Flexible pad and method for manufacturing display device

Abstract

Exemplary embodiments of the present invention relate to a flexible pad for a lamination process of a display device and a method for manufacturing a display device, the flexible pad comprising: a generally straight region having an upper surface defining substantially the same height along a first direction and a generally convex shape along a second direction substantially perpendicular to the first direction; a first inclined region having a first upper surface inclined at a first inclination angle along the first direction and substantially flat along the second direction; and a second inclined region disposed between the first inclined region and the generally straight region, wherein the second inclined region has a second upper surface inclined at a second inclination angle along the first direction at a second inclination angle smaller than the first inclination angle.

Description

Technical Field

[0001] Exemplary embodiments of the present invention generally relate to a flexible pad, and more specifically to a flexible pad for a lamination process of a display device and a method for manufacturing a display device using the flexible pad. Background Technology

[0002] Typically, a display device may include a display panel and a protective window for protecting the display panel. The display panel can be attached to the protective window via a lamination process. Pressing members, such as silicone pads, can be used for conformal contact between the display panel and the protective window.

[0003] The information disclosed in this background section is only for understanding the background of the inventive concept, and therefore may contain information that does not constitute prior art. Summary of the Invention

[0004] The flexible pad and method constructed according to the principles and exemplary embodiments of the present invention provide a flexible pad capable of reducing the concentration of stress applied to a pressed object.

[0005] The method for manufacturing a display device according to the principles and exemplary embodiments of the present invention uses a flexible pad. For example, the flexible pad can be used to attach a display panel to a protective window, thereby preventing damage to the display panel and trapping air bubbles. Furthermore, the flexible pad may include inclined regions that can reduce or disperse pressing loads and / or tensions applied to physically weak areas of the display panel, such as perforated areas.

[0006] Additional features of the inventive concept will be set forth in the description which follows, and will be apparent in part from the description, or may be learned by practice of the inventive concept.

[0007] According to one aspect of the invention, a flexible pad for a display device lamination process includes: a generally straight region having an upper surface defining substantially the same height along a first direction and a generally convex shape along a second direction substantially perpendicular to the first direction; a first inclined region having a first upper surface inclined at a first inclination angle along the first direction and substantially flat along the second direction; and a second inclined region disposed between the first inclined region and the generally straight region, wherein the second inclined region has a second upper surface inclined at a second inclination angle along the first direction at a second inclination angle smaller than the first inclination angle.

[0008] The first inclined region may have a first height, and the second inclined region may have a second height that is greater than the first height.

[0009] The flexible pad may include silicone resin.

[0010] The second upper surface may have a generally circular shape along the first direction.

[0011] In the plan view, the second inclined region may at least partially surround the first inclined region.

[0012] The second upper surface of the second inclined region may be inclined along the second direction.

[0013] The first upper surface may be connected to a first side surface, and the upper surface of the generally straight region may be connected to a second side surface opposite to the first side surface.

[0014] The second upper surface of the second inclined region can be connected to the third side surface and the fourth side surface, which can connect the first side surface to the second side surface, and the third side surface and the fourth side surface are opposite to each other.

[0015] According to another aspect of the present invention, a method for manufacturing a display device includes the steps of: providing a protective window on a display panel including an opening or a cut portion; providing a flexible pad below the display panel; and moving the flexible pad toward the protective window such that the display panel contacts the protective window, wherein the flexible pad includes a generally straight region, a first inclined region overlapping the opening or cut portion of the display panel, and a second inclined region disposed between the generally straight region and the first inclined region, the upper surface of the generally straight region having substantially the same height along a first direction and having a generally convex shape along a second direction substantially perpendicular to the first direction, the upper surface of the first inclined region being inclined along the first direction and being substantially flat along the second direction, and the upper surface of the second inclined region being inclined along the first direction at an angle smaller than the angle of inclination of the upper surface of the first inclined region.

[0016] The display panel may include an organic light-emitting display panel.

[0017] The display panel may include a flexible substrate comprising a polymer material.

[0018] The opening or cut portion of the display panel can form a hole area.

[0019] The method may further include the step of bending the display panel before the display panel contacts the protective window.

[0020] The step of bending the display panel may include moving clamps attached to both ends of the display panel to reduce the distance between the clamps.

[0021] The flexible pad may include silicone resin.

[0022] The upper surface of the second inclined region may have a generally circular shape along the first direction.

[0023] The upper surface of the second inclined region may be inclined along the second direction.

[0024] The first upper surface of the first inclined region can be connected to a first side surface, and the upper surface of the generally straight region can be connected to a second side surface opposite to the first side surface. The second upper surface of the second inclined region can be connected to a third side surface and a fourth side surface, which can connect the first side surface to the second side surface. The third side surface and the fourth side surface can be opposite to each other.

[0025] According to another aspect of the invention, a flexible pad for a display panel lamination process includes: a generally straight region having an upper surface having substantially the same height along a first direction and a generally convex shape along a second direction substantially perpendicular to the first direction; a first inclined region having an upper surface inclined along the first direction and substantially flat along the second direction and connected to a first end of the upper surface of the generally straight region; and a second inclined region having an upper surface inclined along the first direction and substantially flat along the second direction and connected to a second end of the upper surface of the generally straight region opposite to the first end.

[0026] The upper surface of the first inclined region may be connected to a first side surface, and the upper surface of the second inclined region may be connected to a second side surface opposite to the first side surface, wherein the upper surface of the generally straight region may be connected to the first side surface and the second side surface, such that in a plan view, the generally straight region may at least partially surround the first inclined region and the second inclined region, respectively.

[0027] It will 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 claimed invention. Attached Figure Description

[0028] The accompanying drawings are included to provide a further understanding of the invention and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the invention and, together with the description, serve to explain the inventive concept.

[0029] Figure 1 This is a perspective view of an exemplary embodiment of a flexible pad constructed according to the principles of the present invention.

[0030] Figure 2 yes Figure 1 A plan view of the flexible pad.

[0031] Figure 3 It is along Figure 2 The cross-sectional view taken from line I-I'.

[0032] Figure 4 It is along Figure 2 The cross-sectional view taken from line II-II'.

[0033] Figure 5 It is along Figure 2 The cross-sectional view taken from line III-III'.

[0034] Figure 6 It is along Figure 2 The cross-sectional view taken from line IV-IV'.

[0035] Figure 7 This is a cross-sectional view of another exemplary embodiment of a flexible pad constructed according to the principles of the present invention.

[0036] Figure 8 This is a plan view of another exemplary embodiment of a flexible pad constructed according to the principles of the present invention.

[0037] Figure 9 It is along Figure 8 A cross-sectional view taken from line V-V'.

[0038] Figure 10 This is a plan view of an exemplary embodiment of a display panel used in a method for manufacturing a display device according to the principles of the present invention.

[0039] Figure 11 It is shown Figure 10 A cross-sectional view of the display area of ​​the display panel.

[0040] Figures 12 to 17 This is a cross-sectional view illustrating an exemplary method for manufacturing a display device according to the principles of the present invention. Detailed Implementation

[0041] In the following description, numerous specific details are set forth for purposes of explanation, thereby providing a full understanding of various exemplary embodiments or implementations of the invention. As used herein, “embodiment” and “implementation” are interchangeable terms for non-limiting examples employing one or more of the inventive concepts disclosed herein. However, it will be apparent that various exemplary embodiments may be practiced without utilizing these specific details or with one or more equivalent arrangements. In other instances, well-known structures and apparatuses are illustrated in block diagram form to avoid unnecessarily obscuring various exemplary embodiments. Furthermore, the various exemplary embodiments may differ but are not necessarily exclusive. For example, a particular shape, configuration, and characteristic of one exemplary embodiment may be used or implemented in another exemplary embodiment without departing from the inventive concept.

[0042] Unless otherwise stated, the exemplary embodiments shown are to be understood as providing exemplary features detailing variations in how the inventive concept can be implemented in practice. Therefore, unless otherwise stated, features, components, modules, layers, films, panels, areas, and / or aspects (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.

[0043] In the accompanying drawings, the use of crosshairs and / or shading is generally provided to clarify the boundaries between adjacent elements. Thus, unless otherwise stated, the presence or absence of crosshairs or shading does not convey or indicate any preference or requirement for the specific material, material properties, size, scale, commonalities between the elements shown, and / or any other characteristics, properties, performance, etc. Additionally, in the drawings, the dimensions and relative dimensions of elements may be exaggerated for clarity and / or descriptive purposes. When exemplary embodiments can be implemented differently, a particular process sequence may be performed differently than the described sequence. For example, two consecutively described processes may be performed substantially simultaneously or in the reverse order of their description. Furthermore, the same reference numerals denote the same elements.

[0044] When an element such as a layer is referred to as being "on" another element, "connected to," or "coupled to" another element, the element may be directly on, directly connected to, or directly coupled to the other element, or there may be intermediate elements present. However, when an element such as a layer is referred to as being "directly on" another element, "directly connected to," or "directly coupled to" another element, there are no intermediate elements present. Therefore, the term "connection" can refer to a physical connection, electrical connection, and / or fluid connection with or without intermediate elements. Furthermore, the D1, D2, and D3 axes are not limited to the three axes of a Cartesian coordinate system such as the x, y, and z axes, and can be interpreted in a broader sense. For example, the D1, D2, and D3 axes can be perpendicular to each other, or they can represent different directions that are not perpendicular to each other. For the purposes of this disclosure, "at least one of X, Y, and Z" and "at least one selected from the group consisting of X, Y, and Z" can be interpreted as only X, only Y, only Z, or any combination of two or more of X, Y, and Z, such as, for example, XYZ, XYY, YZ, and ZZ. As used herein, the term "and / or" includes any combination and all combinations of one or more of the associated listed items.

[0045] 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. Therefore, without departing from the teachings of this disclosure, the first element discussed below may be referred to as the second element.

[0046] Spatial relative terms such as “below,” “under,” “below,” “lower,” “above,” “upper,” “above,” “higher,” and “side” (e.g., as in “sidewall”) may be used herein for descriptive purposes and thereby describe the relationship of one element to another (or several other elements) as shown in the accompanying drawings. In addition to the orientations depicted in the drawings, spatial relative terms are also intended to cover different orientations of the device during use, operation, and / or manufacture. For example, if the device in the drawings is flipped, an element described as “below” or “under” other elements will subsequently be oriented “above” other elements. Thus, the exemplary term “below” can cover both orientations “above” and “below”. Furthermore, the device may be otherwise oriented (e.g., rotated 90 degrees or in other orientations), and thus the spatial relative descriptive terms used herein may be interpreted accordingly.

[0047] The terminology used herein is for the purpose of describing particular embodiments and is not intended to be limiting. As used herein, the singular forms “a” and “the” are intended to include the plural forms as well, unless the context clearly indicates otherwise. Furthermore, when used in this specification, the terms “comprises” and / or “includes” indicate the presence of stated features, integrals, steps, operations, elements, components, and / or groups thereof, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components, and / or groups thereof. It should also be noted that, as used herein, the terms “basically,” “about,” and other similar terms are used as approximate terms and not as terms of degree, and are thus used to explain the inherent biases in measurements, calculated values, and / or provided values ​​that will be recognized by those skilled in the art.

[0048] In this document, various exemplary embodiments are described with reference to cross-sectional views and / or exploded views of schematic diagrams of idealized exemplary embodiments and / or intermediate structures. Thus, deviations from the illustrated shapes, for example due to manufacturing techniques and / or tolerances, are expected. Therefore, the exemplary embodiments disclosed herein should not necessarily be construed as limited to the specifically shown shapes of the areas, but will include, for example, deviations in shape due to manufacturing processes. In this way, the areas shown in the drawings may be substantially schematic, and the shapes of these areas may not reflect the actual shapes of the areas of the device, and this is not necessarily intended to be limiting.

[0049] Unless otherwise defined, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. Terms such as those defined in a general dictionary shall be interpreted as having a meaning consistent with their meaning in the context of the relevant field and shall not be interpreted in an idealized or overly formal sense unless expressly defined herein.

[0050] Figure 1 This is a perspective view of an exemplary embodiment of a flexible pad constructed according to the principles of the present invention.

[0051] Figure 2 yes Figure 1 A plan view of the flexible pad. Figure 3 It is along Figure 2 The cross-sectional view taken from line I-I'.

[0052] Figure 4 It is along Figure 2 The cross-sectional view taken from line II-II'. Figure 5 It is along Figure 2The cross-sectional view taken from line III-III'. Figure 6 It is along Figure 2 The cross-sectional view taken from line IV-IV'.

[0053] Reference Figures 1 to 4 The flexible pad 10 includes a generally straight region HA having an upper surface 12a and a bottom surface 12d, the generally straight region HA extending longitudinally in the horizontal direction along a first direction D1. Therefore, the generally straight region HA has substantially the same height (thickness) in a cross-sectional view along the first direction D1. In an exemplary embodiment of this disclosure, the height (thickness) is defined as a dimension in a third direction D3. The flexible pad 10 also includes a sloping region LA having upper surfaces 12b and 12c sloping downwards toward the bottom surface 12d along the first direction D1.

[0054] In one exemplary embodiment, the flexible pad 10 may be a silicone pad comprising silicone. For example, the silicone pad may comprise a cured silicone resin.

[0055] For example, the flexible pad 10 may have a basic rectangular shape in a plan view. The length of the flexible pad 10 along the first direction D1 may be greater than the length along the second direction D2 perpendicular to the first direction D1. In an exemplary embodiment, the flexible pad 10 may include a first groove RC1 extending inwardly from the side surface 14b, such as... Figure 2 As shown in the diagram. For example, when display panel 100 (see...) Figure 10 When disposed on the flexible pad 10, the first groove RC1 can receive the bonding portion extending from the display panel 100. The bonding portion can be attached to the drive device.

[0056] Reference Figure 2 The inclined region LA may include a first inclined region LA1 and a second inclined region LA2 inclined at different angles. The second inclined region LA2 may be located between the first inclined region LA1 and the generally straight region HA. In a plan view, the boundary between the second inclined region LA2 and the generally straight region HA may have a generally arcuate shape. Furthermore, in a plan view, the boundary between the second inclined region LA2 and the first inclined region LA1 may have a generally arcuate shape.

[0057] Reference Figure 3 In a cross-sectional view along a second direction D2 that is substantially perpendicular to the first direction D1, the upper surface 12a of the generally straight region HA can have a generally convex shape CVS, in which the height of the central portion is greater than the height of the peripheral portion. For example, the upper surface 12a of the generally straight region HA can have a generally arcuate shape along the second direction D2.

[0058] In a cross-sectional view along the second direction D2, the flexible pad 10 may include a second groove RC2 extending inwardly from the side surfaces 14c and 14d. For example, the second groove RC2 may be formed on both side surfaces 14c and 14d of the flexible pad 10. The second groove RC2 can prevent deformation of the flexible pad 10 from concentrating in the lower region.

[0059] Reference Figure 4 The inclined region LA has a smaller height (thickness) than the approximately straight region HA in the cross-sectional view along the first direction D1.

[0060] The upper surface 12c of the second inclined region LA2 can be connected to the upper surface 12a of the generally straight region HA. The upper surface 12b of the first inclined region LA1 can be connected to the upper surface 12c of the second inclined region LA2 and the first side surface 14a of the flexible pad 10. The upper surface 12a of the generally straight region HA can be connected to the second side surface 14b opposite to the first side surface 14a.

[0061] The upper surface 12b of the first inclined region LA1 and the upper surface 12c of the second inclined region LA2 can be inclined along the first direction D1. For example, the upper surface 12b of the first inclined region LA1 and the upper surface 12c of the second inclined region LA2 can be inclined such that the height of the upper surface 12b of the first inclined region LA1 and the upper surface 12c of the second inclined region LA2 can be reduced in a direction away from the extension of the approximately straight region HA.

[0062] In one exemplary embodiment, in a plan view, the first inclined region LA1 may be adjacent to the first side surface 14a of the flexible pad 10. In a plan view, the second inclined region LA2 may partially surround the first inclined region LA1. For example, as Figure 2 As shown, the first inclined region LA1 can be connected to the first side surface 14a. Figure 2 As further shown, the second inclined region LA2 can be connected to the first side surface 14a, the third side surface 14c which is substantially perpendicular to the first side surface 14a, and the fourth side surface 14d which is substantially perpendicular to the first side surface 14a and opposite to the third side surface 14c. Therefore, the width of the second inclined region LA2 along the second direction D2 can be larger than the width of the first inclined region LA1, such as... Figure 2 As shown in the example. In one exemplary embodiment, the tilt angle of the first tilt region LA1 can be larger than the tilt angle of the second tilt region LA2, such as... Figure 4 As shown in the diagram, the height (thickness) of the first inclined region LA1 is smaller than the height (thickness) of the second inclined region LA2.

[0063] Figure 5A cross-sectional view of the peripheral region along the first direction D1 is shown, in which the first inclined region LA1 is not provided. (Refer to...) Figure 5 In the cross-sectional view, the first inclined region LA1 is absent. Therefore, the upper surface 12c of the second inclined region LA2 can be connected to the upper surface 12a of the generally straight region HA and the first side surface 14a.

[0064] Reference Figure 6 In a cross-sectional view of the inclined region LA along the second direction D2, the upper surface 12b of the first inclined region LA1 can be substantially flat to have substantially the same height, and the upper surface 12c of the second inclined region LA2 can be inclined. For example, in a cross-sectional view of the inclined region LA along the second direction D2, the height (thickness) of the first inclined region LA1 can be greater than the height (thickness) of the second inclined region LA2. The upper surface 12b of the first inclined region LA1 can be connected to the upper surface 12c of the second inclined region LA2. The height of the upper surface 12c of the second inclined region LA2 can be reduced in a direction away from the extension of the first inclined region LA1.

[0065] In an exemplary embodiment, the upper surface 12a of the generally straight region HA may be substantially flat along a first direction D1 and substantially convex along a second direction D2 to have a prominent central portion. The upper surface 12b of the first inclined region LA1 may be inclined along the first direction D1 and substantially flat along the second direction D2. The upper surface 12c of the second inclined region LA2 may be inclined along both the first direction D1 and the second direction D2.

[0066] Figure 7 This is a cross-sectional view of another exemplary embodiment of a flexible pad constructed according to the principles of the present invention. Figure 7 As shown Figure 4 The diagram shows a roughly straight region HA and a sloping region LA along the first direction D1.

[0067] Reference Figure 7 In a cross-sectional view along the first direction D1, the inclined region LA may have a height (thickness) smaller than that of the generally straight region HA. In an exemplary embodiment, the inclined region LA may include a first inclined region LA1 and a second inclined region LA2. The second inclined region LA2 may be disposed between the first inclined region LA1 and the generally straight region HA.

[0068] The upper surface 12c of the second inclined region LA2 can be connected to the upper surface 12a of the generally straight region HA. The upper surface 12b of the first inclined region LA1 can be connected to the upper surface 12c of the second inclined region LA2 and the first side surface 14a of the flexible pad 10. The upper surface 12a of the generally straight region HA can be connected to the second side surface 14b opposite to the first side surface 14a.

[0069] The upper surface 12b of the first inclined region LA1 and the upper surface 12c of the second inclined region LA2 can be inclined along the first direction D1. For example, the upper surface 12b of the first inclined region LA1 and the upper surface 12c of the second inclined region LA2 can be inclined such that the height of the upper surface 12b of the first inclined region LA1 and the upper surface 12c of the second inclined region LA2 can be reduced in a direction away from the extension of the approximately straight region HA.

[0070] In an exemplary embodiment, the upper surface 12b of the first inclined region LA1 may be inclined along a first direction D1 and may extend substantially straight. The upper surface 12c of the second inclined region LA2 may have a generally circular shape, such as a generally arcuate shape.

[0071] Figure 8 This is a plan view of another exemplary embodiment of a flexible pad constructed according to the principles of the present invention. Figure 9 It is along Figure 8 The cross-sectional view taken by line V-V'. (Refer to...) Figure 8 and Figure 9 The flexible pad 10 may include a first inclined region LA1a, a second inclined region LA1b, and a generally straight region HA disposed between the first inclined region LA1a and the second inclined region LA1b. The upper surface 12b' of the first inclined region LA1a and the upper surface 12b" of the second inclined region LA1b may be connected to the upper surface 12a of the generally straight region HA. For example, the upper surface 12b' of the first inclined region LA1a may be connected to a first end of the upper surface 12a of the generally straight region HA, and the upper surface 12b" of the second inclined region LA1b may be connected to a second end of the upper surface 12a of the generally straight region HA opposite to the first end.

[0072] The upper surface 12b' of the first inclined region LA1a and the upper surface 12b" of the second inclined region LA1b can be inclined such that the height of the upper surface 12b' of the first inclined region LA1a and the upper surface 12b" of the second inclined region LA1b can be reduced in a direction away from the extension of the approximately straight region HA.

[0073] The upper surface 12b' of the first inclined region LA1a can be connected to the first side surface 14a, and the upper surface 12b' of the second inclined region LA1b can be connected to the second side surface 14b opposite to the first side surface 14a. The upper surface 12a of the generally straight region HA can be connected to the first side surface 14a and the second side surface 14b, such that in a plan view, the generally straight region HA can partially surround the first inclined region LA1a and the second inclined region LA1b, respectively.

[0074] The tilt angle of the first tilted region LA1a can be substantially the same as the tilt angle of the second tilted region LA1b. However, the exemplary embodiments are not limited thereto. For example, the tilt angle of the first tilted region LA1a can be different from the tilt angle of the second tilted region LA1b. Furthermore, at least one of the upper surface 12b' of the first tilted region LA1a and the upper surface 12b" of the second tilted region LA1b can have a generally circular shape, such as a generally arcuate shape.

[0075] The flexible pad 10 according to some exemplary embodiments can be used as a pressing member in the lamination process. For example, the flexible pad 10 can be used in the manufacturing of a display device to bond the display panel 100 with the protective window WN (see Figure 13 The flexible pad 10 is used in the combined process. It can reduce the load applied to physically weak areas such as the hole area HR and can reduce stress concentration. Therefore, damage to the display panel 100 can be prevented or reduced.

[0076] Figure 10 This is a plan view of an exemplary embodiment of a display panel used in a method for manufacturing a display device according to the principles of the present invention. (Refer to...) Figure 10 The display panel 100 includes a display area DA comprising a pixel array. In an exemplary embodiment, the display panel 100 may be an organic light-emitting display panel. A peripheral area adjacent to the display area DA may be defined as a non-display area.

[0077] In one exemplary embodiment, the display panel 100 may include an aperture region HR. The aperture region HR can be formed by removing a portion of the display panel 100. After the display panel 100 is attached to the protective window WN, functional modules may be disposed below or within the aperture region HR. The functional modules may include at least one of a camera module and a sensor module. In one exemplary embodiment, in a plan view, the aperture region HR may be disposed within the display area DA.

[0078] Figure 11 It is shown Figure 10 A cross-sectional view of the display area of ​​the display panel. (Refer to...) Figure 11The pixel unit disposed in the display area DA may include a driving element disposed on the substrate 110 and a light-emitting element electrically connected to the driving element. In an exemplary embodiment, the light-emitting element may be an organic light-emitting diode 180. The driving element may include at least one thin-film transistor. A buffer layer 120 may be disposed on the substrate 110. An active pattern AP may be disposed on the buffer layer 120.

[0079] For example, the substrate 110 may include glass, quartz, sapphire, or polymer materials. In an exemplary embodiment, the substrate 110 may be a flexible substrate comprising a polymer material. For example, the substrate 110 may include polyethylene naphthalate, polyethylene terephthalate, polyetherketone, polycarbonate, polyarylate, polyethersulfone, polyimide, or combinations thereof.

[0080] The buffer layer 120 can prevent or reduce the penetration of impurities, moisture, or external gases from below the substrate 110, and can reduce the roughness of the upper surface of the substrate 110. For example, the buffer layer 120 may include inorganic materials such as oxides or nitrides.

[0081] A first gate metal pattern, including a gate electrode GE, can be disposed on an active pattern AP. A first insulating layer 130 can be disposed between the active pattern AP and the gate electrode GE.

[0082] A second gate metal pattern, including a capacitor electrode pattern CE, can be disposed on the gate electrode GE. The capacitor electrode pattern CE may include capacitor electrodes for forming a capacitor or wiring for transmitting various signals, etc.

[0083] The second insulating layer 140 may be disposed between the gate electrode GE and the capacitor electrode pattern CE. The third insulating layer 150 may be disposed on the capacitor electrode pattern CE.

[0084] For example, an active patterned AP may include silicon or a metal-oxide-semiconductor. In one embodiment, an active patterned AP may include polycrystalline silicon (PSS) that may be doped with n-type or p-type impurities.

[0085] In another exemplary embodiment or in another transistor not shown, the active pattern AP may include a metal-oxide-semiconductor (MODS). For example, the active pattern AP may include a binary compound (AB) comprising indium (In), zinc (Zn), gallium (Ga), tin (Sn), titanium (Ti), aluminum (Al), hafnium (Hf), zirconium (Zr), and magnesium (Mg). x ), ternary compounds (AB) x C y ) or quaternary compounds (AB) x C y Dz For example, an active patterned AP may include zinc oxide (ZnO). x Gallium oxide (GaO) x Titanium oxide (TiO) x ), Tin oxide (SnO) x Indium oxide (InO) x Indium gallium oxide (IGO), indium zinc oxide (IZO), indium tin oxide (ITO), gallium zinc oxide (GZO), zinc magnesium oxide (ZMO), zinc tin oxide (ZTO), zinc zirconium oxide (ZnZr) x O y Indium gallium zinc oxide (IGZO), indium zinc tin oxide (IZTO), indium gallium hafnium oxide (IGHO), aluminum zinc tin oxide (TAZO), or indium gallium tin oxide (IGTO), etc.

[0086] The first insulating layer 130, the second insulating layer 140, and the third insulating layer 150 may comprise silicon oxide, silicon nitride, silicon carbide, or combinations thereof. Furthermore, the first insulating layer 130, the second insulating layer 140, and the third insulating layer 150 may comprise insulating metal oxides such as aluminum oxide, tantalum oxide, hafnium oxide, zirconium oxide, or titanium oxide. For example, the first insulating layer 130, the second insulating layer 140, and the third insulating layer 150 may each have a single-layer structure or a multi-layer structure comprising silicon nitride and / or silicon oxide, or they may have structures different from each other.

[0087] The gate electrode GE and capacitor electrode pattern CE can include metals, metal alloys, metal nitrides, or conductive metal oxides. For example, the gate electrode GE and capacitor electrode pattern CE can include gold (Au), silver (Ag), aluminum (Al), copper (Cu), nickel (Ni), platinum (Pt), magnesium (Mg), chromium (Cr), tungsten (W), molybdenum (Mo), titanium (Ti), tantalum (Ta), or alloys thereof, and can have a single-layer structure or a multi-layer structure including different metal layers.

[0088] A first source metal pattern may be disposed on a third insulating layer 150. The first source metal pattern may include a source electrode SE and a drain electrode DE that electrically contact the active pattern AP. The source electrode SE and the drain electrode DE may pass through an insulating layer disposed beneath the source electrode SE and the drain electrode DE (e.g., ...). Figure 11 The first insulating layer 130, the second insulating layer 140, and the third insulating layer 150 shown are respectively in contact with the active pattern AP.

[0089] The first source metal pattern may include metals, metal alloys, metal nitrides, or conductive metal oxides. For example, the first source metal pattern may include gold (Au), silver (Ag), aluminum (Al), copper (Cu), nickel (Ni), platinum (Pt), magnesium (Mg), chromium (Cr), tungsten (W), molybdenum (Mo), titanium (Ti), tantalum (Ta), or alloys thereof, and may have a single-layer or multi-layer structure comprising different metal layers. In an exemplary embodiment, the first source metal pattern may have a multi-layer structure including an aluminum layer.

[0090] The fourth insulating layer 160 may be disposed on the first source metal pattern. The fourth insulating layer 160 may include organic materials. For example, the fourth insulating layer 160 may include organic insulating materials such as phenolic resin, acrylic resin, polyimide resin, polyamide resin, silicone resin, or epoxy resin.

[0091] An organic light-emitting diode (OLED) 180 may be disposed on a fourth insulating layer 160. The OLED 180 may include a first electrode 182 with an electrical contact drain electrode DE, an organic light-emitting layer 184 disposed on the first electrode 182, and a second electrode 186 disposed on the organic light-emitting layer 184. The organic light-emitting layer 184 of the OLED 180 may be disposed at least in an opening of a pixel-defining layer 170, which is disposed on the fourth insulating layer 160. The first electrode 182 may be the lower electrode of the OLED 180, and the second electrode 186 may be the upper electrode of the OLED 180.

[0092] The first electrode 182 can be used as an anode. For example, depending on the emission type of the display device, the first electrode 182 can be formed as a transmissive electrode or a reflective electrode. When the first electrode 182 is a transmissive electrode, the first electrode 182 may include indium tin oxide, indium zinc oxide, zinc tin oxide, indium oxide, zinc oxide, or tin oxide, etc. When the first electrode 182 is a reflective electrode, the first electrode 182 may include gold (Au), silver (Ag), aluminum (Al), copper (Cu), nickel (Ni), platinum (Pt), magnesium (Mg), chromium (Cr), tungsten (W), molybdenum (Mo), titanium (Ti), tantalum (Ta), or alloys thereof, and may have a stacked structure that also includes materials that can be used as emission electrodes.

[0093] The pixel defining layer 170 has an opening that overlaps with at least a portion of the first electrode 182. For example, the pixel defining layer 170 may comprise an organic insulating material. The organic light-emitting layer 184 may comprise at least a light-emitting layer, and may further comprise at least one of a hole injection layer (HIL), a hole transport layer (HTL), an electron transport layer (ETL), and an electron injection layer (EIL). For example, the organic light-emitting layer 184 may comprise a low-molecular-weight organic compound or a high-molecular-weight organic compound.

[0094] In one exemplary embodiment, the organic light-emitting layer 184 may emit red, green, or blue light. In another exemplary embodiment, the organic light-emitting layer 184 may emit white light. The organic light-emitting layer 184 emitting white light may have a multilayer structure including a red emitting layer, a green emitting layer, and a blue emitting layer, or it may have a single-layer structure including a mixture of red emitting materials, green emitting materials, and blue emitting materials.

[0095] Depending on the emission type of the display device, the second electrode 186 can be formed as a transmissive electrode or a reflective electrode. For example, the second electrode 186 may include a metal, a metal alloy, a metal nitride, a metal fluoride, a conductive metal oxide, or a combination thereof. For example, at least one of the organic light-emitting layers 184 and the second electrode 186 may be formed as a common layer extending continuously over a plurality of pixels in the display area DA.

[0096] An encapsulation layer 190 may be disposed on the organic light-emitting diode 180. The encapsulation layer 190 may have a stacked structure of inorganic and organic thin films. For example, the encapsulation layer 190 may include a first inorganic thin film 192, an organic thin film 194 disposed on the first inorganic thin film 192, and a second inorganic thin film 196 disposed on the organic thin film 194. If necessary, at least one of a touch sensing structure and a polarization layer may be disposed on the encapsulation layer 190. A support substrate may be disposed below the substrate 110. The support substrate may have openings to reduce bending stress in bending regions.

[0097] Figures 12 to 17 This is a cross-sectional view illustrating an exemplary method for manufacturing a display device according to the principles of the present invention. Figures 12 to 14 and Figure 16 A cross-sectional view is shown along the shorter side direction (e.g., along the second direction D2), and Figure 15 and Figure 17 A cross-sectional view is shown along the longer side direction (e.g., along the first direction D1).

[0098] Reference Figure 12 The display panel 100 is secured by clamps 22 and 24. The display panel 100 may include, for example, Figure 10 The aperture region HR is shown in the figure. However, exemplary embodiments are not limited thereto. The display panel 100 may include an opening or cutout having various shapes such as a generally elongated shape, a generally slit shape, a generally curved shape, or a generally polygonal shape. In some exemplary embodiments, the opening or cutout may form the aperture region HR, as described below. Figure 17 The subject of discussion.

[0099] The clamps 22 and 24 can secure both ends of the display panel 100. For example, the first clamp 22 can secure the first end of the display panel 100, and the second clamp 24 can secure the second end of the display panel 100. The first end and the second end can extend along a first direction D1, and the first clamp 22 and the second clamp 24 can be spaced apart from each other along a second direction D2 that is substantially perpendicular to the first direction D1.

[0100] Reference Figure 13 A protective window WN is disposed on the display panel 100. The protective window WN can be rigid or flexible. For example, the protective window WN may include a glass substrate, a polymer film, or a combination thereof. The protective window WN can be fixed to a fixing member 30. The fixing member 30 may cover the upper surface of the protective window WN and can secure the protective window WN, for example, by applying negative pressure to the protective window WN.

[0101] In one exemplary embodiment, the protective window WN may have bent edges. However, the exemplary embodiments are not limited to this. For example, the flexible pad 10 of some exemplary embodiments may be used to attach the protective window WN, which has a generally flat shape, to the display panel 100.

[0102] The adhesive layer can be disposed on the lower surface of the protective window WN or on the upper surface of the display panel 100. The contact between the display panel 100 and the protective window WN preferably begins at the center and can extend to the periphery to prevent air from accumulating between the display panel 100 and the protective window WN. For example, the display panel 100 can be bent so that the center portion protrudes upwards. For example, as... Figure 13 As shown by the arrow along the second direction D2, the distance between the first clamp 22 and the second clamp 24 can be reduced to bend the display panel 100.

[0103] Reference Figure 14 The flexible pad 10 is disposed below the display panel 100 and as shown in the figure. Figure 14 The display panel 100 moves towards the protective window WN as indicated by the arrow pointing to the third direction D3, allowing the display panel 100 to contact the protective window WN. The flexible pad 10 may have a shape substantially the same as any of the flexible pads 10 described herein. Therefore, a repeated explanation of the flexible pad 10 can be omitted to avoid redundancy.

[0104] Reference Figure 15The flexible pad 10 may include a generally straight region HA and an inclined region LA. The upper surface 12a of the generally straight region HA may have substantially the same height along a first direction D1, and the upper surfaces 12b and 12c of the inclined region LA may be inclined along the first direction D1. The inclined region LA may include a first inclined region LA1 and a second inclined region LA2. The second inclined region LA2 may be located between the first inclined region LA1 and the generally straight region HA. Except at the boundary where the two inclined regions LA1 and LA2 intersect, the height of the upper surface 12b of the first inclined region LA1 may be smaller than the height of the upper surface 12c of the second inclined region LA2.

[0105] Reference Figure 14 and Figure 15 Since the upper surface 12a of the generally straight region HA of the flexible pad 10 has a greater height than the upper surfaces 12b and 12c of the inclined region LA, the generally straight region HA can contact the display panel 100 before the inclined region LA.

[0106] In one exemplary embodiment, the flexible pad 10 may linearly contact the display panel 100 along a line intersecting the central portion of a generally straight region HA along a first direction D1. The contact area may extend from the linear contact area along a second direction D2. If the flexible pad 10 contacts the display panel 100 at its center point and if the contact area extends from the point contact area, the display panel 100 may gradually adhere to the protective window WN at all sides, thereby increasing the internal stress of the display panel 100. Consequently, the durability of the display panel 100 may deteriorate.

[0107] In one exemplary embodiment, the hole region HR of the display panel 100 may overlap with a first inclined region LA1, which has the minimum height (thickness) in the flexible pad 10. Therefore, the hole region HR may be pressed later than other regions and may be pressed with a smaller load than the region that overlaps with the substantially straight region HA.

[0108] The upper surface 12c of the second inclined region LA2 can have a smaller tilt angle than the upper surface 12b of the first inclined region LA1. Therefore, the second inclined region LA2 can prevent abrupt changes in height (thickness) between the substantially straight region HA and the first inclined region LA1, thereby reducing or preventing stress concentration in the boundary region of the display panel 100. The upper surface 12b of the first inclined region LA1 can be inclined along the first direction D1 and can be substantially flat along the second direction D2.

[0109] If the upper surface of the flexible pad 10 overlaps with the hole region HR (e.g., Figure 15The upper surface 12b of the first inclined region LA1 is generally flat along the first direction D1. Even if the height of the upper surface (e.g., upper surface 12b) overlapping the hole region HR is reduced to decrease the pressing load, the silicone resin may still move from the adjacent region to the reduced region. Therefore, the pressing load applied to the hole region HR and the resulting tension may increase significantly. Furthermore, if the upper surface (e.g., upper surface 12b) overlapping the hole region HR is not flat along the second direction D2, the tension applied to the hole region HR along the second direction D2 may increase.

[0110] Therefore, it is preferable that the upper surface of the flexible pad 10 overlapping the hole region HR (e.g., upper surface 12b) is inclined along the first direction D1 and flat along the second direction D2, thereby reducing the pressing load and tension applied to the hole region HR. In some exemplary embodiments, the size, shape, and position of the first inclined region LA1 may vary depending on the construction of the hole region HR.

[0111] Reference Figure 16 and Figure 17 Press the flexible pad 10 towards the display panel 100 and the protective window WN, as shown. Figure 16 The arrows along the second direction D2 and the third direction D3 are shown in the diagram. Because the flexible pad 10 is flexible, it can deform so that the entire upper surface of the display panel 100 can contact the lower surface of the protective window WN.

[0112] As a result, the protective window WN can be attached to the display panel 100. The display panel 100 attached to the protective window WN can have a bent edge corresponding to the bent edge of the protective window WN.

[0113] According to some exemplary embodiments, the flexible pad 10 is used to attach the display panel 100 to the protective window WN. Therefore, damage to the display panel 100 and trapped air can be reduced or prevented.

[0114] In addition, the flexible pad 10 includes inclined regions LA1, LA1a and LA1b, which can reduce or disperse the pressing load and / or tension applied to physically weak areas of the display panel 100, such as the hole area HR.

[0115] Some exemplary embodiments can be applied to various processes that can use flexible pressing components. For example, some exemplary embodiments can be used in lamination processes. For example, exemplary embodiments can be used to manufacture display devices.

Claims

1. A flexible pad for use in the lamination process of a display device, wherein, The flexible pad includes: A straight region having an upper surface that defines the same height along a first direction and a convex shape along a second direction perpendicular to the first direction; A first inclined region having a first upper surface that is inclined at a first angle along the first direction and is flat along the second direction; and A second inclined region is disposed between the first inclined region and the straight region, wherein the second inclined region has a second upper surface inclined along the first direction at a second inclination angle smaller than the first inclination angle. The first inclined region has a first height, and the second inclined region has a second height that is greater than the first height.

2. The flexible pad according to claim 1, wherein, The flexible pad comprises silicone resin.

3. The flexible pad according to claim 1, wherein, The second upper surface has a circular shape along the first direction.

4. The flexible pad according to claim 1, wherein, In the plan view, the second inclined region at least partially surrounds the first inclined region.

5. The flexible pad according to claim 1, wherein, The second upper surface of the second inclined region is inclined along the second direction.

6. The flexible pad according to claim 1, wherein, The first upper surface is connected to the first side surface, and the upper surface of the straight region is connected to the second side surface opposite to the first side surface.

7. The flexible pad according to claim 6, wherein, The second upper surface of the second inclined region is connected to the third side surface and the fourth side surface, which connect the first side surface to the second side surface, and the third side surface and the fourth side surface are opposite to each other.

8. A method for manufacturing a display device, wherein, The method includes the following steps: Install protective windows on the display panel, including openings or cut sections; A flexible pad is provided below the display panel; as well as Move the flexible pad toward the protective window so that the display panel contacts the protective window. The flexible pad includes a straight region, a first inclined region overlapping the opening or cut portion of the display panel, and a second inclined region disposed between the straight region and the first inclined region. The upper surface of the straight region has the same height along a first direction and has a convex shape along a second direction perpendicular to the first direction. The upper surface of the first inclined region is inclined along the first direction and is flat along the second direction. The upper surface of the second inclined region is inclined along the first direction at an angle smaller than the angle of inclination of the upper surface of the first inclined region. The first inclined region has a first height, and the second inclined region has a second height greater than the first height.

9. The method according to claim 8, wherein, The display panel includes an organic light-emitting display panel.

10. The method according to claim 8, wherein, The display panel includes a flexible substrate comprising a polymer material.

11. The method according to claim 8, wherein, The opening or cut portion of the display panel forms a hole area.

12. The method according to claim 8, wherein, The method also includes the step of bending the display panel before the display panel contacts the protective window.

13. The method according to claim 12, wherein, The step of bending the display panel includes moving clamps attached to both ends of the display panel such that the distance between the clamps is reduced.

14. The method according to claim 8, wherein, The flexible pad comprises silicone resin.

Images