Display devices and laminating equipment for manufacturing display devices

Abstract

This application relates to a display device and a laminating apparatus for manufacturing the display device. The display device defines a curved region having a curved shape and a flat region having a planar shape, and includes: a display panel including a first curved portion overlapping the curved region and a first flat portion overlapping the flat region; a window on the display panel, including a second curved portion overlapping the curved region and a second flat portion overlapping the flat region; and an adhesive layer disposed between the display panel and the window. The adhesive layer includes: a first adhesive layer disposed between the first flat portion and the second flat portion, and connecting the first flat portion to the second flat portion; and a second adhesive layer disposed in a first space between the first curved portion and the second curved portion and a second space between the first adhesive layer and the second flat portion.

Description

[0001] Cross-reference to related applications

[0002] This application claims priority to Korean Patent Application No. 10-2010-0103872, filed on August 19, 2020, and all benefits derived therefrom, the contents of which are incorporated herein by reference in their entirety. Technical Field

[0003] Embodiments of the invention herein relate to display devices, laminating apparatus, and lamination methods using laminating apparatus, and more specifically, to display devices having improved transmittance in curved portions, laminating apparatus for manufacturing display devices, and lamination methods using laminating apparatus. Background Technology

[0004] Various display devices have been developed for use in multimedia devices such as televisions, mobile phones, tablet computers, and navigation units. In particular, in recent years, there has been development of display devices with various modified shapes, such as curved or folded shapes.

[0005] Some of the various components constituting this curved display device may have a curved shape. In particular, depending on the curved shape of the display device, the window used to protect the display panel also has a curved shape. Therefore, it is desirable to laminate the modified window and the display panel. Summary of the Invention

[0006] Embodiments of the present invention provide a display device in which transmittance degradation is prevented in curved portions.

[0007] Embodiments of the present invention also provide lamination apparatus for manufacturing display devices having curved shapes and lamination methods using the lamination apparatus.

[0008] Embodiments of the present invention provide a display device defining a curved region having a curved shape and a flat region having a planar shape. The display device includes a display panel, a window, and an adhesive layer. The display panel includes a first curved portion overlapping the curved region and a first flat portion overlapping the flat region, and the window is disposed on the display panel and includes a second curved portion overlapping the curved region and a second flat portion overlapping the flat region. An adhesive layer is disposed between the display panel and the window. The adhesive layer includes a first adhesive layer and a second adhesive layer. The first adhesive layer is disposed between the first flat portion and the second flat portion, connecting the first flat portion to the second flat portion, and the second adhesive layer is disposed in a first space between the first curved portion and the second curved portion and a second space between the first adhesive layer and the second flat portion.

[0009] In an implementation, the first space may include a dam-forming space corresponding to the end of the first curved portion and an injection space corresponding to the area outside the dam-forming space.

[0010] In one embodiment, the first space may include a space in which the second adhesive layer and the first curved portion are in direct contact with each other.

[0011] In one implementation, the first adhesive layer may also be disposed in the dam-forming space.

[0012] In one embodiment, the second adhesive layer can be disposed between the second curved portion and the first adhesive layer within the dam forming space, and can also be disposed between the second curved portion and the first curved portion within the injection space.

[0013] In one embodiment, the second adhesive layer may include: a high-viscosity adhesive layer disposed in the dam forming space; and a low-viscosity adhesive layer disposed in the injection space, wherein the viscosity of the adhesive layer is lower than that of the high-viscosity adhesive layer.

[0014] In one embodiment, the first adhesive layer may also be disposed in the curved area.

[0015] In one embodiment, the second adhesive layer may be disposed within the first space between the second curved portion and the first adhesive layer.

[0016] In one embodiment, the second adhesive layer may include: a high-viscosity adhesive layer disposed in the dam forming space; and a low-viscosity adhesive layer disposed in the injection space, wherein the viscosity of the adhesive layer is lower than that of the high-viscosity adhesive layer.

[0017] In an embodiment of the invention, a laminating apparatus manufactures a display device defining a curved region having a curved shape and a flat region having a planar shape. The laminating apparatus includes a first support unit, a second support unit, an injection unit, and a curing unit. A display panel is disposed on the first support unit, the display panel including a first curved portion overlapping the curved region and a first flat portion overlapping the flat region and having a first adhesive layer disposed thereon. A window is disposed on the second support unit, the window including a second curved portion overlapping the curved region and a second flat portion overlapping the flat region. The injection unit injects adhesive material into a first space between the first curved portion and the second curved portion and a second space between the first adhesive layer and the second flat portion. The curing unit cures the injected adhesive material to form a second adhesive layer.

[0018] In one embodiment, the first support unit may include an expansion pad that expands due to air injection, wherein a first flat portion is disposed on the expansion pad and laminated to a second flat portion when the expansion pad expands.

[0019] In one embodiment, the first support unit may include a fixed pad with a fixed position, wherein a first curved portion is disposed on the fixed pad, and the gap between the first curved portion and the second curved portion remains constant when the expansion pad expands.

[0020] In an implementation, the first space may include a dam-forming space corresponding to the end of the first curved portion and an injection space corresponding to the area outside the dam-forming space. The injection unit may include: a first injection unit for injecting a high-viscosity adhesive material into the dam-forming space; and a second injection unit for injecting a low-viscosity adhesive material into the injection space, wherein the viscosity of the low-viscosity adhesive material is lower than that of the high-viscosity adhesive material.

[0021] In one embodiment, the first adhesive layer may also be disposed in the curved region. The first injection unit may inject high-viscosity adhesive material into the space between the second curved portion and the first adhesive layer within the dam forming space, and the second injection unit may inject low-viscosity adhesive material into the space between the second curved portion and the first adhesive layer within the injection space.

[0022] In one embodiment, the adhesive material may be an ultraviolet (“UV”) curable material, and the curing unit may include a first curing unit that emits ultraviolet light toward the adhesive material and forms a second adhesive layer.

[0023] In one embodiment, the first adhesive layer may include a UV-curable material, and the curing unit may further include a second curing unit, which emits UV light to the first adhesive layer and cures the first adhesive layer.

[0024] In an embodiment of the present invention, the lamination method includes: disposing a display panel on a first support unit, the display panel including a first curved portion overlapping a curved region and a first straight portion overlapping a straight region and having a first adhesive layer disposed thereon; disposing a window on a second support unit, the window including a second curved portion overlapping a curved region and a second straight portion overlapping a straight region; connecting the first support unit to the second support unit to laminate the first adhesive layer to the window; injecting adhesive material into a first space between the first curved portion and the second curved portion and a second space between the first adhesive layer and the second straight portion using an injection unit; curing the adhesive material using a curing unit, thereby laminating the display panel to the window; and separating the connected first support unit and second support unit.

[0025] In one embodiment, the first support unit may include an expansion pad that expands due to air injection, and the lamination method may include using the expansion pad to laminate the first flat portion onto the second flat portion.

[0026] In an embodiment, the first space may include a dam-forming space corresponding to the end of the first curved portion and an injection space corresponding to the area outside the dam-forming space, and the injection of adhesive material may include: injecting a high-viscosity adhesive material into the dam-forming space; and injecting a low-viscosity adhesive material into the injection space.

[0027] In this embodiment, the adhesive material may be a UV-curable material, and curing the adhesive material may include: emitting UV light onto a high-viscosity adhesive material to cure it; and emitting UV light onto a low-viscosity adhesive material to cure it. Attached Figure Description

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

[0029] Figure 1 This is a perspective view illustrating an embodiment of a display device according to the present invention;

[0030] Figure 2A This is a cross-sectional view of an embodiment of the display device according to the present invention;

[0031] Figure 2B This is a perspective view illustrating an embodiment of a display device according to the present invention;

[0032] Figure 2C This is a perspective view illustrating an embodiment of a display device according to the present invention;

[0033] Figure 3 This is a cross-sectional view of an embodiment of the display device according to the present invention;

[0034] Figures 4A to 4E This is a process diagram illustrating the process of laminating a display panel and a window using lamination equipment;

[0035] Figure 5A and Figure 5B This is a process diagram illustrating an embodiment of the process of injecting adhesive material using an injection unit according to the present invention;

[0036] Figure 6A and Figure 6B This is an illustration of an embodiment of a process for curing injected adhesive material and a first adhesive layer using a curing unit according to the present invention;

[0037] Figure 7 This is a flowchart illustrating an embodiment of a lamination method using a lamination apparatus according to the present invention;

[0038] Figure 8This is a flowchart illustrating an embodiment of the injection and curing of the adhesive material according to the present invention. Detailed Implementation

[0039] It will be understood that when a component (or region, layer, part, etc.) is referred to as being on, "on", "connected to", or "attached to" another component, it may be directly placed on, directly connected to, or directly attached to the other component, or may be placed in between as an intermediate component.

[0040] The same numbers always represent the same components. Furthermore, in the accompanying drawings, the thickness, ratios, and dimensions of the components have been exaggerated for the sake of effective description of the technical content.

[0041] The term “and / or” includes any and all combinations of one or more of the related listed items.

[0042] It will be understood that although the terms first, second, etc., may be used herein to describe various elements, these elements should not be limited by these terms. These terms are used only to distinguish one element from another. For example, without departing from the scope of this disclosure, a first element may be referred to as a second element, and similarly, a second element may be referred to as a first element. Unless the context clearly indicates otherwise, the singular form includes the plural form.

[0043] Furthermore, terms such as "below," "down," "above," and "up" may be used to describe the relationships between the components shown in the accompanying drawings. These terms are relative concepts and are based on the directions indicated in the drawings.

[0044] Unless otherwise specified, all terms used herein (including technical and scientific terms) shall have the same meaning as commonly understood by one of ordinary skill in the art to which this disclosure pertains. It will also be understood that terms, such as those defined in commonly used dictionaries, shall be interpreted as having a meaning consistent with their meaning in the context of the relevant art and shall not be interpreted in an idealized or overly formalized sense unless expressly so defined herein.

[0045] It will be understood that, when used in this specification, the terms “comprising” or “including” mean the presence of the stated features, integrals, steps, operations, elements, components or combinations thereof, but do not exclude the presence or addition of one or more other features, integrals, steps, operations, elements, components or combinations thereof.

[0046] As used herein, “about” or “approximately” includes the stated value and the average of the stated value within an acceptable range of deviations from the particular value, as determined by a person of ordinary skill in the art, taking into account the measurement in question and the errors associated with the measurement of the particular quantity (i.e., limitations of the measurement system). For example, “about” may mean within one or more standard deviations, or within ±30%, ±20%, ±10%, or ±5% of the stated value.

[0047] Embodiments are described herein with reference to cross-sectional views, which are schematic diagrams of idealized embodiments. Therefore, differences from the illustrated shapes are expected due to factors such as manufacturing techniques and / or tolerances. Consequently, the embodiments described herein should not be construed as limited to the specific shapes of the areas shown herein, but rather include deviations in shape caused, for example, by manufacturing processes. In embodiments, areas shown or described as flat may generally have rough and / or non-linear characteristics. Furthermore, sharp corners shown may be rounded. Therefore, the areas shown in the figures are schematic in nature, and their shapes are not intended to represent the precise shapes of the areas, nor are they intended to limit the scope of the claims.

[0048] In the following description, embodiments of the present invention will be described with reference to the accompanying drawings.

[0049] Figure 1 This is a perspective view illustrating an embodiment of a display device according to the present invention. Figure 2A This is a cross-sectional view of an embodiment of the display device according to the present invention, and Figure 2B and Figure 2C This is a perspective view illustrating an embodiment of a display device according to the present invention.

[0050] Reference Figure 1 and Figure 2A Display devices include windows (WD) and display panels (DP). Figure 1 One embodiment of the curved display device DD shows a display device DD defining a curved region CA and a flat region LA, wherein the curved region CA has a curved shape and the flat region LA has a planar shape. Each of the window WD and the display panel DP may respectively include a curved portion corresponding to the curved region CA and a flat portion corresponding to the flat region LA. Furthermore, each of the window WD and the display panel DP may have a shape corresponding to the curved region CA and the flat region LA. Figure 1 Different curved shapes. Figure 1 A display device DD with one curved region CA and two flat regions LA is shown, but the invention is not limited thereto. In embodiments, for example, the display device DD may include multiple curved regions CA. Furthermore, the display device DD of the embodiments may include one or more flat regions LA.

[0051] Reference Figure 1 and Figure 2A In the display device DD of the embodiment, the display surface IS on which the image IM is displayed is parallel to the plane defined by the first directional axis DR1 and the second directional axis DR2. In the embodiment, the display surface IS of the display device DD may include a display area DD-DA on which the image IM is displayed and a non-display area DD-NDA surrounding the display area DD-DA. The normal direction of the display surface IS, i.e., the thickness direction of the display device DD, is indicated by the third directional axis DR3. However, the directions indicated by the first directional axis DR1, the second directional axis DR2, and the third directional axis DR3 may be relative concepts and therefore may be changed to other directions.

[0052] The window WD may have a shape corresponding to and facing the display panel DP. The window WD includes a second curved portion CP2 overlapping the curved region CA and second straight portions LP2 overlapping the two straight regions LA respectively. The window WD may include an optically transparent insulating material. In embodiments, for example, the window WD may include glass or plastic. The window WD may have a multilayer or single-layer structure. In embodiments, the window WD may, for example, include multiple plastic films bonded together by an adhesive, or a glass substrate and plastic films bonded together by an adhesive.

[0053] The display panel DP can generate an image IM and provide the generated image IM to the display surface IS. The display panel DP can provide the generated image IM on a third-direction axis DR3. In an embodiment, for example, the display panel DP can be an organic light-emitting display panel. However, the invention is not limited thereto, and the display panel DP can be a liquid crystal display panel, a plasma display panel, an electrophoretic display panel, a microelectromechanical system (“MEMS”) display panel, an electrowetting display panel, etc. Hereinafter, the display panel DP will be described as an organic light-emitting display panel. (See also...) Figure 2A The display panel DP of the embodiment includes a first curved portion CP1 overlapping the curved region CA and first straight portions LP1 overlapping the two straight regions LA respectively. However, the shape of the display panel DP is not limited to this, and the display panel DP can be a flexible display panel that can be bent or unfolded. In the embodiment, for example, the flexible display panel DP can be bent to be inserted into a curved window WD.

[0054] The display panel (DP) includes display elements, such as light-emitting elements. The light-emitting element includes at least an organic light-emitting diode (OLED). A thin-film encapsulation layer seals the light-emitting element. The thin-film encapsulation layer includes at least one inorganic layer (hereinafter also referred to as an encapsulated inorganic layer). The thin-film encapsulation layer includes at least one organic layer (hereinafter also referred to as an encapsulated organic layer). The encapsulated inorganic layer protects the light-emitting element from moisture / oxygen, and the encapsulated organic layer protects the light-emitting element from impurities such as dust particles. In embodiments, the encapsulated inorganic layer may, for example, include a silicon nitride layer, a silicon oxide nitride layer, a silicon oxide layer, a titanium oxide layer, an aluminum oxide layer, etc. The encapsulated organic layer may include an acrylic-based organic layer, but the invention is not limited thereto.

[0055] Furthermore, the display device DD may also include an input sensor layer (not shown). The input sensor layer may be disposed on the display panel DP. The input sensor layer can sense external input applied from the outside. External input may be user input. In embodiments, user input may include various types of external input, such as a part of the user's body, light, heat, a pen, or pressure. The input sensor layer may be disposed on the display panel DP via a continuous process. In this case, the input sensor layer may be represented as being directly disposed on the display panel DP. Here, "directly disposed on..." can mean that no intermediate third component is disposed between the input sensor layer and the display panel DP. That is, a separate adhesive member may not be disposed between the input sensor layer and the display panel DP. However, the invention is not limited to this, and an adhesive member may also be disposed between the input sensor layer and the display panel DP. Figure 1 The illustration shows two flat regions LA symmetrical with respect to a curved region CA, but the invention is not limited thereto. In an embodiment, for example, the display device DD may include two flat regions with different lengths.

[0056] The display device DD may also include an adhesive layer disposed between the display panel DP and the window WD.

[0057] An adhesive layer is disposed between the display panel DP and the window WD to connect the display panel DP to the window WD. The adhesive layer may include a first adhesive layer AD1 and a second adhesive layer AD2. The first adhesive layer AD1 may be disposed between a first flat portion LP1 and a second flat portion LP2 to connect the first flat portion LP1 to the second flat portion LP2. The second adhesive layer AD2 may be disposed in a first space SP1 between a first curved portion CP1 and a second curved portion CP2 to connect the first curved portion CP1 to the second curved portion CP2. Furthermore, the second adhesive layer AD2 may be disposed in a second space SP2 between the first adhesive layer AD1 and the second flat portion LP2 to connect the second flat portion LP2 to the first adhesive layer AD1. The first space SP1 may include a space in which the second adhesive layer AD2 directly contacts the first curved portion CP1.

[0058] The first adhesive layer AD1 may be an optically transparent adhesive (“OCA”) layer. The second adhesive layer AD2 may be an optically transparent adhesive resin layer (“OCRL”). Each of the first adhesive layer AD1 and the second adhesive layer AD2 may include at least one of an acrylic adhesive, a silicone adhesive, or a urethane adhesive. Each of the first adhesive layer AD1 and the second adhesive layer AD2 may also include inorganic particles. In embodiments, for example, each of the first adhesive layer AD1 and the second adhesive layer AD2 may also include inorganic particles such as SiO2 and TiO2, and thus have improved strength.

[0059] When the first adhesive layer AD1 is an OCA layer, based on the characteristics of the OCA layer in its solid film state, a second space SP2 can be defined between the first adhesive layer AD1 and the second straight portion LP2 near the curved region CA while the display panel DP is attached to the window WD. When the second adhesive layer AD2 is an OCRL, the second adhesive layer AD2 can be a layer formed by injecting liquid optically transparent adhesive resin (“OCR”) into the first space SP1 and the second space SP2 and then curing it. Therefore, the second adhesive layer AD2 is provided in the first space SP1 and the second space SP2. The second adhesive layer AD2 provided in the first space SP1 prevents light provided from the display panel DP from being diffusely reflected by the boundary surfaces between the display panel DP and the first space SP1 and between the first space SP1 and the window WD. Therefore, the transmittance of the display device DD can be prevented from decreasing due to diffuse reflection of light. The second adhesive layer AD2 provided in the second space SP2 prevents light provided from the display panel DP from being diffusely reflected by the boundary surfaces between the first adhesive layer AD1 and the second space SP2 and between the second space SP2 and the window WD. Therefore, it is possible to prevent the transmittance of the display device DD from decreasing due to diffuse reflection of light.

[0060] Reference Figure 2A and Figure 2B The first space SP1 may include a dam-forming space DSP corresponding to one end of the first curved portion CP1 and an injection space ISP corresponding to the area outside the dam-forming space DSP.

[0061] The second adhesive layer AD2 may include a high-viscosity adhesive layer AD2a and a low-viscosity adhesive layer AD2b, wherein the viscosity of the low-viscosity adhesive layer AD2b is lower than that of the high-viscosity adhesive layer AD2a. The second adhesive layer AD2 can connect the first curved portion CP1 of the display panel DP to the second curved portion CP2 of the window WD. The second adhesive layer AD2 can be in direct contact with the first curved portion CP1 in the first space SP1. In this case, the high-viscosity adhesive layer AD2a can be disposed in the dam-forming space DSP defined between the second curved portion CP2 and the first curved portion CP1, and the low-viscosity adhesive layer AD2b can be disposed in the injection space ISP defined between the second curved portion CP2 and the first curved portion CP1. In one embodiment of the invention, the high-viscosity adhesive layer AD2a may have a viscosity of about 60,000 centipoise (cps). In an embodiment, for example, the low-viscosity adhesive layer AD2b may have a viscosity of about 500 cps.

[0062] Reference Figure 2A and Figure 2C The first adhesive layer AD1 can also be disposed in the dam forming space DSP. In this case, the second adhesive layer AD2 can be disposed in the injection space ISP. Here, the second adhesive layer AD2 can be a low-viscosity adhesive layer AD2b. In this case, the first adhesive layer AD1 disposed in the dam forming space DSP and the low-viscosity adhesive layer AD2b disposed in the injection space ISP can connect the first curved portion CP1 of the display panel DP to the second curved portion CP2 of the window WD. However, the arrangement of the low-viscosity adhesive layer AD2b is not limited to... Figure 2C The arrangement. In an embodiment, for example, the low-viscosity adhesive layer AD2b may also be disposed in the dam-forming space DSP. In this case, the low-viscosity adhesive layer AD2b may be disposed between the first adhesive layer AD1 and the first curved portion CP1 within the dam-forming space DSP.

[0063] Figure 3 This is a cross-sectional view of an embodiment of the display device according to the present invention. (Refer to...) Figure 3The first adhesive layer AD1 can also be disposed in the curved region CA. The first space SP1 can be the space defined by the first adhesive layer AD1 and the second curved portion CP2. When the first adhesive layer AD1 is also disposed in the curved region CA, but the curvature of the curved region CA of the display panel DP is large, when the display panel DP is connected to the window WD, a second space SP2 can be defined between the first adhesive layer AD1 and the second straight portion LP2, and a first space SP1 can be defined between the first adhesive layer AD1 and the second curved portion CP2. The second adhesive layer AD2 can be disposed in the curved region CA within the first space SP1 defined between the second curved portion CP2 and the first adhesive layer AD1. The second adhesive layer AD2 can also be disposed in the straight region LA within the second space SP2 defined between the first adhesive layer AD1 and the second straight portion LP2. The second adhesive layer AD2 disposed in the first space SP1 prevents light provided from the display panel DP from being diffusely reflected by the boundary surface between the first adhesive layer AD1 and the first space SP1 and the boundary surface between the first space SP1 and the window WD. Therefore, the transmittance of the display device DD can be prevented from decreasing due to diffuse reflection of light. The second adhesive layer AD2, disposed in the second space SP2, prevents light supplied from the display panel DP from being diffusely reflected by the boundary surfaces between the first adhesive layer AD1 and the second space SP2, and between the second space SP2 and the window WD. Therefore, the transmittance of the display device DD can be prevented from decreasing due to diffuse reflection of light.

[0064] Figures 4A to 4E This is a process diagram illustrating the process of laminating a display panel and a window using laminating equipment.

[0065] Reference Figure 2A and Figure 4A A laminating apparatus LE for manufacturing a display device DD in which a curved region CA and a straight region LA are defined may include a first support unit LDP1 and a second support unit LDP2.

[0066] Reference Figure 4A A display panel DP, on which a first adhesive layer AD1 and a guide film GF are disposed, can be disposed (e.g., mounted) on a first support unit LDP1. The display panel DP includes a first curved portion CP1 that overlaps with the curved region CA (see reference). Figure 2AThe display panel DP includes a first flat portion LP1 that overlaps with the flat region LA. The display panel DP can be manufactured as a flexible display panel DP. In one embodiment of the invention, a first adhesive layer AD1 is disposed on the first flat portion LP1 of the display panel DP. The first adhesive layer AD1 can be an OCA layer. However, in one embodiment of the invention, the display panel DP is mounted on a first support unit LDP1, and then the first adhesive layer AD1 can be disposed on the first flat portion LP1 of the display panel DP.

[0067] In one embodiment of the invention, a guide film GF may be disposed between the display panel DP and the first support unit LDP1. The guide film GF may include an organic material. In an embodiment, the guide film GF may, for example, include polypropylene, polyethylene, or polyethylene terephthalate. However, the material of the guide film GF is not necessarily limited to the examples described above. An adhesive member (not shown) may also be disposed between the guide film GF and the display panel DP. In an embodiment, for example, the adhesive member may be an acrylic-based adhesive member.

[0068] The first support unit LDP1 may include an air nozzle AZ through which air is injected from the outside. An air vent (not shown) may be defined in the first support unit LDP1 to discharge the injected air, and the first support unit LDP1 may also include an expansion pad EP that expands with the air discharged from the air vent. Here, the air vent draws air from the outside through the air nozzle AZ, and therefore, the display panel DP can be fixed to the first support unit LDP1.

[0069] The display panel DP is mounted on the first support unit LDP1, so that the first flat portion LP1 (refer to) Figure 2A The first support unit LDP1 may correspond to the expansion pad EP. The first support unit LDP1 may also include a fixing pad FP whose position is fixed. The display panel DP is disposed on the first support unit LDP1 such that the first curved portion CP1 can correspond to the fixing pad FP.

[0070] Including the bending region CA (reference) Figure 2A The second curved portion CP2 overlaps with the second straight portion LP2 that overlaps with the straight region LA (see reference). Figure 2A The window WD can be mounted on the second support unit LDP2.

[0071] Reference Figure 2A and Figure 4BA first support unit LDP1, on which a display panel DP is mounted, can be connected to a second support unit LDP2, on which a window WD is mounted. Here, a gap SP can be defined between the display panel DP and the window WD. In one embodiment of the invention, the gap SP may include the space between the first adhesive layer AD1 and the second straight portion LP2 of the window WD, and the space between the first curved portion CP1 of the display panel DP and the second curved portion CP2 of the window WD.

[0072] Reference Figure 2A and Figure 4C Air is injected from the outside through the air nozzle AZ, and thus, the expansion pad EP, which belongs to the first support unit LDP1, can expand. Here, in order to prevent air bubbles from forming between the display panel DP and the window WD, the expansion pad EP can be relative to... Figure 4C The expansion proceeds sequentially from top to bottom. As the expansion pad EP expands with air, the flexible first flat portion LP1 of the display panel DP moves toward the second flat portion LP2 of the window WD mounted on the second support unit LDP2. Therefore, the first adhesive layer AD1 disposed on the first flat portion LP1 of the display panel DP comes into contact with the second flat portion LP2 of the window WD. That is, the first flat portion LP1 is laminated to the second flat portion LP2 by the first adhesive layer AD1 disposed on the first flat portion LP1. Here, unlike the expansion pad EP, the fixing pad FP does not expand even when air is injected through the air nozzle AZ. Therefore, the position of the display panel DP on the first support unit LDP1, corresponding to the first curved portion CP1 of the fixing pad FP, remains constant. Therefore, the gap between the first curved portion CP1 of the display panel DP and the second curved portion CP2 of the window WD before the expansion pad EP expands can be the same as the gap between them after the expansion pad EP expands.

[0073] Reference Figure 2A and Figure 4D When the expansion pad EP fully expands from top to bottom, the first flat portion LP1 of the display panel DP is laminated to the second flat portion LP2 of the window WD via the first adhesive layer AD1. Furthermore, a first space SP1 is defined between the first curved portion CP1 of the display panel DP and the second curved portion CP2 of the window WD. Additionally, a second space SP2 may be defined between the first adhesive layer AD1 and the second flat portion LP2 of the window WD.

[0074] The injection unit FE injects adhesive material ADM into the first space SP1 and the second space SP2. The adhesive material ADM can be OCR. The amount of adhesive material ADM injected by the injection unit FE can be determined based on the size of the first space SP1 and the second space SP2. Here, the gap between the first curved portion CP1 and the second curved portion CP2 is kept constant by the fixing pad FP, and therefore, the amount of adhesive material ADM injected by the injection unit FE into the first space SP1 between the first curved portion CP1 and the second curved portion CP2 can remain constant.

[0075] When the gap between the first curved portion CP1 and the second curved portion CP2 is approximately 0.5 mm, approximately 1 gram (g) of adhesive material ADM is injected, but the invention is not limited thereto. The amount to be injected can vary depending on the size of the display device DD, etc. Furthermore, the viscosity of the adhesive material ADM to be injected can be high or low, and this can vary depending on the arrangement of the first adhesive layer AD1 within the first space SP1, etc. If the adhesive material ADM injected by the injection unit FE is disposed outside the display device DD in addition to the first space SP1 and the second space SP2, this can be removed by a separate cleaning process. The curing unit CE can cure the injected adhesive material ADM to form a second adhesive layer AD2. The second adhesive layer AD2 disposed therein can be OCRL. The adhesive material ADM is an ultraviolet (“UV”) curable material, and the curing unit CE can emit UV light to the adhesive material ADM to form the second adhesive layer AD2. Here, the transmittance of the first adhesive layer AD1 in the solid film state is similar to that of the second adhesive layer AD2 formed by curing the adhesive material ADM in the liquid state, and therefore, the first adhesive layer AD1 and the second adhesive layer AD2 may be indistinguishable in appearance.

[0076] Reference Figure 4E After the curing process using the curing unit CE, the first support unit LDP1 and the second support unit LDP2 are separated from each other. After separation, a preliminary display device P_DD manufactured by laminating the window WD and the display panel DP can be obtained from the first support unit LDP1. Figure 2A The display device DD shown can be completed by removing the guide film GF from the preliminary display device P_DD. When the guide film GF is attached to the display panel DP via an adhesive member, a process to reduce the adhesive force of the adhesive member can be performed before removing the guide film GF. In one embodiment of the invention, the adhesive member can be a UV reactive film, and the adhesive force of the adhesive member can be reduced when irradiated with UV light. In this case, the adhesive force of the adhesive member can be reduced by irradiating the adhesive member with UV light before separating the guide film GF from the preliminary display device P_DD.

[0077] Figure 5A and Figure 5B This is a process diagram illustrating the process of injecting adhesive material using an injection unit according to the present invention.

[0078] Reference Figure 2A , Figure 5A and Figure 5B Injection unit FE (refer to) Figure 4D The system includes a first injection unit FE1 and a second injection unit FE2. Corresponding to the curved region CA, a first space SP1 is defined between a first curved portion CP1 and a second curved portion CP2. The first space SP1 may include a dam-forming space DSP corresponding to one end of the first curved portion CP1 and an injection space ISP corresponding to the region outside the dam-forming space DSP.

[0079] The first injection unit FE1 injects high-viscosity adhesive material ADMa into the dam formation space DSP, and the second injection unit FE2 injects low-viscosity adhesive material ADMb into the injection space ISP. The viscosity of the low-viscosity adhesive material ADMb is lower than that of the high-viscosity adhesive material ADMa.

[0080] The high-viscosity adhesive ADMa and the low-viscosity adhesive ADMb can directly contact the first curved portion CP1 in the first space SP1. In this case, the first injection unit FE1 injects the high-viscosity adhesive ADMa into the space between the second curved portion CP2 and the first curved portion CP1 within the dam forming space DSP. The second injection unit FE2 injects the low-viscosity adhesive ADMb into the space between the second curved portion CP2 and the first curved portion CP1 within the injection space ISP.

[0081] Reference Figure 3 , Figure 5A and Figure 5B The first adhesive layer AD1 can also be disposed in the bending region CA. In this case, the first injection unit FE1 injects a high-viscosity adhesive material ADMa into the space between the second bending portion CP2 and the first adhesive layer AD1 within the dam forming space DSP. The second injection unit FE2 injects a low-viscosity adhesive material ADMb into the space between the second bending portion CP2 and the first adhesive layer AD1 within the injection space ISP.

[0082] The first adhesive layer AD1 can also be disposed in the dam forming space DSP. In this case, in one embodiment of the invention, the first injection unit FE1 can be omitted, and the second injection unit FE2 can inject adhesive material into the space between the second curved portion CP2 and the first curved portion CP1 within the injection space ISP. However, the invention is not limited thereto, and the second injection unit FE2 can also inject adhesive material into the space between the first adhesive layer AD1 and the first curved portion CP1 within the dam forming space DSP. In this case, the adhesive material can be a low-viscosity adhesive material ADMb.

[0083] A high-viscosity adhesive ADMa can be injected into the dam-forming space DSP from one end of the first curved section CP1 through the first injection unit FE1, and subsequently, a low-viscosity adhesive ADMb can be injected into the injection space ISP from the other end of the first curved section CP1 through the second injection unit FE2. When the high-viscosity adhesive ADMa is injected, it does not spread well in the dam-forming space DSP but clumps. Then, the low-viscosity adhesive ADMb is injected. With the high-viscosity adhesive ADMa injected into the injection space ISP, the injection time becomes longer due to its poor spreading. Therefore, to shorten the process time, the low-viscosity adhesive ADMb can be injected into the injection space ISP. The viscosity of the high-viscosity adhesive ADMa can be approximately 60,000 cps, and the viscosity of the low-viscosity adhesive ADMb can be approximately 500 cps.

[0084] Figure 6A and Figure 6B This is a process diagram illustrating the process of using a curing unit to cure the injected adhesive material and the first adhesive layer according to the present invention.

[0085] Reference Figure 5A , Figure 5B and Figure 6A Curing unit CE (refer to) Figure 4D It may include a first curing unit CE1 and a second curing unit CE2.

[0086] The first curing unit CE1 can emit UV light onto the high-viscosity adhesive material ADMa and the low-viscosity adhesive material ADMb injected into the first space SP1 to form a second adhesive layer AD2. The first curing unit CE1 can also emit UV light onto the high-viscosity adhesive material ADMa injected into the dam-forming space DSP to form a high-viscosity adhesive layer AD2a. The first curing unit CE1 can also emit UV light onto the low-viscosity adhesive material ADMb injected into the injection space ISP to form a low-viscosity adhesive layer AD2b. The formation of the high-viscosity adhesive layer AD2a by emitting UV light into the dam-forming space DSP using the first curing unit CE1 and the formation of the low-viscosity adhesive layer AD2b by emitting UV light into the injection space ISP using the first curing unit CE1 can be performed sequentially.

[0087] Reference Figure 5A , Figure 5B and Figure 6B The first curing unit CE1 may include a first sub-curing unit CE1a and a second sub-curing unit CE1b. In this case, the first sub-curing unit CE1a may emit UV light onto the high-viscosity adhesive material ADMa injected into the dam forming space DSP to form a high-viscosity adhesive layer AD2a. The second sub-curing unit CE1b may emit UV light onto the low-viscosity adhesive material ADMb injected into the injection space ISP to form a low-viscosity adhesive layer AD2b.

[0088] The second curing unit CE2 can emit UV light onto the first adhesive layer AD1. The second curing unit CE2 can cure the first adhesive layer AD1 to laminate the display panel (DP) to the window (WD). The first adhesive layer AD1 may include a UV-curable material. Furthermore, in one embodiment of the invention, the second curing unit CE2 can emit UV light onto the first adhesive layer AD1 and the second adhesive layer AD2. The second curing unit CE2 can cure both the first adhesive layer AD1 and the second adhesive layer AD2.

[0089] After the high-viscosity adhesive ADMa and the low-viscosity adhesive ADMb are cured using the first curing unit CE1, the first adhesive layer AD1 can be cured using the second curing unit CE2. Furthermore, curing using the second curing unit CE2 can be performed after the process of removing air bubbles from the first adhesive layer AD1. In one embodiment of the invention, after the high-viscosity adhesive ADMa and the low-viscosity adhesive ADMb are cured using the first curing unit CE1, the second adhesive layer AD2 can be cured using the second curing unit CE2.

[0090] Figure 7 This is a flowchart illustrating an embodiment of a lamination method using a lamination apparatus according to the present invention. Figure 8This is a flowchart illustrating an embodiment of the injection and curing of the adhesive material according to the present invention. (Refer to...) Figures 4A to 4E and Figure 7 The lamination method of the lamination equipment LE for manufacturing display device DD includes a process of loading display panel DP onto first support unit LDP1 (100S), a process of loading window WD onto second support unit LDP2 (200S), and a process of connecting first support unit LDP1 to second support unit LDP2 (300S).

[0091] In the process (100S) of loading the display panel DP onto the first support unit LDP1, the display panel DP can be loaded onto the first support unit LDP1 with the first adhesive layer AD1 and the guide film GF disposed on the display panel DP. However, the present invention is not limited thereto, and the process (100S) of loading the display panel DP may include loading the display panel DP onto the first support unit LDP1 and disposing the first adhesive layer AD1 on the first flat portion LP1 of the loaded display panel DP.

[0092] In the process (200S) of loading the window WD onto the second support unit LDP2, the window WD, including the second curved portion CP2 overlapping the curved region CA and the second straight portion LP2 overlapping the straight region LA, can be loaded onto the second support unit LDP2.

[0093] In the process (300S) of connecting the first support unit LDP1 to the second support unit LDP2, the first support unit LDP1, on which the display panel DP is mounted, can be connected to the second support unit LDP2, on which the window WD is mounted.

[0094] The lamination method of the lamination equipment also includes a process of laminating the first flat portion LP1 to the second flat portion LP2 using an expansion pad EP (400S), a process of injecting adhesive material ADM into the first space SP1 and the second space SP2 using an injection unit FE and curing the adhesive material ADM using a curing unit CE (500S), and a process of separating the connected first support unit LDP1 and second support unit LDP2 (600S).

[0095] In the process (400S) of laminating the first flat portion LP1 to the second flat portion LP2 using the expansion pad EP, air is injected into the expansion pad EP through the air nozzle AZ. As the expansion pad EP expands due to the injected air, the first flat portion LP1 of the display panel DP moves to the second flat portion LP2 of the window WD and is then laminated to the second flat portion LP2.

[0096] In the process of injecting and curing adhesive material ADM (500S), adhesive material ADM can be injected into the first space SP1 between the first curved portion CP1 and the second curved portion CP2, and into the second space SP2 between the first adhesive layer AD1 and the second straight portion LP2, by the injection unit FE. The injected adhesive material ADM can be cured by the curing unit CE.

[0097] Reference Figures 5A to 6B and Figure 8 The process of injecting and curing the adhesive material ADM (500S) includes injecting the high-viscosity adhesive material ADMa into the dam formation space DSP using the injection unit FE (501S) and curing the high-viscosity adhesive material ADMa using the curing unit CE to form a high-viscosity adhesive layer AD2a (502S). Here, in one embodiment of the present invention, the high-viscosity adhesive material ADMa can be injected through the first injection unit FE1 (501S), and the high-viscosity adhesive material ADMa can be cured through the first curing unit CE1 (502S).

[0098] The process of injecting and curing the adhesive material ADM (500S) may further include injecting the low-viscosity adhesive material ADMb into the injection space ISP using the injection unit FE (503S) and curing the low-viscosity adhesive material ADMb using the curing unit CE to form a low-viscosity adhesive layer AD2b (504S). Here, in one embodiment of the invention, the low-viscosity adhesive material ADMb can be injected through the second injection unit FE2 (503S), and the low-viscosity adhesive material ADMb can be cured through the second curing unit CE2 (504S).

[0099] Return to reference Figure 7 In the process (600S) of separating the first support unit LDP1 and the second support unit LDP2, the first support unit LDP1 and the second support unit LDP2 are separated from each other, and the preliminary display device P_DD (refer to) manufactured by laminating the window WD and the display panel DP can be unloaded from the first support unit LDP1. Figure 4E Here, the guiding membrane GF (refer to...) Figure 4A The device can be attached to the preliminary display device P_DD via an adhesive component. After unloading, the guide film GF can be removed from the preliminary display device P_DD. After the process of separating the first support unit LDP1 from the second support unit LDP2 (600S), UV light is emitted towards the adhesive component attached to the preliminary display device P_DD to reduce the adhesive force of the adhesive component, and subsequently, the preliminary display device P_DD and the guide film GF separate from each other. Figure 2A The display device DD shown can be completed by removing the guide film GF from the initial display device P_DD.

[0100] According to an embodiment of the present invention, the space defined when the curved window and the display panel are laminated can be filled with an adhesive layer. Therefore, it is possible to prevent the deterioration of transmittance in the curved portion of a display device with a curved shape.

[0101] Although described with reference to embodiments of the invention, it will be understood that various changes and modifications to the invention can be made by those skilled in the art or those with ordinary knowledge of the art without departing from the spirit and technical field of the invention as claimed below.

[0102] Therefore, the technical scope of the present invention is not limited to the detailed description in the specification.

Claims

1. A display apparatus in which a curved area having a curved shape and a flat area having a planar shape are defined, the display apparatus comprising: a display panel including a first curved portion overlapping the curved area and a pair of first flat portions overlapping the flat area, the first curved portion being disposed between the pair of first flat portions; a window disposed on the display panel and including a second curved portion overlapping the curved area and a pair of second flat portions overlapping the flat area, the second curved portion being disposed between the pair of second flat portions; and an adhesive layer disposed between the display panel and the window, the adhesive layer including: a first adhesive layer disposed between the first flat portion and the second flat portion and coupling the first flat portion to the second flat portion; and a second adhesive layer disposed in a first space between the first curved portion and the second curved portion and a second space between the first adhesive layer and the second flat portion. The first space includes a dam forming space corresponding to an end portion of the first curved portion and an injection space corresponding to an area other than the dam forming space. The first space includes a space in which the second adhesive layer and the first curved portion are in direct contact with each other.

2. The display device of claim 1, wherein, The first adhesive layer is further disposed in the dam forming space.

3. The display device of claim 2, wherein, The second adhesive layer is disposed between the second curved portion and the first adhesive layer within the dam forming space and between the second curved portion and the first curved portion within the injection space.

4. The display device of claim 3, wherein, The second adhesive layer includes:

5. The display device of claim 4, wherein, a high-viscosity adhesive layer disposed in the dam forming space; and 6. The display device of claim 3, wherein, a low-viscosity adhesive layer disposed in the injection space and having a viscosity lower than that of the high-viscosity adhesive layer. The first adhesive layer is further disposed in the curved area. The second adhesive layer is disposed between the second curved portion and the first adhesive layer within the first space.

7. The display device of claim 2, wherein, The second adhesive layer includes:

8. The display device of claim 7, wherein, a high-viscosity adhesive layer disposed in the dam forming space; and 9. The display device of claim 8, wherein, a low-viscosity adhesive layer disposed in the injection space and having a viscosity lower than that of the high-viscosity adhesive layer. The viscosity of the adhesive layer overlapping the curved area varies depending on a position. 11.A laminating apparatus for manufacturing a display apparatus in which a curved area having a curved shape and a flat area having a planar shape are defined, the laminating apparatus comprising:

10. The display device of claim 1, wherein, a first support unit on which a display panel is disposed, wherein the display panel includes a first curved portion overlapping the curved area and a first flat portion overlapping the flat area and on which a first adhesive layer is disposed; a second support unit on which a window is disposed, wherein the window includes a second curved portion overlapping the curved area and a second flat portion overlapping the flat area; an injection unit injecting an adhesive material into a first space between the first curved portion and the second curved portion and a second space between the first adhesive layer and the second flat portion; and a second support unit on which a window is disposed, wherein the window includes a second curved portion overlapping the curved area and a second flat portion overlapping the flat area. ​ ​ a curing unit that cures the injected adhesive material and forms a second adhesive layer.

12. The lamination apparatus of claim 11, wherein, The first support unit includes an expansion pad that expands due to air injection, wherein the first flat portion is disposed on the expansion pad and is laminated to the second flat portion when the expansion pad expands.

13. The lamination apparatus of claim 12, wherein, The first support unit includes a fixed pad that is fixed in position, wherein the first curved portion is disposed on the fixed pad, and when the expansion pad expands, a gap between the first curved portion and the second curved portion remains constant.

14. The lamination apparatus of claim 11, wherein, The first space includes a dam forming space corresponding to an end portion of the first curved portion and an injection space corresponding to an area outside the dam forming space, and The injection unit includes: a first injection unit that injects a high-viscosity adhesive material into the dam forming space; and a second injection unit that injects a low-viscosity adhesive material into the injection space, the low-viscosity adhesive material having a lower viscosity than the high-viscosity adhesive material.

15. The lamination apparatus of claim 14, wherein, The first adhesive layer is also disposed in the curved area, The first injection unit injects the high-viscosity adhesive material into a space within the dam forming space between the second curved portion and the first adhesive layer, and The second injection unit injects the low-viscosity adhesive material into a space within the injection space between the second curved portion and the first adhesive layer.

16. The lamination apparatus of claim 11, wherein, The adhesive material is an ultraviolet-curable material, and The curing unit includes a first curing unit that emits ultraviolet light to the adhesive material and forms the second adhesive layer.

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