustrated shapes due to, for example, manufacturing techniques and / or tolerances can be envisioned. Accordingly, the exemplary embodiments disclosed herein need not necessarily be construed as limited to the regions of the specific shapes shown, but include shape deviations caused by, for example, manufacturing. In this manner, the regions shown in the drawings are inherently schematic, and the shapes of these regions may not reflect the actual shapes of the regions of the device, and as such, are not necessarily intended to be limiting.

[0067] 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 belongs. 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 expressly so defined herein.

[0068] Figure 1 is a perspective view of an exemplary embodiment of a lamination device constructed in accordance with the principles of the present invention. Figure 2 is Figure 1 a cross-sectional view of the lamination device.

[0069] Referring to Figure 1 and Figure 2 , the lamination device 1 may include a shaping pad support 100, a shaping pad 200 disposed on the shaping pad support 100, a rigid core 300 disposed within the shaping pad 200, and a vertical motor 400 disposed below the shaping pad support 100.

[0070] The laminating device 1 is used to laminate the cover window and the target panel of a display device. In other words, the laminating device 1 can attach the target panel to the cover window through an inter-module bonding member disposed above substantially the entire surface of the target panel. Thus, the laminating device 1 is a device for manufacturing a display device. A process of laminating the target panel and the cover window by the laminating device 1 will be described in detail later.

[0071] The shaping pad support 100 can be used to support the shaping pad 200 disposed above it. As Figure 1 shown, the shaping pad support 100 can include a short side portion extending along a first direction DR1 and a long side portion extending along a second direction DR2 in a plan view.

[0072] The shaping pad support 100 can include a metallic material. Examples of the metallic material can include, but are not limited to, aluminum.

[0073] The shaping pad support 100 can include a main support portion 150, a first sub-support portion 110, and a second sub-support portion 130, wherein the first sub-support portion 110 is disposed on one side of the main support portion 150 in the first direction DR1, and the second sub-support portion 130 is disposed on the other side of the main support portion 150 in the first direction DR1.

[0074] The thickness of the main support portion 150 in a third direction DR3 can be greater than the thicknesses of the adjacent first sub-support portion 110 and second sub-support portion 130 in the third direction DR3. Thus, as Figure 1 shown, the surface of the main support portion 150 can protrude upward from the surfaces of the first sub-support portion 110 and the second sub-support portion 130 in the third direction DR3.

[0075] The main support portion 150 can further include an attachment portion CP to which the rigid core 300 is bonded. As Figure 1 shown, the attachment portion CP of the main support portion 150 can be recessed in a curved shape from the surface of the main support portion 150 in the thickness direction. The recessed curved shape of the attachment portion CP is Figures 15A to 15C and Figures 19A to 19B best shown in and forms a base for receiving and physically bonding the core connection portion 310 of the rigid core 300 for rotational movement, as described later. The attachment portions CP of the main support portion 150 can be respectively positioned at one end of the main support portion 150 in the first direction DR1 and at the other end of the main support portion 150 in the first direction DR1. The attachment portions CP of the main support portion 150 can be formed to extend along the second direction DR2.

[0076] The shaping pad 200 can be disposed on the shaping pad support member 100 and firmly fixed thereto. Accordingly, when the shaping pad support member 100 is raised, the shaping pad 200 is also raised. As will be described later, the guiding film on the shaping pad 200, and the target panel and the module-to-module bonding member on the guiding film come into contact with the cover window to cause deformation, thereby attaching the target panel to the cover window.

[0077] As Figure 1 shown, the shaping pad 200 may have a rectangular shape in a plan view. In other words, similar to the shaping pad support member 100, the shaping pad 200 may include a short side portion extending along a first direction DR1 and a long side portion extending along a second direction DR2. However, the exemplary embodiment is not limited thereto, and the planar shape of the shaping pad 200 may be various shapes such as a square, a circle, an ellipse, or other polygons. Hereinafter, for simplicity of description, the case where the planar shape of the shaping pad 200 is a rectangular shape including a short side portion and a long side portion will be mainly described.

[0078] The shaping pad 200 may include an elastic material having a higher elasticity than that of the shaping pad support member 100. For example, the shaping pad 200 may include a material such as silicon (Si). Accordingly, even when the shape deformation occurs as the shaping pad support member 100 is raised such that the target panel comes into contact with the cover window as described above, physical damage to the target panel and the cover window can be prevented.

[0079] In addition, the shaping pad 200 may include an elastic material having a higher elasticity than that of the constituent material of the rigid core 300, which will be described later. Accordingly, the movement resistance of the rigid core 300 within the shaping pad 200 can be minimized when the shaping pad 200 is pressed.

[0080] The shaping pad 200 may include a main pad portion 250 disposed overlapping on the main support portion 150, a first sub-pad portion 210 disposed overlapping on the first sub-support portion 110, and a second sub-pad portion 230 disposed overlapping on the second sub-support portion 130.

[0081] In the exemplary embodiment, the constituent materials of the main pad portion 250, the first sub-pad portion 210, and the second sub-pad portion 230 may have substantially the same density.

[0082] In some exemplary embodiments, the constituent materials of the first sub-pad portion 210 and the second sub-pad portion 230 may have a density smaller than that of the constituent material of the main pad portion 250, which can also promote the movement of the rigid core 300 disposed within the second sub-pad portion 230 and the first sub-pad portion 210, as will be described later.

[0083] The rigid core 300 may be along as Figure 1extends in the second direction DR2 as shown. The rigid core 300 may include a core connection portion 310 and a main core portion 330. The core connection portion 310 is physically connected to the attachment portion CP of the main support portion 150 of the shaping pad support 100, and the main core portion 330 is connected to the core connection portion 310 and disposed within the sub-pad portions 210 and 230.

[0084] The core connection portion 310 of the rigid core 300 may be physically coupled to the attachment portions CP at one end and the other end of the main support portion 150 in the first direction DR1. The core connection portion 310 may be connected to the attachment portion CP of the main support portion 150 so as to be rotatable in the third direction DR3 (i.e., in the thickness direction). Thus, the main core portion 330 may easily move along the thickness direction.

[0085] The main core portion 330 of the rigid core 300 may be respectively disposed within the first sub-pad portion 210 and the second sub-pad portion 230. Since the main core portion 330 is respectively disposed within the first sub-pad portion 210 and the second sub-pad portion 230, when the main pad portion 250 of the shaping pad 200 is squeezed as described later, since the constituent material of the main pad portion 250 moves toward the adjacent sub-pad portions 210 and 230 due to the squeezing caused by the upward movement of the vertical motor 400, the main core portion 330 may move in the thickness direction. Thus, the sub-pad portions 210 and 230 may be deformed more convexly toward one side and the other side in the first direction DR1, thereby further promoting the adhesion at the bending portions and the side portions of the target panel and the cover window.

[0086] The rigid core 300 may be made of a material having a higher stiffness than the constituent material of the shaping pad 200 so as to be movable within the shaping pad 200. In other words, the main core portion 330 of the rigid core 300 may include a metallic material having a higher stiffness than the constituent material of the sub-pad portions 210 and 230. For example, the rigid core 300 may be formed to include at least one of aluminum and an alloy containing aluminum, but the exemplary embodiments are not limited thereto.

[0087] The vertical motor 400 may be disposed below the shaping pad support 100. The vertical motor 400 may vertically move the shaping pad support 100 and the shaping pad 200 disposed above it to generate a pressure that promotes the adhesion of the cover window and the target panel.

[0088] Reference Figure 2, the main core portion 330 of the rigid core 300 can be disposed within the sub-pad portions 210 and 230 and may not be in direct contact with the surfaces of the sub-pad portions 210 and 230. In other words, a first average width W1 from the main support portion 150 of the shaped pad support 100 to one end of each of the sub-support portions 110 and 130 can be greater than a second average width W2 from the core connection portion 310 to one end of the main core portion 330. Accordingly, it is possible to prevent the contact pressure between the cover window and the target panel from abnormally increasing as the main core portion 330 of the rigid core 300 comes into direct contact with the surface of the shaped pad 200.

[0089] Hereinafter, a method for manufacturing a display device using the laminating apparatus 1 will be described. In the following exemplary embodiments, components identical to those of the above-described exemplary embodiments are denoted by the same reference numerals, and their descriptions will be omitted or simplified to avoid redundancy.

[0090] Figure 3 is a flowchart of an exemplary embodiment of a method for manufacturing a display device according to the principles of the present invention. Figures 4 to 8 is a cross-sectional view of an exemplary embodiment of a step of a method for manufacturing a display device according to the principles of the present invention. Figures 9 to 11 is a cross-sectional view of an exemplary embodiment of a step in a case where a rigid core is used to attach a bent portion and a side portion of a cover window to a target panel.

[0091] As Figure 3 shown, the method for manufacturing a display device may include: placing a target panel on a shaped pad and placing a cover window above the target panel (S10); and moving a rigid core disposed within the shaped pad from a panel flat portion of the target panel toward a panel bent portion of the target panel and pressing the target panel to couple the cover window to the target panel (S20).

[0092] Referring to Figure 3 and Figure 4 , a guide film GF is disposed on the shaped pad 200, the target panel 10 is disposed on the guide film GF, an inter-module bonding member 30 is disposed on the target panel 10, the cover window 50 is separately located above the inter-module bonding member 30, clamping members CLP are disposed at one end and the other end of the guide film GF in a first direction DR1 to simultaneously clamp and fix one end portion and the other end portion of the guide film GF in the first direction DR1, and a roller portion RL is disposed on the clamping members CLP.

[0093] As Figure 4 shown, the guide film GF may further extend outward from the shaped pad 200 on one side and on the other side in the first direction DR1. The target panel 10 may be directly placed on a central portion of the guide film GF to contact therewith.

[0094] The target panel 10 is a panel for displaying an image through an input data signal. Panels such as an organic light emitting display panel, a liquid crystal display panel, a plasma display panel, and an electrophoretic display panel can be used as the target panel 10. In the illustrated exemplary embodiment, the organic light emitting display panel is used as the target panel 10.

[0095] The target panel 10 may have a shape similar to the planar shape of the shaping pad 200 described above with reference to Figure 1 In other words, in a plan view, the target panel 10 may have a rectangular shape including a short side portion extending along a first direction DR1 and a long side portion extending along a second direction DR2, or a rectangular shape including rounded corners. However, the exemplary embodiment is not limited thereto, and the planar shape of the target panel 10 may be various shapes.

[0096] The target panel 10 may include a display portion and a driving portion. The display portion may be disposed in a substantially central region of the target panel 10, and the driving portion may be disposed on one side and / or the other side of the display portion of the target panel 10 in the first direction DR1 and / or on the periphery thereof.

[0097] The display portion includes a plurality of pixels. Each pixel may include a light emitting layer and a circuit layer for controlling the amount of light emitted from the light emitting layer. The circuit layer may include display wirings, display electrodes, and at least one transistor. The light emitting layer may include an organic light emitting material. The light emitting layer may be encapsulated by an encapsulation layer. The encapsulation layer may encapsulate the light emitting layer to prevent moisture and the like from infiltrating from the outside. The encapsulation layer may be a single or multi-layer inorganic film, or a laminated film composed of alternately stacked inorganic films and organic films.

[0098] The driving portion may be disposed on the periphery of the display portion in the first direction DR1, for example, on one side and / or the other side. The driving portion may be a non-display portion that does not display an image. Different from the display portion, the driving portion may not include pixels. When the display portion has a rectangular shape including rounded corners, the driving portion is disposed adjacent to at least one side of the rectangular shape of the display portion. The driving portion may include driving wiring pads and driving wirings connected to the display wirings of the pixels. External components such as a driving chip or a printed circuit board may be mounted on the driving wiring pads.

[0099] In one exemplary embodiment, the target panel 10 may include a flexible substrate. The flexible substrate may be formed to include a flexible plastic material such as, for example, polyimide. The target panel 10 may have flexibility. In other words, the target panel 10 may be formed of a material or structure that can be bent, folded, or curled, such that the target panel 10 can be bent, folded, or curled.

[0100] The inter-module bonding member 30 can be disposed on the target panel 10. The inter-module bonding member 30 can be directly formed on the upper surface of the target panel 10. The planar shape of the inter-module bonding member 30 can be substantially the same as or similar to the planar shape of the target panel 10. In other words, the planar dimensions of the inter-module bonding member 30 can be substantially the same as the planar dimensions of the target panel 10. When the inter-module bonding member 30 and the target panel 10 are pressed into the cover window 50 as will be described later, the inter-module bonding member 30 can be bent together with the target panel 10.

[0101] The inter-module bonding member 30 can be used to attach the target panel 10 to the cover window 50. The inter-module bonding member 30 can include an adhesive layer, a bonding layer, or a resin layer. For example, the inter-module bonding member 30 can contain a polymer material classified as a silicone polymer, a urethane polymer, an SU polymer having a silicone urethane hybrid structure, an acrylic polymer, an isocyanate polymer, a polyvinyl alcohol polymer, a gelatin polymer, an ethylene polymer, a latex polymer, a polyether polymer, an aqueous polyester polymer, etc.

[0102] The cover window 50 can be located above the inter-module bonding member 30. Although not shown, the cover window 50 can be fixed by a jig device. For example, the jig device can be used to fix the cover window 50 above the inter-module bonding member 30 such that they are spaced apart from each other by a vacuum adsorption method or an adhesion method.

[0103] The cover window 50 can be made of transparent glass or plastic. In other words, the cover window 50 can be formed of a light-transmitting material.

[0104] The cover window 50 can be flexible. In other words, the cover window 50 can be formed of a material or structure that can be bent, folded, or curled such that the cover window 50 can be bent, folded, or curled.

[0105] The cover window 50 can include a bottom surface facing the target panel 10 and a top surface opposite to the bottom surface.

[0106] The clamp CLP and the roller portion RL can be respectively disposed on one side and the other side of the guide film GF in the first direction DR1. The clamp CLP can be used to clamp and fix the upper and lower surfaces of one end portion and the other end portion of the guide film GF in the first direction DR1. The roller portion RL can be disposed on the clamp CLP. The roller portion RL can include an end portion that contacts the upper surface of the guide film GF as shown in Figure 4 As will be described later, the roller portion RL can move toward the target panel 10 and can be used to bend the target panel 10 and the inter-module bonding member 30. The roller portion RL can move together with the clamp CLP while being fixed to the clamp CLP.

[0107] After that, refer to Figure 3and Figure 5 , the clamping member CLP and the roller portion RL are moved downward in the third direction DR3 to lower the opposite end portions of the guiding film GF in the first direction DR1.

[0108] Thus, while the central region of the guiding film GF that overlaps with the shaping pad 200 in the thickness direction remains flat as it is, the peripheral regions of the guiding film GF that do not overlap with the shaping pad 200 can be bent downward to follow the lowering of the clamping member CLP and the roller portion RL.

[0109] As Figure 5 shown, the guiding film GF may include a first flat portion GF1, a guiding connection portion GF3, and a second flat portion GF2, wherein the first flat portion GF1 overlaps with the shaping pad 200, the guiding connection portion GF3 overlaps with the clamping member CLP and the roller portion RL, and the second flat portion GF2 is disposed between the first flat portion GF1 and the guiding connection portion GF3 to connect them and is inclined at a predetermined inclination. As Figure 5 shown, the target panel 10 may overlap with the first flat portion GF1 of the guiding film GF, but may not overlap with the guiding connection portion GF3 and the second flat portion GF2 of the guiding film GF.

[0110] The flexible cover window 50 includes a plurality of regions. The cover window 50 may include a cover flat portion W_FR, a first cover bending portion W_BS1, and a second cover bending portion W_BS2, wherein the cover flat portion W_FR is located in the central region, the first cover bending portion W_BS1 is located on one side of the cover flat portion W_FR in the first direction DR1, and the second cover bending portion W_BS2 is located on the other side of the cover flat portion W_FR in the first direction DR1. The first cover bending portion W_BS1 may include a first cover bending section W_BR1 and a first cover side section W_SR1, wherein the first cover bending section W_BR1 is connected to the cover flat portion W_FR and is bent in the thickness direction, and the first cover side section W_SR1 is connected to the first cover bending section W_BR1 and is located between the first cover bending section W_BR1 and one end portion of the cover window 50. As Figure 5 shown, the upper surface and the lower surface of the first cover side section W_SR1 may be oriented in the first direction DR1, while the upper surface and the lower surface of the cover flat portion W_FR may be oriented in the third direction DR3.

[0111] The cover window 50 may have an angle of 90 degrees or more between the upper surface and the lower surface of the first cover side section W_SR1 and the upper surface and the lower surface of the cover flat portion W_FR. However, the exemplary embodiments are not limited thereto, and the angle between the upper surface and the lower surface of the first cover side section W_SR1 and the upper surface and the lower surface of the cover flat portion W_FR may be an acute angle less than 90 degrees or an obtuse angle greater than 90 degrees.

[0112] The second cover bending portion W_BS2 may have substantially the same configuration as the first cover bending portion W_BS1. In other words, the second cover bending portion W_BS2 may include a second cover bending part W_BR2 and a second cover side part W_SR2, wherein the second cover bending part W_BR2 is connected to the cover flat portion W_FR and is bent in the thickness direction, and the second cover side part W_SR2 is connected to the second cover bending part W_BR2 and is located between the second cover bending part W_BR2 and the other end of the cover window 50. As Figure 5 shown, the upper and lower surfaces of the second cover bending part W_BR2 may be oriented in the first direction DR1, while the upper and lower surfaces of the cover flat portion W_FR may be oriented in the third direction DR3.

[0113] The angle between the upper and lower surfaces of the second cover side part W_SR2 and the upper and lower surfaces of the cover flat portion W_FR may be 90 degrees or greater. However, the exemplary embodiments are not limited thereto, and the angle between the upper and lower surfaces of the second cover side part W_SR2 and the upper and lower surfaces of the cover flat portion W_FR may be an acute angle less than 90 degrees or an obtuse angle greater than 90 degrees.

[0114] Reference Figure 3 and Figure 6 , the roller part RL then moves towards the shaping pad 200. In other words, by moving the roller part RL and the clamping part CLP inwards towards the shaping pad 200, the inclination angle of the guiding connection part GF3 of the guiding film GF can be increased. At the same time, the area of the first flat part GF1 of the guiding film GF can be reduced and the area of the guiding connection part GF3 can be increased. Therefore, the target panel 10 overlapping with the first flat part GF1 of the guiding film GF can also be arranged on the guiding connection part GF3 with an increased area. In other words, the target panel 10 can be substantially arranged on the first flat part GF1 of the guiding film GF and can be partially arranged on the guiding connection part GF3 with an increased area. The target panel 10 arranged on the guiding connection part GF3 can be bent along the thickness direction (e.g., the third direction DR3).

[0115] Specifically, as Figure 6As shown, the target panel 10 may include a panel flat portion FR and panel bending portions BS1 and BS2 positioned around the panel flat portion FR. The panel bending portions BS1 and BS2 of the target panel 10 may be disposed adjacent to the long side portions of the shaping pad 200. More specifically, the target panel 10 may include a panel flat portion FR, a first panel bending portion BS1, and a second panel bending portion BS2, wherein the panel flat portion FR is located at the center, the first panel bending portion BS1 is located on one side of the panel flat portion FR in a first direction DR1, and the second panel bending portion BS2 is located on the other side of the panel flat portion FR in the first direction DR1.

[0116] The first panel bending portion BS1 may include a first panel bending section BR1 and a first panel side section SR1, wherein the first panel bending section BR1 is connected to the panel flat portion FR and bends in the thickness direction, and the first panel side section SR1 is connected to the first panel bending section BR1 and is located between the first panel bending section BR1 and one end of the target panel 10. As Figure 6 shown, the upper and lower surfaces of the first panel side section SR1 may be oriented in the first direction DR1, while the upper and lower surfaces of the panel flat portion FR may be oriented in a third direction DR3.

[0117] The target panel 10 may have an angle of 90 degrees or greater between the upper and lower surfaces of the first panel side section SR1 and the upper and lower surfaces of the panel flat portion FR. However, the exemplary embodiment is not limited thereto, and the angle between the upper and lower surfaces of the first panel side section SR1 and the upper and lower surfaces of the panel flat portion FR may be an acute angle less than 90 degrees or an obtuse angle greater than 90 degrees.

[0118] The second panel bending portion BS2 may have substantially the same configuration as the first panel bending portion BS1. In other words, the second panel bending portion BS2 may include a second panel bending section BR2 and a second panel side section SR2, wherein the second panel bending section BR2 is connected to the panel flat portion FR and bends in the thickness direction, and the second panel side section SR2 is connected to the second panel bending section BR2 and is located between the second panel bending section BR2 and the other end of the target panel 10. As Figure 6 shown, the upper and lower surfaces of the second panel side section SR2 may be oriented in the first direction DR1, while the upper and lower surfaces of the panel flat portion FR may be oriented in a third direction DR3.

[0119] The angles between the upper and lower surfaces of the second panel side portion SR2 and the upper and lower surfaces of the panel flat portion FR can be 90 degrees or greater. However, the exemplary embodiments are not limited thereto, and the angles between the upper and lower surfaces of the second panel side portion SR2 and the upper and lower surfaces of the panel flat portion FR can be an acute angle less than 90 degrees or an obtuse angle greater than 90 degrees.

[0120] The inter-module bonding member 30 disposed on the upper surface of the target panel 10 can be bent together with the target panel 10 at one end and the other end to follow the shape of the panel flat portion FR and the panel bending portions BS1 and BS2 of the target panel 10. In other words, the shape of the inter-module bonding member 30 can be substantially the same as the shape of the target panel 10.

[0121] As Figure 6 shown, the cover window 50 can have dimensions that externally cover the inter-module bonding member 30 and the target panel 10, and it will be described below. In other words, the first panel bending portion BS1, the second panel bending portion BS2, and the panel flat portion FR of the target panel 10 can be covered by the first cover bending portion W_BS1, the second cover bending portion W_BS2, and the cover flat portion W_FR of the cover window 50.

[0122] Subsequently, referring to Figure 7 and Figure 8 , the shaping pad support 100, the shaping pad 200, the guiding film GF, the target panel 10, and the inter-module bonding member 30 are raised toward the cover window 50.

[0123] When the shaping pad support 100, the shaping pad 200, the guiding film GF, the target panel 10, and the inter-module bonding member 30 are raised toward the cover window 50, as Figure 8 shown, the portion of the inter-module bonding member 30 that overlaps with the panel flat portion FR of the target panel 10 can contact the cover flat portion W_FR of the cover window 50, and the portions of the inter-module bonding member 30 that overlap with the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel 10 can respectively contact the first cover bending portion W_BS1 and the second cover bending portion W_BS2 of the cover window 50.

[0124] As a result, the panel flat portion FR, the first panel bending portion BS1, and the second panel bending portion BS2 of the target panel 10 can be respectively bonded to the cover flat portion W_FR, the first cover bending portion W_BS1, and the second cover bending portion W_BS2 of the cover window 50 through the inter-module bonding member 30 disposed therebetween.

[0125] When the portion of the inter-module bonding member 30 that overlaps with the panel flat portion FR of the target panel 10 contacts the cover flat portion W_FR in the thickness direction due to the vertical motor 400 moving in the vertical direction (e.g., in the thickness direction), the material of the shaping gasket 200 that overlaps with the panel flat portion FR of the target panel 10 and the cover flat portion W_FR of the cover window 50 can move peripherally in the first direction DR1 through the fixed cover window 50. For example, the constituent materials of the main gasket portion 250, the first sub-gasket portion 210, and the second sub-gasket portion 230 of the shaping gasket 200 that overlap with the panel flat portion FR of the target panel 10 and the cover flat portion W_FR of the cover window 50 can move peripherally in the first direction DR1 to the periphery of the shaping gasket 200.

[0126] When the portion of the inter-module bonding member 30 that overlaps with the panel flat portion FR of the target panel 10 contacts the cover flat portion W_FR in the thickness direction, sufficient contact pressure can be generated between the panel flat portion FR of the target panel 10 and the cover flat portion W_FR of the cover window 50 to provide sufficient adhesive force.

[0127] Insufficient adhesive force may not be generated between the first panel bending portion BS1 of the target panel 10 and the first cover bending portion W_BS1 of the cover window 50, and between the second panel bending portion BS2 and the second cover bending portion W_BS2. More specifically, as described above, since the vertical motor 400 moves the target panel 10 and the inter-module bonding member 30 in the thickness direction toward the cover window 50, the contact pressure in the first direction DR1 between the first panel bending portion BS1 and the first cover bending portion W_BS1, and between the second panel bending portion BS2 and the second cover bending portion W_BS2 may not be sufficient.

[0128] In addition, the constituent materials of the main gasket portion 250, the first sub-gasket portion 210, and the second sub-gasket portion 230 of the shaping gasket 200 can move peripherally in the first direction DR1 to the periphery of the shaping gasket 200 and be biased to the regions of the sub-gasket portions 210 and 230 adjacent to the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel 10. Even if the contact pressure between the first panel bending portion BS1 and the first cover bending portion W_BS1, and between the second panel bending portion BS2 and the second cover bending portion W_BS2 is increased to some extent, the contact pressure therebetween may still not be sufficient to provide sufficient adhesive force.

[0129] To increase the contact pressure between the first panel bending portion BS1 and the first cover bending portion W_BS1, and between the second panel bending portion BS2 and the second cover bending portion W_BS2, it is necessary to vertically move the shaping pad 200, the target panel 10, and the inter-module bonding member 30 in the direction toward the cover window 50. In this case, the contact pressure between the panel flat portion FR of the target panel 10 and the cover flat portion W_FR of the cover window 50 is excessive, and thus, components of the target panel 10 (e.g., multiple conductive layers and insulating layers of the circuit layer) may be broken due to the increased contact pressure and may be physically damaged, resulting in defects in the target panel 10.

[0130] However, the lamination device 1 can be configured as described above to further include a rigid core 300, which is bonded to the shaping pad support 100 of the lamination device 1 and moves sequentially from the panel flat portion FR of the target panel 10 toward the first panel bending portion BS1 within the shaping pad 200. Therefore, even if the shaping pad 200, the target panel 10, and the inter-module bonding member 30 are not vertically moved in the direction toward the cover window 50, it is possible to increase the contact pressure between the first panel bending portion BS1 and the first cover bending portion W_BS1, and between the second panel bending portion BS2 and the second cover bending portion W_BS2.

[0131] In this case, the core connection portion 310 serves as the rotation axis of the main core portion 330, and the rigid core 300 disposed within the shaping pad 200 moves from the panel flat portion FR of the target panel 10 toward the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel 10 to squeeze the target panel 10. Therefore, the step of bonding the cover window 50 to the target panel 10 may further include moving the main core portion 330 from the panel flat portion FR toward the first panel bending portion BS1 and the second panel bending portion BS2 with the core connection portion 310 as the rotation axis.

[0132] Reference Figure 3 and Figure 9 As shown in FIGS. 13 and 14, when the shaping pad 200, the target panel 10, and the inter-module bonding member 30 are moved toward the cover window 50 by the vertical motor 400, as described above, the material of the shaping pad 200 that overlaps with the panel flat portion FR of the target panel 10 and the cover flat portion W_FR of the cover window 50 moves peripherally in the first direction DR1, and at the same time, a contact pressure is generated between the panel flat portion FR of the target panel 10 and the cover flat portion W_FR of the cover window 50, such that the panel flat portion FR and the cover flat portion W_FR can be bonded to each other through the inter-module bonding member 30.

[0133] Subsequently, referring to FIGS. 17 and 18, similar to Figure 3 and Figure 10 , similar to Figure 9In this case, the shaping pad 200, the target panel 10, and the inter-module bonding member 30 move further vertically in the direction toward the cover window 50. At the same time, since the material of the shaping pad 200 that overlaps with the panel flat portion FR moves toward the periphery in the first direction DR1, the main core portion 330 of the rigid core 300 moves in the thickness direction (e.g., the third direction DR3). In other words, the main core portion 330 can move from the panel flat portion FR of the target panel 10 to the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel 10. Specifically, the main core portion 330 can move from the panel flat portion FR to the first panel bending portion BR1 and the first panel side portion SR1 of the first panel bending portion BS1 in sequence. Similarly, the main core portion 330 can move from the panel flat portion FR to the second panel bending portion BR2 and the second panel side portion SR2 of the second panel bending portion BS2 in sequence.

[0134] Therefore, as Figure 10 shown, the moving material of the shaping pad 200 can cause the first sub-pad portion 210 adjacent to the first panel bending portion BR1 of the first panel bending portion BS1 of the target panel 10 to expand, so as to increase the contact pressure between the first panel bending portion BR1 and the first cover bending portion W_BR1. Therefore, the bonding force between the first panel bending portion BR1 and the first cover bending portion W_BR1 can be increased.

[0135] Similarly, the moving material of the shaping pad 200 can cause the second sub-pad portion 230 adjacent to the second panel bending portion BR2 of the second panel bending portion BS2 of the target panel 10 to expand, so as to increase the contact pressure between the second panel bending portion BR2 and the second cover bending portion W_BR2. Therefore, the bonding force between the second panel bending portion BR2 and the second cover bending portion W_BR2 can be increased.

[0136] Subsequently, referring to Figure 3 and Figure 11 , similar to Figure 9 the case, the shaping pad 200, the target panel 10, and the inter-module bonding member 30 move further vertically in the direction toward the cover window 50. At the same time, since the material of the shaping pad 200 that overlaps with the panel flat portion FR moves toward the periphery in the first direction DR1, the main core portion 330 of the rigid core 300 moves in the thickness direction (e.g., the third direction DR3). Therefore, as Figure 11 shown, the moving material of the shaping pad 200 can cause the first sub-pad portion 210 adjacent to the first panel side portion SR1 of the first panel bending portion BS1 of the target panel 10 to expand, so as to increase the contact pressure between the first panel side portion SR1 and the first cover side portion W_SR1. Therefore, the bonding force between the first panel side portion SR1 and the first cover side portion W_SR1 can be increased.

[0137] Similarly, the movement material of the shaping pad 200 can cause the second sub-pad portion 230 of the second panel side portion SR2 adjacent to the second panel bending portion BS2 of the target panel 10 to expand, so as to increase the contact pressure between the second panel side portion SR2 and the second cover side portion W_SR2. Therefore, the adhesion between the second panel side portion SR2 and the second cover side portion W_SR2 can be increased.

[0138] Figure 12 Exemplary embodiments showing the contact pressure between the target panel and the cover window depending on whether a rigid core is included. In Figure 12 which, (a) and (b) show the vertical movement distances of the shaping pad 200 for applying the same contact pressure between the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel 10 and the first cover bending portion W_BS1 and the second cover bending portion W_BS2 of the cover window 50, which depend on whether the laminating device 1 includes a rigid core 300.

[0139] More specifically, in the exemplary embodiment without the rigid core 300, as Figure 12 (a) of shows, the extrusion distance (i.e., the vertical movement distance) of the shaping pad 200 for applying a contact pressure of 0.1 MPa between the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel 10 and the first cover bending portion W_BS1 and the second cover bending portion W_BS2 of the cover window 50 is about 7.6 mm. As a result, it can be seen that the contact pressure between the panel flat portion FR and the cover flat portion W_FR is 0.96 Mpa. In the exemplary embodiment including the rigid core 300, as Figure 12 (b) of shows, the extrusion distance (i.e., the vertical movement distance) of the shaping pad 200 for applying a contact pressure of 0.1 MPa between the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel 10 and the first cover bending portion W_BS1 and the second cover bending portion W_BS2 of the cover window 50 is about 6.9 mm. As a result, it can be seen that the contact pressure between the panel flat portion FR and the cover flat portion W_FR is 0.78 Mpa.

[0140] In other words, since the rigid core 300 can reduce the extrusion distance of the shaping pad 200 (i.e., the pad extrusion distance) and can also reduce the contact pressure between the panel flat portion FR and the cover flat portion W_FR, the laminating device 1 including the rigid core 300 respectively disposed in the first sub-pad portion 210 and the second sub-pad portion 230 can also promote the adhesion between the target panel 10 and the cover window 50 in the bending regions of the target panel 10 and the cover window 50 and the side regions connected thereto.

[0141] In addition, by reducing the extrusion distance (i.e., the vertical movement distance) of the shaping pad 200 for applying the same contact pressure between the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel 10 and between the first cover bending portion W_BS1 and the second cover bending portion W_BS2 of the cover window 50, the contact pressure between the panel flat portion FR and the cover flat portion W_FR can be reduced. Therefore, it is possible to prevent the contact pressure between the panel flat portion FR of the target panel 10 and the cover flat portion W_FR of the cover window 50 from becoming excessive and prevent the components of the target panel 10 (e.g., the multiple conductive layers and insulating layers of the circuit layer) from cracking and being physically damaged due to the increased contact pressure, thereby preventing defects in the target panel 10.

[0142] Hereinafter, a lamination device according to another exemplary embodiment will be described. In the following exemplary embodiment, the same components as those in the above exemplary embodiment are denoted by the same reference numerals, and their descriptions will be omitted or simplified.

[0143] Figure 13A is a perspective view of another exemplary embodiment of the cover window, and Figure 13B is a perspective view of another exemplary embodiment of the target panel. Figure 14 is a perspective view of another exemplary embodiment of a lamination device constructed according to the principles of the present invention.

[0144] Referring to Figure 13A and Figure 14 , the cover window 50_1 is different from the cover window 50 according to the above exemplary embodiment in that: bending portions are formed in the short side portions. In addition, the lamination device 2 is different from the lamination device 1 according to the above exemplary embodiment in that: a rigid core 300 is further provided on the short side portions of the shaping pad 200.

[0145] More specifically, as Figure 13A shown, in the cover window 50_1, different from the cover window 50, the short side portions may also have bending portions. In other words, the cover window 50_1 may have a third cover bending portion W_BS3 and a fourth cover bending portion W_BS4 respectively formed in the short side portions.

[0146] The third cover bending portion W_BS3 may include a third cover bending part W_BR3 and a third cover side part W_SR3. Among them, the third cover bending part W_BR3 is adjacent to the cover flat portion W_FR, and the third cover side part W_SR3 is spaced apart from the cover flat portion W_FR by the third cover bending part W_BR3 inserted therebetween. The fourth cover bending portion W_BS4 may include a fourth cover bending part W_BR4 and a fourth cover side part W_SR4. Among them, the fourth cover bending part W_BR4 is adjacent to the cover flat portion W_FR, and the fourth cover side part W_SR4 is spaced apart from the cover flat portion W_FR by the fourth cover bending part W_BR4 inserted therebetween. Except that the third cover bending portion W_BS3 and the fourth cover bending portion W_BS4 are provided on the short side portion of the cover window 50_1, the third cover bending portion W_BS3 and the fourth cover bending portion W_BS4 have substantially the same shape as the first cover bending portion W_BS1 and the second cover bending portion W_BS2 described in the reference Figure 5 and thus, redundant descriptions will be omitted.

[0147] As Figure 14 shown, in the lamination device 2, the second rigid core 300a may also be provided at the short side portion of the shaping pad 200. In other words, the shaping pad support member 100a of the lamination device 2 may also include an attachment portion CP at the short side portion extending along the first direction DR1. The second rigid core 300a may also be connected to the attachment portion CP at the short side portion extending along the first direction DR1. The attachment portions CP at the short side portion may be respectively located at one end of the main support portion 150 in the second direction DR2 and at the other end of the main support portion 150 in the second direction DR2. The attachment portions CP at the short side portion may be formed to extend along the first direction DR1.

[0148] Each of the second rigid cores 300a may be provided within the shaping pad 200.

[0149] Reference Figure 13B , the cover window 50_1 is bonded to the target panel 10_1 having a bending portion formed at the short side portion by using the lamination device 2.

[0150] In other words, the target panel 10_1 may include not only the first panel bending portion BS1 and the second panel bending portion BS2, but also a third panel bending portion BS3 and a fourth panel bending portion BS4 provided on the short side portion of the target panel 10_1. The third panel bending portion BS3 may include a third panel bending part BR3 and a third panel side part SR3, wherein the third panel bending part BR3 is adjacent to the panel flat part FR, and the third panel side part SR3 is spaced apart from the panel flat part FR by the third panel bending part BR3 interposed therebetween. The fourth panel bending portion BS4 may include a fourth panel bending part BR4 and a fourth panel side part SR4, wherein the fourth panel bending part BR4 is adjacent to the panel flat part FR, and the fourth panel side part SR4 is spaced apart from the panel flat part FR by the fourth panel bending part BR4 interposed therebetween.

[0151] The inter-module bonding member 30 provided on the upper surface of the target panel 10_1 may be bent together with the target panel 10_1 at its end to follow the shape of the panel flat part FR and the panel bending portions BS1, BS2, BS3, and BS4 of the target panel 10_1. In other words, the shape of the inter-module bonding member 30 may be substantially the same as the shape of the target panel 10_1.

[0152] The shaping pad support 100a, the shaping pad 200, Figures 4 to 8 the guide film GF, the target panel 10_1, and the inter-module bonding member 30 shown in FIG. are raised toward the cover window 50_1. In other words, when the shaping pad support 100a, the shaping pad 200, the guide film GF, the target panel 10_1, and the inter-module bonding member 30 are raised toward the cover window 50_1, the portion of the inter-module bonding member 30 overlapping the panel flat part FR of the target panel 10_1 may contact the cover flat part W_FR of the cover window 50_1, and the portions of the inter-module bonding member 30 overlapping the first panel bending portion BS1, the second panel bending portion BS2, the third panel bending portion BS3, and the fourth panel bending portion BS4 of the target panel 10_1 may contact the first cover bending portion W_BS1, the second cover bending portion W_BS2, the third cover bending portion W_BS3, and the fourth cover bending portion W_BS4 of the cover window 50_1, respectively.

[0153] As a result, the panel flat part FR, the first panel bending portion BS1, the second panel bending portion BS2, the third panel bending portion BS3, and the fourth panel bending portion BS4 of the target panel 10_1 may be respectively bonded to the cover flat part W_FR, the first cover bending portion W_BS1, the second cover bending portion W_BS2, the third cover bending portion W_BS3, and the fourth cover bending portion W_BS4 of the cover window 50_1 through the inter-module bonding member 30 provided therebetween.

[0154] When the portion of the inter-module bonding member 30 that overlaps with the panel flat portion FR of the target panel 10_1 contacts the cover flat portion W_FR in the thickness direction due to the vertical movement of the vertical motor 400 in the vertical direction (e.g., in the thickness direction), the material of the shaping pad 200 that overlaps with the panel flat portion FR of the target panel 10_1 and the cover flat portion W_FR of the cover window 50_1 can move peripherally in the first direction DR1 and the second direction DR2 through the fixed cover window 50_1. For example, the constituent materials of the main pad portion 250, the first sub-pad portion 210, and the second sub-pad portion 230 of the shaping pad 200 that overlap with the panel flat portion FR of the target panel 10_1 and the cover flat portion W_FR of the cover window 50_1 can move peripherally in the first direction DR1 and the second direction DR2 to the periphery of the shaping pad 200.

[0155] As described above, sufficient adhesive force may not be obtained between the first panel bending portion BS1 of the target panel 10_1 and the first cover bending portion W_BS1 of the cover window 50_1, and between the second panel bending portion BS2 and the second cover bending portion W_BS2. Similarly, sufficient adhesive force may not be obtained between the third panel bending portion BS3 of the target panel 10_1 and the third cover bending portion W_BS3 of the cover window 50_1, and between the fourth panel bending portion BS4 and the fourth cover bending portion W_BS4.

[0156] However, the laminating device 2 can be configured as described above to further include a second rigid core 300a that is bonded to the shaping pad support member 100a of the laminating device 2 and moves sequentially from the panel flat portion FR of the target panel 10_1 to each adjacent panel bending portion BS1, BS2, BS3, and BS4 within the shaping pad 200. Therefore, even if the shaping pad 200, the target panel 10_1, and the inter-module bonding member 30 do not move vertically in the direction toward the cover window 50_1, the contact pressure between the first panel bending portion BS1 and the first cover bending portion W_BS1, between the second panel bending portion BS2 and the second cover bending portion W_BS2, between the third panel bending portion BS3 and the third cover bending portion W_BS3, and between the fourth panel bending portion BS4 and the fourth cover bending portion W_BS4 can be increased.

[0157] As described above in Figure 7 and Figure 8As explained above, when the shaping pad 200, the target panel 10_1, and the inter-module bonding member 30 are moved toward the cover window 50_1 by the vertical motor 400, as described above, the material of the shaping pad 200 that overlaps with the panel flat portion FR of the target panel 10_1 and the cover flat portion W_FR of the cover window 50_1 moves peripherally in the first direction DR1 and the second direction DR2. At the same time, a contact pressure is generated between the panel flat portion FR of the target panel 10_1 and the cover flat portion W_FR of the cover window 50_1, so that the panel flat portion FR and the cover flat portion W_FR can be bonded to each other through the inter-module bonding member 30.

[0158] Subsequently, as explained above in Figures 9 to 11 when the shaping pad 200, the target panel 10_1, and the inter-module bonding member 30 are further vertically moved in the direction toward the cover window 50_1, since the material of the shaping pad 200 that overlaps with the panel flat portion FR moves peripherally in the first direction DR1 and the second direction DR2, the main core portion 330a of the second rigid core 300a moves around the core connection portion 310a of the second rigid core 300a in the thickness direction (e.g., the third direction DR3). In other words, the main core portion 330a can move from the panel flat portion FR to the first panel bending portion BS1, the second panel bending portion BS2, the third panel bending portion BS3, and the fourth panel bending portion BS4 of the target panel 10_1. Specifically, the main core portion 330a can sequentially move from the panel flat portion FR to the first panel bending portion BR1 and the first panel side portion SR1 of the first panel bending portion BS1. Similarly, it can sequentially move from the panel flat portion FR to the second panel bending portion BR2 and the second panel side portion SR2 of the second panel bending portion BS2, from the panel flat portion FR to the third panel bending portion BR3 and the third panel side portion SR3 of the third panel bending portion BS3, and from the panel flat portion FR to the fourth panel bending portion BR4 and the fourth panel side portion SR4 of the fourth panel bending portion BS4.

[0159] Therefore, the moving material of the shaping pad 200 can cause the first sub-pad portion 210 adjacent to the first panel bending portion BR1 of the first panel bending portion BS1 of the target panel 10_1 to expand, so as to increase the contact pressure between the first panel bending portion BR1 and the first cover bending portion W_BR1. Therefore, the bonding force between the first panel bending portion BR1 and the first cover bending portion W_BR1 can be increased.

[0160] Similarly, the moving material of the shaping pad 200 can cause the second sub-pad portion 230 of the second panel bending portion BR2 of the second panel bending part BS2 adjacent to the target panel 10_1 to expand, so as to increase the contact pressure between the second panel bending portion BR2 and the second cover bending portion W_BR2. Therefore, the adhesion between the second panel bending portion BR2 and the second cover bending portion W_BR2 can be increased.

[0161] In addition, the moving material of the shaping pad 200 can cause the sub-pad portion of the third panel bending portion BR3 of the third panel bending part BS3 adjacent to the target panel 10_1 to expand, so as to increase the contact pressure between the third panel bending portion BR3 and the third cover bending portion W_BR3. Therefore, the adhesion between the third panel bending portion BR3 and the third cover bending portion W_BR3 can be increased.

[0162] In addition, the moving material of the shaping pad 200 can cause the sub-pad portion of the fourth panel bending portion BR4 of the fourth panel bending part BS4 adjacent to the target panel 10_1 to expand, so as to increase the contact pressure between the fourth panel bending portion BR4 and the fourth cover bending portion W_BR4. Therefore, the adhesion between the fourth panel bending portion BR4 and the fourth cover bending portion W_BR4 can be increased.

[0163] Subsequently, when the shaping pad 200, the target panel 10_1 and the inter-module bonding member 30 further move vertically in the direction towards the cover window 50_1, since the material of the shaping pad 200 overlapping with the panel flat portion FR moves towards the periphery in the first direction DR1, the main core portion 330a of the second rigid core 300a moves in the thickness direction (for example, the third direction DR3). Therefore, the moving material of the shaping pad 200 can cause the first sub-pad portion 210 of the first panel side portion SR1 of the first panel bending part BS1 adjacent to the target panel 10_1 to expand, so as to increase the contact pressure between the first panel side portion SR1 and the first cover side portion W_SR1. Therefore, the adhesion between the first panel side portion SR1 and the first cover side portion W_SR1 can be increased.

[0164] Similarly, the moving material of the shaping pad 200 can cause the second sub-pad portion 230 of the second panel side portion SR2 of the second panel bending part BS2 adjacent to the target panel 10_1 to expand, so as to increase the contact pressure between the second panel side portion SR2 and the second cover side portion W_SR2. Therefore, the adhesion between the second panel side portion SR2 and the second cover side portion W_SR2 can be increased.

[0165] In addition, similarly, the moving material of the shaping pad 200 can cause the sub-pad portion of the third panel side portion SR3 of the third panel bending portion BS3 adjacent to the target panel 10_1 to expand, so as to increase the contact pressure between the third panel side portion SR3 and the third cover side portion W_SR3. Therefore, the adhesion between the third panel side portion SR3 and the third cover side portion W_SR3 can be increased.

[0166] Similarly, the moving material of the shaping pad 200 can cause the sub-pad portion of the fourth panel side portion SR4 of the fourth panel bending portion BS4 adjacent to the target panel 10_1 to expand, so as to increase the contact pressure between the fourth panel side portion SR4 and the fourth cover side portion W_SR4. Therefore, the adhesion between the fourth panel side portion SR4 and the fourth cover side portion W_SR4 can be increased.

[0167] The lamination device 2 includes a second rigid core 300a disposed within the shaping pad 200, thereby further promoting the adhesion between the target panel 10_1 and the cover window 50_1 in the bending regions of the target panel 10_1 and the cover window 50_1 and the side regions connected thereto.

[0168] In addition, by reducing the extrusion distance (i.e., the vertical movement distance) of the shaping pad 200 for applying the same contact pressure between the first panel bending portion BS1 to the fourth panel bending portion BS4 of the target panel 10_1 and the first cover bending portion W_BS1 to the fourth cover bending portion W_BS4 of the cover window 50_1, the contact pressure between the panel flat portion FR and the cover flat portion W_FR can be reduced. Therefore, it is possible to prevent the contact pressure between the panel flat portion FR of the target panel 10_1 and the cover flat portion W_FR of the cover window 50_1 from becoming too large and the components of the target panel 10_1 (e.g., the multiple conductive layers and insulating layers of the circuit layer) from breaking and being physically damaged due to the increased contact pressure, thereby preventing defects in the target panel 10_1.

[0169] Figures 15A to 15C A cross-sectional view showing an exemplary embodiment of the rigid core of the lamination device.

[0170] Reference Figures 15A to 15C , the rigid core of the lamination device can have various shapes.

[0171] More specifically, as Figure 15A shown, one end of the main core portion 330_1 of the rigid core 300_1 can have a curved shape.

[0172] Since the end of the rigid core 300_1 is formed in a curved shape, even if the end of the rigid core 300_1 is formed to extend beyond the surface of the shaping pad 200, physical damage to the guiding film GF and the target panel disposed above it can be prevented in advance.

[0173] As Figure 15B shown, one end of the main core portion 330_2 of the rigid core 300_2 may have a pointed end shape.

[0174] As Figure 15C shown, the rigid core 300_3 may have a width that decreases from the core connection portion 310 to one end of the main core portion 330_3.

[0175] The lamination device includes the rigid cores 300_1, 300_2, and 300_3 disposed within the shaping pad 200, thereby further facilitating adhesion between the target panel and the cover window in the bending regions of the target panel and the cover window and the side regions connected thereto.

[0176] In addition, by reducing the extrusion distance (i.e., the vertical movement distance) of the shaping pad 200 for applying the same contact pressure between the first panel bending portion BS1 and the second panel bending portion BS2 of the target panel and the first cover bending portion W_BS1 and the second cover bending portion W_BS2 of the cover window, the contact pressure between the panel flat portion FR and the cover flat portion W_FR can be reduced.

[0177] Therefore, it is possible to prevent the contact pressure between the panel flat portion FR of the target panel and the cover flat portion W_FR of the cover window from becoming excessive and prevent the components of the target panel (e.g., the multiple conductive layers and insulating layers of the circuit layer) from cracking and being physically damaged due to the increased contact pressure, thereby preventing defects in the target panel.

[0178] Figure 16 is a perspective view of yet another exemplary embodiment of a lamination device constructed in accordance with the principles of the present invention. Figure 17 is Figure 16 a cross-sectional view of the lamination device.

[0179] Referring Figure 16 and Figure 17 , the lamination device 3 differs from the lamination device 1 according to the above exemplary embodiment in that: the rigid core 300_4 further includes a sub-core portion.

[0180] More specifically, in the lamination device 3, the rigid core 300_4 may further include a sub-core portion 350. The sub-core portion 350 may be physically connected to the main core portion 330 of the rigid core 300_4. The extending direction of the sub-core portion 350 may cross the extending direction of the main core portion 330.

[0181] The sub-core portion 350 can be in contact with the surface of the shaping pad 200 to contact the guiding film GF disposed thereabove. Since the sub-core portion 350 is in contact with the surface of the shaping pad 200 to contact the guiding film GF disposed thereabove, as described above, when the main-core portion 330 moves from the panel flat portion FR of the target panel 10 towards the panel bending portions BS1 and BS2, the movement speed of the main-core portion 330 can be controlled. In other words, the length of the sub-core portion 350 towards the surface of the shaping pad 200 can be adjusted. For example, in order to reduce the moving speed of the main-core portion 330, the length of the sub-core portion 350 towards the surface of the shaping pad 200 can be increased to reduce the speed by contacting the guiding film GF.

[0182] In addition, since the sub-core portions 350 are formed to have a certain length such that they contact the guiding film GF, the main-core portion 330 can be prevented from moving back from the panel bending portions BS1 and BS2 towards the panel flat portion FR, thereby promoting the adhesion between the target panel 10 and the cover window 50.

[0183] As Figure 16 shown, the sub-core portion 350 can have a length equal to the extension length of the main-core portion 330 in the second direction DR2 and can extend along the second direction DR2.

[0184] Figure 18 is a perspective view of another exemplary embodiment of a laminating device constructed according to the principles of the present invention.

[0185] Refer to Figure 18 , the laminating device 4 is different from the laminating device 3 of the exemplary embodiment according to Figure 16 and Figure 17 in that: the sub-core portion 350_1 has a length different from the extension length of the main-core portion 330 in the second direction DR2, and is only disposed at the outer end portions of the main-core portion 330 in the second direction DR2, without extending along the second direction DR2.

[0186] More specifically, the sub-core portion 350_1 can have a length different from the extension length of the main-core portion 330 in the second direction DR2, and can be only disposed at one end and the other end of the main-core portion 330 in the second direction DR2, without extending along the second direction DR2. Therefore, by the sub-core portion 350_1 contacting the guiding film GF, the contact pressure can be prevented from increasing over the entire area of the long side portion of the target panel 10.

[0187] In some exemplary embodiments, without being limited thereto, the sub-core portion 350_1 can be disposed between one end and the other end of the main-core portion 330 in the second direction DR2. In other words, the sub-core portion 350_1 can be disposed in the central region of the main-core portion 330 in the second direction DR2.

[0188] Figure 19A and Figure 19B A cross-sectional view showing other exemplary embodiments of the rigid core of the lamination device.

[0189] Referring to Figure 19A and Figure 19B , the lamination device includes sub-core portions 350_2, 350_3 having shapes different from the shape of the sub-core portion 350 of the lamination device according to the above-described exemplary embodiments.

[0190] More specifically, as Figure 19A shown, the end of the sub-core portion 350_2 of the rigid core 300_6 may have a curved shape.

[0191] In addition, as Figure 19B shown, the sub-core portion 350_3 of the rigid core 300_7 may have a width that gradually increases from the portion connected to the main core portion 330 towards one end thereof. However, without being limited thereto, the sub-core portion 350_3 may have a width that gradually decreases from the portion connected to the main core portion 330 towards one end thereof.

[0192] Although certain exemplary embodiments and examples have been described herein, other embodiments and modifications will be apparent from this description. Accordingly, the inventive concept is not limited to such embodiments, but rather to the broader scope of the appended claims and to various obvious modifications and equivalent arrangements that will be apparent to those of ordinary skill in the art.

Claims

1. A method for manufacturing a display device, the method comprising the steps of: placing a panel having a panel flat portion and a panel bent portion on a deformable pad having a core member; placing a cover window over the panel; and moving the core member disposed within the pad from a first position adjacent to the panel flat portion of the panel to a second position adjacent to the panel bent portion of the panel, and squeezing the panel to bond the cover window to the panel, wherein the material of the core member has a higher stiffness than the material of the pad, and wherein the core member does not contact the surface of the pad adjacent to the panel bent portion of the panel.

2. The method according to claim 1, wherein, the panel bent portion of the panel includes a panel bent section and a panel side portion, the panel bent section is adjacent to the panel flat portion of the panel, and the panel side portion is spaced apart from the panel flat portion of the panel by the panel bent section interposed therebetween, and the cover window includes a cover flat portion and a cover bent portion, the cover bent portion includes a cover bent section adjacent to the cover flat portion and a cover side portion spaced apart from the cover flat portion by the cover bent section interposed therebetween.

3. The method according to claim 2, wherein, the step of moving the core member and squeezing the panel to bond the cover window to the panel further includes the step of raising the pad to bond the panel flat portion to the cover flat portion.

4. The method according to claim 3, further comprising the steps of: after raising the pad to bond the panel flat portion to the cover flat portion, bonding the panel bent section to the cover bent section by squeezing the panel bent section with the core member.

5. The method according to claim 4, further comprising the steps of: after bonding the panel bent section to the cover bent section by squeezing the panel bent section with the core member, bonding the panel side portion to the cover side portion by squeezing the panel side portion with the core member.

6. The method according to claim 3, wherein, the step of raising the pad to bond the panel flat portion to the cover flat portion further includes the step of squeezing the pad to move the constituent material of the pad towards the periphery of the pad.

7. The method according to claim 6, wherein, the core member moves from the first position to the second position as the constituent material of the pad moves towards the periphery.

8. The method according to claim 2, further comprising the steps of: placing a guiding member between the pad and the panel, the guiding member extending beyond opposite ends of the pad.

9. The method according to claim 8, further comprising the step of fixing, with a clamping member, the portion of the guiding member extending beyond the ends of the pad.

10. The method according to claim 9, further comprising the steps of: After fixing the portion of the guiding member extending beyond the end of the pad using the clamping member, lower the clamping member to lower the portion of the guiding member extending beyond the end of the pad.

11. The method according to claim 10, further comprising the steps of: After lowering the clamping member to lower the portion of the guiding member extending beyond the end of the pad, move the roller portion fixed to the clamping member towards the pad.

12. The method according to claim 11, wherein, When the roller portion fixed to the clamping member moves inwards towards the pad, the panel bending portion of the panel is formed.

13. The method according to claim 1, wherein, The pad is a shaped pad, and the core member includes a rigid core connection portion and a rigid main core portion, wherein the core connection portion is connected to a support member provided below the pad, and the main core portion is provided within the pad and connected to the core connection portion.

14. The method according to claim 13, wherein, The step of moving the core member and pressing the panel to bond the cover window to the panel further includes the steps of: moving the main core portion from the first position to the second position using the core connection portion as a rotation axis.

15. The method according to claim 14, wherein, The core member further includes a sub-core portion extending in a direction crossing the longitudinal direction of the main core portion.

16. The method according to claim 15, wherein, The step of moving the main core portion from the first position to the second position using the core connection portion as a rotation axis further includes the steps of: bringing the sub-core portion into contact with the surface of the pad.

17. The method according to claim 1, wherein, The step of moving the core member and pressing the panel to bond the cover window to the panel further includes the steps of: moving the core member without contacting any outer surface of the pad.

18. An apparatus for manufacturing a display device, the apparatus comprising: A support member; A motor, provided below the support member and operable to linearly move the support member; A deformable pad, provided on the support member, wherein the pad is for supporting a panel having a panel flat portion and a panel bending portion; and A core member, connected to the support member and provided within the pad, wherein the material of the core member has a higher stiffness than the material of the pad, and wherein the core member does not contact the surface of the pad adjacent to the panel bending portion of the panel.

19. The apparatus according to claim 18, wherein, The support member includes a pad support member having a main support portion, a first sub-support portion provided on one side of the main support portion, and a second sub-support portion provided on the other side of the main support portion, and The main support portion has a first thickness, the first sub-support portion has a second thickness, and the second sub-support portion has a third thickness, and the first thickness is greater than the second thickness or the third thickness.

20. The device according to claim 19, wherein, the main support portion includes a groove recessed from the surface of the main support portion, and the core member includes a rigid core connection portion engaged with the groove of the main support portion and a rigid main core portion connected to the core connection portion.

21. The device according to claim 20, wherein, the pad includes a main pad portion overlapping with the main support portion, a first sub-pad portion overlapping with the first sub-support portion, and a second sub-pad portion overlapping with the second sub-support portion, and the first sub-pad portion and the second sub-pad portion have a uniform thickness.

22. The device according to claim 21, wherein, the thickness of the main pad portion is less than the thicknesses of the first sub-pad portion and the second sub-pad portion.

23. The device according to claim 21, wherein, the main core portion of the core member is disposed within each of the first sub-pad portion and the second sub-pad portion of the pad.

24. The device according to claim 23, wherein, the ends of the main core portion are located within each of the first sub-pad portion and the second sub-pad portion.

25. The device according to claim 23, wherein, the pad includes silicon, and the main core portion includes a metallic material.

26. The device according to claim 21, wherein, the core member further includes a rigid sub-core portion connected to the main core portion and extending in a direction crossing the longitudinal axis of the main core portion.

27. The device according to claim 26, wherein, the sub-core portion is in contact with the surface of at least one of the first sub-pad portion and the second sub-pad portion.

28. The device according to claim 27, wherein, one end of the sub-core portion has a pointed shape or a curved shape.

29. The device according to claim 20, wherein, one end of the main core portion has a pointed shape or a curved shape.

30. The device according to claim 20, wherein, the main core portion has a width that gradually decreases from the portion connected to the core connection portion to one end of the main core portion.

31. The device according to claim 18, wherein, the support member includes: a main support portion, a first sub-support portion, a second sub-support portion, a third sub-support portion, and a fourth sub-support portion, wherein the first sub-support portion is disposed on one side of the main support portion in a first direction, the second sub-support portion is disposed on the other side of the main support portion in the first direction, the third sub-support portion is disposed on one side of the main support portion in a second direction crossing the first direction, the fourth sub-support portion is disposed on the other side of the main support portion in the second direction, and the main support portion has a greater thickness than the thickness of each of the first to fourth sub-support portions.

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