Method of manufacturing a display device

Abstract

A method of manufacturing a display device is disclosed, the method including: providing a display panel including a folding region and a flat region adjacent to the folding region, the display panel being foldable at the folding region; providing a protective film on both the flat region and the folding region of the display panel; removing a portion of the protective film corresponding to the folding region from the display panel such that the folding region is exposed outside a remaining portion of the protective film, wherein the remaining portion of the protective film defines a bulge of the protective film at a portion of the flat region closest to the folding region; and removing a portion of the bulge from the portion of the flat region.

Description

[0001] Cross - reference to related applications

[0002] This application claims the priority and all rights arising therefrom of Korean Patent Application No. 10 - 2019 - 0085327, filed on July 15, 2019, the content of which is incorporated herein by reference in its entirety. Technical field

[0003] The present disclosure relates to an apparatus for removing bulges from a display device and a method of manufacturing a display device using the apparatus. Background art

[0004] Optical display devices, such as liquid crystal display devices and organic light - emitting diode display devices, include a flexible film as an alternative to a glass substrate or a relatively high - hardness substrate. Thus, foldable and unfoldable, flexible display devices have been developed. Summary of the invention

[0005] One or more embodiments provide a method of manufacturing a display device that can easily remove bulges incidentally occurring when setting or forming a folding region of the display device, and an apparatus for removing bulges used in the method.

[0006] A method of manufacturing a display device includes: providing a display panel that includes a folding region and a flat region adjacent to the folding region, the display panel being foldable at the folding region; providing a protective film on both the flat region and the folding region of the display panel; removing a portion of the protective film corresponding to the folding region from the display panel to expose the folding region outside the remaining portion of the protective film, wherein the remaining portion of the protective film defines a bulge of the protective film at the portion of the flat region closest to the folding region; and removing a portion of the bulge from the portion of the flat region.

[0007] In an embodiment, exposing the folding region may include removing the portion of the protective film corresponding to the folding region by using a hot block as a heating element.

[0008] In an embodiment, when exposing the folding region, the ratio of the thickness of the protective film to the width of the exposed folding region may be from about 1:5 to about 1:15.

[0009] In an embodiment, a cutter may include a blade that can be applied to the bulge to separate the portion of the bulge and a handle connected to the blade, and using the handle, the blade can be applied to the bulge.

[0010] In an embodiment, the angle formed between the cutting surface of the blade and the bottom surface of the blade may be equal to or less than about 30°.

[0011] In an embodiment, the cutting surface of the blade may be inclined with respect to the longitudinal direction of the blade.

[0012] In an embodiment, the cutting surface of the blade may define a side surface of the blade.

[0013] In an embodiment, the blade may have a V-shaped, U-shaped, quadrilateral, trapezoidal or hemispherical cross-section.

[0014] In an embodiment, the cutter may further include a support portion connecting the handle and the blade to each other, and the support portion may support the handle such that the length of the handle is inclined with respect to a direction perpendicular to the bottom surface of the blade.

[0015] In an embodiment, the angle formed between the central axis in the longitudinal direction of the handle and the central axis in the longitudinal direction of the support portion may be equal to or greater than about 45° and may be equal to or less than about 135°.

[0016] In an embodiment, the angle formed between the bottom surface of the blade and the central axis in the longitudinal direction of the support portion may be equal to or greater than about 45° and may be equal to or less than about 135°.

[0017] In an embodiment, the angle formed between the central axis in the longitudinal direction of the support portion and the central axis in the longitudinal direction of the handle may be equal to or greater than the angle formed between the central axis in the longitudinal direction of the support portion and the bottom surface of the blade.

[0018] In an embodiment, a protrusion protrudes from a reference plane within the protective film, and removing a portion of the protrusion using the cutter sets the bottom surface of the blade at an angle with respect to the reference plane of the protective film, wherein the angle may be equal to or less than about 45°.

[0019] In an embodiment, removing the protrusion may include defining a thickness of the protrusion based on the reference plane of the protective film that is equal to or less than 100 micrometers (μm).

[0020] A cutter for manufacturing a display device includes: a blade, by which a portion of a protrusion of a protective film can be removed from a flat region of a display panel of the display device, wherein the protrusion is provided at a portion of the flat region of the display panel closest to a folding region of the display panel, and the blade includes a cutting surface and a bottom surface opposite the cutting surface; and a handle connected to the blade, and by which the blade can be applied to the protrusion by an applicator.

[0021] In an embodiment, the angle formed between the cutting surface of the blade and the bottom surface of the blade may be equal to or less than about 30°.

[0022] In an embodiment, the cutting surface of the blade may be inclined with respect to the longitudinal direction of the blade.

[0023] In an embodiment, the cutting surface of the blade may define the side surface of the blade.

[0024] In an embodiment, the blade may have a V-shaped, U-shaped, quadrilateral, trapezoidal or hemispherical cross-section.

[0025] In an embodiment, the cutter may further include a support portion located between the handle and the blade and connecting the handle and the blade to each other, wherein the support portion supports the handle such that the length of the handle is inclined with respect to a direction perpendicular to the bottom surface of the blade.

[0026] In an embodiment, the angle formed between the central longitudinal axis of the handle and the central longitudinal axis of the support portion may be equal to or greater than about 45° and may be equal to or less than about 135°.

[0027] In an embodiment, the angle formed between the bottom surface of the blade and the central longitudinal axis of the support portion may be equal to or greater than about 45° and may be equal to or less than about 135°.

[0028] In an embodiment, the angle formed between the central longitudinal axis of the support portion and the central longitudinal axis of the handle may be equal to or greater than the angle formed between the central longitudinal axis of the support portion and the bottom surface of the blade.

[0029] According to one or more embodiments, by removing a part of the protective film, the cutter can be used to easily remove the bulge of the protective film that incidentally appears when forming the folding area of the display panel. Therefore, the folding interference phenomenon of the display device due to the bulge at the position closest to the folding area can be effectively prevented, thereby improving the quality of the display device. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] The above and other features of the present disclosure will become more apparent by describing the embodiments of the present disclosure in more detail with reference to the accompanying drawings, in which:

[0031] Figure 1A and Figure 1B are cross-sectional views showing the processes in the embodiments of the method of manufacturing a display device in sequence;

[0032] Figure 2A is Figure 1A a top view of the display panel of the display device shown in Figure 2B and is an enlarged cross-sectional view of an embodiment of the display panel;

[0033] Figure 3 is an enlarged cross-sectional view showing an embodiment of the folded display device manufactured by the manufacturing method;

[0034] Figure 4A is a top view of an embodiment of the cutter, and Figure 4B is a side sectional view of the cutter;

[0035] Figure 5 is a top view of an embodiment of the process of removing a bulge using the cutter;

[0036] Figure 6A is a top view of an embodiment of the cutter, Figure 6B is a side sectional view of the cutter, Figure 6C_(1) to Figure 6C_(4) is a sectional view of an embodiment of the blade of the cutter;

[0037] Figure 7 is a sectional view of an embodiment showing the shape of the bulge;

[0038] Figure 8A to Figure 8C is a side sectional view of an embodiment of the cutter;

[0039] Figure 8D and Figure 8E is a top view of an embodiment of the cutter;

[0040] Figure 9 is a view showing an embodiment of the process of removing a bulge using the cutter; and

[0041] Figure 10A is a side sectional view of an embodiment of the cutter, and Figure 10B is a top view of the cutter. Detailed Embodiments

[0042] The present disclosure may be modified in various ways and have various forms. Accordingly, the embodiments will be shown in the drawings and will be described in detail in the specification. However, it should be understood that the present disclosure is not intended to be limited to the disclosed forms, and the present disclosure includes all modifications, equivalents, and alternatives within the spirit and technical scope of the present disclosure.

[0043] When describing each drawing, like reference numerals are used for like components. In the drawings, for the clarity of the present disclosure, the dimensions of the structures are shown enlarged from the actual dimensions.

[0044] The terms "first", "second", etc. may be used to describe various components, but these components should not be limited by these terms. These terms are only used for the purpose of distinguishing one component from another. For example, without departing from the scope of the present disclosure, the first component may be referred to as the second component, and similarly, the second component may also be referred to as the first component. Singular expressions include plural expressions unless the context clearly indicates otherwise.

[0045] The terms used in this specification are for the purpose of describing particular embodiments only and are not intended to be limiting. As used herein, "a," "an," "the," and "at least one" do not denote a limitation of quantity and are intended to include both the singular and the plural, unless the context clearly indicates otherwise. For example, "a component" has the same meaning as "at least one component" unless the context clearly indicates otherwise. "At least one" should not be construed as limiting "a" or "an." "Or" means "and / or." As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items. It should be understood that in this application, terms such as "comprising," "having," etc. are used to specify the presence of the described features, numbers, steps, operations, components, parts, or combinations thereof in the specification, but do not preclude the possibility of the presence or addition of one or more other features, numbers, steps, operations, components, parts, or combinations thereof.

[0046] In addition, in a case where a part of a layer, film, region, plate, etc. is referred to as being related to another element (such as "on" another part), it includes not only the case where the part is directly "on" the other part, but also the case where there is another part between the part and the other part. Conversely, in a case where a part of a layer, film, region, plate, etc. is referred to as being related to another element (such as directly "on" another part), there is no other part or element (such as an intermediate member) between the part and the other element.

[0047] In addition, in this specification, when a part of a layer, film, region, plate, etc. is "on" another part, the forming direction is not limited to the upward direction, but includes parts on the side surface and / or in the downward direction. Conversely, when a part of a layer, film, region, plate, etc. is "below" another part, this includes not only the case where the part is directly "below" the other part, but also the case where there is another part between the part and the other part.

[0048] In addition, relative terms such as "lower" or "bottom" and "upper" or "top" may be used herein to describe the relationship of one element to another element as shown in the drawings. It should be understood that, in addition to the orientation depicted in the drawings, the relative terms are intended to include different orientations of the device. For example, if the device in one of the drawings is flipped, the element described as being on the "lower" side of another element will then be oriented on the "upper" side of the other element. Thus, the exemplary term "lower" can include both the "lower" and "upper" orientations depending on the specific orientation of the drawing. Similarly, if the device in one of the drawings is flipped, the element described as being "below" or "beneath" another element will then be oriented as being "above" the other element. Thus, the exemplary terms "below" or "beneath" can include both the "above" and "below" orientations.

[0049] As used herein, "about" or "approximate" includes the stated value and the average value within an acceptable deviation range of the specific value determined by those of ordinary skill in the art considering the measurements discussed and the errors associated with the measurements of the specific quantity (i.e., the limitations of the measurement system). For example, "about" can mean within one or more standard deviations of the stated value, or within ±30%, ±20%, ±10%, or ±5% of the stated value.

[0050] 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 pertains. It will be further understood that 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 this disclosure, and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0051] Exemplary embodiments are described herein with reference to cross-sectional views that are schematic illustrations of idealized embodiments. As such, variations in the shape of the illustrations due to, for example, manufacturing techniques and / or tolerances are to be expected. Accordingly, the embodiments described herein should not be construed as limited to the particular shapes of regions shown herein, but should include deviations in shape that result, for example, from manufacturing. For example, regions shown or described as flat will generally have rough and / or non-linear features. Additionally, the sharp corners shown may be rounded. Thus, the regions shown in the figures are schematic in nature, and their shapes are not intended to show the exact shape of the regions and are not intended to limit the scope of the current claims.

[0052] During the manufacturing process, a display device can be manufactured by providing a protective film 200 for protecting the display panel 100. In the method of manufacturing a display device, a portion of the protective film 200 is heated and removed to provide a folding region A where the display panel 100 can be folded. That is, the folding region A is a planar region where the protective film 200 can be removed from the display panel 100. When the protective film 200 is heated and removed, the protective film 200 that may melt at the folding region A may be pushed onto the surface of the protective film 200, and thus a bulge 210 having a protruding shape is formed. The bulge 210 is provided at the boundary between the folding region A and the flat region B. If the bulge 210 having a protruding shape remains on the display panel 100, interference with the folding operation of the display panel 100 may occur.

[0053] Hereinafter, embodiments of the present disclosure will be described in detail with reference to the accompanying drawings.

[0054] Figure 1A and Figure 1B are cross-sectional views sequentially showing the processes in an embodiment of the method of manufacturing a display device,Figure 2A is Figure 1A a top view of the display panel 100 of the display device shown in Figure 2B is Figure 2A an enlarged cross-sectional view of an embodiment of the display panel 100 in Figure 3 is an enlarged cross-sectional view showing an embodiment of a folded display device manufactured by a manufacturing method.

[0055] Refer to Figure 1A and Figure 1B The method of manufacturing a display device includes: disposing a protective film 200 on one surface of the display panel 100 of the display device; exposing the folding region A of the display panel 100; and removing a part of the bulge 210.

[0056] The display panel 100 may be provided with thin film transistors 110 and light emitting elements 120 for realizing an image on a flexible substrate 130 (for example, a base substrate). Since the display panel 100 uses a flexible substrate 130 instead of a relatively rigid glass substrate, the display panel 100 can be folded and unfolded within the range allowed by its flexibility. That is, the display panel 100 can implement a flexible display panel that can be folded and unfolded.

[0057] The display panel 100 may include a folding region A and a non-folding region (for example, a flat region B) adjacent to the folding region A. The flat region B may be provided in plurality, and the plurality of flat regions B include a first flat region and a second flat region. In the direction along the flexible substrate 130, two non-folding regions (or flat regions B) may face each other, and the folding region A is therebetween.

[0058] Figure 2A schematically shows the planar structure of the display panel 100. The display device, the display panel 100, and various components of these elements may be provided in a plane defined by a first direction and a second direction intersecting the first direction. In Figure 2A for example, the horizontal direction and the vertical direction may differently represent the first direction and the second direction. The thickness of the display device, the display panel 100, and various components of these elements may be defined along a third direction intersecting both the first direction and the second direction. In Figure 1A , Figure 1B and Figure 2B for example, the vertical direction represents the thickness direction, while the horizontal direction differently represents the first direction and / or the second direction.

[0059] Refer to Figure 2A, the display panel 100 may include a display area DA where an image is displayed and a non-display area NDA adjacent to the display area DA. The display area DA may include pixel areas PA (e.g., a plurality of pixel areas PA) arranged in a plurality, and may provide each pixel area PA with pixels that are arranged in a plurality as a plurality of pixels (not shown) and generate and / or emit light. Light emitted from the plurality of pixels provided in the display area DA may be used to provide an image.

[0060] In an embodiment, the non-display area NDA may be arranged to surround the display area DA, but is not limited thereto. The non-display area NDA may include drivers for transmitting an electrical signal to the plurality of pixels provided in the display area DA, such as a scan driver (not shown) and / or a data driver (not shown).

[0061] In Figure 2A it, the non-display area NDA surrounds the display area DA. However, the present disclosure is not limited thereto, and the non-display area NDA may be arranged on one side of the display area DA to reduce a planar area where an image is not displayed, that is, an inactive area. The non-display area NDA may be a planar area where an image is not displayed.

[0062] In one of the pixel areas PA in the display area DA, a thin film transistor 110 and a light emitting element 120 (such as an organic light emitting diode or element) may be provided, as Figure 2B shown in. The structure of the thin film transistor 110 will be described. A buffer layer 111 may be provided on the flexible substrate 130, and an active layer 116 of the thin film transistor 110 may be provided on the buffer layer 111.

[0063] The flexible substrate 130 may include a flexible material such as polyimide, polyethylene naphthalate, polyethylene terephthalate, polyarylate, polycarbonate, polyetherimide, or polyethersulfone, or may be formed of a flexible material such as polyimide, polyethylene naphthalate, polyethylene terephthalate, polyarylate, polycarbonate, polyetherimide, or polyethersulfone, but the material of the flexible substrate 130 is not limited thereto.

[0064] The active layer 116 may have a source region and a drain region doped with N-type or P-type impurities at a relatively high concentration. In addition, the active layer 116 may include an oxide semiconductor, or may be formed of an oxide semiconductor. In an embodiment, for example, the oxide semiconductor may include an oxide of a material selected from Group IIIA, Group IVA, Group IVB, and Group IIB metal elements (such as zinc (Zn), indium (In), gallium (Ga), tin (Sn), cadmium (Cd), germanium (Ge), or hafnium (Hf)) and combinations thereof.

[0065] A gate electrode 117 of the thin film transistor 110 may be provided or formed on the active layer 116, and a gate insulating layer 112 (e.g., a first insulating layer) is interposed between the active layer 116 and the gate electrode 117. A source electrode 118 and a drain electrode 119 of the thin film transistor 110 may be provided or formed on the gate electrode 117.

[0066] An interlayer insulating film 113 (e.g., a second insulating layer) may be respectively provided between the gate electrode 117 and each of the source electrode 118 and the drain electrode 119. A passivation film 114 may be respectively provided between each of the source electrode 118 and the drain electrode 119 and an anode 121 of the light emitting element 120.

[0067] An insulating planarization film 115 (e.g., a third insulating layer) may be provided on the anode 121. The insulating planarization film 115 may include an acrylic material or the like. An opening 124 is provided or defined in the insulating planarization film 115 to pass through a part of the insulating planarization film 115.

[0068] The light emitting element 120 may emit red light, green light, and blue light according to the flow of current to display image information. The light emitting element 120 as an organic light emitting diode may include, for example, an anode 121 (e.g., a first electrode) connected to the drain electrode 119 of the thin film transistor 110 to receive a positive power, a cathode 123 (e.g., a second electrode) provided to cover a plurality of pixels or provided commonly with respect to a plurality of pixels and providing a negative power, and a light emitting layer 122 provided between the anode 121 and the cathode 123.

[0069] Although not explicitly shown, the light emitting element 120 may further include a hole injection layer ("HIL"), a hole transport layer ("HTL"), an electron transport layer ("ETL"), an electron injection layer ("EIL"), etc., which may be provided adjacent to the light emitting layer 122.

[0070] The light emitting layer 122 (e.g., a light emitting pattern) may be provided separately for each pixel such that pixels emitting red light, pixels emitting green light, and pixels emitting blue light together form a unit of the pixels. Alternatively, the light emitting layer 122 may be provided commonly throughout the entire display area DA and / or pixel area PA regardless of the position of the pixels within the display area DA.

[0071] In an embodiment, the light emitting layer 122 may be provided or formed by vertically stacking or combining a layer including a light emitting material emitting red light, a layer including a light emitting material emitting green light, and a layer including a light emitting material emitting blue light. In an embodiment, as long as the light emitting layer 122 can emit white light, different color combinations may be made. In addition, a color conversion layer (not shown) or a color filter (not shown) for converting the emitted white light into light of different colors may also be provided.

[0072] A thin film encapsulation layer (not shown) in which an organic film and an inorganic film are stacked may be provided or formed on the negative electrode 123.

[0073] Since the display panel 100 can be flexibly deformed, the display panel 100 and its various components can be foldable or unfoldable and used according to the folding operation and unfolding operation of the display device.

[0074] The protective film 200 may be provided on the surface of the display panel 100 having the above layers and components. In particular, the protective film 200 may be provided on the surface (e.g., the first surface) of the display panel 100 opposite to the surface (e.g., the display surface or the second surface) of the display panel 100 that provides an image. Referring again to Figure 1A and Figure 1B , the display surface of the display panel 100 where an image is provided is the lower surface, and the protective film 200 is provided on the surface opposite to the display surface.

[0075] Referring to Figure 3 , the display panel 100 may be folded to define an end portion where a folding region A is provided. The folded display panel 100 causes the surface of the display panel 100 on which the protective film 200 is provided to face inward, such that portions of the protective film 200 face each other. The folded display panel 100 causes the display surface to face the outside of the display panel 100 (e.g., exposed to the outside of the display panel 100 at its end portion).

[0076] In an embodiment of a method of manufacturing a display device, the protective film 200 may be attached to the display panel 100, such as by providing an adhesive or an adhesive film (not shown) on the surface of the display panel 100. Alternatively, the protective film 200 may be provided or formed by coating a protective film material or a protective film forming composition on the surface of the display panel 100 and curing the protective film forming composition.

[0077] The protective film 200 may include a plastic material, such as a plastic film including at least one of polyethylene terephthalate (“PET”), polyethylene (“PE”), polyvinyl chloride (“PVC”), polypropylene (“PP”), polystyrene (“PS”), polyacrylonitrile (“PAN”), styrene-acrylonitrile copolymer (“SAN”), acrylonitrile-butadiene-styrene (“ABS”), and polymethyl methacrylate (“PMMA”).

[0078] The polyethylene terephthalate film may be suitable as the protective film 200 because the polyethylene terephthalate film has heat resistance, fatigue strength, electrical properties, etc., and is less affected by temperature and humidity compared to other materials.

[0079] In the above method of manufacturing a display device, a protective film 200 is disposed on the surface of a display panel 100 of the display device. The protective film 200 is disposed in both a folding region A and a flat region B. The protective film 200 may be a single-layer material disposed on the surface of the display panel 100, and the single-layer material corresponds to both the folding region A and the flat region B.

[0080] Reference Figure 1A , the folding region A covered by the protective film 200 can be exposed to the outside of the protective film 200, for example, by removing a portion of the protective film 200 corresponding to the folding region A. Removing this portion of the protective film 200 may include using a hot block 10 (which is a heating element) to expose the folding region A of the display panel 100 from the remaining portion of the protective film 200 corresponding to the flat region B. Exposing the folding region A includes applying heat to the portion of the protective film 200 corresponding to the folding region A through the hot block 10 to remove this portion of the protective film 200 from the display panel 100. That is, a heating element such as the hot block 10 can be used to melt and remove the protective film 200 disposed on the folding region A.

[0081] Reference Figure 1A and Figure 1B , the display panel 100 may include a flat region B and a folding region A adjacent to the flat region B. The flat region B may refer to a planar region (e.g., a non-folding region) where the display panel 100 does not fold or the display panel 100 is not foldable. Reference Figure 3 , a region of the flat region B adjacent to the folding region A in the direction of the display panel 100 may be slightly bent as the display panel 100 is folded. That is, the folded display panel 100 may bend a portion of the flat region B of the display panel 100 closest to the folding region A relative to the remaining portion of the flat region B of the display panel 100 away from the folding region A.

[0082] The folding region A may be a planar region where the display panel 100 can be folded (e.g., foldable). By removing the portion of the protective film 200 corresponding to the folding region A, the display panel 100 can be smoothly folded at the folding region A. In addition, by removing the portion of the protective film 200 corresponding to the folding region A, peeling or separation of the protective film 200 from the display panel 100 due to repeated folding and unfolding operations of the display panel 100 can be suppressed.

[0083] A protective film 200 can be applied to the surface of the display panel 100 to have a thickness h1. In an embodiment, a single-layer material for forming the protective film 200 can be applied across the entire planar region of the surface of the display panel 100 with the thickness h1, but is not limited thereto. The thickness h1 can be the minimum thickness of the protective film 200, but is not limited thereto. Due to, for example, melting and removing a portion of the protective film 200 corresponding to the folding region A by using the above heating element, the portion of the protective film 200 closest to the folding region A can have an increased thickness greater than the thickness h1.

[0084] Reference Figure 1A , the ratio of the thickness h1 of the protective film 200 provided on the surface of the display panel 100 to the width W of the folding region A, such as being exposed to the outside of the protective film 200 by using a heating element such as the heat block 10, can be from about 1:5 to about 1:15. That is, the unfolded or flat display panel 100 defines the ratio of the thickness h1 of the protective film 200 to the width W of the exposed folding region A. In an embodiment, the ratio of the thickness h1 of the protective film 200 to the width W of the exposed folding region A can be from about 1:6.5 to about 1:13, from about 1:8 to about 1:11, from about 1:5 to about 1:9, or from about 1:10 to about 1:15.

[0085] The bent or folded display panel 100 sets the folding region A to have a radius of curvature at the end portion of the display panel 100. When the radius of curvature of the folding region A is equal to or greater than about 0.25 millimeters (mm) and equal to or less than about 0.35 mm, within the folded display device, the ratio of the thickness h1 of the protective film 200 to the width W of the exposed folding region A can be from about 1:5 to about 1:10. When the radius of curvature of the folding region A is equal to or greater than about 0.4 mm and equal to or less than about 0.5 mm, within the folded display device, the ratio of the thickness h1 of the protective film 200 to the width W of the exposed folding region A can be from about 1:11 to about 1:15.

[0086] When the ratio of the thickness h1 of the protective film 200 to the width W of the exposed folding region A is within the above range, contact of a portion of the protective film 200 when the display device is folded can be reduced or effectively prevented. Reference Figure 1A and Figure 1B , for example, the ends of the protective film 200 closest to the folding region A face each other in the direction along the display panel 100. That is, when the ratio of the thickness h1 of the protective film 200 to the width W of the exposed folding region A is within the above range, the folded display device (or the display panel 100) sets the facing ends of the protective film 200 to be spaced apart from each other (for example, not in contact with each other).

[0087] When the hot block 10 is used to melt and remove the protective film 200 located on the folding area A, the material of the protective film 200 melted by the hot block 10 is pushed toward two opposite sides of the folding area A to be transferred from the folding area A. The melted material is collected at the portion of the flat area B closest to the folding area A, and thus a bulge 210 adjacent to the folding area A is incidentally formed.

[0088] The protruding portion (e.g., the bulge 210) of the protective film 200 defines a thickness of the protective film 200 greater than the above-mentioned thickness h1. The vertically extending portion of the protective film 200 having the thickness h1 can define a reference surface or a reference plane coplanar with the upper surface of the protective film 200. The portion of the protective film 200 above this reference surface or reference plane can define the bulge 210.

[0089] Reference Figure 1A and Figure 1B Moreover, the bulges 210 provided at each of the opposite sides of the folding area A can define the end portions of the protective film 200 facing each other across the folding area A. The folded display device (or the display panel 100) can be arranged such that the end portions of the protective film 200 facing each other (e.g., at the bulges 210) are in contact with each other. In the case where the bulges 210 come into contact with each other when the display panel 100 is folded, inappropriate folding of the display panel 100 may occur. Therefore, in one or more embodiments, a part of the bulge 210 can be removed from the remaining portion of the protective film 200 by using a removal tool such as the cutter 20.

[0090] Hereinafter, the cutter 20 for removing the bulge 210 and the method of removing the bulge 210 by using the cutter 20 will be described.

[0091] Figure 4A is a top view of an embodiment of the cutter 20, Figure 4B is Figure 4A a side sectional view of the cutter 20 in Figure 5 is a top view of an embodiment of the process of removing the bulge 210 by using the cutter 20, Figure 6A is a top view of an embodiment of the cutter 20, Figure 6B is Figure 6A a side sectional view of the cutter 20 in Figure 6C_(1) to Figure 6C_(4) and is a sectional view of an embodiment of the blade 23 of the cutter 20.

[0092] The cutter 20 can be used to remove a part of the protrusion 210 protruding from the remaining portion of the protective film 200. The cutter 20 can remove the increased thickness portion of the protective film 200, and the increased thickness portion defines the protrusion 210 at a position closest to the folding area A of the display panel 100. The folding area A of the display panel 100 is exposed by previously removing the corresponding portion of the protective film 200 corresponding to the folding area A of the display device. The remaining portion of the protective film 200 can be a portion corresponding to the flat area B adjacent to the folding area A within the display panel 100 of the display device.

[0093] The cutter 20 can be a manual tool used by a person or a part of a machine (e.g., an applicator) that applies force to the cutter 20 respectively. The cutter 20 can include a handle 21 and a blade 23. The cutter 20 is connected to the applicator at the handle 21, and the cutter 20 is manipulated through the applicator using the handle 21 to remove the protrusion 210. The blade 23 is connected to the handle 21, and the protrusion 210 is separated from the remaining portion of the protective film 200 through the blade 23. In addition, the cutter 20 can further include a support portion 22 disposed between the handle 21 and the blade 23, and the handle 21 is supported on the blade 23 through the support portion 22. The support portion 22 and the handle 21 can form the main body of the cutter 20 together, and the blade 23 extends from the main body.

[0094] Reference Figure 4A and Figure 4B , the blade 23 can include a cutting surface CS or an edge that contacts the protrusion 210 during the removal of a part of the protrusion 210 and a bottom surface LS that is opposite to the cutting surface CS and is disposed adjacent to the protective film 200 when removing the protrusion 210. The angle θ2 formed between the cutting surface CS of the blade 23 and the bottom surface LS of the blade 23 can be equal to or less than about 30°.

[0095] When the angle θ2 formed between the cutting surface CS of the blade 23 and the bottom surface LS of the blade 23 is within the above range, the protrusion 210 can be easily removed from the remaining portion of the protective film 200. In particular, the cutting surface CS of the blade 23 is a surface that penetrates the protective film 200, such as for cutting the protrusion 210 from the remaining portion of the protective film 200 at the lower portion of the protrusion 210. The fragments (e.g., the protrusion 210) of the protective film 200 that are cut by the blade 23 and separated from the protective film 200 are pushed toward the upper side of the cutting surface CS (e.g., in the direction away from the remaining portion of the protective film 200). At this time, by setting the angle θ2 between the cutting surface CS of the blade 23 and the bottom surface LS of the blade 23 to the above range, the fragment can be easily removed from the remaining portion of the protective film 200 by the upward force provided by the cutting surface CS inclined with respect to the bottom surface LS. Since the angle θ2 between the cutting surface CS of the blade 23 and the bottom surface LS of the blade 23 exerts an upward force when the cutter 20 moves along the protective film 200, less additional force can be utilized when removing the protrusion 210.

[0096] The cutting surface CS of the blade 23 may be provided with a diagonal edge inclined with respect to the longitudinal direction of the blade 23. Refer to Figure 4A , the longitudinal direction of the blade 23 may mean a direction parallel to the direction in which the handle 21, the support portion 22, and the blade 23 are arranged along their connection (e.g., the length of the cutter 20). The blade 23 may include a longitudinal direction extending from the handle 21 to the distal end of the blade 23, where the distal end of the blade 23 is the farthest from the handle 21. Along the longitudinal direction, the first side of the blade 23 may be shorter than the second side of the blade 23, and the cutting surface CS may connect the first side to the second side to define an inclined edge of the blade 23 in a top view.

[0097] Since the cutting surface CS defines an inclined edge of the blade 23 with respect to the longitudinal direction of the blade 23, the protrusion 210 can be more easily removed from the remaining portion of the protective film 200. Refer to Figure 5 , the traveling direction or the removal direction (indicated by the arrow) corresponds to the direction along which the protrusion 210 is adjacent to the remaining portion of the protective film 200. Since the cutting surface CS defines a diagonal edge, the length of the cutter 20 can be positioned inclined with respect to the traveling direction while maintaining the maximum contact of the diagonal edge with the protrusion 210, so as to more easily apply a force to the cutter 20 to remove the protrusion 210.

[0098] In addition, the length of the cutter 20 that is inclined with respect to the traveling direction is such that the handle 21 does not overlap with the protective film 200. Since the handle 21 is not located above the protective film 200 during the removal of the protrusion 210, interference with the traveling of the cutter 20 relative to the protective film 200 caused by contact between the applicator at the handle 21 and the protective film 200 can be prevented.

[0099] The blade 23 may have a V-shaped, U-shaped, quadrilateral, trapezoidal, or hemispherical cross-section. Figure 6A and Figure 6B A top view and a cross-sectional view of the cutter 20 including the blade 23 having a V-shaped cross-section shown in FIG. 6C_(1) are respectively shown. FIG. 6C_(2) shows that the cross-section of the blade 23 is U-shaped, FIG. 6C_(3) shows that the cross-section of the blade 23 is quadrilateral, and FIG. 6C_(4) shows that the cross-section of the blade 23 is trapezoidal. Figure 6C_(1) to Figure 6C_(4) The view can be taken along the longitudinal direction (e.g., length) of the cutter 20 (e.g., in Figure 6A and Figure 6B from right to left). By forming the cross-section of the blade 23 into one of the above shapes, surface damage to the protective film 200 can be minimized and the protrusion 210 can be removed.

[0100] During the removal of the protrusion 210, the length of the cutter 20 that is inclined with respect to the traveling direction not only arranges the handle 21 not to overlap with the protective film 200 ( Figure 5 ), but also forms an angle equal to or less than about 45° between the bottom surface LS of the blade 23 and the surface of the protective film 200. Referring to Figure 1B , the angle θ1 formed between the bottom surface LS of the blade 23 and the reference surface or reference plane of the protective film 200 can be equal to or greater than about 0° and equal to or less than about 45°, equal to or greater than about 0° and equal to or less than about 35°, equal to or greater than about 0° and equal to or less than about 20°, or equal to or greater than about 0° and equal to or less than about 10°.

[0101] By adjusting the angle θ1 formed between the bottom surface LS of the blade 23 and the reference surface or reference plane of the protective film 200 to the above range, the force applied to the protrusion 210 from the applicator can be more concentrated on the protrusion 210, and the protrusion 210 can be easily removed. In addition, after the process of removing the protrusion 210, the reference surface or reference plane of the protective film 200 from which the protrusion 210 has been removed can be set or formed to be flatter. In addition, damage to the reference surface or reference plane of the protective film 200 during the removal of the protrusion 210 can be suppressed.

[0102] Figure 7 is a cross-sectional view showing an embodiment of the shape of the protrusion 210.

[0103] Removing the protrusion 210 may include completely removing the protrusion 210 relative to the surface of the protective film 200 or removing a part of the protrusion 210. Referring to the Figure 1A obtained from Figure 7 , a part of the protrusion 210 may remain on the reference surface or reference plane of the protective film 200 because not all of the protrusion 210 is removed from the remaining portion of the protective film 200 by using the cutter 20.

[0104] The remaining portion of the protrusion 210 may include a protrusion height h2 relative to the reference surface or reference plane. Figure 7 The protrusion height h2 in Figure 1A is less than the height of the protrusion 210 in Figure 1A . The protrusion height h2 of the remaining portion of the protrusion 210 based on the reference plane of the protective film 200 may be equal to or less than about 100 micrometers (μm). By adjusting the protrusion height h2 of the protrusion 210 that remains as part of the protective film 200 based on the reference plane of the protective film 200 to be equal to or less than about 100 μm, the limitation or interference with the folding operation of the display device caused by the protrusion 210 remaining protruding at the folding region A can be reduced or effectively prevented.

[0105] Figure 8A to Figure 8C is a side sectional view of an embodiment of the cutter 20, Figure 8D and Figure 8E is a top view of an embodiment of the cutter 20, Figure 9 is a view showing a process of removing the protrusion 210 using the cutter 20, Figure 10A is a side sectional view of an embodiment of the cutter 20, and Figure 10B is a top view of the cutter 20.

[0106] Inside the cutter 20, the length of the handle 21 may be inclined with respect to a direction perpendicular to the bottom surface LS of the blade 23 (e.g., perpendicular to the plane defined by the bottom surface LS). The support portion 22 of the cutter 20 may position the handle 21 inclined with respect to a direction perpendicular to the bottom surface LS of the blade 23. The length of the handle 21 may be defined along a longitudinal direction central axis CA1 (e.g., a first longitudinal direction central axis), and the length of the support portion 22 may be defined along a longitudinal direction central axis CA2 (e.g., a second longitudinal direction central axis). Referring to Figure 8A and Figure 8B , the angle θ3 formed between the longitudinal direction central axis CA1 of the handle 21 and the longitudinal direction central axis CA2 of the support portion 22 may be equal to or greater than about 45° and equal to or less than about 135°.

[0107] The handle 21 can be connected to the support portion 22 at the first end of the handle 21. The second end of the handle 21 is opposite to its first end. The longitudinal direction of the handle 21 can refer to a direction parallel to the direction in which the first end and the second end of the handle 21 face each other along that direction, and the longitudinal direction central axis CA1 of the handle 21 can refer to an axis passing through the center of the handle 21 and parallel to the longitudinal direction of the handle 21.

[0108] In addition, the support portion 22 can be connected to the handle 21 at the first end of the support portion 22. The second end of the support portion 22 is opposite to the first end of the support portion 22. The support portion 22 can be connected to the blade 23 at the second end of the support portion 22. The longitudinal direction of the support portion 22 can refer to a direction parallel to the direction in which the first end and the second end of the support portion 22 face each other along that direction. The longitudinal direction central axis CA2 of the support portion 22 can refer to an axis passing through the center of the support portion 22 and parallel to the longitudinal direction of the support portion 22.

[0109] By adjusting the angle θ3 between the longitudinal direction central axis CA1 of the handle 21 and the longitudinal direction central axis CA2 of the support portion 22 to the above range, the applicator can stably grip the cutter 20 when removing the bulge 210, and the force applied by the applicator to the cutter 20 can be easily transmitted to the blade 23.

[0110] Figure 8A It is shown that the angle θ3 formed between the longitudinal direction central axis CA1 of the handle 21 and the longitudinal direction central axis CA2 of the support portion 22 is an obtuse angle, and Figure 8B It is shown that the angle θ3 formed between the longitudinal direction central axis CA1 of the handle 21 and the longitudinal direction central axis CA2 of the support portion 22 is an acute angle.

[0111] Reference Figure 8A and Figure 8B and, the angle θ4 formed between the bottom surface LS of the blade 23 and the longitudinal direction central axis CA2 of the support portion 22 can be equal to or greater than about 45° and equal to or less than about 135°. By adjusting the angle θ4 formed between the bottom surface LS of the blade 23 and the longitudinal direction central axis CA2 of the support portion 22 to the above range, even when the handle 21 is spaced apart from the blade 23 in a direction perpendicular to the bottom surface LS of the blade 23 (e.g., the perpendicular direction in Figure 8A to Figure 8C ), the support portion 22 can stably support the handle 21 and the blade 23 in relative positions to each other.

[0112] The magnitude of the angle θ3 formed between the central axis CA2 in the longitudinal direction of the support portion 22 and the central axis CA1 in the longitudinal direction of the handle 21 may be equal to or greater than the magnitude of the angle θ4 formed between the central axis CA2 in the longitudinal direction of the support portion 22 and the bottom surface LS of the blade 23.

[0113] When the magnitude of the angle θ3 is equal to or greater than the magnitude of the angle θ4, the applicator that grasps or is coupled to the handle 21 can stably apply a force to the blade 23 through the support portion 22, and thus the applicator can easily remove the bulge 210 from the remaining portion of the protective film 200.

[0114] Figure 8C It shows that the magnitude of the angle θ3 formed between the central axis CA2 in the longitudinal direction of the support portion 22 and the central axis CA1 in the longitudinal direction of the handle 21 is the same as the magnitude of the angle θ4 formed between the central axis CA2 in the longitudinal direction of the support portion 22 and the bottom surface LS of the blade 23.

[0115] Figure 8D and Figure 8E shows the top view of the cutter 20 according to the Figure 8A to Figure 8C structure in. Figure 8D shows the top view of the cutter 20, in which the cutting surface CS is formed to be inclined with respect to the longitudinal direction of the blade 23, and Figure 8E shows the top view of the cutter 20, in which the cutting surface CS is formed to be perpendicular to the longitudinal direction of the blade 23.

[0116] When the support portion 22 supports the handle 21 relative to the blade 23 such that the length of the handle 21 is set to be inclined with respect to the bottom surface LS of the blade 23, the applicator can easily remove the bulge 210 using the cutter 20. Refer to Figure 9 , since the bulge 210 can be removed by moving the cutter 20 with the bottom surface LS of the blade 23 set parallel to the surface of the protective film 200 in the traveling direction (indicated by the arrow in Figure 9 ), the surface of the protective film 200 or the reference plane from which the bulge 210 is removed can be maintained flat. That is, the position of the bottom surface LS of the blade 23 in the thickness direction of the protective film 200 corresponds to the surface of the protective film 200 or the reference plane from which the bulge 210 can be removed.

[0117] Furthermore, since the handle 21 is spaced apart from the surface of the protective film 200 or the reference plane in the thickness direction of the protective film 200 when the bulge 210 is removed, the interference of the traveling of the cutter 20 relative to the protective film 200 caused by the contact between the applicator that grasps the cutter 20 at the handle 21 of the cutter 20 and the protective film 200 can be reduced or effectively prevented.

[0118] The cutting surface CS of the blade 23 can be provided on the side surface of the blade 23. In particular, the cutting surface CS of the blade 23 can extend along the side surface of the blade 23 parallel to the traveling direction of the blade 23. As Figure 10B shown, the cutting surface CS can form a diagonal line inclined with respect to the longitudinal direction of the blade 23 and can be provided along the entire side surface of the blade 23. The entire side surface of the blade 23 can be defined from the support portion 22 to the distal end of the blade 23 (e.g., Figure 10B the horizontal direction in). The blade 23 can include a side surface extending from the handle 21 to the distal end of the blade 23 farthest from the handle 21, and the cutting surface CS can define the side surface of the blade 23.

[0119] Figure 10A and Figure 10B the length of the cutter 20 shown in can be positioned inclined with respect to the traveling direction of the cutter 20, as Figure 5 shown. Since the bottom surface LS of the blade 23 can guide the cutter 20 in a direction parallel to the surface of the protective film 200 or the reference plane as Figure 9 shown, the surface of the protective film 200 or the reference plane from which the bulge 210 is removed can be maintained flat, and the interference between the cutter 20 and the protective film 200 can be reduced or effectively prevented.

[0120] The foregoing detailed description has shown and described the present disclosure. In addition, the foregoing description has only shown and described embodiments of the present disclosure, and as described above, the present disclosure can be used in various other combinations, modifications, and environments, and the present disclosure can be changed or modified within the scope of the concept of the present disclosure disclosed in this specification, the scope equivalent to the disclosed disclosure, and / or the scope of the technology or knowledge in the art. Therefore, the detailed description of the present disclosure is not intended to limit the present disclosure to the disclosed embodiments. In addition, the appended claims should be construed to include other embodiments.

Claims

1. A method of manufacturing a display device, the method comprising: Providing a display panel including a folding region and a flat region adjacent to the folding region, the display panel being foldable at the folding region; Providing a protective film on both the flat region and the folding region of the display panel; Removing a portion of the protective film corresponding to the folding region from the display panel to expose the folding region outside the remaining portion of the protective film, wherein the remaining portion of the protective film defines a bulge of the protective film at a portion of the flat region closest to the folding region; And Removing a portion of the bulge from the portion of the flat region by a cutter, the cutter including a blade capable of being applied to the bulge to separate the portion of the bulge, Wherein when the blade is applied to the bulge, a longitudinal direction of the blade is inclined with respect to a traveling direction of the cutter movement.

2. The method according to claim 1, wherein, Exposing the folding region includes: applying heat to the portion of the protective film corresponding to the folding region by a hot block to remove the portion of the protective film from the display panel.

3. The method according to claim 1, wherein, Providing the protective film on the flat region of the display panel defines a thickness of the protective film, exposing the folding region defines a width of the folding region, and A ratio of the thickness of the protective film to the width of the folding region is from 1:5 to 1:

15.

4. The method according to claim 1, wherein, Removing the portion of the bulge includes separating the portion of the bulge from the remaining portion of the protective film using the cutter, and the cutter further includes: A handle connected to the blade, and using the handle, the blade can be applied to the bulge.

5. The method according to claim 4, wherein, The blade of the cutter includes a cutting surface and a bottom surface opposite to the cutting surface, Inside the cutter, an angle between the cutting surface and the bottom surface of the blade is equal to or less than 30°, and The blade applied to the bulge makes the cutting surface contact the bulge.

6. The method according to claim 4, wherein Inside the cutter, the blade includes: A cutting surface spaced apart from the handle, and The longitudinal direction extending from the handle to a distal end of the blade farthest from the handle, wherein the cutting surface of the blade is inclined with respect to the longitudinal direction of the blade.

7. The method according to claim 4, wherein Inside the cutter, the blade includes: A side surface extending from the handle to a distal end of the blade farthest from the handle, and A cutting surface defining the side surface of the blade.

8. The method according to claim 4, wherein, The cutter further includes a support portion located between the handle and the blade and connecting the handle and the blade to each other, and Inside the cutter: The blade includes a cutting surface and a bottom surface opposite to the cutting surface, and The support portion connecting the handle and the blade to each other is arranged such that the length of the handle is inclined with respect to a direction perpendicular to the bottom surface of the blade.

9. The method according to claim 4, wherein, the protrusion protrudes from a reference plane within the protective film, the blade includes a cutting surface and a bottom surface opposite the cutting surface, and removing the portion of the protrusion using the cutter sets the bottom surface of the blade at an angle with respect to the reference plane of the protective film, wherein the angle is equal to or less than 45°.

10. The method according to claim 1, wherein, the protrusion protrudes from a reference plane within the protective film, and removing the portion of the protrusion defines that the thickness of the protective film at the portion closest to the folding region in the flat region with respect to the reference plane of the protective film is equal to or less than 100 microns.

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