Display module and method for manufacturing display device

Abstract

A display module and a method for manufacturing a display device are disclosed, which may include: preparing a display panel; attaching a film portion to the display panel; forming an alignment key on or in the film portion; using an alignment module with a camera to identify the alignment key; aligning a window with the film portion using the alignment module; removing at least a portion of the film portion; and combining the display panel with the window.

Description

[0001] CROSS-REFERENCE TO RELATED APPLICATIONS

[0002] This application claims priority to and the benefit of Korean Patent Application No. 10-2019-0159945, filed on Dec. 4, 2019, which is hereby incorporated by reference for all purposes as if fully set forth herein. Technical Field

[0003] Embodiments / implementations of the present invention generally relate to display modules having improved reliability and methods of manufacturing display devices. Background Art

[0004] Various display devices are being developed for use in multimedia devices such as televisions, mobile phones, navigation systems, computer monitors, game consoles, etc. The display device includes a display panel that provides image information to a user and a window that protects the display panel. The window can be combined with the display panel. In order to combine the window with the display panel, it is necessary to align the window with the display panel.

[0005] The above information disclosed in this Background section is only for understanding the background of the present inventive concept and therefore it may contain information that does not constitute prior art. Summary of the invention

[0006] A display device constructed according to an embodiment of the present invention can provide a display module with improved reliability, and a method according to an exemplary implementation can manufacture the display device.

[0007] Additional features of the inventive concept will be set forth in the description which follows, and in part will be apparent from the description, or may be learned by practice of the inventive concept.

[0008] According to an embodiment of the present invention, a method for manufacturing a display device may include: preparing a display panel; attaching a film portion to the display panel; forming an alignment key on or in the film portion; using an alignment module with a camera to identify the alignment key; aligning a window with the film portion using the alignment module; removing at least a portion of the film portion; and combining the display panel with the window.

[0009] In an embodiment, the film portion may include an optical film and a protective film disposed on the optical film, and forming the alignment key on or in the film portion may include forming the alignment key on or in a top surface of the protective film.

[0010] In an embodiment, removing at least a portion of the film portion may include removing a protective film.

[0011] In an embodiment, forming the alignment key may include patterning a top surface of the film portion using a laser beam.

[0012] In an embodiment, forming the alignment key may include printing ink on a top surface of the membrane portion.

[0013] In an embodiment, forming the alignment key may be performed before attaching the film portion to the display panel.

[0014] In an embodiment, forming the alignment key may be performed after attaching the film portion to the display panel.

[0015] In an embodiment, the display panel may include: a first region including a first edge, a second edge extending from the first edge in a direction crossing the first edge, a third edge parallel to the first edge and extending from the second edge, and a fourth edge parallel to the second edge and extending from the third edge; a second region extending from the first edge; a third region extending from the second edge; a fourth region extending from the third edge; and a fifth region extending from the fourth edge. At least a portion of each of the second to fifth regions may be curved.

[0016] In an implementation, an alignment key may be formed on at least one of the second to fifth regions.

[0017] In an implementation, an alignment key may be formed on the first region.

[0018] In an embodiment, forming the alignment key may include forming a plurality of alignment keys in at least two different shapes.

[0019] In an embodiment, the display panel may include a display area and a non-display area adjacent to the display area. The alignment key may be formed at a position overlapping the display area.

[0020] In an embodiment, the alignment module may further include a control unit.The method may further include storing position information about the aligned position of the window in the control unit.

[0021] In an embodiment, the method may further include aligning the window with the film portion using the position information stored in the control unit after removing at least a portion of the film portion.

[0022] In an embodiment, identifying the alignment key and aligning the window with the film portion may be performed simultaneously.

[0023] In an embodiment, the alignment key may be provided in plurality. The membrane portion may include: a first alignment region; a second alignment region adjacent to the first alignment region; a third alignment region adjacent to the first alignment region and spaced apart from the second alignment region; and a fourth alignment region adjacent to the second alignment region and the third alignment region. Forming the alignment key may include forming a plurality of alignment keys on or in at least two of the first to fourth alignment regions.

[0024] According to an embodiment of the inventive concept, a display module may include: a display panel including a display area and a non-display area adjacent to the display area; an optical film disposed on the display panel; and a protective film disposed on the optical film. At least one alignment key may be disposed on or in a top surface of the protective film.

[0025] In an embodiment, the alignment key may overlap the display area when viewed in a plan view.

[0026] In an embodiment, the alignment key may be defined by a hollow area that is recessed downward from a top surface of the protective film, and a depth of the hollow area may be less than or equal to a thickness of the protective film.

[0027] In an implementation, the alignment key may include an ink pattern disposed on a top surface of the protection film.

[0028] It is to be understood that both the foregoing general description and the following detailed description are exemplary and explanatory and are intended to provide further explanation of the invention as claimed. BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The accompanying drawings, which are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification, illustrate embodiments of the invention and together with the description serve to explain the inventive concept.

[0030] Figure 1 is a perspective view illustrating a display device according to an embodiment of the inventive concept.

[0031] Figure 2 is a perspective view illustrating an exploded structure of a display device according to an embodiment of the inventive concept.

[0032] Figure 3 is a flowchart illustrating a method of manufacturing a display device according to an embodiment of the inventive concept.

[0033] Figure 4 is a cross-sectional view illustrating a step of forming an alignment key according to an embodiment of the inventive concept.

[0034] Figure 5 is a plan view illustrating a film portion according to an embodiment of the present inventive concept.

[0035] Fig. 6A and Figure 6B is a perspective view illustrating a step of attaching a film portion on a display panel according to an embodiment of the inventive concept.

[0036] Figure 7is a perspective view illustrating a portion of a method of manufacturing a display device according to an embodiment of the inventive concept.

[0037] Figure 8 is a perspective view illustrating a step of removing at least a portion of a film portion according to an embodiment of the present inventive concept.

[0038] Fig. 9 and Fig.10 is a cross-sectional view illustrating a step of combining a window with a display panel according to an embodiment of the inventive concept.

[0039] Fig.11 is a cross-sectional view illustrating a step of forming an alignment key on a film portion according to an embodiment of the inventive concept.

[0040] Fig.12 is a flowchart illustrating a method of manufacturing a display device according to an embodiment of the inventive concept.

[0041] Fig.13 is a cross-sectional view illustrating a step of forming an alignment key according to an embodiment of the inventive concept.

[0042] Fig.14 is a cross-sectional view illustrating a step of forming an alignment key according to an embodiment of the inventive concept. DETAILED DESCRIPTION

[0043] In the following description, for the purpose of explanation, many specific details are set forth to provide a thorough understanding of various embodiments or implementations of the present invention. As used herein, "embodiment" and "implementation" are interchangeable words, which are non-limiting examples of devices or methods using one or more inventive concepts disclosed herein. However, it is apparent that various embodiments can be practiced without these specific details or using one or more equivalent arrangements. In other examples, known structures and devices are shown in block diagram form to avoid unnecessary ambiguity of various embodiments. In addition, various embodiments may be different, but need not be exclusive. For example, without departing from the inventive concept, the specific shape, configuration and characteristics of the embodiment may be used or implemented in another embodiment.

[0044] Unless otherwise specified, the illustrated embodiments should be understood as providing exemplary features of varying details of some ways in which the inventive concept can be implemented in practice. Therefore, unless otherwise specified, the features, components, modules, layers, films, panels, regions and / or aspects, etc. (hereinafter individually or collectively referred to as "elements") of various embodiments may be combined, separated, interchanged and / or rearranged in other ways without departing from the inventive concept.

[0045] The use of cross hatching and / or shading in the drawings is generally provided to clarify the boundaries between adjacent elements. Therefore, unless otherwise stated, the presence or absence of cross hatching or shading does not convey or indicate any preference or requirement for a particular material, material property, size, ratio, commonality between the elements shown, and / or any other characteristics, attributes, properties, etc. of the elements. In addition, in the drawings, the size and relative size of the elements may be exaggerated for the purpose of clarity and / or description. When the embodiments may be implemented differently, a specific process sequence may be performed differently from the described sequence. For example, two processes described in succession may be performed substantially simultaneously, or may be performed in an order opposite to the described sequence. In addition, the same reference numerals represent the same elements.

[0046] When an element, such as a layer, is referred to as being "on," "connected to," or "coupled to" another element or layer, it may be directly on, directly connected to, or directly coupled to the other element or layer, or there may be intervening elements or layers. However, when an element or layer is referred to as being "directly on," "directly connected to," or "directly coupled to" another element or layer, there are no intervening elements or layers. For this purpose, the term "connected" may refer to a physical connection, an electrical connection, and / or a fluid connection with or without the presence of intervening elements. In addition, the DR1 axis, the DR2 axis, and the DR3 axis are not limited to the three axes of a rectangular coordinate system (such as, the x-axis, the y-axis, and the z-axis), and may be interpreted in a broader sense. For example, the DR1 axis, the DR2 axis, and the DR3 axis may be perpendicular to each other, or may represent different directions that are not perpendicular to each other. For the purpose of this disclosure, "at least one of X, Y, and Z" and "at least one selected from the group consisting of X, Y, and Z" may be interpreted as only X, only Y, only Z, or any combination of two or more of X, Y, and Z, such as XYZ, XYY, YZ, and ZZ for example. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0047] Although the terms "first", "second", etc. may be used herein to describe various types of elements, these elements should not be limited by these terms. These terms are used to distinguish one element from another element. Therefore, without departing from the teachings of the present disclosure, the first element discussed below may be referred to as the second element.

[0048] For descriptive purposes, spatially relative terms such as "below," "below," "below," "above," "up," "above," "higher," "side" (e.g., as in "sidewall"), etc. may be used herein and thereby describe the relationship of one element to another element (or multiple elements) as shown in the accompanying drawings. In addition to the orientation depicted in the accompanying drawings, spatially relative terms are intended to encompass different orientations of the device in use, operation, and / or manufacture. For example, if the device in the accompanying drawings is flipped, an element described as being "below" or "beneath" other elements or features will then be oriented to be "above" the other elements or features. Thus, the exemplary term "below" can encompass both above and below orientations. Additionally, the device may be otherwise oriented (e.g., rotated 90 degrees or in other orientations), and therefore, the spatially relative descriptors used herein should be interpreted accordingly.

[0049] The terms used herein are for the purpose of describing specific embodiments and are not intended to be limiting. As used herein, the singular forms "a", "an" and "the" are intended to also include plural forms unless the context clearly indicates otherwise. In addition, when used in this specification, the terms "comprises", "comprising", "includes" and / or "including" specify the existence of the features, integral bodies, steps, operations, elements, components and / or groups thereof described, but do not exclude the existence or addition of one or more other features, integral bodies, steps, operations, elements, components and / or groups thereof. It should also be noted that, as used herein, the terms "substantially", "about" and other similar terms are used as approximate terms rather than as terms of degree, and therefore, are used to allow for the inherent deviations of the measured values, calculated values ​​and / or provided values ​​that will be recognized by those of ordinary skill in the art.

[0050] Various embodiments are described herein with reference to cross-sectional views and / or exploded views of schematic diagrams of idealized embodiments and / or intermediate structures. Therefore, variations in the shapes of the diagrams caused by, for example, manufacturing techniques and / or tolerances will be expected. Therefore, the embodiments disclosed herein should not be interpreted as being limited to the specific illustrated shapes of the regions, but rather include deviations in shapes caused by, for example, manufacturing. In this way, the regions shown in the drawings may be schematic in nature, and the shapes of these regions may not reflect the actual shapes of the regions of the device, and therefore, are not necessarily intended to be limiting.

[0051] As is customary in the art, some embodiments are described and shown in the accompanying drawings in the form of functional blocks, units and / or modules. It will be understood by those skilled in the art that these blocks, units and / or modules are physically implemented by electrical (or optical) circuits such as logic circuits, discrete components, microprocessors, hard-wired circuits, memory elements, wiring connectors, etc., which can be formed using semiconductor-based manufacturing techniques or other manufacturing techniques. In the case where blocks, units and / or modules are implemented by microprocessors or other similar hardware, they can be programmed and controlled by software (e.g., microcode) to perform the various functions discussed herein, and they can be selectively driven by firmware and / or software. It will also be envisioned that each block, unit and / or module can be implemented by dedicated hardware, or can be implemented as a combination of dedicated hardware for performing some functions and processors (e.g., one or more programmed microprocessors and related circuits) for performing other functions. In addition, without departing from the scope of the inventive concept, each block, unit and / or module of some embodiments can be physically separated into two or more interactive and discrete blocks, units and / or modules. Furthermore, without departing from the scope of the inventive concept, the blocks, units and / or modules of some embodiments may be physically combined into more complex blocks, units and / or modules.

[0052] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by those of ordinary skill in the art to which the present disclosure belongs. Terms such as those defined in commonly used dictionaries should be interpreted as having a meaning consistent with their meaning in the context of the relevant art, and should not be interpreted in an idealized or overly formal sense, unless explicitly defined as such in this article.

[0053] Figure 1 is a perspective view illustrating a display device according to an embodiment of the inventive concept.

[0054] Reference Figure 1 , the display device DD can be activated by an electrical signal applied thereto. The display device DD can be implemented in various forms. For example, the display device DD can be used in large electronic devices (e.g., televisions and monitors) or small or medium-sized electronic devices (e.g., mobile phones, tablet computers, car navigation systems, game consoles, and smart watches). In this embodiment, the display device DD can be, for example, Figure 1 Smart phone shown in .

[0055] A display area DA may be defined in the display device DD, and the display area DA may include a first display area DA1, a second display area DA2, a third display area DA3, a fourth display area DA4, and a fifth display area DA5.

[0056] The first display area DA1 may be parallel to a plane defined by the first direction DR1 and the second direction DR2. The normal direction of the first display area DA1 may correspond to a thickness direction DR3 (hereinafter referred to as a third direction) of the display device DD. In this specification, the third direction DR3 will be used to distinguish the front surface or top surface and the rear surface or bottom surface of each element or member. The front surface and the rear surface may be two surfaces opposite to each other in the third direction DR3. The third direction DR3 may not be parallel to the first direction DR1 and the second direction DR2. In an embodiment, the first direction DR1, the second direction DR2 and the third direction DR3 may be orthogonal to each other.

[0057] In this specification, the directions indicated by the first direction DR1, the second direction DR2, and the third direction DR3 may be relative concepts, and in an embodiment, they may be used to indicate other directions. In addition, the surface defined by the first direction DR1 and the second direction DR2 may be defined as a "plane", and the expression "when viewed in a plan view" may be used to mean viewing an object in the third direction DR3.

[0058] The second display area DA2 may be an area extending from a first edge of the first display area DA1. The third display area DA3 may be an area extending from a second edge of the first display area DA1. The fourth display area DA4 may be an area extending from a third edge of the first display area DA1. The fifth display area DA5 may be an area extending from a fourth edge of the first display area DA1.

[0059] Each of the second display area DA2 , the third display area DA3 , the fourth display area DA4 , and the fifth display area DA5 may be curved with a certain curvature.

[0060] Due to the curved shapes of the second display area DA2 , the third display area DA3 , the fourth display area DA4 , and the fifth display area DA5 of the display device DD, an area of ​​the display area DA viewed by a user may be increased.

[0061] The display area DA may be used to display an image IM. Figure 1 An example is shown in which a clock window and some icons are set as part of the image IM. In an embodiment, a clock window may be displayed on the first display area DA1, and icons may be displayed on at least one of the second display area DA2, the third display area DA3, the fourth display area DA4, and the fifth display area DA5.

[0062] Figure 2 is a perspective view illustrating an exploded structure of a display device according to an embodiment of the inventive concept.

[0063] Reference Figure 2 , the display device DD may include a window WM, an optical film POL, a display panel DP, a printed circuit board PCB-M, a support member SPT, and a frame FRM.

[0064] The window WM may be provided on the display panel DP. The window WM may protect the display panel DP from external impacts, etc. The window WM may be formed of a transparent material, or include a transparent material. For example, the window WM may be formed of at least one of glass and a transparent synthetic resin, or include at least one of glass and a transparent synthetic resin.

[0065] The window WM may include transmission areas TA1, TA2, TA3, TA4, and TA5. The transmission areas TA1, TA2, TA3, TA4, and TA5 may include first, second, third, fourth, and fifth transmission areas TA1, TA2, TA3, TA4, and TA5.

[0066] The first transmission area TA1 may be parallel to the first direction DR1 and the second direction DR2. The first transmission area TA1 may include a first edge ED1 extending in a direction parallel to the first direction DR1, a second edge ED2 extending from the first edge ED1 in a direction parallel to the second direction DR2, a third edge ED3 extending from the second edge ED2 in a direction parallel to the first direction DR1, and a fourth edge ED4 extending from the third edge ED3 in a direction parallel to the second direction DR2. The first edge ED1 and the third edge ED3 may be parallel to each other, and the second edge ED2 and the fourth edge ED4 may be parallel to each other.

[0067] The second transmission area TA2 may extend from the first edge ED1 of the first transmission area TA1. The third transmission area TA3 may extend from the second edge ED2 of the first transmission area TA1. The fourth transmission area TA4 may extend from the third edge ED3 of the first transmission area TA1. The fifth transmission area TA5 may extend from the fourth edge ED4 of the first transmission area TA1.

[0068] At least a portion of each of the second, third, fourth, and fifth transmission areas TA2, TA3, TA4, and TA5 may be bent with a certain curvature.

[0069] The optical film POL may be disposed between the window WM and the display panel DP. The optical film POL may include, for example, a polarizing film. The polarizing film may reduce the reflectance of external light incident through the window WM.

[0070] The display panel DP may be an element that generates an image IM (see, for example, Figure 1). According to an embodiment of the inventive concept, the display panel DP may be a light-emitting display panel, but the inventive concept is not limited to a specific type of display panel DP. For example, the display panel DP may be an organic light-emitting display panel or a quantum dot light-emitting display panel. The light-emitting layer of the organic light-emitting display panel may be formed of an organic light-emitting material or include an organic light-emitting material. The light-emitting layer of the quantum dot light-emitting display panel may include quantum dots and / or quantum rods.

[0071] The display panel DP may include a first area AR1, a second area AR2, a third area AR3, a fourth area AR4, a fifth area AR5, and a sixth area AR6.

[0072] The first area AR1 may be parallel to the first direction DR1 and the second direction DR2. The first area AR1 may include a first edge ED11 extending in a direction parallel to the first direction DR1, a second edge ED12 extending from the first edge ED11 in a direction parallel to the second direction DR2, a third edge ED13 extending from the second edge ED12 in a direction parallel to the first direction DR1, and a fourth edge ED14 extending from the third edge ED13 in a direction parallel to the second direction DR2. The first edge ED11 and the third edge ED13 may be parallel to each other, and the second edge ED12 and the fourth edge ED14 may be parallel to each other.

[0073] The second area AR2 may extend from the first edge ED11 of the first area AR1. The third area AR3 may extend from the second edge ED12 of the first area AR1. The fourth area AR4 may extend from the third edge ED13 of the first area AR1. The fifth area AR5 may extend from the fourth edge ED14 of the first area AR1.

[0074] When viewed in a plan view, the first area AR1 may overlap the first transmission area TA1. The second area AR2 may overlap the second transmission area TA2. The third area AR3 may overlap the third transmission area TA3. The fourth area AR4 may overlap the fourth transmission area TA4. The fifth area AR5 may overlap the fifth transmission area TA5.

[0075] The first area AR1 may display an image IM through the first transmission area TA1 (eg, see Figure 1 The second area AR2 may display an image IM through the second transmission area TA2 (see, for example, Figure 1 The third area AR3 may display an image IM through the third transmission area TA3 (see, for example, Figure 1 The fourth area AR4 may display an image IM through the fourth transmission area TA4 (eg, see Figure 1The fifth area AR5 may display an image IM through the fifth transmission area TA5 (eg, see Figure 1 ).

[0076] The second to third to fourth and fifth areas AR2, AR3, AR4, and AR5 may be bent with a certain curvature so that they have shapes corresponding to the second to third to fourth to fifth transmission areas TA2, TA3, TA4, and TA5.

[0077] In this specification, the first area AR1 may be referred to as a first display area DA1 (see, for example, Figure 1 The second area AR2 may be referred to as a second display area DA2 (see, for example, Figure 1 The third area AR3 may be referred to as a third display area DA3 (see, for example, Figure 1 ). The fourth area AR4 may be referred to as a fourth display area DA4 (see, for example, Figure 1 The fifth area AR5 may be referred to as a fifth display area DA5 (see, for example, Figure 1 ). The sixth area AR6 may be referred to as a non-display area.

[0078] The first corner region EG1 may be a region adjacent to the second region AR2 and the fifth region AR5. The first corner region EG1 may be disposed between the second region AR2 and the fifth region AR5. When viewed in a plan view, the first corner region EG1 may have a convex edge. The second corner region EG2 may be a region adjacent to the second region AR2 and the third region AR3. The second corner region EG2 may be disposed between the second region AR2 and the third region AR3. When viewed in a plan view, the second corner region EG2 may have a convex edge. The third corner region EG3 may be a region adjacent to the third region AR3 and the fourth region AR4. The third corner region EG3 may be disposed between the third region AR3 and the fourth region AR4. When viewed in a plan view, the third corner region EG3 may have a convex edge. The fourth corner region EG4 may be a region adjacent to the fourth region AR4 and the fifth region AR5. The fourth corner region EG4 may be disposed between the fourth region AR4 and the fifth region AR5. When viewed in a plan view, the fourth corner region EG4 may have a convex edge.

[0079] The sixth area AR6 may extend from the fourth area AR4 in the second direction DR2. The sixth area AR6 may include an upper area AR-H, a bending area BA, and a lower area AR-L.

[0080] The upper area AR-H may extend from the fourth area AR4, the bending area BA may extend from the upper area AR-H, and the lower area AR-L may extend from the bending area BA.

[0081] A pad PD may be provided on the lower area AR-L, and a data driving circuit DIC may be mounted on the lower area AR-L. The pad PD may be electrically connected to the light emitting layer of the display panel DP. The data driving circuit DIC may provide a display area DA (eg, see Figure 1 ) provides a data signal. The display panel DP may be electrically connected to the printed circuit board PCB-M via the pad PD. A control circuit CIC may be mounted on the printed circuit board PCB-M. The control circuit CIC may control the data driving circuit DIC.

[0082] The support member SPT may be disposed under the display panel DP. The support member SPT may support at least one of elements constituting the display panel DP.

[0083] The frame FRM may be disposed under the support member SPT. The frame FRM may be configured to accommodate at least a portion of the support member SPT, the display panel DP, and the window WM. In an embodiment, the frame FRM may be combined with the window WM.

[0084] Figure 3 is a flowchart illustrating a method of manufacturing a display device according to an embodiment of the inventive concept, and Figure 4 is a cross-sectional view illustrating a step of forming an alignment key according to an embodiment of the inventive concept.

[0085] Reference Figure 3 and Figure 4 The film portion FP may include an optical film POL and a protective film PF. The protective film PF may be disposed on the optical film POL. The protective film PF may protect the optical film POL.

[0086] The alignment key AK may be formed in the film portion FP (in step S100 ). The alignment key AK may be formed in advance before attaching the film portion FP to the display panel DP.

[0087] The laser irradiation unit LM may be disposed over the protective film PF. The laser irradiation unit LM may be configured to irradiate a laser beam LZ. The laser beam LZ may include an excimer laser, a yttrium aluminum garnet (YAG) laser, a glass laser, a yttrium vanadate (YVO4) laser, or an argon (Ar) laser.

[0088] The laser beam LZ may be used to perform a patterning process on the top surface PF-U of the protection film PF. For example, the laser beam LZ may be used to etch the top surface PF-U of the protection film PF in the third direction DR3, and thereby form a hollow area. The thickness TK-PF of the protection film PF may be greater than or equal to the depth TK-AK of the hollow area of ​​the alignment key AK. The hollow area may constitute the alignment key AK.

[0089] Figure 5 is a plan view illustrating a film portion according to an embodiment of the present inventive concept.

[0090] Reference Figure 3 and Figure 5 , the film portion FP may include a first alignment area AA1 , a second alignment area AA2 , a third alignment area AA3 , and a fourth alignment area AA4 .

[0091] The second alignment area AA2 may be adjacent to the first alignment area AA1 in the first direction DR1. The third alignment area AA3 may be adjacent to the first alignment area AA1 in the second direction DR2 and may be spaced apart from the second alignment area AA2. The fourth alignment area AA4 may be adjacent to the second alignment area AA2 in the second direction DR2 and may be adjacent to the third alignment area AA3 in the first direction DR1.

[0092] In an embodiment, a plurality of alignment keys AK may be provided. The alignment key AK may include a first alignment key AK1 and a second alignment key AK2. Figure 5 An example is shown in which two alignment keys AK are provided, but the number of the alignment keys is not limited thereto. For example, four alignment keys may be provided in the first alignment area AA1, the second alignment area AA2, the third alignment area AA3, and the fourth alignment area AA4, respectively.

[0093] In an embodiment, the alignment key AK may be formed in at least two of the first alignment area AA1, the second alignment area AA2, the third alignment area AA3, and the fourth alignment area AA4. For example, the first alignment key AK1 may be disposed in the first alignment area AA1, and the second alignment key AK2 may be disposed in the fourth alignment area AA4. However, the inventive concept is not limited to this example, and the positions of the first alignment key AK1 and the second alignment key AK2 may be changed.

[0094] In an embodiment, all or some of the alignment keys AK may be disposed in one of the first alignment area AA1 , the second alignment area AA2 , the third alignment area AA3 , and the fourth alignment area AA4 of the protection film PF.

[0095] An example is shown in which one first alignment key AK1 is disposed in the first alignment area AA1, but the inventive concept is not limited to this example. For example, two or more alignment keys may be disposed in the first alignment area AA1.

[0096] In an embodiment, the alignment key AK may be formed to have at least two different shapes. For example, the first alignment key AK1 may be formed to have a rectangular shape, and the second alignment key AK2 may be formed to have a rhombus shape. However, the inventive concept is not limited to the shape of the alignment key. For example, each of the alignment keys may be formed to have a polygonal, cross, elliptical, or circular shape. In an embodiment, all of the alignment keys AK may be formed to have the same shape.

[0097] Fig. 6A is a perspective view illustrating a step of attaching a film portion on a display panel according to an embodiment of the inventive concept.

[0098] Reference Figure 3 and Fig. 6A , a display module DM may be prepared. The display module DM may include a display panel DP and a film portion FP. The display panel DP may be disposed on the stage ST. The film portion FP having the align key AK may be attached to the display panel DP (in step S200).

[0099] A first adhesive layer (not shown) may be disposed between the display panel DP and the film portion FP. The first adhesive layer may be an optically clear adhesive (OCA) film, an optically clear resin (OCR) film, or a pressure sensitive adhesive (PSA) film.

[0100] In an embodiment, the film portion FP may be attached to the display panel DP such that the align keys AK1 and AK2 are disposed in the display area DA (eg, see FIG. 2 ). Figure 1 )superior.

[0101] When viewed in a plan view, the align keys AK1 and AK2 may be disposed or formed in a region aligned with the display area DA (eg, see Figure 1 ) at a position where the alignment keys AK1 and AK2 overlap. The alignment keys AK1 and AK2 may be disposed or formed on the first area AR1. When viewed in a plan view, the alignment keys AK1 and AK2 may not overlap with the sixth area AR6 (eg, see Figure 2 )'s non-display area.

[0102] In an embodiment, the alignment keys AK1 and AK2 may be disposed in the display area DA (eg, see Figure 1 ). In this case, even when at least a portion of the display panel DP is bent, the alignment keys AK1 and AK2 can be viewed on the front side of the display panel DP. Therefore, the window WM (for example, see Figure 2 ) is combined with the display panel DP. This can make it possible to realize a highly reliable display device (for example, Figure 1 DD) in and a method for manufacturing a display device become possible.

[0103] Figure 6B is a perspective view illustrating a step of attaching a film portion on a display panel according to an embodiment of the inventive concept.

[0104] Reference Figure 3 and Figure 6B The display module DMa may include a display panel DP and a film portion FPa. The film portion FPa may be attached to the display panel DP (in step S200). The alignment keys AK1a and AK2a may be formed at a position aligned with the display area DA (eg, see Figure 1 ) overlap.

[0105] The alignment keys AK1a and AK2a may be formed or disposed on at least one of the second area AR2, the third area AR3, the fourth area AR4, and the fifth area AR5. For example, the first alignment key AK1a may be formed or disposed on the second area AR2, and the second alignment key AK2a may be formed or disposed on the fourth area AR4. However, the inventive concept is not limited to this example, and the positions of the first alignment key AK1a and the second alignment key AK2a may be changed. When viewed in a plan view, the alignment keys AK1a and AK2a may not be aligned with the alignment keys corresponding to the sixth area AR6 (for example, see Figure 2 )'s non-display area.

[0106] In some embodiments, the alignment key may be formed not only on the first area AR1 but also on at least one of the second area AR2, the third area AR3, the fourth area AR4, and the fifth area AR5.

[0107] Figure 7 is a perspective view illustrating a portion of a method of manufacturing a display device according to an embodiment of the inventive concept.

[0108] Reference Figure 3 and Figure 7 , the alignment module AM ​​may include a transfer module MO, cameras CM1 and CM2, and a control unit CU.

[0109] The transfer module MO can be configured to grip the window WM. For example, the transfer module MO can grip the window WM in a suction manner.

[0110] The alignment module AM ​​(e.g., cameras CM1 and CM2 of the alignment module AM) may be used to identify the alignment keys AK1 and AK2, respectively (in step S300). The cameras CM1 and CM2 may be arranged to correspond to the alignment keys AK1 and AK2 in a one-to-one manner. The cameras CM1 and CM2 may include a first camera CM1 and a second camera CM2. When viewed in a plan view, the first camera CM1 may overlap the first alignment key AK1. The second camera CM2 may overlap the second alignment key AK2. Figure 7 An example is shown in which two cameras CM1 and CM2 are provided, but the inventive concept is not limited to this example. In an embodiment, the number of cameras may be equal to the number of alignment keys. In some embodiments, the number of cameras may be greater or less than the number of alignment keys.

[0111] In an embodiment, the alignment keys AK1 and AK2 may be disposed in the display area DA (eg, see Figure 1 ) on. Before combining the film portion FP with the window WM, the portion of the film portion FP having the alignment keys AK1 and AK2 may be removed. Therefore, there may be no limitation on the size of the alignment keys AK1 and AK2. This may make it possible to increase the size of the alignment keys AK1 and AK2, and in this case, the alignment keys AK1 and AK2 may be more accurately recognized by the cameras CM1 and CM2. That is, the combination accuracy between the window WM and the display panel DP may be improved. This may make it possible to realize a highly reliable display device (e.g., Figure 1 DD) in and a method for manufacturing a display device become possible.

[0112] The window WM may be aligned with the desired position on the film part FP by the alignment module AM ​​(in step S400). For example, the alignment position of the window WM may be adjusted by the transfer module MO. Identifying the alignment keys AK1 and AK2 (in step S300) and aligning the window WM with the film part FP (in step S400) may be performed simultaneously.

[0113] The control unit CU may store information about the aligned position of the window WM aligned by the transfer module MO as position information. The position information may be obtained from the alignment keys AK1 and AK2 recognized by the cameras CM1 and CM2.

[0114] Figure 8 is a perspective view illustrating a step of removing at least a portion of a film portion according to an embodiment of the present inventive concept.

[0115] Reference Figure 3 and Figure 8 At least a portion of the film portion FP may be removed (in step S500). For example, the protective film PF of the film portion FP may be removed from the display panel DP and the optical film POL.

[0116] Although the alignment keys AK1 and AK2 are formed or arranged to be aligned with the display area DA (see, for example, Figure 1 ) overlap, but the presence of the alignment keys AK1 and AK2 may not affect the display area DA (for example, see Figure 1 ), because the protective film PF is removed.

[0117] In an embodiment, the film portion FP may include only the protection film PF, and in this case, the entire film portion FP may be removed from the display panel DP.

[0118] In an embodiment, the protective film PF having the alignment keys AK1 and AK2 may be removed before combining the window WM with the display panel DP. In this case, the alignment keys AK1 and AK2 may be formed on a surface that can be easily aligned by the alignment module AM ​​(eg, see Figure 7 ) without any restrictions on their positions. Therefore, it is easy to align the window WM and improve the accuracy of the window WM in alignment. In addition, this makes it possible to improve the combination accuracy between the window WM and the display panel DP. Therefore, a highly reliable display device (for example, Figure 1 DD) in and a method for manufacturing a display device.

[0119] Fig. 9 and Fig.10 is a cross-sectional view illustrating a step of combining a window with a display panel according to an embodiment of the inventive concept.

[0120] Reference Figure 3 , Fig. 9 and Fig.10 , the display panel DP may be combined with the window WM (in step S600). The transfer module MO may place the window WM on the display panel DP. The alignment module AM ​​may align the window WM with a position on the display panel DP using the position information about the alignment position of the window WM stored in the control unit CU.

[0121] The display panel DP may be curved. The second area AR2 (eg, see Figure 2 ) may be bent to have a shape similar to that of the second transmission area TA2 (eg, see Figure 2 ) corresponding to the shape of the third area AR3 (for example, see Figure 2 ) may be bent to have a shape similar to that of the third transmission area TA3 (eg, see Figure 2 The fourth area AR4 (for example, see Figure 2 ) may be bent to have a shape similar to that of the fourth transmission area TA4 (eg, see Figure 2 The fifth area AR5 (for example, see Figure 2) may be bent to have a shape similar to that of the fifth transmission area TA5 (eg, see Figure 2 )’s shape.

[0122] The window WM may be attached to the display panel DP. A second adhesive layer (not shown) may be provided between the window WM and the optical film POL. The second adhesive layer may be an optically clear adhesive (OCA) film, an optically clear resin (OCR) film, or a pressure-sensitive adhesive (PSA) film.

[0123] In an embodiment, in step S300 of identifying the alignment keys AK1 and AK2 using the alignment module AM ​​(see, for example, Figure 7 ) may be stored in the control unit CU. During the removal of the protective film PF (in step S500), the positions of the window WM and the alignment module AM ​​may be changed. Here, a space for removing the protective film PF may be provided. After removing the protective film PF, the stored position information may be used to realign the display panel DP and the window WM with each other. When the display panel DP and the window WM are aligned with each other, combining the display panel DP and the window WM may be performed (in step S600). Therefore, the accuracy when combining the display panel DP and the window WM may be improved. This may enable the implementation of a highly reliable display device (e.g., Figure 1 DD) in and a method for manufacturing a display device become possible.

[0124] Fig.11 is a cross-sectional view showing a step of forming an alignment key on a film portion according to an embodiment of the inventive concept. Fig.11 In the description of Figure 4 Described elements may be identified by the same reference numerals without repeating their repeated descriptions.

[0125] Reference Figure 3 , Figure 4 and Fig.11 , an alignment key AK-1 may be formed on the film portion FP-1 (in step S100). The forming of the alignment key AK-1 (in step S100) may be performed before the step S200 of attaching the film portion FP-1 to the display panel DP.

[0126] The film portion FP-1 may include an optical film POL and a protective film PF-1. An inkjet unit IN may be placed on the protective film PF-1. The inkjet unit IN may eject ink INK. The ink INK may be printed on a top surface PF-1U of the protective film PF-1. An alignment key AK-1 may be formed on the top surface PF-1U of the protective film PF-1.

[0127] In the case of using the printing method using the inkjet unit IN, unlike the case of forming the alignment key AK using the laser irradiation unit LM, the thickness TK-PF1 of the protection film PF-1 may not be considered when forming the alignment key AK-1. Therefore, the process of forming the alignment key AK-1 on the film portion FP may be performed more easily.

[0128] Fig.12 is a flowchart illustrating a method of manufacturing a display device according to an embodiment of the inventive concept, and Fig.13 is a cross-sectional view showing a step of forming an alignment key according to an embodiment of the inventive concept. Fig.12 and Fig.13 In the description of Figure 3 and Figure 4 Described elements may be identified by the same reference numerals without repeating their repeated descriptions.

[0129] Reference Fig.12 and Fig.13 , the film portion FP-2 may be attached to the display panel DP (in step S100-1). Next, the alignment key AK-2 may be formed in the film portion FP-2 (in step S200-1). In other words, the step of forming the alignment key AK-2 may be performed on the film portion FP-2 attached to the display panel DP.

[0130] In an embodiment, the step of forming the alignment key AK-2 (in step S200-1) may be performed simultaneously with the step of the display device manufacturing process using the laser beam LZ. For example, the step of forming the alignment key AK-2 in the film portion FP-2 using the laser beam LZ and the step of cutting the display panel DP using the laser beam LZ may be performed in the same process. In this case, the manufacturing process of the display device (e.g., Figure 1 The total process time spent in DD).

[0131] In an embodiment, the alignment key AK-2 may be disposed in parallel with the display area DA (eg, see Figure 1 ) overlap. Before combining the window WM and the display panel DP with each other, the protective film PF-2 in which the alignment key AK-2 is formed may be removed, and in this case, the alignment key AK-2 may be formed at a position that can be easily recognized by the alignment module AM ​​without any restriction on its position. That is, the combination accuracy between the window WM and the display panel DP may be improved. This may enable the realization of a highly reliable display device (e.g., Figure 1 DD) in and a method for manufacturing a display device become possible.

[0132] Fig.14 is a cross-sectional view showing a step of forming an alignment key according to an embodiment of the inventive concept. Fig.14 In the description of Fig.11 Described elements may be identified by the same reference numerals without repeating their repeated descriptions.

[0133] Reference Fig.12 and Fig.14 , the film portion FP-3 may be attached to the display panel DP. Next, the alignment key AK-3 may be formed on the film portion FP-3. In other words, the step of forming the alignment key AK-3 may be performed on the film portion FP-3 attached to the display panel DP.

[0134] An inkjet unit IN may be placed over the protection film PF-3. The align key AK-3 may be formed by using ink INK ejected from the inkjet unit IN.

[0135] According to an embodiment of the present invention, an alignment key for aligning a window with a display panel may be formed on or in the portion of the film to be removed. This may make it possible to set the alignment key at a position overlapping with the display area of ​​the display panel. In addition, the alignment key may be placed in the front of the display panel even when at least a portion of the display panel is bent. Thus, the window may be aligned with the display panel with high alignment accuracy, and therefore, the process of combining the window with the display panel may be performed with improved accuracy.

[0136] Although certain embodiments and implementations have been described herein, other embodiments and modifications will be apparent from this description. Therefore, the inventive concept is not limited to such embodiments, but to the broader scope of the appended claims and various obvious modifications and equivalent arrangements as will be apparent to those of ordinary skill in the art.

Claims

1. A method for manufacturing a display device, comprising: Prepare the display panel; attaching a film portion to the display panel; forming an alignment key on or in the membrane portion; identifying the alignment key using an alignment module having a camera; aligning a window with the membrane portion using the alignment module; after aligning the window with the film portion, removing at least a portion of the film portion, the at least a portion including the alignment key; as well as after removing the at least a portion of the film portion including the alignment key, combining the display panel with the window, Wherein, the alignment key is formed at a position overlapping with the display area of ​​the display panel, the film portion includes an optical film and a protective film arranged on the optical film, and forming the alignment key on or in the film portion includes forming the alignment key in the top surface of the film portion by patterning the top surface of the film portion using a laser beam to form a hollow area recessed downward from the top surface of the protective film, and the depth of the hollow area is less than or equal to the thickness of the protective film.

2. The method according to claim 1, wherein: Removing the at least a portion of the film portion includes removing the protective film.

3. The method according to claim 1, wherein: Forming the alignment keys is performed before attaching the film portion to the display panel.

4. The method according to claim 1, wherein: Forming the alignment key is performed after attaching the film portion to the display panel.

5. The method according to claim 1, wherein: The display area includes: a first region including a first edge, a second edge extending from the first edge in a direction crossing the first edge, a third edge parallel to the first edge and extending from the second edge, and a fourth edge parallel to the second edge and extending from the third edge; a second region extending from the first edge, and at least a portion of the second region is curved; a third region extending from the second edge, wherein at least a portion of the third region is curved; a fourth region extending from the third edge, wherein at least a portion of the fourth region is curved; and A fifth region extends from the fourth edge, and at least a portion of the fifth region is curved.

6. The method according to claim 5, wherein: The alignment key is formed on at least one of the second region, the third region, the fourth region, and the fifth region.

7. The method according to claim 5, wherein: The alignment key is formed on the first area.

8. The method according to claim 1, wherein: Forming the alignment key includes forming a plurality of alignment keys in at least two different shapes.

9. The method according to claim 1, wherein: The alignment module also includes a control unit, and The method further comprises storing position information regarding the aligned position of the window in the control unit.

10. The method according to claim 9, further comprising: After removing the at least a portion of the film portion, the window is aligned with the film portion using the position information stored in the control unit.

11. The method according to claim 1, wherein: Identifying the alignment key and aligning the window with the film portion are performed simultaneously.

12. The method according to claim 1, wherein: The alignment key is provided in plurality. The membrane portion comprises: a first alignment region; a second alignment region, adjacent to the first alignment region; a third alignment region adjacent to the first alignment region and spaced apart from the second alignment region; and a fourth alignment region, adjacent to the second alignment region and the third alignment region, and Forming the alignment key includes forming a plurality of the alignment keys on or in at least two of the first alignment area, the second alignment area, the third alignment area, and the fourth alignment area.

13. Display module, including: A display panel comprising a display area and a non-display area adjacent to the display area; An optical film, disposed on the display panel; as well as a protective film disposed on the optical film, wherein at least one alignment key is disposed on or in the top surface of the protective film, wherein the alignment key overlaps with the display area when viewed in a plan view, and wherein the alignment key is defined by a hollow area that is recessed downward from the top surface of the protective film, and wherein the depth of the hollow area is less than or equal to the thickness of the protective film.

14. The display module according to claim 13, wherein: The alignment key includes an ink pattern disposed on the top surface of the protection film.

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