Display device and method for manufacturing the same

Abstract

The present application relates to a display device and a manufacturing method thereof. The display device includes a first non-foldable region, a second non-foldable region, and a foldable region. The display device includes: a display module including a display panel; a support substrate supporting the display module, including an upper surface facing the display module and a lower surface opposite to the upper surface, and provided with a groove defined in the lower surface to overlap with the foldable region; a first support plate disposed under the support substrate; and a second support plate disposed under the support substrate and spaced apart from the first support plate in the foldable region.

Description

[0001] Cross - reference to related applications

[0002] This application claims priority and all benefits arising therefrom to Korean Patent Application No. 10 - 2020 - 0026893, filed on March 4, 2020, the content of which is incorporated herein by reference in its entirety. Technical Field

[0003] The present disclosure relates to a display device and a method of manufacturing the same. More specifically, the present disclosure relates to a display device having improved reliability and a method of manufacturing the display device. Background Art

[0004] A display device displays various images through a display screen to provide information to a user. Generally, the display device displays information in a designated screen area. Flexible display devices including flexible display panels capable of being folded are being developed. Different from a rigid display device, a flexible display device is foldable, rollable, or bendable. Regardless of the original size of the display screen, a flexible display device capable of being transformed into various shapes is easy to carry and improves user convenience. Summary of the Invention

[0005] The present disclosure provides a display device having improved reliability.

[0006] The present disclosure provides a method of manufacturing a display device to prevent appearance defects from occurring in a foldable area of the display device.

[0007] Embodiments of the inventive concept provide a display device including a first non - foldable area, a second non - foldable area, and a foldable area. The display device includes: a display module including a display panel; a support substrate supporting the display module, including an upper surface facing the display module and a lower surface opposite the upper surface, and having a groove defined in the lower surface to overlap with the foldable area in the thickness direction of the support substrate; a first support plate disposed under the support substrate; and a second support plate disposed under the support substrate and spaced apart from the first support plate in the foldable area.

[0008] The groove may overlap with the entire foldable area.

[0009] The support substrate may further include a protective layer disposed along a surface of the groove.

[0010] The protective layer may include an ultraviolet coating member.

[0011] The protective layer may include an antistatic material.

[0012] In the thickness direction, the thickness of the support substrate can be greater than the thickness of the first support plate and greater than the thickness of the second support plate.

[0013] The thickness of the support substrate can be in the range of about 0.2 millimeters (mm) to about 0.25 mm.

[0014] The depth of the groove in the thickness direction of the support substrate can be equal to or less than half of the thickness of the support substrate.

[0015] The grooves can be provided in plurality, and the grooves can be arranged continuously or discontinuously in the foldable region.

[0016] The first support plate and the second support plate can include a metallic material.

[0017] The display device can further include: a first buffer member disposed under the first support plate and overlapping a part of the foldable region and a part of the first non-foldable region in the thickness direction; and a second buffer member disposed under the second support plate and overlapping another part of the foldable region and a part of the second non-foldable region in the thickness direction.

[0018] Each of the first buffer member and the second buffer member can have a thickness of about 6 micrometers to about 10 micrometers.

[0019] The display device can further include: a first auxiliary plate disposed under the first buffer member and overlapping the first buffer member in the thickness direction; and a second auxiliary plate disposed under the second buffer member and overlapping the second buffer member in the thickness direction.

[0020] The display module can have a first state and a second state. In the first state, the display module is flat. In the second state, the display module can be bent in the foldable region such that a portion of the display module corresponding to the first non-foldable region faces a portion of the display module corresponding to the second non-foldable region.

[0021] Embodiments of the inventive concept provide a method of manufacturing a display device, the method including: providing a display module including a first non-foldable region, a second non-foldable region, and a foldable region; providing a support substrate under the display module; and providing a first support plate and a second support plate spaced apart from each other in the foldable region under the support substrate. The support substrate includes an upper surface facing the display module and a lower surface opposite the upper surface, and the support substrate is provided with a groove defined in the lower surface to overlap the foldable region in the thickness direction of the support substrate.

[0022] Providing the support substrate can include: providing a preliminary support substrate; and defining the groove in the preliminary support substrate using a jig.

[0023] Providing the preliminary support substrate may include: coating a foam resin on a release film; and defining the groove may include: drying the coated foam resin while pressing the preliminary support substrate using a jig.

[0024] The jig may include a coating layer formed on a surface of the jig and in contact with the preliminary support substrate.

[0025] Providing the support substrate may further include: coating a protective layer along a surface of the defined groove.

[0026] The jig may include protrusions formed on a surface of the jig and in contact with the preliminary support substrate to overlap with a foldable region in a thickness direction and correspond to the groove.

[0027] Providing the support substrate may include: disposing a first adhesive member on an upper surface of the support substrate; and disposing a display module on the first adhesive member.

[0028] Providing the first support plate and the second support plate may include: disposing a second adhesive member on a lower surface of the support substrate to overlap with a first non-foldable region and a second non-foldable region in a thickness direction; and disposing the first support plate and the second support plate on the second adhesive member.

[0029] According to the above, the support substrate disposed below the display panel as a buffer layer may have a thick thickness to support the display panel. In addition, since the groove is formed in the lower surface of the support substrate to overlap with the foldable region, the display panel can be easily folded even though the support substrate has a thick thickness, and when foreign substances are introduced, the foreign substances can be collected and discharged. Therefore, defects caused by indentation or pressing can be prevented. BRIEF DESCRIPTION OF THE DRAWINGS

[0030] When considered in conjunction with the accompanying drawings, the above and other advantageous effects of the present disclosure will become apparent by reference to the following detailed description, in which:

[0031] Figure 1A and Figure 1B is a perspective view showing a display device according to an exemplary embodiment of the present disclosure;

[0032] Figure 2A and Figure 2B is a perspective view showing a display device according to another exemplary embodiment of the present disclosure;

[0033] Figure 3 is a cross-sectional view schematically showing a display device according to an exemplary embodiment of the present disclosure;

[0034] Figure 4is a cross-sectional view showing a display module according to an exemplary embodiment of the present disclosure;

[0035] Figure 5A is a perspective view showing a support substrate according to an exemplary embodiment of the present disclosure;

[0036] Figure 5B is a plan view showing a support substrate according to an exemplary embodiment of the present disclosure;

[0037] Figure 6A and Figure 6B is a cross-sectional view showing a display device according to an exemplary embodiment of the present disclosure;

[0038] Figures 7A to 7H is a view showing a method of manufacturing a display device according to an exemplary embodiment of the present disclosure;

[0039] Figures 8A to 8D is a cross-sectional view showing a display device according to other exemplary embodiments of the present disclosure; and

[0040] Figure 9 is a cross-sectional view showing a display device according to another exemplary embodiment of the present disclosure. DETAILED DESCRIPTION

[0041] In the present disclosure, it will be understood that when an element or layer is referred to as being "on", "connected to" or "coupled to" another element or layer, the element or layer can be directly on, directly connected to or directly coupled to the other element or layer, or there can be intervening elements or layers therebetween.

[0042] The same reference numerals throughout the drawings denote the same elements. In the drawings, the thickness, ratio and dimensions of the components are exaggerated for effective description of the technical content. As used herein, the term "and / or" includes any and all combinations of one or more of the associated listed items.

[0043] "Or" means "and / or".

[0044] It will be understood that although the terms first, second, etc. may be used herein to describe various elements, components, regions, layers, and / or sections, these elements, components, regions, layers, and / or sections should not be limited by these terms. These terms are only used to distinguish one element, component, region, layer, or section from another. Thus, without departing from the teachings of the present disclosure, the first element, first component, first region, first layer, or first section discussed below may be referred to as a second element, second component, second region, second layer, or second section. As used herein, the singular forms "a", "an", and "the" are intended to include the plural forms (including "at least one") as well, unless the context clearly indicates otherwise. "At least one" will not be construed as limiting "a" or "an".

[0045] For ease of description, spatial relative terms such as "below", "beneath", "lower", "above", "upper", etc. may be used herein to describe the relationship of one element or feature to another (other) element or feature as shown in the figures.

[0046] It will also be understood that when used in this specification, the terms "comprises" and / or "comprising" indicate the presence of the stated features, integers, steps, operations, elements, and / or components, but do not preclude the presence or addition of one or more other features, integers, steps, operations, elements, components, and / or groups thereof.

[0047] Unless otherwise defined, all terms (including technical and scientific terms) used herein have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will also be understood that terms, such as those defined in commonly used dictionaries, should be interpreted as having a meaning consistent with their meaning in the context of the relevant art and will not be interpreted in an idealized or overly formal sense unless expressly so defined herein.

[0048] Hereinafter, exemplary embodiments of the present disclosure will be described with reference to the accompanying drawings.

[0049] Figure 1A and Figure 1B is a perspective view showing a display device 1000 according to an exemplary embodiment of the present disclosure.

[0050] Figure 1A is a perspective view showing an unfolded state of the display device 1000 according to an exemplary embodiment of the present disclosure. Figure 1B is a view showing Figure 1A a perspective view of the folded state of the display device 1000 shown in

[0051] Referring to Figure 1A and Figure 1B, the display device 1000 may be a foldable display device. The display device 1000 according to an exemplary embodiment of the present disclosure may be applied to large electronic articles such as televisions or monitors, or small and medium-sized articles such as mobile phones, tablet computers, automotive navigation units, gaming units, or smart watches.

[0052] The upper surface of the display device 1000 may be defined as a display surface DS, and the display surface DS may have a planar surface defined by a first direction DR1 and a second direction DR2.

[0053] The display surface DS may include a display area DA and a non-display area NDA surrounding the display area DA. The display area DA may be an effective area through which an image IM is displayed, and the non-display area NDA may be a non-effective area through which the image IM is not displayed. Figure 1A An application icon is shown as a representative example of the image IM.

[0054] The display area DA may have a quadrilateral shape. The non-display area NDA may surround the display area DA. However, the shapes of the display area DA and the non-display area NDA of the present disclosure should not be limited to this or restricted thereby. The shape of the display area DA and the shape of the non-display area NDA may be designed relative to each other.

[0055] The display device 1000 may include a first non-foldable area NFA1, a foldable area FA, and a second non-foldable area NFA2 sequentially defined in the display device 1000 along the second direction DR2. That is, the foldable area FA may be defined between the first non-foldable area NFA1 and the second non-foldable area NFA2. Figure 1A and Figure 1B One foldable area FA and two non-foldable areas (e.g., the first non-foldable area NFA1 and the second non-foldable area NFA2) are shown. However, the number of foldable areas and non-foldable areas of the present disclosure should not be limited to this or restricted thereby. For example, in another embodiment, the display device 1000 may include three or more non-foldable areas and foldable areas provided between the non-foldable areas.

[0056] The display device 1000 may be folded about a folding axis FX. That is, the foldable area FA may be folded about the folding axis FX. The folding axis FX may extend in the first direction DR1. The folding axis FX may be defined as a short folding axis substantially parallel to the short side of the display device 1000.

[0057] When the display device 1000 is folded, the portion of the display surface DS corresponding to the first non-foldable region NFA1 and the portion of the display surface DS corresponding to the second non-foldable region NFA2 can face each other. Accordingly, in the folded state, the display surface DS may not be exposed to the outside. However, this is merely exemplary. According to another exemplary embodiment of the present disclosure, when the display device 1000 is folded, the portion of the display surface DS corresponding to the first non-foldable region NFA1 and the portion of the display surface DS corresponding to the second non-foldable region NFA2 can face in opposite directions. Accordingly, the display surface DS may be exposed to the outside in the folded state.

[0058] Figure 2A is a perspective view showing a display device 1000-1 according to an exemplary embodiment of the present disclosure. Figure 2B is a view showing Figure 2A the folded state of the display device 1000-1 shown in

[0059] Referring to Figure 2A and Figure 2B , the display device 1000-1 may include a first non-foldable region NFA1-1, a foldable region FA-1, and a second non-foldable region NFA2-1 sequentially defined in the display device 1000-1 along a first direction DR1. That is, the foldable region FA-1 may be defined between the first non-foldable region NFA1-1 and the second non-foldable region NFA2-1.

[0060] The display device 1000-1 may be folded about a folding axis FX-1. That is, the foldable region FA-1 may be folded about the folding axis FX-1. The folding axis FX-1 may extend in a second direction DR2. The folding axis FX-1 may be defined as a long folding axis substantially parallel to the long side of the display device 1000-1.

[0061] Hereinafter, the structure of the display device 1000 folded about a short folding axis will be described in detail. However, the structure described below may be applied to the display device 1000-1 folded about a long folding axis.

[0062] Figure 3 is a cross-sectional view schematically showing a display device 1000 according to an exemplary embodiment of the present disclosure.

[0063] Referring to Figure 3 , the display device 1000 may include a display module 10, a support substrate 20, a support plate 30, and a buffer member 40.

[0064] The display module 10 may display an image IM (refer to Figure 1A ) and may sense an external input TC (refer to Figure 1A)。The external input TC can be a user input. The user input can include various types of external inputs, such as a part of the user's body, light, heat, or pressure. In Figure 1A , the external input TC is shown as the user's hand applied to the display surface DS. However, this is merely exemplary. As described above, the external input TC can be provided in various forms. In addition, the display device 1000 can sense the external input TC applied to the side surface or the rear surface of the display device 1000 according to its structure. However, it should not be limited to a specific embodiment. This will be described in more detail with reference to Figure 4 .

[0065] A cover panel and members (hereinafter referred to as "lower members") can be provided below the display module 10. The cover panel can include a support substrate 20 and a heat dissipation plate (not shown). The lower members can include a support plate 30, a buffer member 40, and an auxiliary plate 50 (refer to Figure 9 ). In this application, "below" is measured in the drawing where the arrow in the third direction DR3 points upward.

[0066] The support substrate 20 can support the display module 10. The support substrate 20 can include sponge, foam, or polyurethane resin. The support substrate 20 can protect the display module 10 from the influence of external shocks.

[0067] The support plate 30 can be provided below the support substrate 20. The support plate 30 can include stainless steel, aluminum, or an alloy thereof. The strength of the support plate 30 can be greater than the strength of the display module 10. The support plate 30 can support the display module 10 and the support substrate 20, and can protect the display module 10 from the influence of external shocks. The support plate 30 can prevent foreign objects from entering the display module 10. The support plate 30 can have a thickness of about 100 micrometers to about 150 micrometers.

[0068] The buffer member 40 can be provided below the support plate 30. The buffer member 40 can include a thermoplastic polyurethane material. The buffer member 40 can be a thin material and can protect the support plate 30 from the influence of external shocks. The buffer member 40 can have a thickness of about 8 micrometers to about 12 micrometers.

[0069] Figure 3 A cross-section of the stacked structure of the display device 1000 according to an exemplary embodiment is schematically shown, and hereinafter, it will be described in more detail with reference to Figures 4 to 9 .

[0070] Figure 4 is a cross-sectional view of the display module 10 according to an exemplary embodiment of the present disclosure.

[0071] Refer to Figure 4, the display module 10 may include a display panel 100, an anti-reflection layer 200, a window 300, an upper protective film 400, and a lower protective film 500. Although not shown in the figure, the display module 10 may further include an input sensing layer that obtains coordinate information of an external input.

[0072] The display panel 100 according to an exemplary embodiment of the present disclosure may be a light-emitting display panel. However, the type of the display panel 100 of the present disclosure should not be particularly limited. For example, the display panel 100 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 include an organic light-emitting material. The light-emitting layer of the quantum dot light-emitting display panel may include quantum dots or quantum rods.

[0073] The input sensing layer may be directly disposed on the display panel 100. For example, the input sensing layer may be directly formed on the display panel 100 through a continuous manufacturing process. The input sensing layer may include a plurality of insulating layers and a plurality of conductive layers. The conductive layer may form a sensing electrode for sensing an external input, a sensing line connected to the sensing electrode, and a sensing pad connected to the sensing line. The input sensing layer may sense an external input by a mutual capacitance method and / or a self-capacitance method. However, the method for sensing an external input of the present disclosure should not be limited thereto or thereby.

[0074] The display panel 100 may include a first region 100-1, a second region 100-2, and a third region 100-3 defined in the display panel 100 along a second direction DR2. The first region 100-1 may correspond to Figure 1A the first non-foldable region NFA1, the second region 100-2 may correspond to Figure 1A the foldable region FA, and the third region 100-3 may correspond to Figure 1A the second non-foldable region NFA2. That is, each of the first region 100-1 and the third region 100-3 may be a non-foldable region, and the second region 100-2 may be a foldable region.

[0075] The anti-reflection layer 200 may be disposed on the display panel 100. The anti-reflection layer 200 may reduce the reflectance of external light incident from outside the anti-reflection layer 200. The anti-reflection layer 200 according to an exemplary embodiment of the present disclosure may include a retarder and a polarizer. The retarder may be a film type or a liquid crystal coating type, and may include a λ / 2 retarder and / or a λ / 4 retarder. The polarizer may be a film type or a liquid crystal coating type. The film type polarizer may include a stretched synthetic resin film, and the liquid crystal coating type polarizer may include liquid crystals arranged in a predetermined arrangement. The retarder and the polarizer may further include a protective film.

[0076] The antireflection layer 200 may include a color filter. The color filter may have a predetermined arrangement. The arrangement of the color filter may be determined by considering the emission colors of pixels included in the display panel 100. The antireflection layer 200 may further include a black matrix disposed adjacent to the color filter.

[0077] The antireflection layer 200 may include a destructive interference structure. For example, the destructive interference structure may include a first reflective layer and a second reflective layer disposed on different layers from each other. First reflected light and second reflected light reflected by the first reflective layer and the second reflective layer, respectively, may destructively interfere with each other, and thus, the reflectance of external light may be reduced.

[0078] The adhesive layer 1100 may be disposed between the display panel 100 and the antireflection layer 200. The display panel 100 and the antireflection layer 200 may be coupled to each other through the adhesive layer 1100. In another exemplary embodiment of the present disclosure, the adhesive layer 1100 may be omitted. The adhesive layer described in the present disclosure may include a conventional adhesive. As an example, each adhesive layer may include a pressure-sensitive adhesive (“PSA”), an optically clear adhesive (“OCA”), or an optically clear resin (“OCR”).

[0079] The window 300 may be disposed on the antireflection layer 200. The window 300 may include a base layer 301 and a functional coating layer 302. The base layer 301 may include a glass substrate and / or a synthetic resin film. For example, the base layer 301 may include a polyimide film. The base layer 301 of the present disclosure should not be limited to a single-layer structure. In another embodiment, the base layer 301 may include two or more films coupled to each other through an adhesive member. The functional coating layer 302 may include at least one of an anti-fingerprint layer, an antireflection layer, and a hard coating layer.

[0080] The adhesive layer 1200 may be disposed between the window 300 and the antireflection layer 200. However, in another embodiment, the adhesive layer 1200 may be omitted.

[0081] The upper protective film 400 may be disposed on the window 300. When the upper protective film 400 is added, the impact resistance characteristics of the display device 1000 may be improved. The upper protective film 400 may be a polymer film or a tempered glass film. The adhesive layer 1300 may be disposed between the upper protective film 400 and the window 300. However, in another embodiment, the adhesive layer 1300 may be omitted. In addition, in another exemplary embodiment of the present disclosure, the upper protective film 400 may be omitted.

[0082] The lower protective film 500 may be disposed below the display panel 100. The lower protective film 500 may protect the rear surface (i.e., the lower surface) of the display panel 100. The lower protective film 500 may include a synthetic resin film, such as a polyimide film or a polyethylene terephthalate film. However, this is merely exemplary, and the lower protective film 500 of the present disclosure should not be limited thereto or thereby restricted. The adhesive layer 1400 may be disposed between the lower protective film 500 and the display panel 100.

[0083] In an exemplary embodiment of the present disclosure, the support substrate 20 (refer to Figure 3 ) may be disposed below the lower protective film 500 of the display module 10. The first adhesive member AD1 (refer to Figure 6A ) may be disposed between the lower protective film 500 and the support substrate 20.

[0084] Figure 6A and Figure 6B are cross-sectional views showing a display device 1000 according to an exemplary embodiment of the present disclosure. Figure 6B is a view showing Figure 6A the folded state of the display device 1000. Figure 5A is a perspective view showing a support substrate 20 according to an exemplary embodiment of the present disclosure. Figure 5B is a plan view showing a support substrate 20 according to an exemplary embodiment of the present disclosure.

[0085] Refer to Figures 5A to 6B , the display device 1000 may include a display module 10, a support substrate 20, a first support plate 32 and a second support plate 34, and a first buffer member 42 and a second buffer member 44.

[0086] Refer to Figure 6A and Figure 6B , the display device 1000 may include a first non-foldable area NFA1, a second non-foldable area NFA2, and a foldable area FA. The display module 10 may be in a first state of being in a flat state (i.e., an unfolded state) as shown in Figure 6A , or may be in a second state of being in a folded state as shown in Figure 6B . In the folded state of the display device 1000, the display module 10 and the support substrate 20 may be folded in the foldable area FA, and may be maintained in a flat state in the first non-foldable area NFA1 and the second non-foldable area NFA2. According to an exemplary embodiment, a portion of the display module 10 corresponding to the foldable area FA is folded in the second state, and thus, a portion of the display module 10 corresponding to the first non-foldable area NFA1 and a portion of the display module 10 corresponding to the second non-foldable area NFA2 may face each other in the second state.

[0087] The display module 10 may include a display panel 100. Repeated descriptions are omitted.

[0088] Referring to Figures 5A to 6B , the support substrate 20 may be disposed below the display module 10 and may support the display module 10. The support substrate 20 may serve as a buffer to prevent the display module 10 from being damaged. In the present exemplary embodiment, the thickness TH1 of the support substrate 20 may be 2 to 2.5 times greater than the thickness of a conventional support substrate (not shown). For example, the thickness TH1 of the support substrate 20 in the thickness direction (i.e., the third direction DR3) may be in the range of about 200 micrometers (0.2 millimeters) to about 300 micrometers (0.3 millimeters). In the present exemplary embodiment, since the support substrate 20 can support the display module 10 and can serve as a buffer to protect the display module 10 from the impact, the thickness TH1 of the support substrate 20 may be greater than the thickness of a conventional support substrate.

[0089] The support substrate 20 may include an upper surface facing the display module 10 and a lower surface opposite the upper surface. At least one groove GR may be defined in the lower surface of the support substrate 20. In the drawings (e.g., Figures 5A to 6B ), three grooves GR are defined. However, the number of grooves GR of the present disclosure should not be limited to three. The support substrate 20 may have a thickness TH1 sufficient to define the groove GR. That is, the support substrate 20 may have a thick enough thickness TH1 so as to serve as a buffer even when the thickness is reduced in the foldable region FA due to the arrangement of the groove GR. In a plan view, the groove GR may overlap with the foldable region FA. In an exemplary embodiment, the groove GR may be defined to overlap with the entire foldable region FA. As shown in the figure, three grooves GR overlap with the entire foldable region FA. However, they should not be limited to this or restricted thereby. In another embodiment, regardless of the number of grooves GR, the groove GR may overlap with a part of the foldable region FA. The groove GR may be provided in plurality, and the groove GR may be arranged continuously, and may have a plurality of curved recessed shapes in the thickness direction of the support substrate 20. In the present application, "overlap" is interpreted to mean "overlap in the thickness direction in the unfolded state" unless otherwise clearly indicated.

[0090] When the groove GR is provided in plurality, the groove GR may be arranged continuously or discontinuously in the foldable region FA. That is, when the groove GR is arranged discontinuously, there may be a flat surface between the grooves GR.

[0091] In an exemplary embodiment, the depth WT of the groove GR in the third direction DR3 may be equal to or less than half of the thickness TH1 of the support substrate 20. When the depth WT of the groove GR is too large, the support substrate 20 may not be used as a buffer in the foldable region FA. For example, the depth WT of the groove GR may be in the range of about 80 micrometers to about 150 micrometers.

[0092] Referring Figures 5A to 6B , the support substrate 20 may further include a protective layer CM. The protective layer CM may be disposed along the surface of at least one groove GR. The protective layer CM may overlap the foldable region FA in a plan view. The protective layer CM may be disposed on a portion of the lower surface of the support substrate 20 that overlaps the entire foldable region FA and defines the groove GR. The protective layer CM may include a non-sticky material. In the case where foreign matter enters the groove GR, the protective layer CM may prevent the foreign matter from adhering to the surface of the groove GR. The protective layer CM may include an ultraviolet coating member. That is, the protective layer CM may be formed by coating an ultraviolet curable material on the surface of the groove GR and curing the coated ultraviolet curable material.

[0093] The protective layer CM may include an antistatic material. When the display device 1000 is repeatedly folded and unfolded, static electricity may be generated on the surface of the groove GR. However, since the protective layer CM disposed on the surface of the groove GR may include an antistatic material, the occurrence of static electricity can be prevented.

[0094] The support plate 30 may include a first support plate 32 and a second support plate 34. The first support plate 32 and the second support plate 34 may be metal plates. The first support plate 32 and the second support plate 34 may be spaced apart from each other in the foldable region FA. In Figure 6B , when the display device 1000 is in a folded state, the first support plate 32 and the second support plate 34 may face each other in the third direction DR3. The first support plate 32 and the second support plate 34 may be disposed below the support substrate 20 in an unfolded state to support the support substrate 20 and the display module 10, and may prevent the support substrate 20 and the display module 10 from being pressed, dented, etc. The support substrate 20 may prevent foreign matter from entering the display device 1000. Each of the first support plate 32 and the second support plate 34 may have a thickness TH2 of about 150 micrometers in the third direction DR3. Therefore, the thickness TH1 of the support substrate 20 may be greater than the thickness TH2 of each of the first support plate 32 and the second support plate 34.

[0095] The buffer member 40 may include a first buffer member 42 and a second buffer member 44. In the deployed state, the first buffer member 42 may be disposed below the first support plate 32, and the second buffer member 44 may be disposed below the second support plate 34. The first buffer member 42 may be disposed to overlap with a part of the foldable region FA and a part of the first non-foldable region NFA1, and the second buffer member 44 may be disposed to overlap with another part of the foldable region FA and a part of the second non-foldable region NFA2. The first buffer member 42 and the second buffer member 44 may respectively support the first support plate 32 and the second support plate 34, and may prevent the first support plate 32 and the second support plate 34 from being impacted, pressed, and deformed by an external force. The first buffer member 42 and the second buffer member 44 may have a thickness of about 6 micrometers to about 10 micrometers in the third direction DR3.

[0096] The first adhesive member AD1 may be disposed between the display module 10 and the support substrate 20. The second adhesive member AD2 may be disposed between the support substrate 20 and each of the first support plate 32 and the second support plate 34, and the third adhesive member AD3 may be disposed between the first support plate 32 and the first buffer member 42 and between the second support plate 34 and the second buffer member 44. The first adhesive member AD1, the second adhesive member AD2, and the third adhesive member AD3 may be tapes. The first adhesive member AD1, the second adhesive member AD2, and the third adhesive member AD3 may be a pressure-sensitive adhesive (PSA), an optically clear adhesive (OCA), or an optically clear resin (OCR).

[0097] The step difference compensation member SCM may be disposed below the first support plate 32 and the second support plate 34 in a region where the first buffer member 42 or the second buffer member 44 is not provided. The step difference compensation member SCM may be various types of adhesives including a pressure-sensitive adhesive. Although not shown in the figure, the step difference compensation member SCM may couple the first support plate 32 and the second support plate 34 to a lower set. The lower set may correspond to a housing that covers the display module 10, the cover panel, and the lower member.

[0098] Figures 7A to 7H is a view showing a method of manufacturing a display device according to an exemplary embodiment of the present disclosure.

[0099] Refer to Figures 7A to 7H, a method of manufacturing a display device may include: providing a display module 10, the display module 10 including a first non-foldable area NFA1, a second non-foldable area NFA2, and a foldable area FA; providing a support substrate 20 below the display module 10; and providing a first support plate 32 and a second support plate 34, the first support plate 32 and the second support plate 34 being disposed below the support substrate 20 and spaced apart from each other in the foldable area FA.

[0100] Providing the support substrate 20 may include: providing a preliminary support substrate 20-1; and forming at least one groove GR in the preliminary support substrate 20-1 using a jig ZG.

[0101] Figure 7A The preliminary support substrate 20-1 shown in may include a foam resin, a polyurethane resin, or a sponge. According to an exemplary embodiment, the preliminary support substrate 20-1 may be formed by coating (spraying) a foam resin on a first release film CF1. The first release film CF1 may be a medium-thin release film. When providing the preliminary support substrate 20-1, the foam resin surface of the preliminary support substrate 20-1 is pressed by the jig ZG, and thus, at least one groove GR may be formed. The jig ZG may be a mold for forming the support substrate 20 by forming various patterns on the preliminary support substrate 20-1. The jig ZG may include at least one protrusion formed on the surface of the jig ZG in contact with the preliminary support substrate 20-1 to overlap with the foldable area FA and correspond to at least one groove GR. The at least one protrusion may correspond to the at least one groove GR.

[0102] Referring to Figure 7B , forming at least one groove GR may include: pressing the foam resin surface of the preliminary support substrate 20-1 using the jig ZG while drying the coated foam resin.

[0103] In an exemplary embodiment, the jig ZG may include a coating layer NAL formed on the surface of the jig ZG in contact with the preliminary support substrate 20-1. The coating layer NAL may prevent the preliminary support substrate 20-1 from adhering to the jig ZG when the preliminary support substrate 20-1 comes into contact with the jig ZG. The coating layer NAL may include a primer having excellent water repellency or low surface energy. However, the coating layer NAL of the present disclosure should not be limited thereto or thereby. The coating layer NAL may include various non-sticky materials.·

[0104] Referring to Figure 7C and Figure 7D, Providing the support substrate 20 may include: coating a protective layer CM on the surface of at least one groove GR formed using a jig ZG. The protective layer CM may be formed by a UV coating process or a primer coating process with a low surface energy. As another approach, the protective layer CM may be formed using a variety of non-sticky materials that will not adhere to foreign objects. In an exemplary embodiment, the protective layer CM may further include an antistatic material having a non-sticky material, which prevents static electricity from occurring during folding or unfolding operations. The protective layer CM may be coated to cover the entire foldable area FA.

[0105] Referring to Figures 7E to 7H , A method of manufacturing a display device may include: disposing a display module 10 on a support substrate 20; and disposing a first support plate 32 and a second support plate 34 under the support substrate 20.

[0106] The support substrate 20 may include an upper surface facing the display module 10 and a lower surface opposite the upper surface. A method of manufacturing a display device may include disposing a second adhesive member AD2 on the lower surface of the support substrate 20 to overlap with a first non-foldable area NFA1 and a second non-foldable area NFA2. In addition, a method of manufacturing a display device may include: disposing a first support plate 32 and a second support plate 34 on the second adhesive member AD2. Referring to Figure 7E , Disposing the first support plate 32 and the second support plate 34 may include: coating the second adhesive member AD2; and attaching a second release film CF2 to the support substrate 20 through the second adhesive member AD2. Referring to Figure 7F , A method of manufacturing a display device may include: removing a first release film CF1; coating a first adhesive member AD1 on the support substrate 20; and attaching a third release film CF3 on the first adhesive member AD1. In an exemplary embodiment, each of the second release film CF2 and the third release film CF3 may be a medium-thin release film or a thin release film.

[0107] Referring to Figure 7G , After removing the second release film CF2, the first support plate 32 and the second support plate 34 may be attached to the second adhesive member AD2. In an exemplary embodiment, when the second release film CF2 is a medium-thin release film, the second release film CF2 may be removed after replacing the second release film CF2 with a thin release film. This is to prevent the removal of other unwanted release films when removing the second release film CF2. Referring to Figure 7H , After removing the third release film CF3, the display module 10 may be attached to the first adhesive member AD1. Similarly, when the third release film CF3 is a medium-thin release film, the third release film CF3 may be removed after replacing the third release film CF3 with a thin release film.

[0108] In Figures 7E to 7H , after setting the first support plate 32 and the second support plate 34, the display module 10 is set. However, the order of the setting of the present disclosure should not be limited to this or restricted thereby. In another embodiment, after removing the third release film CF3 from the upper surface of the support substrate 20 and setting the display module 10, the second release film CF2 is removed, and then the first support plate 32 and the second support plate 34 can be set on the lower surface of the support substrate 20.

[0109] Figures 8A to 8D is a cross-sectional view showing a display device according to other exemplary embodiments of the present disclosure.

[0110] Referring to Figure 8A , at least one groove GR having a shape that tapers in the thickness direction of the support substrate 20 can be provided, and the grooves GR can be provided in plural. In the present exemplary embodiment, the grooves GR can be arranged continuously. For example, the depth of the grooves GR in the third direction DR3 can be maximum at the center of the foldable area FA, and can become smaller and smaller in the direction from the center of the foldable area FA to the first non-foldable area NFA1 or the second non-foldable area NFA2. The grooves GR can be arranged to overlap the entire foldable area FA. In the present exemplary embodiment, the grooves GR can overlap the entire foldable area FA. However, in another embodiment, the grooves GR can be arranged to be slightly spaced apart from each of the first non-foldable area NFA1 and the second non-foldable area NFA2. This is to prevent defects from occurring in the folded portion of the support substrate 20 when the support substrate 20 is folded.

[0111] Referring to Figure 8B , the groove GR can be provided in a curved shape that is recessed in the thickness direction of the support substrate 20. The groove GR can have a recessed elliptical shape.

[0112] Referring to Figure 8C , the grooves GR can be provided in plural, and the grooves GR can be arranged discontinuously. The grooves GR can overlap the entire foldable area FA. The grooves GR can be recessed in the thickness direction of the support substrate 20, and discontinuous surfaces having a convex curved shape in a direction opposite to the thickness direction of the support substrate 20 (i.e., a direction opposite to the third direction DR3) can be provided between the grooves GR.

[0113] Referring to Figure 8D, a plurality of grooves GR may be provided, and the grooves GR may be arranged in a non - continuous linear shape. In the present exemplary embodiment, the grooves GR may be arranged to be spaced apart from the first non - foldable region NFA1 and the second non - foldable region NFA2. That is, at least one groove GR may not overlap with the entire foldable region FA. A portion of the lower surface of the support substrate 20 that does not include the groove GR may be provided adjacent to the first non - foldable region NFA1 or the second non - foldable region NFA2.

[0114] Figure 9 FIG. is a cross - sectional view showing a display device according to another exemplary embodiment of the present disclosure.

[0115] Referring to Figure 9 , the display device may include a first auxiliary plate 52 and a second auxiliary plate 54.

[0116] The first auxiliary plate 52 may be provided to overlap with the first buffer member 42 and may support the first buffer member 42, and the second auxiliary plate 54 may be provided to overlap with the second buffer member 44 in a plan view and may support the second buffer member 44. The first auxiliary plate 52 and the second auxiliary plate 54 may include a metal plate. For example, the first auxiliary plate 52 and the second auxiliary plate 54 may include stainless steel, aluminum, or an alloy thereof. The first auxiliary plate 52 and the second auxiliary plate 54 may prevent foreign substances from entering the display device 1000, and may prevent the display module 10 from being pressed or dented.

[0117] In the present exemplary embodiment, a fourth adhesive member AD4 may be provided between the first buffer member 42 and the first auxiliary plate 52 and between the second buffer member 44 and the second auxiliary plate 54. The fourth adhesive member AD4 may be a pressure - sensitive adhesive (PSA), an optically clear adhesive (OCA), or an optically clear resin (OCR).

[0118] Although the exemplary embodiments of the present disclosure have been described, it should be understood that the present disclosure should not be limited to these exemplary embodiments, but rather, within the spirit and scope of the present disclosure as claimed herein, those of ordinary skill in the art can make various changes and modifications. Therefore, the disclosed subject matter should not be limited to any single embodiment described herein, and the scope of the inventive concept should be determined according to the appended claims.

Claims

1. A display device, comprising a first non-foldable region, a second non-foldable region, and a foldable region, the display device comprising: A display module, comprising a display panel; A support substrate that supports the display module, comprising an upper surface facing the display module and a lower surface opposite to the upper surface, and provided with a groove defined in the lower surface to overlap with the foldable region in the thickness direction of the support substrate; A first support plate provided below the support substrate; And A second support plate provided below the support substrate and spaced apart from the first support plate in the foldable region, Wherein, the support substrate further comprises a protective layer provided along the surface of the groove to overlap with the entire foldable region and comprising a non-sticky antistatic material.

2. The display device according to claim 1, wherein The groove overlaps with the entire foldable region.

3. The display device according to claim 1, wherein, The protective layer comprises an ultraviolet coating member.

4. The display device according to claim 1, wherein, In the thickness direction, the thickness of the support substrate is greater than the thickness of the first support plate and greater than the thickness of the second support plate.

5. The display device according to claim 1, wherein, The thickness of the support substrate is in the range of 0.2 mm to 0.25 mm.

6. The display device according to claim 1, wherein, The depth of the groove in the thickness direction of the support substrate is equal to or less than half of the thickness of the support substrate.

7. The display device according to claim 1, wherein, The grooves are provided in plurality, and the grooves are arranged continuously or discontinuously in the foldable region.

8. The display device according to claim 1, wherein, The first support plate and the second support plate comprise a metallic material.

9. The display device according to claim 1, further comprising: A first buffer member provided below the first support plate and overlapping with a part of the foldable region and a part of the first non-foldable region in the thickness direction; And A second buffer member provided below the second support plate and overlapping with another part of the foldable region and a part of the second non-foldable region in the thickness direction.

10. The display device according to claim 9, wherein, Each of the first buffer member and the second buffer member has a thickness of 6 microns to 10 microns.

11. The display device according to claim 9, further comprising: A first auxiliary plate provided below the first buffer member and overlapping with the first buffer member in the thickness direction; And A second auxiliary plate provided below the second buffer member and overlapping with the second buffer member in the thickness direction.

12. The display device according to claim 1, wherein, The display module has a first state and a second state. In the first state, the display module is flat. In the second state, the display module can be bent in the foldable region such that a part of the display module corresponding to the first non-foldable region faces a part of the display module corresponding to the second non-foldable region.

13. A method of manufacturing a display device, comprising: Providing a display module, the display module comprising a first non-foldable region, a second non-foldable region, and a foldable region; Providing a support substrate below the display module; And Providing a first support plate and a second support plate spaced apart from each other in the foldable region below the support substrate; Wherein, the support substrate includes an upper surface facing the display module and a lower surface opposite to the upper surface, and the support substrate is provided with a groove defined in the lower surface to overlap with the foldable area in the thickness direction of the support substrate, and Wherein, providing the support substrate includes: coating a protective layer including a non-sticky antistatic material on the surface of the defined groove and overlapping with the entire foldable area.

14. The method according to claim 13, wherein Providing the support substrate further includes: Providing a preliminary support substrate; and Defining the groove in the preliminary support substrate using a jig.

15. The method according to claim 14, wherein Providing the preliminary support substrate includes: coating a foam resin on a release film; and Defining the groove includes: drying the coated foam resin while pressing the preliminary support substrate with the jig.

16. The method according to claim 14, wherein, The jig includes a coating layer formed on the surface of the jig and in contact with the preliminary support substrate.

17. The method according to claim 14, wherein The jig includes a protrusion formed on the surface of the jig and in contact with the preliminary support substrate to overlap with the foldable area in the thickness direction and correspond to the groove.

18. The method according to claim 13, wherein Providing the support substrate further includes: Providing a first adhesive member on the upper surface of the support substrate; and Disposing the display module on the first adhesive member.

19. The method according to claim 13, wherein Providing the first support plate and the second support plate includes: Providing a second adhesive member on the lower surface of the support substrate to overlap with the first non-foldable area and the second non-foldable area in the thickness direction; and Disposing the first support plate and the second support plate on the second adhesive member.

Images