Display device and method for manufacturing the same

Abstract

The present invention relates to a display device and a method for manufacturing the display device. The display device includes: a display panel having a folding area; a buffer structure, the buffer structure including: a plurality of protruding patterns arranged on the display panel; an elastic component arranged on the protruding pattern in a manner that at least a portion of the upper portion of each of the protruding patterns is sunk into the interior thereof. The buffer structure may have a relatively thin thickness and may not fall off the display panel. The buffer structure may prevent the protruding pattern from being separated from the first substrate and may help to make the folding area of ​​the display device easy to fold and unfold. Since the vacant space defined by the bottom surface of four adjacent protruding patterns in the protruding pattern and the elastic component is filled with air, the protruding pattern and the elastic component may further reduce external impact. Accordingly, although the thickness of the buffer structure is relatively reduced, the impact resistance of the buffer structure may be relatively increased.

Description

Technical Field

[0001] The present invention relates to a display device and a method for manufacturing the display device, and in particular to a flexible display device and a method for manufacturing the flexible display device. Background Art

[0002] Flat panel display devices are used as display devices to replace cathode ray tube display devices due to their lightness, thinness, etc. Representative examples of such flat panel display devices include liquid crystal display devices and organic light emitting display devices.

[0003] Recently, the lower substrate and the upper substrate of the display panel included in such a display device may contain flexible materials, and a flexible display device in which a portion of the display panel can be bent or folded is being developed. For example, the lower substrate included in the display panel may be formed using a polyimide substrate, and the upper substrate included in the display panel may have a thin film encapsulation structure. In addition, the flexible display device may also display an image in the portion where the display panel is folded. In other words, the flexible display device may include a display area for displaying an image, and a portion of the display area may be folded. In order to protect the display panel, the flexible display device may arrange a protective film on the display panel. However, in the case where the thickness of the protective film is increased in order to ensure impact resistance, the problem of the protective film falling off from the display panel may occur. Summary of the invention

[0004] An object of the present invention is to provide a flexible display device.

[0005] Another object of the present invention is to provide a method for manufacturing a flexible display device.

[0006] However, the present invention is not limited to the above-mentioned objects, and various extensions can be made without departing from the spirit and scope of the present invention.

[0007] In order to achieve the above-mentioned purpose of the present invention, a display device according to an exemplary embodiment of the present invention may include: a display panel having a folding area; and a buffer structure, wherein the buffer structure includes: a plurality of protruding patterns arranged on the display panel; and an elastic component arranged on the plurality of protruding patterns in such a manner that at least a portion of an upper portion of each of the plurality of protruding patterns is sunken into an interior of the elastic component.

[0008] In an exemplary embodiment, each of the plurality of protrusion patterns may have a hemispherical shape.

[0009] In an exemplary embodiment, a vacant space may be defined by adjacent four convex patterns of the plurality of convex patterns and a bottom surface of the elastic member.

[0010] In an exemplary embodiment, the empty space may be filled with air.

[0011] In an exemplary embodiment, the air may be confined within the empty space.

[0012] In an exemplary embodiment, the plurality of protrusion patterns may be arranged in a lattice shape on the display panel.

[0013] In an exemplary embodiment, two adjacent protrusion patterns among the plurality of protrusion patterns may contact each other.

[0014] In an exemplary embodiment, the buffer structure may further include: a first substrate disposed on a bottom surface of each of the plurality of protrusion patterns.

[0015] In an exemplary embodiment, the buffer structure may further include: a second substrate arranged opposite to the first substrate and arranged on an upper surface of the elastic component.

[0016] In an exemplary embodiment, the plurality of convex patterns may include four convex patterns arranged adjacent to each other, and the four convex patterns arranged adjacent to each other and a bottom surface of the elastic member define a first empty space, the first empty space being filled with air.

[0017] In an exemplary embodiment, if the four protruding patterns can be set as the kth protruding pattern, the k+1th protruding pattern, the jth protruding pattern, and the j+1th protruding pattern, respectively, the plurality of protruding patterns also include a k-1th protruding pattern and a j-1th protruding pattern adjacent to the kth protruding pattern and the jth protruding pattern, respectively, and the k-1th protruding pattern and the j-1th protruding pattern are also adjacent to each other, wherein k and j are both integers greater than 1, and a second vacant space is defined by the k-1th protruding pattern, the kth protruding pattern, the j-1th protruding pattern, the j-1th protruding pattern, the jth protruding pattern and the bottom surface of the elastic component, and the second vacant space is filled with air.

[0018] In an exemplary embodiment, the first vacant space and the second vacant space may be arranged adjacent to each other and spatially connected to each other.

[0019] In an exemplary embodiment, a vacant space may be defined by adjacent three convex patterns of the plurality of convex patterns and a bottom surface of the elastic member.

[0020] In order to achieve the above-mentioned other purpose of the present invention, a manufacturing method of a display device according to an exemplary embodiment of the present invention may include the following steps: providing a first substrate; forming a plurality of protruding patterns on the upper surface of the first substrate; providing a second substrate; forming an uncured resin layer on the bottom surface of the second substrate; pressurizing the upper surface of the second substrate formed with the uncured resin layer along a first direction so that at least a portion of the upper portion of each of the plurality of protruding patterns is sunken into the interior of the uncured resin layer; curing the uncured resin layer to form an elastic component; providing a display panel having a folding area; and forming a buffer structure including the first substrate, the plurality of protruding patterns, the elastic component and the second substrate on the display panel.

[0021] In an exemplary embodiment, after the step of forming a plurality of protrusion patterns on the upper surface of the first substrate, a step of curing the plurality of protrusion patterns may be further included.

[0022] In an exemplary embodiment, each of the plurality of convex patterns may have a hemispherical shape, a void space is defined by adjacent four of the plurality of convex patterns and a bottom surface of the elastic member, and the void space is filled with air.

[0023] In an exemplary embodiment, each of the plurality of protrusion patterns may have a first viscosity, and the uncured resin layer may have a second viscosity lower than the first viscosity.

[0024] In an exemplary embodiment, the elastic member may include at least one of silicone, urethane, polyurethane, thermoplastic polyurethane, and the like.

[0025] In an exemplary embodiment, the protrusion pattern may include at least one of photoresist, polyacrylate-based resin, polyimide-based resin, polyamide-based resin, siloxane-based resin, acrylic-based resin, epoxy-based resin, silicon-based resin, and the like.

[0026] In an exemplary embodiment, the first substrate and the second substrate may include at least one of transparent polyimide, transparent polyethylene naphthalate, transparent polyamide, transparent polyethylene terephthalate, transparent polypropylene, transparent polycarbonate, transparent polystyrene, transparent polysulfone, transparent low-density polyethylene, transparent polyphthalamide, transparent polyethersulfone, transparent polyarylate, transparent polycarbonate oxide, transparent modified polyphenylene ether, transparent polyetherimide, etc.

[0027] In the display device according to the exemplary embodiment of the present invention, since at least a portion of the upper portion of each of the hemispherical protrusion patterns is located inside the elastic component, a relatively thin buffer structure can be provided, thereby preventing the buffer structure from falling off from the display panel.

[0028] Also, at least a portion of the upper portion of each of the protruding patterns is located inside the elastic member, thereby preventing the protruding pattern from being separated from the first substrate and facilitating the folding region of the display device to be easily folded and unfolded.

[0029] In addition, the convex pattern and the elastic member can further reduce external impact by filling the empty space defined by the bottom surface of the four adjacent convex patterns and the elastic member. Therefore, although the thickness of the buffer structure is relatively reduced, the impact resistance of the buffer structure can be relatively increased.

[0030] However, the effects of the present invention are not limited to the above-mentioned effects, and various extensions can be made without departing from the spirit and scope of the present invention. BRIEF DESCRIPTION OF THE DRAWINGS

[0031] Figure 1 is a plan view showing a display device according to an exemplary embodiment of the present invention.

[0032] Figure 2 It is shown Figure 1 A three-dimensional diagram of a display device including a display panel in a folded shape.

[0033] Figure 3 Yes Figure 1 A cross-sectional view of the display device taken along line II'.

[0034] Figure 4 It is an enlarged image Figure 3 A cross-sectional view of the “A” region of a display device.

[0035] Figure 5 It is shown Figure 1 A plan view of an example of a protruding pattern included in a display device.

[0036] Figure 6 It is shown Figure 1 A plan view of another example of a protruding pattern included in a display device.

[0037] Figures 7 to 10 1 and 2 are a perspective view and a cross-sectional view illustrating a method of manufacturing a display device according to an exemplary embodiment of the present invention.

[0038] Explanation of symbols

[0039] 10: Display area 20: Folding area

[0040] 100: Display device 110: Substrate

[0041] 130: Active layer 150: Gate insulating layer

[0042] 170: Gate electrode 190: Interlayer insulation layer

[0043] 200: display panel 210: source electrode

[0044] 230: Drain electrode 250: Semiconductor element

[0045] 270: planarization layer 290: lower electrode

[0046] 310: Pixel definition film 330: Light emitting layer

[0047] 340: Upper electrode 410: Lower buffer member

[0048] 451: first thin film encapsulation layer 452: second thin film encapsulation layer

[0049] 453: third thin film encapsulation layer 500: supporting member

[0050] 600: Buffer structure 610: First substrate

[0051] 630: second substrate 650, 651, 652, 655: protruding pattern

[0052] 670: elastic member 675: uncured resin layer DETAILED DESCRIPTION

[0053] Hereinafter, a display device and a method for manufacturing a display device according to an exemplary embodiment of the present invention will be described in detail with reference to the accompanying drawings. In the accompanying drawings, the same or similar reference numerals are used for the same or similar components.

[0054] Figure 1 is a plan view showing a display device according to an exemplary embodiment of the present invention, Figure 2 It is shown Figure 1 A three-dimensional diagram of a display device including a display panel in a folded shape, Figure 3 Yes Figure 1 A cross-sectional view of a display device taken along line II'. For example, Figure 1 The state in which the display device 100 is unfolded is shown.

[0055] Reference Figure 1 , Figure 2 and Figure 3The display device 100 may include a display panel 200, a buffer structure 600, a support member 500, a lower buffer member 410, etc. Figure 1 As shown, the display device 100 may include a display area 10 and a folding area 20. The display area 10 is an area where an image is displayed from the display panel 200, and the folding area 20 is an area where the display device 100 is folded or unfolded. A portion of the display area 10 may be defined as the folding area 20. Figure 3 As shown, the buffer structure 600 may include a first substrate 610, a plurality of protruding patterns 650, an elastic component 670, and a second substrate 630. In an exemplary embodiment, as shown in FIG. Figure 1 and Figure 7 As shown, a protrusion pattern 650 may be arranged on the display panel 200 .

[0056] A display panel 200 may be provided. The display panel 200 may include a plurality of pixels and may display an image through the pixels. For example, the display panel 200 may have a first surface S1 for displaying an image and a second surface S2 opposite to the first surface S1. Also, the display panel 200 may have a first side surface SS1 and a second side surface SS2 facing the first side surface SS1. Figure 2 As shown, when the display panel 200 located in the folding area 20 is folded, the first side surface SS1 and the second side surface SS2 may be arranged adjacent to each other. Also, the shape of the display panel 200 located in the folding area 20 may have a curved shape. In this case, the first surface S1 may be located on the inner side, and the second surface S2 may be located on the outer side. Alternatively, the display panel 200 may also be folded such that the first surface S1 is located on the outer side, and the second surface S2 is located on the inner side.

[0057] However, although the display device 100 is described as including one folding region 20, the configuration of the present invention is not limited thereto. For example, the display device 100 may also include at least two folding regions.

[0058] A lower buffer component 410 may be arranged on the second surface S2 of the display panel 200. In other words, the lower buffer component 410 may be arranged between the support component 500 and the display panel 200. The lower buffer component 410 may protect the display panel 200 from external impact. In addition, the lower buffer component 410 may include a ductile substance so that the display panel 200 is easy to be folded. For example, the lower buffer component 410 may include a foam-shaped substance such as polyurethane foam, polystyrene foam, etc. In another exemplary embodiment, an additional buffer structure 600 may also be arranged between the display panel 200 and the support component 500 instead of the lower buffer component 410.

[0059] A support member 500 may be arranged on the bottom surface of the lower buffer member 410. In other words, the support member 500 may be arranged on the second surface S2 of the display panel 200, and may include an opening formed in the folding region 20. The support member 500 may perform a role of supporting the display panel 200, and may also perform a role of helping to fold the display panel 200. For example, the support member 500 may be arranged on the entire second surface S2 of the display panel 200 to support the display panel 200, and may help the display panel 200 to be folded through the opening formed in the folding region 20.

[0060] The support member 500 may include a metal or plastic having a relatively large elastic force or a relatively large restoring force. In an exemplary embodiment, the support member 500 may include steel stainless steel (SUS). Alternatively, the support member 500 may also include alloys (e.g., superelastic metals) such as nickel-titanium (Ni-Ti), nickel-aluminum (Ni-Al), copper-zinc-nickel (Cu-Zn-Ni), copper-aluminum-nickel (Cu-Al-Ni), copper-aluminum-manganese (Cu-Al-Mn), titanium-nickel-copper-molybdenum (Ti-Ni-Cu-Mo), cobalt-nickel-gallium: iron (Co-Ni-Ga:Fe), silver-nickel (Ag-Ni), gold-cadmium (Au-Cd), iron-platinum (Fe-Pt), iron-nickel (Fe-Ni), indium-cadmium (In-Cd), etc.

[0061] A first substrate 610 may be disposed on the first surface S1 of the display panel 200. For example, the first substrate 610 may be disposed on the bottom surface of each of the protruding patterns 650. The first substrate 610 may be transparent. For example, the first substrate 610 may include polyimide (PI), polyethylene naphthalate (PEN), polyamide (PA), polyethylene terephthalate (PET), polypropylene (PP), polycarbonate (PC), polystyrene (PS), polysulfone (PSul), low-density polyethylene (PE), polyphthalamide (PPA), polyethersulfone (PES), polyarylate (PAR), polycarbonate oxide (PCO), modified polyphenylene oxide (MPPO), polyetherimide (PEI), etc.

[0062] Refer again Figure 1 , Figure 3 and Figure 7 , a protruding pattern 650 may be arranged on the upper surface of the first substrate 610. In other words, the protruding pattern 650 may be repeatedly arranged along the first direction D1 and the second direction D2 on the upper surface of the first substrate 610, and may protrude along the third direction D3. Here, the first direction D1 may be a direction parallel to the upper surface of the first substrate 610, the second direction D2 may be perpendicular to the first direction D1, and the third direction D3 may be perpendicular to the first direction D1 and the second direction D2. That is, the protruding pattern 650 may be arranged in a lattice shape on the display panel 200. For example, the height of each of the protruding patterns 650 may be about 50 microns or more and 75 microns or less, and the pitch between the protruding patterns 650 may be about 75 microns or less. In addition, the cone angle of the upper surface of each of the protruding patterns 650 may be about 45 degrees or less.

[0063] In an exemplary embodiment, each of the protruding patterns 650 may have a half sphere shape (or, an embossed shape). Also, at least a portion of an upper portion of each of the protruding patterns 650 may sink into the inside of the elastic member 670. In other words, at least a portion of an upper portion of each of the protruding patterns 650 may intrude into the inside of the elastic member 670. Two adjacent protruding patterns of the protruding patterns 650 may contact each other.

[0064] Each of the protrusion patterns 650 may include a photoresist, a polyacryl-based resin, a polyimide-based resin, a polyamide-based resin, a siloxane-based resin, an acryl-based resin, an epoxy-based resin, a silicon-based resin, or the like.

[0065] The upper surface of each of the protruding patterns 650 is arc-shaped, and a portion of the upper surface intrudes into the inside of the elastic member 670 and includes a relatively low-viscosity substance, so that the protruding pattern 650 can have a structure that reduces external impact and a structure that has elasticity. That is, the protruding pattern 650 can protect the display panel 200 from external impact, and the protruding pattern 650 can help the folding area 20 of the display device 100 to be easily folded and unfolded.

[0066] In another exemplary embodiment, the first substrate 610 may not be arranged, but the protruding pattern 650 may be arranged on the upper surface of the display panel 200. In addition, a polarizing film, a sensing structure, etc. may be additionally arranged between the protruding pattern 650 and the display panel 200. In this case, the protruding pattern 650 may also be arranged on the upper surface of the polarizing film or the upper surface of the sensing structure.

[0067] However, although the case where the shape of each of the protruding patterns 650 has a hemispherical plane shape is described, the shape is not limited thereto. For example, the shape of each of the protruding patterns 650 may also have a triangular plane shape, a quadrilateral plane shape, a rhombus plane shape, a polygonal plane shape, a circular plane shape, a track-shaped plane shape, or an elliptical plane shape.

[0068] Furthermore, although the description has been made of a case where two adjacent protrusion patterns 650 are in contact with each other, the configuration of the present invention is not limited thereto. For example, the protrusion patterns 650 may also be arranged to be spaced apart from each other.

[0069] In addition, although Figure 1 The figure shows a case where there are 24 protrusion patterns 650 , but the configuration of the present invention is not limited thereto. For example, the number of protrusion patterns 650 may be equal to or less than the number of pixels included in the display panel 200 .

[0070] Refer again Figure 1 and Figure 3 , an elastic member 670 may be arranged on the protruding pattern 650. As described above, at least a portion of the upper surface of each of the protruding patterns 650 may intrude into the bottom surface of the elastic member 670. In other words, at least a portion of the upper surface of each of the protruding patterns 650 may be located inside the elastic member 670.

[0071] For example, in the case where at least a portion of the upper surface of each of the protruding patterns 650 is not located inside the elastic member 670, the protruding pattern 650 may also be separated from the first substrate 610 during the period in which the display device 100 is repeatedly folded and unfolded. In an exemplary embodiment, at least a portion of the upper surface of each of the protruding patterns 650 is located inside the elastic member 670, so that the intervals between the protruding patterns 650 located in the folding area 20 can be prevented from being excessively spaced apart during the period in which the display device 100 is repeatedly folded and unfolded, and the protruding pattern 650 is not separated from the first substrate 610.

[0072] Furthermore, a free space may be defined by four adjacent protrusion patterns in the protrusion pattern 650 and the bottom surface of the elastic member 670. The free space may be filled with air, and the air may be confined in the free space. Since there is air in the free space, the protrusion pattern 650 and the elastic member 670 may have a structure that reduces external impact. That is, the protrusion pattern 650 and the elastic member 670 may protect the display panel 200 from external impact. In an exemplary embodiment, the height, the pitch, and the taper angle of the protrusion pattern 650 may be determined in such a way that the free space is formed between the elastic member 670 and the protrusion pattern 650.

[0073] Optionally, in order to protect the protruding pattern 650 or confine the air in the empty space, an edge member sandwiched between the first substrate 610 and the elastic member 670 and surrounding the protruding pattern 650 may be added. In this case, the protruding pattern 650 may be completely surrounded by the first substrate 610, the elastic member 670 and the edge member.

[0074] Since the elastic member 670 is stretched and contracted during the period when the display device 100 repeatedly performs folding and unfolding, the elastic member 670 may include an elastic polymer (elastomer), a thermoplastic elastic polymer, or a resin having a relatively large elastic force or a relatively large restoring force. In other words, the elastic polymer may have a low modulus. For example, the elastic polymer may include an elastic material such as silicone, urethane, polyurethane, thermoplastic polyurethane (TPU: Thermoplastic polyurethane). The elastic member 670 includes the elastic material, so that the folding area 20 of the display device 100 can be easily folded and unfolded.

[0075] In an exemplary embodiment, the protrusion pattern 650 may include four protrusion patterns arranged adjacent to each other, and the four protrusion patterns arranged adjacent to each other and the bottom surface of the elastic member 670 define a first empty space, and the first empty space is filled with air. If the four protrusion patterns are respectively set as the kth protrusion pattern, the k+1th protrusion pattern, the jth protrusion pattern, and the j+1th protrusion pattern, the plurality of protrusion patterns further include the k-1th protrusion pattern and the j-1th protrusion pattern adjacent to the kth protrusion pattern and the jth protrusion pattern, respectively, and the k-1th protrusion pattern and the j-1th protrusion pattern are also adjacent to each other, wherein k and j are both integers greater than 1, and a second empty space may be defined by the k-1th protrusion pattern, the kth protrusion pattern, the j-1th protrusion pattern, the jth protrusion pattern, and the bottom surface of the elastic member 670. The second empty space may be filled with air. The first empty space and the second empty space may be arranged adjacent to each other and may be spatially connected to each other, and air may be confined in the first empty space and the second empty space.

[0076] A second substrate 630 may be disposed on the elastic member 670. The second substrate 630 may be opposite to the first substrate 610, and may include substantially the same material as the first substrate 610. For example, the second substrate 630 may be transparent, and may include PI, PEN, PA, PET, PP, PC, PS, PSul, PE, PPA, PES, PAR, PCO, MPPO, PEI, etc. In another exemplary embodiment, in order to protect the display device 100, a hard coating layer, a window film, etc. may also be additionally disposed on the second substrate 630.

[0077] Accordingly, a buffer structure 600 including a first substrate 610 , a protruding pattern 650 , an elastic member 670 , and a second substrate 630 may be arranged.

[0078] For example, in order to protect the display panel, the existing flexible display device may be provided with a protective film on the display panel. However, in order to ensure the impact resistance, the thickness of the protective film may be relatively thick. In this case, when the display device is folded and unfolded, the problem of the protective film falling off from the display panel may occur.

[0079] For the display device 100 according to the exemplary embodiment of the present invention, at least a portion of the upper surface of each of the hemispherical protrusion patterns 650 is located inside the elastic member 670, so a relatively thin buffer structure 600 can be included. Therefore, the buffer structure 600 can be prevented from falling off from the display panel 200.

[0080] Furthermore, at least a portion of the upper surface of each of the protruding patterns 650 is located inside the elastic component 670, so that the buffer structure 600 can prevent the protruding pattern 650 from being separated from the first substrate 610 and can help the folding area 20 of the display device 100 to be easily folded and unfolded.

[0081] In addition, the protrusion pattern 650 and the elastic member 670 can further reduce external impact by filling the air in the empty space defined by the bottom surface of the four adjacent protrusion patterns in the protrusion pattern 650 and the elastic member 670. Therefore, although the thickness of the buffer structure 600 is relatively reduced, the impact resistance of the buffer structure 600 can be relatively increased.

[0082] Figure 4 It is an enlarged image Figure 3 A cross-sectional view of the “A” region of a display device.

[0083] The display panel 200 may include a substrate 110, a semiconductor element 250, a planarization layer 270, a lower electrode 290, a pixel definition film 310, a light emitting layer 330, an upper electrode 340, a first thin film encapsulation layer 451, a second thin film encapsulation layer 452, a third thin film encapsulation layer 453, etc. The semiconductor element 250 may include an active layer 130, a gate insulating layer 150, a gate electrode 170, an interlayer insulating layer 190, a source electrode 210, and a drain electrode 230.

[0084] A substrate 110 including a transparent material or an opaque material may be provided. The substrate 110 may be arranged on the lower buffer part 410. The substrate 110 may also be formed using a transparent resin substrate. An example of a transparent resin substrate that can be used as the substrate 110 may be a polyimide substrate. In this case, the polyimide substrate may include a first polyimide layer, a barrier film layer, a second polyimide layer, and the like. In another exemplary embodiment, the substrate 110 may also include a quartz substrate, a synthetic quartz substrate, a calcium fluoride substrate, a fluorine-doped quartz substrate, a sodalime glass substrate, a non-alkali glass substrate, and the like.

[0085] A buffer layer may also be arranged on the substrate 110. The buffer layer can prevent the phenomenon that metal atoms or impurities diffuse from the substrate 110 to the semiconductor element 250, and can adjust the heat transfer rate during the crystallization process for forming the active layer to obtain a substantially uniform active layer. In addition, in the case where the surface of the substrate 110 is uneven, the active layer can perform the function of improving the flatness of the surface of the substrate 110. Depending on the type of the substrate 110, more than two buffer layers may be provided on the substrate 110, or the buffer layer may not be arranged. For example, the buffer layer may include an organic substance or an inorganic substance.

[0086] An active layer 130 may be disposed on the substrate 110. The active layer 130 may include a metal oxide semiconductor, an inorganic semiconductor (eg, amorphous silicon, polysilicon), or an organic semiconductor, etc. The active layer 130 may have a source region and a drain region.

[0087] A gate insulating layer 150 may be arranged on the active layer 130. For example, the gate insulating layer 150 may fully cover the active layer 130 on the substrate 110, and may have a substantially flat upper surface without generating a step difference around the active layer 130. Alternatively, the gate insulating layer 150 may also cover the active layer 130 on the substrate 110, and be arranged with a uniform thickness along the contour of the active layer 130. The gate insulating layer 150 may include a silicon compound, a metal oxide, and the like. For example, the gate insulating layer 150 may include silicon oxide (SiO), silicon nitride (SiN), silicon oxynitride (SiON), silicon oxycarbide (SiOC), silicon carbon nitride (SiCN), aluminum oxide (AlO), aluminum nitride (AlN), tantalum oxide (TaO), hafnium oxide (HfO), zirconium oxide (ZrO), titanium oxide (TiO), and the like. In another exemplary embodiment, the gate insulating layer 150 may also have a multilayer structure including a plurality of insulating layers. For example, the insulating layers may have mutually different thicknesses or include mutually different materials.

[0088] A gate electrode 170 may be disposed on the gate insulating layer 150. The gate electrode 170 may be disposed on a portion of the gate insulating layer 150 where the active layer 130 is disposed at a lower portion thereof. The gate electrode 170 may include metal, alloy, metal nitride, conductive metal oxide, transparent conductive material, or the like. For example, the gate electrode 170 may include gold (Au), silver (Ag), aluminum (Al), tungsten (W), copper (Cu), platinum (Pt), nickel (Ni), titanium (Ti), palladium (Pd), magnesium (Mg), calcium (Ca), lithium (Li), chromium (Cr), tantalum (Ta), molybdenum (Mo), scandium (Sc), neodymium (Nd), iridium (Ir), aluminum alloy, aluminum nitride (AlN), silver alloy, tungsten nitride (WN), copper alloy, molybdenum alloy, titanium nitride (TiN), chromium nitride (CrN), tantalum nitride (TaN), strontium ruthenium oxide (SrRuO), zinc oxide (ZnO), indium tin oxide (ITO), tin oxide (SnO), indium oxide (InO), gallium oxide (GaO), indium zinc oxide (IZO), etc. These substances may be used alone or in combination with each other. In another exemplary embodiment, the gate electrode 170 may include a multilayer structure including a plurality of metal layers. For example, the metal layers may have thicknesses different from each other or include substances different from each other.

[0089] An interlayer insulating layer 190 may be arranged on the gate electrode 170. For example, the interlayer insulating layer 190 may fully cover the gate electrode 170 on the gate insulating layer 150, and may have a substantially flat upper surface without generating a step difference around the gate electrode 170. Optionally, the interlayer insulating layer 190 may also cover the gate electrode 170 on the gate insulating layer 150, and be arranged with a uniform thickness along the contour of the gate electrode 170. The interlayer insulating layer 190 may include a silicon compound, a metal oxide, etc. Optionally, the interlayer insulating layer 190 may also have a multilayer structure including a plurality of insulating layers. For example, the insulating layers may have mutually different thicknesses or include mutually different substances.

[0090] A source electrode 210 and a drain electrode 230 may be arranged on the interlayer insulating layer 190. The source electrode 210 may be connected to the source region of the active layer 130 by means of a contact hole formed by removing the first portion of the gate insulating layer 150 and the interlayer insulating layer 190, and the drain electrode 230 may be connected to the drain region of the active layer 130 by means of a contact hole formed by removing the second portion of the gate insulating layer 150 and the interlayer insulating layer 190. The source electrode 210 and the drain electrode 230 may include metals, alloys, metal nitrides, conductive metal oxides, transparent conductive substances, etc., respectively. These substances may be used alone or in combination with each other. In another exemplary embodiment, the source electrode 210 and the drain electrode 230 may also have a multilayer structure including a plurality of metal layers, respectively. For example, the metal layers may have different thicknesses or include different substances.

[0091] Accordingly, a semiconductor element 250 including an active layer 130 , a gate insulating layer 150 , a gate electrode 170 , an interlayer insulating layer 190 , a source electrode 210 , and a drain electrode 230 may be disposed.

[0092] However, although the semiconductor element 250 has an upper gate structure, the present invention is not limited thereto. For example, the semiconductor element 250 may have a lower gate structure, a double gate structure, or the like.

[0093] Furthermore, although the display device 100 includes one semiconductor element, the configuration of the present invention is not limited thereto. For example, the display device 100 may also include at least one semiconductor element and at least one storage capacitor.

[0094] A planarization layer 270 may be arranged on the interlayer insulating layer 190, the source electrode 210, and the drain electrode 230. For example, the planarization layer 270 may be arranged to be relatively thick. In this case, the planarization layer 270 may have a substantially flat upper surface. In order to achieve the flat upper surface of the planarization layer 270 as described above, a planarization process may be added to the planarization layer 270. Optionally, the planarization layer 270 may also be arranged on the interlayer insulating layer 190 along the contours of the source electrode 210 and the drain electrode 230 with a uniform thickness. The planarization layer 270 may be composed of an organic substance or an inorganic substance. In an exemplary embodiment, the planarization layer 270 may include an organic substance. For example, the planarization layer 270 may include a photoresist, a polyacrylate-based resin, a polyimide-based resin, a polyamide-based resin, a siloxane-based resin, an acrylic-based resin, an epoxy-based resin, and the like.

[0095] The lower electrode 290 may be arranged on the planarization layer 270. The lower electrode 290 may be connected to the drain electrode 230 by means of a contact hole formed by removing a portion of the planarization layer 270, and the lower electrode 290 may be electrically connected to the semiconductor element 250. The lower electrode 290 may include a metal, an alloy, a metal nitride, a conductive metal oxide, a transparent conductive substance, etc. These substances may be used alone or in combination with each other. In another exemplary embodiment, the lower electrode 290 may also have a multilayer structure including a plurality of layers. For example, the metal layers may have different thicknesses or include different substances.

[0096] The pixel definition film 310 may be disposed on the planarization layer 270. For example, the pixel definition film 310 may cover both sides of the lower electrode 290 and expose a portion of the upper surface of the lower electrode 290. The pixel definition film 310 may be formed using an organic substance or an inorganic substance. In an exemplary embodiment, the pixel definition film 310 may include an organic substance.

[0097] The light-emitting layer 330 may be arranged on the pixel definition film 310 and the lower electrode 290. The light-emitting layer 330 may be formed using at least one of the light-emitting materials that can emit light of different colors (i.e., red light, green light, blue light, etc.) according to the pixel. Different from this, the light-emitting layer 330 may also be stacked with a plurality of light-emitting materials that can emit light of different colors such as red light, green light, blue light, etc., and emit white light as a whole. In this case, a color filter may also be arranged on the light-emitting layer 330 arranged on the lower electrode 290. The color filter may include at least one of a red color filter, a green color filter, and a blue color filter. Optionally, the color filter may also include a yellow color filter, a cyan color filter, and a magenta color filter. The color filter may include a photosensitive resin or a color photoresist.

[0098] The upper electrode 340 may be arranged on the light emitting layer 330 and the pixel definition film 310. The upper electrode 340 may include a metal, an alloy, a metal nitride, a conductive metal oxide, a transparent conductive material, etc. These materials may be used alone or in combination. In another exemplary embodiment, the upper electrode 340 may also have a multilayer structure including a plurality of metal layers. For example, the metal layers may have different thicknesses or include different materials.

[0099] A first thin film encapsulation layer 451 may be disposed on the upper electrode 340. The first thin film encapsulation layer 451 may cover the upper electrode 340 and be disposed along the contour of the upper electrode 340 with a uniform thickness. The first thin film encapsulation layer 451 may prevent the light emitting layer 330 from being degraded due to the penetration of moisture, oxygen, etc. In addition, the first thin film encapsulation layer 451 may also perform a function of protecting the display panel 200 from external impact. The first thin film encapsulation layer 451 may include an inorganic substance having flexibility.

[0100] A second thin film encapsulation layer 452 may be disposed on the first thin film encapsulation layer 451. The second thin film encapsulation layer 452 may improve the flatness of the display panel 200 and may protect the display panel 200. The second thin film encapsulation layer 452 may include an organic substance having flexibility.

[0101] A third thin film encapsulation layer 453 may be arranged on the second thin film encapsulation layer 452. The third thin film encapsulation layer 453 may cover the second thin film encapsulation layer 452 and be arranged with a uniform thickness along the contour of the second thin film encapsulation layer 452. The third thin film encapsulation layer 453 may prevent the light emitting layer 330 from being degraded due to the penetration of moisture, oxygen, etc. together with the first thin film encapsulation layer 451. In addition, the third thin film encapsulation layer 453 may also perform the function of protecting the display panel 200 from external impact together with the first thin film encapsulation layer 451 and the second thin film encapsulation layer 452. The third thin film encapsulation layer 453 may include an inorganic substance having flexibility.

[0102] Accordingly, a display panel 200 including a substrate 110, a semiconductor element 250, a planarization layer 270, a lower electrode 290, a pixel definition film 310, a light emitting layer 330, an upper electrode 340, a first thin film encapsulation layer 451, a second thin film encapsulation layer 452 and a third thin film encapsulation layer 453 may be arranged.

[0103] However, although the display device 100 is limited to an organic light emitting display device, the present invention is not limited thereto. In another exemplary embodiment, the display device 100 may also include a liquid crystal display device (LCD), a field emission display device (FED), a plasma display device (PDP), or an electrophoretic image display device (EPD).

[0104] Figure 5 It is shown Figure 1 A plan view of an example of a protruding pattern included in a display device.

[0105] Reference Figure 3 and Figure 5 , a protruding pattern 651 may be arranged on the upper surface of the first substrate 610. In other words, the protruding pattern 651 may be repeatedly arranged along the diagonal direction L1 on the upper surface of the first substrate 610, and may protrude along the third direction D3. Here, the diagonal direction L1 may be a direction parallel to the upper surface of the first substrate 610, and may be a direction different from the first direction D1 and the second direction D2.

[0106] In an exemplary embodiment, each of the protruding patterns 651 may have a hemispherical shape or an embossed shape. Also, at least a portion of an upper portion of each of the protruding patterns 651 may sink into the interior of the elastic member 670. In other words, at least a portion of an upper portion of each of the protruding patterns 651 may intrude into the interior of the elastic member 670. Two adjacent protruding patterns of the protruding patterns 651 may contact each other.

[0107] The free space may be defined by three adjacent protrusion patterns in the protrusion pattern 651 and the bottom surface of the elastic member 670. The free space may be filled with air, and the air may be confined in the free space. Since there is air in the free space, the protrusion pattern 651 and the elastic member 670 may have a structure that reduces external impact. That is, the protrusion pattern 651 and the elastic member 670 may protect the display panel 200 from external impact. In an exemplary embodiment, the height, the pitch, and the taper angle of the protrusion pattern 651 may be determined so that the free space is formed between the elastic member 670 and the protrusion pattern 651.

[0108] Figure 6 It is shown Figure 1 A plan view of another example of a protruding pattern included in a display device.

[0109] Reference Figure 3 and Figure 6 , a protruding pattern 652 may be arranged on the upper surface of the first substrate 610. In other words, the protruding pattern 652 may be repeatedly arranged along the zigzag direction L2 on the upper surface of the first substrate 610, and may protrude along the third direction D3. Here, the zigzag direction L2 may be a direction parallel to the upper surface of the first substrate 610, and may be a direction different from the first direction D1 and the second direction D2.

[0110] In an exemplary embodiment, the protrusion patterns 652 may have a hemispherical shape or an embossed shape, respectively. Also, at least a portion of an upper portion of each of the protrusion patterns 652 may sink into the interior of the elastic member 670. In other words, at least a portion of an upper portion of each of the protrusion patterns 652 may invade the interior of the elastic member 670. Two adjacent protrusion patterns of the protrusion patterns 652 may contact each other.

[0111] A free space may be defined by three adjacent protrusion patterns in the protrusion pattern 652 and the bottom surface of the elastic member 670. The free space may be filled with air, and the air may be confined in the free space. Since there is air in the free space, the protrusion pattern 652 and the elastic member 670 may have a structure that reduces external impact. That is, the protrusion pattern 652 and the elastic member 670 may protect the display panel 200 from external impact. In an exemplary embodiment, the height, the pitch, and the taper angle of the protrusion pattern 652 may be determined so that the free space is formed between the elastic member 670 and the protrusion pattern 652.

[0112] Figures 7 to 10 1 and 2 are a perspective view and a cross-sectional view illustrating a method of manufacturing a display device according to an exemplary embodiment of the present invention.

[0113] Reference Figure 7 , a first substrate 610 may be provided. The first substrate 610 may be transparent. For example, the first substrate 610 may be formed using PI, PEN, PA, PET, PP, PC, PS, PSul, PE, PPA, PES, PAR, PCO, MPPO, PEI, etc.

[0114] A plurality of protruding patterns 655 may be formed on the upper surface of the first substrate 610. In other words, the protruding patterns 655 may be repeatedly arranged along the first direction D1 and the second direction D2 on the upper surface of the first substrate 610, and may protrude along the third direction D3. That is, the protruding patterns 655 may be arranged in a lattice shape on the first substrate 610. In an exemplary embodiment, each of the protruding patterns 655 may have a hemispherical shape or an embossed shape. Two adjacent protruding patterns in the protruding patterns 655 may contact each other. The protruding patterns 655 may be formed using photoresist, polyacrylate-based resin, polyimide-based resin, polyamide-based resin, siloxane-based resin, acrylic-based resin, epoxy-based resin, silicon-based resin, etc. In an exemplary embodiment, the protruding patterns 655 are in an uncured state.

[0115] Reference Figure 8 , the protruding pattern 655 can be cured. For example, ultraviolet rays (UV), laser, visible light, etc. can be irradiated onto the protruding pattern 655 to cure the protruding pattern 655.

[0116] Reference Fig. 9 , the protrusion pattern 655 may be cured to form the protrusion pattern 650 on the first substrate 610. The protrusion pattern 650 may have a first viscosity.

[0117] A second substrate 630 may be provided. The second substrate 630 may be formed using substantially the same material as the first substrate 610. For example, the second substrate 630 may be transparent.

[0118] An uncured resin layer 675 may be formed on the bottom surface of the second substrate 630. In an exemplary embodiment, the uncured resin layer 675 may have a second viscosity lower than the first viscosity. The upper surface of the second substrate 630 formed with the uncured resin layer 675 may be pressurized along a fourth direction D4. Here, the fourth direction D4 may be a direction opposite to the third direction D3. The uncured resin layer 675 may be formed using an elastic polymer, a thermoplastic elastic polymer or a resin, etc.

[0119] Reference Fig.10 , at least a portion of the upper portion of each of the protruding patterns 650 may sink into the interior of the uncured resin layer 675. For example, since the uncured resin layer 675 has a relatively low viscosity, at least a portion of the upper surface of each of the protruding patterns 650 may easily invade the interior of the uncured resin layer 675.

[0120] After at least a portion of the upper surface of each of the protruding patterns 650 intrudes into the uncured resin layer 675, the uncured resin layer 675 may be cured. For example, the uncured resin layer 675 may be cured by irradiating ultraviolet (UV), laser, visible light, etc. onto the second substrate 630.

[0121] Reference Figure 3 The uncured resin layer 675 may be cured to form the elastic member 670 . The viscosity of the elastic member 670 may be higher than the viscosity of the uncured resin layer 675 .

[0122] Accordingly, a buffer structure 600 including the first substrate 610 , the second substrate 630 , the protruding pattern 650 and the elastic component 670 may be formed.

[0123] In an exemplary embodiment, a free space may be defined by four adjacent protrusion patterns in the protrusion pattern 650 and the bottom surface of the elastic member 670. The free space may be filled with air, and the air may be confined in the free space. Since there is air in the free space, the protrusion pattern 650 and the elastic member 670 may have a structure that reduces external impact. In the process of forming the protrusion pattern 650, the height, the pitch, and the taper angle of the protrusion pattern 650 may be determined so that the free space is formed between the elastic member 670 and the protrusion pattern 650.

[0124] A display panel 200 may be provided. The display panel 200 may include a plurality of pixels and may display an image through the pixels. For example, the display panel 200 may have a first surface S1 for displaying an image and a second surface S2 opposite to the first surface S1. Also, the display panel 200 may have a first side surface SS1 and a second side surface SS2 facing the first side surface SS1.

[0125] A lower buffer component 410 may be disposed on the second surface S2 of the display panel 200. The lower buffer component 410 may protect the display panel 200 from external impact. Also, the lower buffer component 410 may include a ductile substance so that the display panel 200 is easily folded. For example, the lower buffer component 410 may be formed using a foam-shaped substance such as polyurethane foam, polystyrene foam, or the like.

[0126] A support member 500 may be formed on the bottom surface of the lower buffer member 410. The support member 500 may support the display panel 200 and may also assist in folding the display panel 200. For example, the support member 500 is arranged on the entire second surface S2 of the display panel 200 to support the display panel 200, and may assist in folding the display panel 200 through the opening formed in the folding region 20.

[0127] The support member 500 may be formed of a metal or plastic having a relatively large elastic force or a relatively large restoring force. In an exemplary embodiment, the support member 500 may include steel stainless steel (SUS). Alternatively, the support member 500 may also include alloys such as nickel-titanium (Ni-Ti), nickel-aluminum (Ni-Al), copper-zinc-nickel (Cu-Zn-Ni), copper-aluminum-nickel (Cu-Al-Ni), copper-aluminum-manganese (Cu-Al-Mn), titanium-nickel-copper-molybdenum (Ti-Ni-Cu-Mo), cobalt-nickel-gallium: iron (Co-Ni-Ga:Fe), silver-nickel (Ag-Ni), gold-cadmium (Au-Cd), iron-platinum (Fe-Pt), iron-nickel (Fe-Ni), indium-cadmium (In-Cd), etc.

[0128] The buffer structure 600 is formed on the first surface S1 of the display panel 200, so that the Figure 3 The display device 100 shown includes a buffer structure 600 , a display panel 200 , a lower buffer component 410 and a supporting component 500 .

[0129] As described above, although the present invention has been described with reference to exemplary embodiments, it will be apparent to those skilled in the art that various modifications and changes may be made to the present invention without departing from the spirit and scope of the present invention.

[0130] Industrial Applicability

[0131] The present invention can be applied to various display devices that can be equipped with a display device. For example, the present invention can be applied to a large number of display devices such as display devices for vehicles, ships, and aircraft, portable communication devices, display devices for display or information transmission, and medical display devices.

Claims

1. A display device, include: A display panel having a folding area; as well as Buffer structures, Wherein, the buffer structure comprises: a plurality of protruding patterns arranged on the display panel; and an elastic member arranged on the plurality of protruding patterns in such a manner that at least a portion of an upper portion of each of the plurality of protruding patterns is sunken into the interior of the elastic member, The plurality of protruding patterns are directly arranged on the upper surface of the display panel, or are arranged on the upper surface of a first substrate arranged on the upper surface of the display panel. Each of the plurality of protrusion patterns has a hemispherical shape, A vacant space is defined by adjacent three or four convex patterns among the plurality of convex patterns and the bottom surface of the elastic member, The empty space is filled with air.

2. The display device according to claim 1, It is characterized in that The air is confined in the empty space.

3. The display device according to claim 1, It is characterized in that The plurality of protrusion patterns are arranged in a lattice shape on the display panel.

4. The display device according to claim 1, It is characterized in that Two adjacent protrusion patterns among the plurality of protrusion patterns are in contact with each other.

5. The display device according to claim 1, It is characterized in that The protruding pattern has a structure having elasticity.

6. The display device according to claim 1, It is characterized in that In the case where the first substrate is arranged on the upper surface of the display panel, The first substrate is transparent, The buffer structure further includes: a transparent second substrate, which is arranged opposite to the first substrate and is arranged on the upper surface of the elastic component.

7. The display device according to claim 1, It is characterized in that The plurality of convex patterns include four convex patterns arranged adjacent to each other, and the four convex patterns arranged adjacent to each other and a bottom surface of the elastic member define a first empty space, the first empty space being filled with air.

8. The display device according to claim 7, It is characterized in that If the four protruding patterns are respectively set as the kth protruding pattern, the k+1th protruding pattern, the jth protruding pattern, and the j+1th protruding pattern, the plurality of protruding patterns further include the k-1th protruding pattern and the j-1th protruding pattern respectively adjacent to the kth protruding pattern and the jth protruding pattern, and the k-1th protruding pattern and the j-1th protruding pattern are also adjacent to each other, wherein k and j are both integers greater than 1, A second vacant space is defined by the k-1th convex pattern, the kth convex pattern, the j-1th convex pattern, the jth convex pattern, and the elastic component, and the second vacant space is filled with air.

9. The display device according to claim 8, It is characterized in that The first empty space and the second empty space are arranged adjacent to each other and spatially connected to each other.

10. A method for manufacturing a display device, comprising the following steps: providing a first substrate; forming a plurality of protruding patterns on the upper surface of the first substrate and curing the same; providing a second substrate; forming an uncured resin layer on the bottom surface of the second substrate; Pressing the upper surface of the second substrate on which the uncured resin layer is formed in a first direction so that at least a portion of an upper portion of each of the plurality of protruding patterns is sunken into the uncured resin layer; curing the uncured resin layer to form an elastic member; providing a display panel having a folding area; as well as A buffer structure including the first substrate, the plurality of protruding patterns, the elastic component and the second substrate is formed on the display panel.

11. The method for manufacturing a display device according to claim 10, It is characterized in that The protruding pattern has a structure having elasticity.

12. The method for manufacturing a display device according to claim 10, It is characterized in that Each of the plurality of protrusion patterns has a first viscosity, and the uncured resin layer has a second viscosity lower than the first viscosity.

13. The method for manufacturing a display device according to claim 10, It is characterized in that The elastic component includes at least one of silicone, urethane, polyurethane, and thermoplastic polyurethane.

14. The method for manufacturing a display device according to claim 10, It is characterized in that The plurality of protrusion patterns include at least one of photoresist, polyacrylate-based resin, polyimide-based resin, polyamide-based resin, siloxane-based resin, acrylic-based resin, epoxy-based resin, and silicon-based resin.

15. The method for manufacturing a display device according to claim 10, It is characterized in that The first substrate and the second substrate are transparent and respectively include at least one of transparent polyimide, transparent polyethylene naphthalate, transparent polyamide, transparent polyethylene terephthalate, transparent polypropylene, transparent polycarbonate, transparent polystyrene, transparent polysulfone, transparent low-density polyethylene, transparent polyphthalamide, transparent polyethersulfone, transparent polyarylate, transparent polycarbonate oxide, transparent modified polyphenylene ether, and transparent polyetherimide.

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