Display module and method of manufacturing a display module

Abstract

Provided are a display module and a method of manufacturing a display module, the method including: preparing a first preliminary display module including a display panel and a polarizing film disposed on the display panel; irradiating a first laser beam to the first preliminary display module at a first angle; a first cutting operation of cutting the first preliminary display module to form a second preliminary display module; irradiating a second laser beam to the second preliminary display module at a second angle different from the first angle; and a second cutting operation of cutting the second preliminary display module to form the display module.

Description

[0001] This application claims priority to Korean Patent Application No. 10-2020-0034225, filed on March 20, 2020, the entire contents of which are incorporated herein by reference. Technical Field

[0002] This disclosure relates to a display module and a method for manufacturing a display module, and to a method for manufacturing a display module by means of reducing processing time and a display module in which the area of ​​the heat-affected portion is reduced. Background Technology

[0003] The display device may include a display module. The display module can be provided by cutting from a preliminary display module separate from the mother substrate. A laser can be used to cut the preliminary display module. Summary of the Invention

[0004] This disclosure provides a method for manufacturing a display module with reduced processing time.

[0005] This disclosure also provides a display module with a reduced area of ​​heat-affected zone.

[0006] An embodiment of the inventive concept provides a method for manufacturing a display module, the method comprising the following steps: preparing a first preliminary display module including a display panel and a polarizing film disposed on the display panel; irradiating the first preliminary display module with a first laser beam at a first angle; a first cutting operation cutting the first preliminary display module to form a second preliminary display module; irradiating the second preliminary display module with a second laser beam at a second angle different from the first angle; and a second cutting operation cutting the second preliminary display module to form a display module.

[0007] In an embodiment, the first preliminary display module may include an effective area and an invalid area, and the first laser beam may be incident from the effective area toward the invalid area.

[0008] In one embodiment, the second laser beam can be directed to the boundary between the effective and ineffective regions.

[0009] In an embodiment, the first preliminary display module may include a first processing surface and a second processing surface opposite to each other, wherein a first laser beam can irradiate from the first processing surface toward the second processing surface, wherein the second preliminary display module may include a third processing surface formed from the first processing surface and a fourth processing surface formed from the second processing surface, wherein the area of ​​the third processing surface may be smaller than the area of ​​the fourth processing surface.

[0010] In one embodiment, the polarizing film may be positioned closer to the second processing surface than the display panel.

[0011] In an embodiment, the method may further include a third cutting operation of cutting the second preliminary display module by irradiating a third laser beam in a direction from the fourth processing surface toward the third processing surface, wherein the third cutting operation may be performed between the first cutting operation and the second cutting operation.

[0012] In an embodiment, the intensity of the first laser beam and the intensity of the third laser beam may each be greater than the intensity of the second laser beam.

[0013] In an embodiment, the display module may include: a first surface having an area equal to that of the third processing surface; and a second surface formed from the fourth processing surface and having an area smaller than that of the fourth processing surface.

[0014] In an embodiment, the first angle can be the angle between the normal of the first processing surface and the direction of travel of the first laser beam, and the second angle can be the angle between the normal of the first processing surface and the direction of travel of the second laser beam. The first angle can be greater than 0 degrees and less than 90 degrees.

[0015] In this embodiment, the second angle can be 0 degrees.

[0016] In one embodiment, the first preliminary display module may further include a protective film disposed below the display panel, wherein the display panel, the polarizing film, and the protective film may all be cut during the first cutting operation.

[0017] In an embodiment, during the second cutting operation, the polarizing film or the polarizing film and the display panel can be cut.

[0018] In this embodiment, the first preliminary display module can be set on the worktable, wherein the position of the worktable can be fixed during the first cutting operation and the second cutting operation, and the irradiation direction of the first laser beam and the irradiation direction of the second laser beam can be changed.

[0019] In one embodiment, the first preliminary display module can be mounted on the worktable, wherein the irradiation direction of the first laser beam and the irradiation direction of the second laser beam can be the same, and the position of the worktable in the second cutting operation can be tilted from the position of the worktable in the first cutting operation.

[0020] In an embodiment of the inventive concept, a display module includes: a display panel, including a first surface and a second surface opposite to each other; a protective film disposed below the first surface of the display panel and including a first side surface inclined relative to the first surface; and a polarizing film disposed on the second surface of the display panel and including a second side surface inclined relative to the second surface, wherein a first angle between the first surface and the first side surface is greater than 0 degrees and less than 75 degrees.

[0021] In an embodiment, the second angle between the second surface and the second side surface may be greater than the first angle.

[0022] In an embodiment, the second angle can be 90 degrees.

[0023] In an embodiment, the difference between the first angle and the second angle can be 15 degrees or greater but less than 90 degrees.

[0024] In an embodiment of the inventive concept, a method of manufacturing a display module includes the following steps: preparing a first preliminary display module; forming a second preliminary display module having a first side surface by completely cutting the first preliminary display module; and partially cutting a portion of the first side surface to form a display module having a first side surface and a second side surface inclined from the first side surface.

[0025] In an embodiment, the first preliminary display module may include a protective film, a display panel disposed on the protective film, and a polarizing film disposed on the display panel. In the step of forming the second preliminary display module, a first laser beam of first intensity can be used to cut the entire protective film, display panel, and polarizing film to form a first side surface. In the step of forming the display module, a second side surface can be formed by cutting the polarizing film with a second laser beam of second intensity that is weaker than the first intensity. Attached Figure Description

[0026] The accompanying drawings are included to provide a further understanding of the inventive concept and are incorporated in and constitute a part of this specification. The drawings illustrate exemplary embodiments of the inventive concept and, together with the description, serve to explain the principles of the inventive concept. In the drawings:

[0027] Figure 1 This is a plan view of a display module according to an embodiment of the inventive concept;

[0028] Figure 2A According to the embodiments along Figure 1 The cross-sectional view shown is taken along line I-I'.

[0029] Figure 2B According to the embodiments along Figure 1 The cross-sectional view shown is taken along line I-I'.

[0030] Figure 3 This is a plan view of a first preliminary display module according to an embodiment of the inventive concept;

[0031] Figure 4 It is along Figure 3 The cross-sectional view taken by line II-II' shown in the figure;

[0032] Figure 5This is a plan view of a second preliminary display module according to an embodiment of the inventive concept;

[0033] Figure 6 It is along Figure 5 The cross-sectional view taken by line III-III' shown in the figure;

[0034] Figure 7 This is a plan view of a third preliminary display module according to an embodiment of the inventive concept;

[0035] Figure 8 It is along Figure 7 The cross-sectional view shown is taken along line IV-IV'.

[0036] Figure 9A This is a view illustrating a first cutting operation according to an embodiment of the inventive concept;

[0037] Figure 9B This is a view illustrating a second cutting operation according to an embodiment of the inventive concept;

[0038] Figure 10A This is a view illustrating a first cutting operation according to an embodiment of the inventive concept;

[0039] Figure 10B This is a view illustrating a second cutting operation according to an embodiment of the inventive concept; and

[0040] Figures 11A to 11D This is a diagram illustrating a method for manufacturing a display module according to an embodiment of the inventive concept. Detailed Implementation

[0041] In this specification, when a component (or region, layer, part, etc.) is referred to as being "on" another component, "connected to" or "integrated into" another component, it means that the component may be directly on, connected to or integrated into the other component, or that a third component may be present between them.

[0042] The same reference numerals refer to the same elements. Additionally, in the accompanying drawings, the thickness, proportions, and dimensions of the components are exaggerated for the purpose of effective description.

[0043] "And / or" includes all of one or more combinations defined by the relevant components (components).

[0044] It will be understood that the terms "first" and "second" are used herein to describe various components, but these components should not be limited by these terms. The terms are used only to distinguish one component from another. For example, without departing from the scope of the inventive concept, a first component may be referred to as a second component, and vice versa. Unless otherwise stated, singular terms may include plural forms.

[0045] In addition, terms such as “below,” “lower side,” “above,” and “upper side” are used to describe the relationships of the structures shown in the accompanying drawings. These terms are described as relative concepts based on the directions shown in the accompanying drawings.

[0046] 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 invention pertains. Generally, terms defined in dictionaries shall be considered to have the same meaning as in the context of the relevant field, and shall not be interpreted unusually or construed as having an overly formal meaning unless clearly defined herein.

[0047] In various embodiments of the inventive concept, the terms "comprising" or "including" and variations thereof describe the presence of attributes, areas, fixed quantities, steps, processes, elements and / or components, but do not exclude other attributes, areas, fixed quantities, steps, processes, elements and / or components.

[0048] In the following description, embodiments of the inventive concept will be illustrated with reference to the accompanying drawings.

[0049] Figure 1 This is a plan view of a display module 1000 according to an embodiment of the inventive concept.

[0050] Reference Figure 1 The active area AA and the peripheral area NAA can be defined within the display module 1000. The active area AA can be an area activated by an electrical signal. The drive circuit or drive line for driving the active area AA can be provided in the peripheral area NAA.

[0051] The effective area AA of the display module 1000 may include a plane defined by a first direction DR1 and a second direction DR2. The thickness direction of the display module 1000 may be parallel to a third direction DR3 that intersects the first direction DR1 and the second direction DR2. Therefore, the front surface (or upper surface) and rear surface (or lower surface) of the components constituting the display module 1000 may be defined based on the third direction DR3. In this specification, "when viewed from a plane" may be interpreted as viewed from the thickness direction of the display module 1000 or viewed from the third direction DR3.

[0052] Figure 2A According to the embodiments along Figure 1 The cross-sectional view shown is taken along line I-I'.

[0053] Reference Figure 2A The display module 1000 may include a display panel 100, a polarizing film 200, and a protective film 300.

[0054] The display panel 100 can be configured to generate images. The display panel 100 can be a light-emitting display panel. For example, the display panel 100 can be an organic light-emitting display panel, a quantum dot light-emitting display panel, or a micro-LED display panel.

[0055] The display panel 100 may also include an input sensor that senses external input applied from the outside. External input can be user input. User input can include various types of external input, such as a part of the user's body, light, heat, a pen, or pressure.

[0056] For example, the display panel 100 may include a display layer and a sensor layer. The sensor layer may be formed on the display layer using a continuous process. In this case, it can be described as the sensor layer being directly disposed on the display layer. "Directly disposed" may mean that no third component is disposed between the sensor layer and the display layer. That is, no separate adhesive component may be disposed between the sensor layer and the display layer.

[0057] Optionally, the display panel 100 may include a display layer, an adhesive layer, and a sensor layer. In this case, the sensor layer can be bonded to the display layer and the adhesive layer.

[0058] The display panel 100 may include a first surface 100s1 and a second surface 100s2 facing each other. The first surface 100s1 may be referred to as the lower surface, and the second surface 100s2 may be referred to as the upper surface. Each of the first surface 100s1 and the second surface 100s2 may be the outermost surface of the display panel 100.

[0059] A protective film 300 may be disposed below the first surface 100s1. The protective film 300 protects the display panel 100. A polarizing film 200 may be disposed on the second surface 100s2. The polarizing film 200 reduces the reflectivity of external light incident from the outside. The polarizing film 200 may comprise a stretched synthetic resin film. For example, the polarizing film 200 may be provided by printing an iodine compound onto a polyvinyl alcohol (PVA) film.

[0060] The protective film 300 includes a first side surface 300s inclined relative to the first surface 100s1, and the polarizing film 200 includes a second side surface 200s inclined relative to the second surface 100s2. The angle between the first surface 100s1 and the first side surface 300s can be defined as a first angle AG1, and the angle between the second surface 100s2 and the second side surface 200s can be defined as a second angle AG2.

[0061] According to an embodiment of the inventive concept, the second angle AG2 can be greater than the first angle AG1. The first angle AG1 can be, for example, greater than 0 degrees and less than 75 degrees. The second angle AG2 can be 90 degrees. Therefore, the difference between the first angle AG1 and the second angle AG2 can be 15 degrees or greater and less than 90 degrees.

[0062] The display module 1000 can be cut by laser beams incident at different angles. Therefore, the slope of the first side surface 300s and the slope of the second side surface 200s can be different from each other.

[0063] Unlike the embodiments of the inventive concept, when a display module is formed by adjusting only the intensity of a laser beam incident at the same angle, the angular difference between the side surfaces depending on the intensity of the laser beam can be less than 10 degrees. However, according to the embodiments of the inventive concept, since the incident angle of the laser beam is adjusted, the angular difference between the first side surface 300s and the second side surface 200s can be 15 degrees or greater.

[0064] Figure 2B According to the embodiments along Figure 1 The cross-sectional view shown is taken along line I-I'.

[0065] Reference Figure 2B The protective film 300a may include multiple side surfaces 300s1 and 300s2. For example, the multiple side surfaces 300s1 and 300s2 may include a first side surface 300s1 and a second side surface 300s2. The inclination of the first side surface 300s1 relative to the first surface 100s1 may be different from the inclination of the second side surface 300s2 relative to the first surface 100s1. The angle AG1a between the first side surface 300s1 and the first surface 100s1 may be greater than 0 degrees and less than 75 degrees. The angle between the second side surface 300s2 and the first surface 100s1 may be 90 degrees.

[0066] The first side surface 300s1 may be a side surface cut by a laser beam incident at a first angle, and the second side surface 300s2 may be a side surface cut by a laser beam incident at a second angle different from the first angle.

[0067] Figure 3 This is a plan view of the first preliminary display module 1001 according to an embodiment of the inventive concept. Figure 4 It is along Figure 3 The cross-sectional view shown is taken along line II-II'. Figure 4 The illustration shows a first cutting operation in which a first laser beam 2001 is irradiated onto a first preliminary display module 1001 at a first angle 2001AG.

[0068] Reference Figure 3 and Figure 4Prepare a first preliminary display module 1001. The first preliminary display module 1001 may include a valid area 1001a and an invalid area 1001b. The valid area 1001a may be the same as that of the display module 1000 (see...). Figure 1 The corresponding region is the invalid region 1001b, which may correspond to the region removed by the cutting process.

[0069] The first preliminary display module 1001 may include a first carrier film 401, a protective film 301, a display panel 101, a polarizing film 201, and a second carrier film 501, which are stacked sequentially along the third direction DR3. The first carrier film 401 may be attached to the protective film 301, and the second carrier film 501 may be attached to the polarizing film 201.

[0070] The outermost surface of the first carrier film 401 can be defined as the first processing surface 1001m1, and the outermost surface of the second carrier film 501 can be defined as the second processing surface 1001m2. The first processing surface 1001m1 and the second processing surface 1001m2 can face each other. The polarizing film 201 can be configured to be closer to the second processing surface 1001m2 than the display panel 101.

[0071] A first laser beam 2001 can be directed onto a first preliminary display module 1001. The first preliminary display module 1001 can be cut by the first laser beam 2001. The first preliminary display module 1001 can be completely cut by the first laser beam 2001. Complete cutting can mean that the entire thickness of the first preliminary display module 1001 is cut off.

[0072] The first laser beam 2001 can be incident in a direction inclined relative to the first processing surface 1001m1. For example, the first laser beam 2001 can irradiate the first processing surface 1001m1 at a first angle 2001AG relative to the normal 1001nl of the first processing surface 1001m1. The first angle 2001AG can be 15 degrees or greater and less than 90 degrees. The first angle 2001AG can be defined as the angle between the direction of travel of the first laser beam 2001 and the normal 1001nl. The first laser beam 2001 can be incident from the effective region 1001a toward the ineffective region 1001b. Therefore, the first laser beam 2001 can be incident on the effective region 1001a and output to the ineffective region 1001b.

[0073] The first angle 2001AG can be adjusted according to the total thickness of the first preliminary display module 1001. For example, as the thickness of the first preliminary display module 1001 decreases, the first angle 2001AG can be increased.

[0074] The intensity of the first laser beam 2001 can be greater than that of the second laser beam 2002, which will be described later (see...). Figure 6The intensity of the first laser beam 2001. For example, the first laser beam 2001 may be 20 watts or more and 400 watts or less, but the intensity of the first laser beam 2001 is not limited to this.

[0075] When the intensity of the first laser beam 2001 is 20 watts, the thickness of the first carrier film 401 is 85 micrometers, the thickness of the protective film 301 is 68 micrometers, the thickness of the display panel 101 is 30 micrometers, the thickness of the polarizing film 201 is 56 micrometers, and the thickness of the second carrier film 501 is 85 micrometers, the processing time of the first cutting operation can be approximately 7 seconds.

[0076] According to an embodiment of the inventive concept, since a relatively strong first laser beam 2001 is used to cut the first preliminary display module 1001, the speed can be further increased. Therefore, the time spent cutting the first preliminary display module 1001 can be shortened.

[0077] Figure 5 This is a plan view of the second preliminary display module 1002 according to an embodiment of the inventive concept. Figure 6 It is along Figure 5 The cross-sectional view shown is taken from line III-III'. Figure 6 The second cutting operation is shown, in which a second laser beam 2002 is irradiated onto a second preliminary display module 1002 at a second angle.

[0078] Reference Figure 5 and Figure 6 First, the first preliminary display module 1001 (see...) Figure 3 The second preliminary display module 1002 is cut to form a second preliminary display module 1002. The second preliminary display module 1002 may include a first carrier film 402, a protective film 302, a display panel 102, a polarizing film 202 and a second carrier film 502, which are stacked sequentially along the third direction DR3.

[0079] The outermost surface of the first carrier membrane 402 can be defined as the third processing surface 1001m3, and the outermost surface of the second carrier membrane 502 can be defined as the fourth processing surface 1001m4. The third processing surface 1001m3 can be formed from the first processing surface 1001m1, and the fourth processing surface 1001m4 can be formed from the second processing surface 1001m2. The area of ​​the third processing surface 1001m3 can be smaller than the area of ​​the fourth processing surface 1001m4.

[0080] The second preliminary display module 1002 may have a first side surface 1002s. The first side surface 1002s is illuminated by a first laser beam 2001 (see...). Figure 4 The side surface of the cut. The angle 1002AG between the first side surface 1002s and the fourth processed surface 1001m4 can be greater than 0 degrees and less than 75 degrees.

[0081] After the initial cutting, a heat-affected zone 202haz is formed in the polarizing film 202. The heat-affected zone 202haz can be referred to as the haze area. The heat-affected zone 202haz can refer to the part of the polarizing film 202 that changes color and turns yellow due to heat.

[0082] The second laser beam 2002 can be directed onto the second preliminary display module 1002. The second preliminary display module 1002 can be cut by the second laser beam 2002. Through the second cutting operation, a portion of the first side surface 1002s can be completely cut. In the second cutting operation, the display panel 102, the polarizing film 202, and the second carrier film 502 can be cut.

[0083] The second laser beam 2002 can be directed onto the boundary between the effective region 1001a and the ineffective region 1001b. For example, the second laser beam 2002 can be incident along a direction parallel to the normal 1002nl of the third processing surface 1001m3. Therefore, the second angle between the direction of travel of the second laser beam 2002 and the normal 1002nl can be 0 degrees.

[0084] The intensity of the second laser beam 2002 can be less than that of the first laser beam 2001 (see...). Figure 4 The intensity of the second laser beam 2002 can be greater than 0 watts and less than 10 watts.

[0085] When the intensity of the second laser beam 2002 is 7 watts, the thickness of the display panel 102 is 30 micrometers, the polarizing film 202 has a thickness of 56 micrometers, and the thickness of the second carrier film 502 is 85 micrometers, the processing time of the second cutting operation can be approximately 12 seconds.

[0086] According to an embodiment of the inventive concept, a second laser beam 2002 with relatively weak intensity is used to cut the second preliminary display module 1002. Therefore, the area of ​​the heat-affected portion in the portion cut by the second laser beam 2002 can be smaller than that cut by the first laser beam 2001 (see...). Figure 4 The area of ​​the heat-affected zone in the section cut by the second laser beam 2002. Additionally, the thickness of the area cut by the second laser beam 2002 is less than that cut by the first laser beam 2001 (see...). Figure 4 The thickness of the area to be cut. Therefore, even if the second laser beam 2002 with a weak intensity is used to cut the second preliminary display module 1002, the processing time will not be significantly increased.

[0087] Figure 7 This is a plan view of the third preliminary display module 1003 according to an embodiment of the inventive concept. Figure 8 It is along Figure 7 The cross-sectional view shown is taken along line IV-IV'.

[0088] Reference Figure 7 For the second preliminary display module 1002 (refer to...) Figure 5 A second cut is performed to form a third preliminary display module 1003. The third preliminary display module 1003 may include a first carrier film 402, a display module 1000, and a second carrier film 503 stacked sequentially along the third direction DR3. When the first carrier film 402 and the second carrier film 503 are removed from the third preliminary display module 1003, the display module 1000 can be formed.

[0089] The third preliminary display module 1003 may have a first side surface 1002s1 and a second side surface 1003s inclined from the first side surface 1002s1. The second side surface 1003s corresponds to the second laser beam 2002 (see...). Figure 6 The cut side surface, the first side surface 1002s1 corresponds to Figure 6 Another part of the first side surface 1002s shown in the figure.

[0090] The second side surface 1003s may include the side surface of the polarizing film 200. The second side surface 1003s may be subjected to a second laser beam 2002 with a relatively weak intensity (see reference). Figure 6 The surface is cut. Therefore, the area of ​​the heat-affected portion 200 Hz formed in the polarizing film 200 after the second cut can be smaller than [the area of ​​the cut surface]. Figure 6 The area of ​​the heat-affected portion 202 haz is shown in the figure. For example, the width of the heat-affected portion 200 haz can be 60 micrometers or less.

[0091] Reference Figure 4 , Figure 6 and Figure 8 After the first preliminary display module 1001 is cut for the first time using a first laser beam 2001 with relatively high intensity, the second preliminary display module 1002 is cut for the second time using a second laser beam 2002 with relatively low intensity.

[0092] Since the initial cut is performed using a first laser beam 2001 with relatively high intensity, the initial cut time can be shortened. Furthermore, because the first laser beam 2001 is angled relative to the normal 1001nl of the first preliminary display module 1001, the second preliminary display module 1002, after being cut by the first laser beam 2001, has an angled surface. Therefore, the thickness of the object cut in the second cut is thinner than the thickness of the object cut in the first cut, thereby shortening the second cut time.

[0093] Furthermore, the second cut removes at least a portion of the heat-affected zone 202 haz generated during the initial cut. Since the intensity of the second laser beam 2002 is less than that of the first laser beam 2001, the area of ​​the heat-affected zone 200 haz generated by the second laser beam 2002 is smaller than the area of ​​the heat-affected zone 202 haz generated by the first laser beam 2001.

[0094] According to the inventive concept, the area of ​​the heat-affected zone 200 Hz remaining in the final display module 1000 is reduced, and the processing time of the display module 1000 can be shortened. In other words, according to the inventive concept, a method for manufacturing the display module 1000 can be provided that satisfies both the quality conditions associated with the heat-affected zone 200 Hz and the reduction in the processing time of the display module 1000.

[0095] Figure 9A This is a view illustrating a first cutting operation according to an embodiment of the inventive concept. Figure 9B This is a view illustrating a second cutting operation according to an embodiment of the inventive concept.

[0096] The first preliminary display module 1001 is placed on the worktable 3000. The laser irradiation device 4000 is placed above the first preliminary display module 1001. The laser irradiation device 4000 can use its built-in optical system to control the irradiation direction of the laser beam.

[0097] Reference Figure 9A The laser irradiation device 4000 can irradiate the first preliminary display module 1001 with a first laser beam 2001. The first laser beam 2001 cuts the first preliminary display module 1001, which can be referred to as the first cutting operation.

[0098] Reference Figure 9B The first preliminary display module 1001 can be cut to form the second preliminary display module 1002. The laser irradiation device 4000 can irradiate the second preliminary display module 1002 with a second laser beam 2002. Cutting the second preliminary display module 1002 by the second laser beam 2002 can be referred to as the second cutting operation.

[0099] Reference Figure 9A and Figure 9B In both the first and second cutting operations, the position of the worktable 3000 can be fixed. Only the direction of the laser beam provided by the laser irradiation device 4000 can be changed.

[0100] Figure 10A This is a view illustrating a first cutting operation according to an embodiment of the inventive concept. Figure 10B This is a view illustrating a second cutting operation according to an embodiment of the inventive concept.

[0101] Reference Figure 10A The first preliminary display module 1001 is placed on the worktable 3001. A laser irradiation device 4001 is positioned above the first preliminary display module 1001. The laser irradiation device 4001 can irradiate the first preliminary display module 1001 with a first laser beam 2001a. Cutting the first preliminary display module 1001 with the first laser beam 2001a can be referred to as the first cutting operation.

[0102] Reference Figure 10B The first preliminary display module 1001 can be cut to form the second preliminary display module 1002. The laser irradiation device 4001 can irradiate the second preliminary display module 1002 with a second laser beam 2002a. Cutting the second preliminary display module 1002 by the second laser beam 2002a can be referred to as the second cutting operation.

[0103] Reference Figure 10A and Figure 10B The first laser beam 2001a and the second laser beam 2002a emitted from the laser irradiation device 4001 can have the same irradiation direction. The position 3001P of the worktable 3001 in the first cutting operation can be different from the position of the worktable 3001 in the second cutting operation. That is, the incident angle of the laser beam incident on the first preliminary display module 1001 or the second preliminary display module 1002 can be controlled by tilting the worktable 3001.

[0104] Figures 11A to 11D This is a diagram illustrating a method of manufacturing a display module 1000 according to an embodiment of the inventive concept.

[0105] Reference Figure 11A The first laser beam 2001 can be directed onto the first preliminary display module 1001. The first laser beam 2001 can be tilted relative to the first processing surface 1001m1 to be incident on. The first preliminary display module 1001 can be completely cut by the first laser beam 2001.

[0106] Reference Figure 11B The first preliminary display module 1001 can be cut first to form the second preliminary display module 1002a. The outermost surface of the first carrier film 402 of the second preliminary display module 1002a can be defined as the third processing surface 1001m3, and the outermost surface of the second carrier film 502 of the second preliminary display module 1002a can be defined as the fourth processing surface 1001m4. The third processing surface 1001m3 can be formed from the first processing surface 1001m1, and the fourth processing surface 1001m4 can be formed from the second processing surface 1001m2.

[0107] The second laser beam 2002b can be directed onto the second preliminary display module 1002a. The second laser beam 2002b can be tilted relative to the fourth processing surface 1001m4 to which it is to be incident. The second laser beam 2002b can irradiate from the fourth processing surface 1001m4 toward the third processing surface 1001m3. The second preliminary display module 1002a can be completely cut by the second laser beam 2002b.

[0108] When compared with the above references Figure 4 , Figure 6 and Figure 8 When comparing with the described embodiments, refer to Figures 11A to 11D The described embodiments are further provided therein. Figure 11B An embodiment of the operation is shown. Therefore, the second laser beam 2002b can be referred to as the third laser beam, and Figure 11B The operation shown can be referred to as the third cutting operation.

[0109] Reference Figure 11C The second preliminary display module 1002a can be cut a second time to form the third preliminary display module 1003a. The third preliminary display module 1003a may include a first carrier film 402, a protective film 302, a display panel 102, a polarizing film 203a and a second carrier film 503a stacked sequentially along the third direction DR3.

[0110] A heat-affected zone 203haz is formed on the polarization film 203a of the third preliminary display module 1003a. The heat-affected zone 203haz can be formed by... Figure 11A The initial cut shown in the image and Figure 11B The portion formed by the second cut is shown in the image.

[0111] The third laser beam 2003 can be directed onto the third preliminary display module 1003a. The third preliminary display module 1003a can be cut by the third laser beam 2003. The third laser beam 2003 can be incident along a direction parallel to the normal 1003nl of the fourth processing surface 1001m4. Therefore, the angle between the direction of travel of the third laser beam 2003 and the normal 1003nl can be 0 degrees.

[0112] The intensity of the third laser beam 2003 can be less than the intensity of the first laser beam 2001a and the second laser beam 2002b. For example, the intensity of the first laser beam 2001a and the second laser beam 2002b can be 20 watts or more and 400 watts or less, and the intensity of the third laser beam 2003 can be greater than 0 watts and less than 10 watts.

[0113] Reference Figure 11DThe third preliminary display module 1003a is then cut a third time to form the fourth preliminary display module 1004. The fourth preliminary display module 1004 may include a first carrier film 402, a display module 1000, and a second carrier film 504 stacked sequentially along the third direction DR3. The display module 1000 can be formed by removing the first carrier film 402 and the second carrier film 504 from the fourth preliminary display module 1004.

[0114] The side surface of the polarizing film 200 can be a surface cut by a third laser beam 2003 with a relatively weak intensity. Therefore, the area of ​​the heat-affected portion 200 Hz formed in the polarizing film 200 after the third cut can be smaller than [the area of ​​the heat-affected portion 200 Hz]. Figure 11C The area of ​​the heat-affected portion shown is 203 haz.

[0115] According to an embodiment of the inventive concept, a relatively strong laser beam is used to cut a preliminary display module to form a sloping side surface, while a relatively weak laser beam can cut a portion of the sloping side surface of the preliminary display module. Therefore, the area of ​​the heat-affected zone 200 Hz remaining in the display module 1000 can be reduced, and the processing time of the display module 1000 can be shortened.

[0116] As described above, since the initial cut is performed using a first laser beam with relatively high intensity, the initial cut time can be shortened. Furthermore, because the first laser beam is angled relative to the normal of the processing surface of the first preliminary display module, the second preliminary display module cut by the first laser beam has an angled surface. Therefore, the thickness of the object cut in the second cut is thinner than the thickness of the object cut in the first cut, thereby shortening the second cut time.

[0117] Furthermore, the second cut removes at least a portion of the heat-affected zone generated during the initial cut. Since the intensity of the second laser beam is less than that of the first laser beam, the area of ​​the heat-affected zone generated by the second laser beam is smaller than the area of ​​the heat-affected zone generated by the first laser beam.

[0118] According to embodiments of the inventive concept, the area of ​​the heat-affected zone remaining in the final display module is reduced, and the processing time of the display module can be shortened.

[0119] While exemplary embodiments of the inventive concept have been described, it is understood that the inventive concept should not be limited to these exemplary embodiments, but rather that various changes and modifications can be made by those skilled in the art within the spirit and scope of the claimed inventive concept.

Claims

1. A method for manufacturing a display module, the method comprising the following steps: Prepare a first preliminary display module, which includes a display panel and a polarizing film disposed on the display panel; The first laser beam is irradiated onto the first preliminary display module at a first angle; A first cutting operation to cut the first preliminary display module to form a second preliminary display module; The second laser beam is directed onto the second preliminary display module at a second angle different from the first angle. as well as A second cutting operation is performed to cut the second preliminary display module to form the display module. The first preliminary display module includes a first processing surface and a second processing surface that are opposite each other. The first laser beam irradiates from the first processed surface toward the second processed surface. The second preliminary display module includes: a third processing surface formed from the first processing surface; and a fourth processing surface formed from the second processing surface. Wherein, the area of ​​the third processing surface is smaller than the area of ​​the fourth processing surface. Wherein, the intensity of the first laser beam is greater than the intensity of the second laser beam. Wherein, the first angle is the angle between the normal to the first processed surface and the direction of travel of the first laser beam. Wherein, the second angle is the angle between the normal of the first processed surface and the travel direction of the second laser beam, and In both the first and second cutting operations, the polarizing film is cut.

2. The method according to claim 1, wherein, The first preliminary display module includes an effective area and an ineffective area, and the first laser beam is incident from the effective area toward the ineffective area. The second laser beam is irradiated at the boundary between the effective region and the ineffective region.

3. The method according to claim 1, wherein, The polarizing film is positioned closer to the second processing surface than the display panel.

4. The method according to claim 3, further comprising the following step: The third cutting operation involves irradiating the second preliminary display module with a third laser beam in a direction from the fourth processing surface toward the third processing surface. The third cutting operation is performed between the first cutting operation and the second cutting operation, and The intensity of the third laser beam is greater than the intensity of the second laser beam.

5. The method according to claim 3, wherein, The display module includes a first surface and a second surface, the first surface having an area equal to that of the third processing surface, and the second surface being formed from the fourth processing surface and having an area smaller than that of the fourth processing surface.

6. The method according to claim 3, in, The first angle is greater than 0 degrees and less than 90 degrees, and The second angle is 0 degrees.

7. The method according to claim 1, wherein, The first preliminary display module also includes a protective film disposed below the display panel. In the first cutting operation, the display panel, the polarizing film, and the protective film are all cut, and In the second cutting operation, the polarizing film or the polarizing film and the display panel are cut.

8. The method according to claim 1, wherein, The first preliminary display module is set on the workbench. In both the first and second cutting operations, the position of the worktable is fixed, while the irradiation direction of the first laser beam and the irradiation direction of the second laser beam are changed.

9. The method according to claim 1, wherein, The first preliminary display module is set on the workbench. Wherein, the irradiation direction of the first laser beam is the same as that of the second laser beam, and The position of the worktable in the second cutting operation is tilted from the position of the worktable in the first cutting operation.

10. A display module, the display module comprising: The display panel includes a first surface and a second surface opposite to each other, and a side surface connecting the first surface and the second surface; A protective film is disposed below the first surface of the display panel and includes a first side surface extending from the side surface and a second side surface extending from the first side surface; as well as A polarizing film is disposed on the second surface of the display panel and includes a third side surface. The side surface of the display panel, the first side surface of the protective film, and the third side surface of the polarizing film are disposed on the same plane. Wherein, the first angle between the first surface and the second side surface is greater than 0 degrees and less than 75 degrees. Wherein, the second angle between the second surface and the third side surface is greater than the first angle. Wherein, the difference between the first angle and the second angle is 15 degrees or greater and less than 90 degrees, and The third angle between the first surface and the first side surface is different from the first angle.

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